Tigon Complete 100 & 200 Hour Service Instructions (Part 2 of 2)
Tigon Complete 100 & 200 Hour Service Instructions
Feb 2024 orig., Jun 2024 rev.
Table of Contents
Recommendations and Warnings
Cane Creek recommends only trained suspension technicians perform service on all suspension, using all required tools and following all proper procedures. Anyone without access to the proper equipment or with any concerns on the procedures should defer to an authorized Cane Creek service center for service. Improper service can result in loss of performance or suspension failure. All Cane Creek shocks have pressurized nitrogen and oil, even coil shocks. Follow the service procedures exactly as written to avoid possible injury or harm to the suspension. Always wear eye protection while performing suspension service.
Please dispose of all waste products and materials through proper channels to avoid contamination of the environment.
Any damage or issues resulting from improper service will not be covered by warranty. If you have a shock still in its original warranty period and do not wish to void your warranty, please contact an authorized Cane Creek service center.
These service instructions cover the basic service procedures using standard service kits. If your suspension requires parts beyond standard replacement parts – shaft, damper tubes, end eyes – please consult your authorized Cane Creek service center or contact us at our Cane Creek Support Center.
Service Notes
The Standard and Trunnion variants of the Tigon have identical service procedures other than where to clamp the cylinder head. Some images in these instructions may not be identical to the valve body, but process is the same for the shock in the image and the shock on your bench.
100 vs. 200 hour service
The only difference between the 100 hour service and the 200 hour service is whether to service or replace the Oil Seal Head. At 100 hours, the Seal Head should be cleaned, serviced and reinstalled. At 200 hours, it should be replaced. If uncertain on hours, check for wear on the dual bushings inside the Seal Head. When in doubt, replace.
Service Kits
BDD0341– Tigon Complete 100 Hour Rebuilt Kit
OR
BDD0343– Tigon Complete 200 Hour Rebuilt Kit
Required Cane Creek Tools
BDD0320 – Tigon Oil Seal Head Pin Spanner
ADD0327 – Tigon Shaft Seal Head Bullet
ADD0328 – Tigon IFP Service Plug
AAD1361-01 – DBCoil/ DBAir – Oil Fill Needle Adapter
DBT016 – DB Gas Fill Needle
Additional Tools & Supplies
Shaft Clamp – 12.7mm (1/2″)
Allen wrench – 4mm
Torx wrench – T20
Crowfoot wrenches – 12 & 34mm
Open end wrench – 19mm
Torque wrenches
Knipex pliers
Pick – metal & plastic
Strap wrench
M8 x 1.25 bolt, min. 45mm length
Suspension Grease
Motorex 4wt Racing Fork Oil
Vacuum Oil Fill Machine
Nitrogen Fill System
Torque, Loctite, Oil & Nitrogen Specs
Torque & Loctite Chart
| Part | Torque Spec | Loctite Spec |
|---|---|---|
| Inner Shaft to Outer Shaft | None | 263 (Red) |
| Shaft Assembly to Valve Body | 10 Nm | 263 (Red) |
| Oil Seal Head | 30 Nm | None |
| RAMP Tube | 14.5 Nm | None |
Oil Chart
| Oil Location | Oil Type | Oil Amount |
|---|---|---|
| Damper Fill | Motorex 4wt Racing Fork Oil | Fill to 3 Bars |
Nitrogen Chart
| Nitrogen Location | Nitrogen Pressure |
|---|---|
| Valve Body | 11 - 12 Bars |
Related Technical Service Bulletins
Review all related TSBs before performing any service.
No Tigon specific TSBs at this time.
Damper Reassembly
Step 1 – IFP Install
Thoroughly grease and install IFP quad ring (.DB11120). Reinstall IFP into IFP tube. Use plastic pick to help work past tube rim. Remove bolt from IFP. Set IFP just below flush with the edge of the IFP tube. No deeper than 10mm.
IFP Quad Ring Greased
IFP Quad Ring Install
IFP Quad Ring Installed
IFP Install 1
IFP Install 2
IFP Installed
Step 2 – Oil Seal Head Assembly
100 hour service – Thoroughly grease and install inner (ADD0129) & outer (ADD0138) quad rings and o-ring (AAD0771) on oil seal head. Inner quad ring will require Shaft Seal Head Bullet (ADD0327).
200 hour service – Thoroughly grease outer inner quad ring on new oil seal head (ADD0342).
Both – Install spring and sleeve into oil seal head. Press on spring to seat properly.
Oil Seal Head O-Ring Install
Oil Seal Head Outer Quad Ring Install
Oil Seal Head Outer Quad & O-Rings Installed
Oil Seal Head Inner Quad Ring Install
Oil Seal Head Inner Quad Ring Install w/ Plastic Pick
Oil Seal Head Inner Quad Ring Install w/ Bullet Tool
Greasing Oil Seal Head Inner Quad Ring
Oil Seal Head Spring & Sleeve Install
Oil Seal Head Spring & Sleeve Installed
Oil Seal Head Spring & Sleeve Compressed to Seat
Step 3 – Oil Seal Head Assembly Install
Insert Shaft Seal Head Bullet tool (ADD0327) into non-threaded end of shaft. Slide oil seal head onto shaft followed by coupler o-ring. Sleeve may slide out of assembly. Slide it back into spring.
Oil Seal Head Bullet Tool Install
Oil Seal Head Bullet Tool Installed
Oil Seal Head Install 1
Oil Seal Head Install 2
Oil Seal Head Installed
Coupler O-Ring Install
Step 4 – Main Piston Install
Lightly grease piston o-ring (AAD0800) and install. Install piston ring (ADD0182). Install shim stack and piston on inner shaft. Ensure rounded edge of stop washer goes towards coupler shelf. Concave side of piston faces out. Install shaft nut and finger tighten.
Stop Washer Orientation on Coupler
Main Piston Orientation on Coupler
Main Piston Installed
Main Piston & Shims Installed
Shaft Nut Install
Complete Shim Stack Orientation
Step 5 – Complete Shaft Assembly
Insert inner shaft into outer shaft. Apply red (263) Loctite to inner shaft threads. Thread shafts together. Grease and install shaft o-ring (ADD0183) on shaft. Apply red (263) Loctite outer shaft threads.
Inner Shaft Install
Loctite on Inner Shaft Threads
Shaft O-Ring Install
Loctite on Shaft Assembly Threads
Step 6 – Valve Body Prep
Grease and install inner (AAG0445) and outer (ACD0317) valve body o-rings into valve body. Clamp valve body in soft jaw vise.
Inner Valve Body O-Ring Greased
Inner Valve Body O-Ring Install 1
Inner Valve Body O-Ring Install 2
Outer Valve Body O-Ring Greased
Outer Valve Body O-Ring Install 1
Outer Valve Body O-Ring Install 2
Outer Valve Body O-Ring Install 3
Outer Valve Body O-Ring Install 4
Step 7 – Shaft Assembly Install
Thread shaft into valve body. Using 12mm crowsfoot or socket, tighten entire shaft assembly onto valve body to 10 Nm.
Shaft Assembly Install
Threading Shaft Assembly into Valve Body
Tightening Shaft Assembly into Valve Body
Torquing Shaft Assembly into Valve Body
Step 8 – Damper Tube Install
Apply suspension oil to piston band. Install outer damper tube onto oil seal head and thread it on. Clamp end eye in vise. Using Tigon Oil Seal Head Pin Spanner (BDD0320), torque seal head to 30 Nm.
Lubing Main Piston Band
Damper Tube Install
Threading Damper Tube onto Oil Seal Head
Torquing Oil Seal Head onto Damper Tube
Damper Fill
Step 1 – Prepping Shock for Fill
Remove fill screw using T20 wrench. Discard o-ring. Insert Tigon IFP Service Plug (ADD0328) into IFP tube, pushing the IFP to the correct depth. Install the reservoir tube onto the IFP tube to secure the IFP Plug in place. Hand tighten. Thread fill nozzle onto valve body with new fill screw o-ring (.DB11102) either on tool or in shock. Back all adjusters to fully open and open Climb Switch. Fully compress damper. Attach oil fill machine to fill port per your manufacturer’s instructions.
Fill Screw Removed
IFP Service Plugs
IFP Service Plug Install
Securing IFP Service Plug
Hand Tightening Res Tube on IFP Tube
Attaching Fill Needle
Fill Needle Attached, Shock Compressed
Fill Machine Connected, Shock Compressed
Step 2 – Vacuum and Oil Fill Process
Vacuum system to (4) mbar. Pressure with Oil to (3) bar. Slowly cycle shaft finishing with shaft fully out. Cut fill and equalize pressure. Vacuum system to (4) mbar, leaving shaft out. Pressure again with Oil to (3) bar. Slowly cycle shaft finishing with shaft fully out. Cut fill.
Oil Pre-Fill
Damper Fill, Shaft Extended
Vacuum System to (-4) mbar
Damper Fill, Shaft Compressed
Oil Fill to 3 bar
Damper Fill, Final Shaft Extension
Step 3 – Valve Body Closure
Holding horizontal, disconnect fill machine. Drip some oil on to top of fill. Install oil fill screw with T20, ensuring o-ring is present. Remove res tube and IFP Plug.
Fill Screw Install
Res Tube and IFP Plug Removal
RAMP Tube Reassembly
Step 1 – Reservoir Tube Install
Install new gas fill plug (.DB11115) in reservoir tube. Chamfer goes towards res tube. Using 4mm Allen, reinstall set screw, but do not tighten. Thread res tube onto valve body. Tighten with strap wrench.
Gas Fill Plug Chamfer
Gas Fill Plug Install
Gas Fill Set Screw Install
Res Tube Install
Threading Res Tube onto Valve Body
Tightening Res Tube onto Valve Body
Step 2 – Nitrogen Fill
Insert gas fill needle in gas fill port on reservoir tube. Pressurize to 11-12 bars of nitrogen. Tighten fill plug set screw with 4mm. Compress shaft and ensure proper gas by observing shaft return to full extension. Submerge valve body in water to check for gas leaks.
If mechanical dyno equipment is available, run shock on dyno at this point.
Inserting Fill Needle
Fill Needle Attached
Connect Nitrogen Hose
Nitrogen Filled to Pressure
Gas Plug Set Screw Tightened
Gas Leak Dunk Test
Step 3 – RAMP Tube Install
Lightly grease inner rim of RAMP tube and outer edge of oil seal head. Install RAMP tube on damper tube, using a pick to work RAMP tube past oil seal head. Install stroke reduction if needed. Be sure to seat fin on reduction in valve body properly. Clamp valve body in soft jaw vise. Using 34mm crowsfoot, tighten RAMP tube onto valve body to 14.5 Nm.
Greasing RAMP Tube
Greasing Oil Seal Head
RAMP Tube Install
Working Oil Seal Head Past RAMP Tube Lip 1
Working Oil Seal Head Past RAMP Tube Lip 2
RAMP Tube Past Oil Seal Head
Stroke Reduction Install
Stroke Reduction Installed on Shaft
Stroke Reduction Installed in Valve Body
Seating RAMP Tube on Valve Body
RAMP Tube Seated on Valve Body
Valve Body Clamped for RAMP Tube Install
Threading RAMP Tube on Valve Body
Torquing RAMP Tube on Valve Body
Final Testing and Set Up
Step 1 – Dyno Test
Set adjusters to factory neutral. Using hand dyno, test shock for function. Ensure Climb Switch engages and operates properly. Turn individual adjusters to test each one. Set back to original tune if desired.
Step 2 – Spring Reinstall
Set adjusters to factory neutral. Using hand dyno, test shock for function. Ensure Climb Switch engages and operates properly. Turn individual adjusters to test each one. Set back to original tune if desired.
Tigon Preload Clip & Spacer Chart
Tigon Preload Clip & Spacer Orientation
Spring Spacer Install
Spring Install
Spring Preloader Install
Spring Preloader Clip Install
Spring Preloader Clip Installed