Boxxer 2006 Service Guide

For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website atwww.rockshox.com.

Information contained in this publication is subject to change at anytime without prior notice. For the latest technical information, visit our website at www.rockshox.com. Names used in this manual may be trademarks or registered trademarks of others.

© SRAM Corporation • July 2005 PN 95.4311.775.000, Rev. A

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2 © SRAM Corporation • 2006 BOXXER SERVICE GUIDE

2006 Boxxer Service Guide

G E T T I N G S TA R T E D

T O O L S

L O W E R L E G R E M O VA L

• Perform service every 100 hours of riding (less depending on riding conditions and riding style).• Regular maintenance will ensure your RockShox suspension fork performs as it should.• For dust seal, foam ring, oil seal, and bushing removal and installation, please reference the Bushing Service Guide.• Right side equals rider’s right; left side equals rider’s left.

1. Remove fork from bicycle.2. Spray entire fork with isopropyl alcohol and wipe all dirt and mud from fork. Clean around dust seals and upper tubes.3. Lay tools out on work bench, and create a clean work area for internal's service.4. Place oil pan under fork on floor.

• Safety Glasses• Clean Rags• Oil Pan or Bucket• Bicycle Stand/Clean Work

Table/Area• 24mm and 10mm 6-point Socket• Plastic-Faced Mallet• Snap Ring Pliers (internal and

external)• Shock Pump• 2, 2.5 and 5mm Hex Wrench

• Long and Short Plastic or WoodDowel, 3/4" diameter (non-metallic)

• Torque Wrench• Sharp Pick/Dental Pick• Oil Mixing Syringe and Measuring

Cup• Isopropyl Alcohol/Spray Bottle• 5wt and 15wt Suspension Oil• Suspension Oil Height Tool

2. Spray isopropyl alcohol onto upper tube, under uppertube/frame bumpers (fig 2a).

Twist and pull up to remove (figs 2b/2c).

1. Loosen upper crown bolts with a 5mm hex wrench (fig 1a).

Remove upper crown (figs 1b/1c).

BOXXER RIDE PICTURED. Be sure to flip the U-Turntravel adjuster knob to the position pictured whenremoving crowns.

1b 1c

2b 2c2a

PROCEDURES FOR 2006 BOXXER RACE, RIDE, TEAM AND WORLD CUP LOWER LEG REMOVAL AND INSTALLATION ARETHE SAME FOR EACH MODEL. BOXXER TEAM LOWER LEGS PICTURED HERE.

1a

PN 95.4311.775.000, REV. A 3


4. Using a 5mm hex wrench loosenlower crown bolts (fig 4a).

Using a twisting motion, slideeach upper down and out ofcrown (figs 4b/4c/4d).

3. BOXXER RIDE: Using a 2.5mm hex wrench, remove U-Turn travel adjuster knobscrew. (fig 3a).

Remove knob (fig 3b).

Using a magnet, remove detent ball bearings and detent springs.

5. BOXXER WORLD CUP (SOLO AIR): Remove air cap. Press schrader valve and release all air pressure (fig 5).

ALL 2006 BOXXER MODELS: It is not necessary to remove Motion Control knob at this point.

3a 3b

4c 4d4b

5

4aJeremiah

6. Pull to remove external rebound adjuster knob (fig 6a).

Using a 5mm hex wrench, loosenleft and right shaft bolts about 3turns (figs 6b/6c).

Using a plastic mallet, tap eachshaft bolt until you feel the shaftbreak free from the lower leginternally (fig 6d). Each shaft isseated tightly inside the bolt hole shaft bore inside the lower leg.

6c 6d6b

7. Hold the bottom of the lower legsover an oil pan to allow oil todrain.

Pull each upper tube/shaftassembly out of lower leg (figs7a/7b).

Allow all oil to drain into oil pan.(figs 7c/7d).

Spray isopropyl alcohol inside each lower leg. Wrap a clean rag around a long wooden or plastic dowel, insert into each lower leg sideand clean thoroughly. Spray each dust seal and clean with a rag. Replace if worn or leaking oil. See the ‘Bushing Service Guide’ forprocedures.

7c 7d7b

6a

7a



Disassembly and service should be performed on a clean work surface.

8. MOTION CONTROL COMPRESSION DAMPER REMOVAL AND SERVICE

Using a 24mm socket wrench, loosen compression damper top cap (figs 8a/8b).

There is no need to remove the blue compression adjuster knob.

8a 8d

9. Slowly pull compression damper out of upper tube (figs 9a/9b/9c). You may need to twist from side to side to ease the compressiondamper from upper tube.

Spray compression damper with isopropyl alcohol andwipe all grease and oil clean.

9b 9c9a

11. Pour damping oil into an oil pan (fig 11).11

12. REBOUND DAMPER REMOVAL

AND SERVICE Using snap ringpliers remove rebound damperseal head retaining ring. (fig 12a)

Pull rebound damper shaft andseal head out of upper tube (figs12b/12c).

12c12b12a

10. Remove and replace lower and upper Motion Control compression damper o-rings(figs 10a/10b). 10a 10b

B O X X E R R I D E , R A C E , T E A M , W O R L D C U P M O T I O N C O N T R O L D A M P I N G( R I G H T U P P E R T U B E )

PN 95.4311.775.000, REV. A 5


16. Insert rebound damper piston into bottom of upper tube(fig 16a).

Slide rebound damper seal head/upper tube ring and sealhead up rebound damper shaft and insert into the uppertube seal head step. Gently press into place with yourthumb (fig 16b).

Using snap ring pliers, reinstall retaining ring (sharp endfacing out) (fig 16c). Set upper tube aside.

Insert rebound adjuster knob into bottom of rebound damper shaft and turn counterclockwise to open rebound damper valve. This ensures proper oil flow when filling damping system with suspension oil.

14. Apply fresh grease to the inner seal head o-ring (fig 14a).

Slide seal head/upper tube ring and seal head back ontorebound damper shaft. (fig 14b)

Apply fresh grease to the outer seal head o-ring (fig 14c).

14b 14c

16b 16c16a

15. Spray the upper tube (inner and outer surfaces) withisopropyl alcohol or degreaser and wipe with a clean rag(fig 15a).

Wrap a clean rag around the end of a wood or plasticdowel and insert into upper tube to clean (figs 15b/15c).

15b 15c15a

14a

17. Turn the compression adjuster knob to the open position (fig 17a).

Opening the compression piston window eases installation (fig 17b).

17a 17b

13. Remove and replace rebound damper piston glide ring (fig 13a).

Slide rebound damper seal headfrom damper shaft (fig 13b).Using a pick, carefully removeand replace the inner seal head o-ring seal (fig 13c).

Remove and replace the outerseal head o-ring (fig 13d).

IMPORTANT! DO NOT SCRATCH O-RING GROOVES WHEN REMOVING O-RINGS. DAMAGE CAUSES PERMANENT AIR LEAK.

13c 13d13b13a

Open Position



18. Hold upper tube upright and pour 150ml/cc of 5wtsuspension oil into upper tube (fig 18a).

OPTIONAL PROCEDURE:If you choose to measure oil height using a suspension oilheight tool, use the following steps:a. Measure and set the syringe needle stop to 205mm (fig18b)b. Insert the syringe needle into the upper tube, resting thestop flat on upper tube (fig 18c).c. Pull out excess oil with syringe plunger (fig 18c).d. Remove oil height tool from upper tube.

18b 18c

20. Clamp U-Turn spring upper tube into bicycle stand clamp.

Using a 24mm socket wrench, loosen and remove U-Turnspring top cap (figs 20a/20b). The spring is attached tothe top cap and spring shaft. Pull and lift entire springassembly from upper tube (fig 20c).

IMPORTANT! PRESS DOWN FIRM WHEN LOOSENINGTOP CAPS.

20b 20c20a

19. Gently insert the Motion Control compression damper into upper tube. Press down and gently ease the piston o-ring past the uppertube/top cap threads (figs 19a/19b).

Press down and slowly twisti side to side to ease thedamper into the upper tube. Hand-thread thecompression damper top cap into the upper tube threads.

Using a 24mm socket wrench tighten the top cap to 60in-lb (fig 19c). Set upper tube/damper assembly aside fornow.

19b 19c19a

R E M O VA L

21. Spray entire spring assembly with isopropyl alcohol and wipe all grease and oil from top cap, spring and spring shaft. Apply grease to outside of entire coil spring and spring isolators.

B O X X E R R I D E U - T U R N S P R I N G ( L E F T U P P E R T U B E )

I N S TA L L AT I O N22. Insert spring assembly into left upper tube, through crown (fig 22a). Align and seat

the spring shaft through shaft guide/base plate.

Press down on U-Turn spring top cap and hand-thread into upper tube/crown.Using a 24mm socket wrench, tighten to 60 in-lb (fig 22b).

22a 22b

18a

PN 95.4311.775.000, REV. A 7


24. Using snap ring pliers remove the spring shaft base plate retaining ring (fig 24a).

Pull spring shaft and base plate from upper tube (figs24b/24c).

Spray isopropyl alcohol onto spring shaft and wipe clean.

Check for any damaged parts, and replace assembly ifnecessary.

24b 24c24a

23. Using a 24mm socket wrench, loosen and remove spring spring top cap (figs 23a/23b).

Remove spring pre-load spacers (fig 23c). Pull spring from upper tube (fig 23d). Spray isopropyl alcohol onto spring and springisolators. Apply fresh grease (oil soluble) to spring and spring isolators (fig 23e).

IMPORTANT! PRESS DOWN SQUARE AND FIRM WHEN LOOSENING TOP CAPS.

R E M O VA L

B O X X E R R A C E / T E A M S P R I N G ( L E F T U P P E R T U B E )

23d 23e23b 23c23a

I N S TA L L AT I O N

25. Spray the upper tube (inner and outer surfaces) withisopropyl alcohol or degreaser and wipe with a clean rag(figs 25a/25b).

Wrap a clean rag around the end of a wood or plasticdowel and insert into upper tube to clean (figs 25c).

26. Insert spring shaft assembly back into bottom of upper tube (fig 24c/24b).

Seat base plate assembly into upper tube step and secure with retaining ring (sharp end out) (fig 24a).

25b 25c25a

27. Insert spring back into upper tube (fig 23d).

Place spring preload spacer(s) on top of spring inside upper tube (fig 23c).

Clean top cap with a clean rag. Apply a thin amount grease to top cap threads.

Hand-thread the top cap back into upper tube (fig 23b). Using a 24mm socket wrench, tighten to 60 in-lb (fig 23a). Wipe away anyexcess grease.



R E M O VA L

B O X X E R W O R L D C U P S O L O A I R S P R I N G ( L E F T U P P E R T U B E )

28. Using a small hex wrench pressschrader air valve and release allair pressure (fig 28a).

Using a 24mm socket wrench,loosen and remove Solo Air topcap (figs 28b/28c/28d).

28c 28d28b28a

29. Pour any air seal lubrication oil from air spring upper tube into an oil pan.

Use your finger to press the airseal head into upper tube. Youwill feel it break free and slideinto the tube about 3mm(fig 29a). Using snap ring pliersremove spring shaft seal headretaining ring from upper tube(fig 29b).

Pull Solo Air spring shaft assembly out of upper tube (figs 29c/29d).

29c 29d29b29a

30. Spray Solo Air spring assemblywith isopropyl alcohol and wipeclean. (fig 30a)

Pinch the main air seal o-ringand remove. Replace with new ao-ring (fig 30b).

Slide negative air seal/sleeve offair spring shaft. (fig 30c).

Pinch the negative air seal o-ring and remove. Use a sharp pick to remove inner sleeve o-ring. Replace with new o-rings (fig 30d).

30c 30d30b30a Main Air PistonO-ring

31. Inspect the Solo Air retaining ringand spring washer to ensure fit issecure (fig 31a).

Apply fresh grease to the newinner sleeve o-ring (fig 31b), thenew main air seal o-ring (fig 31c)and negative air seal o-ring(fig 31d).

31c 31d31b

Negative PistonO-ring

Inner SleeveO-ring

31a

PN 95.4311.775.000, REV. A 9


33. Slide negative sleeve back onto air shaft assembly.

Insert air piston into upper tube. Slide assembly into upper tube. Press seal headwith your thumb into upper tube (fig 33a).

Using snap ring pliers, install retaining ring, sharp side out (fig 33b).

33a 33b

32. Spray the upper tube (inner and outer surfaces) withisopropyl alcohol or degreaser and wipe with a clean rag(figs 32a/32b).

Wrap a clean rag around the end of a wood or plasticdowel and insert into upper tube to clean (figs 32c).

32b 32c32a

34. Holding the upper tube, pour 3-5 cc/ml of 5wt suspensionoil into the upper tube (fig 34a). This oil will lubricate theair piston o-rings during suspension movement.

Clean the air top cap and upper tube threads. Hand-threadthe air top cap into upper tube (fig 34b).

Using a 24mm socket wrench, tighten to 60 in-lb (fig 34c).

34b 34c34a

35. Thoroughly clean each foam ring and dust seal in the lower legs. If extremely wornor contaminated, replace both. Refer to the ‘Bushing Service Guide’ forprocedures.

Pour 15wt suspension oil onto each foam ring and saturate (fig 35a).

Apply fresh grease to the inside surface of each dust seal (fig 35b.).

35a 35b

B O X X E R L O W E R L E G I N S TA L L AT I O N ( A L L M O D E L S )

36. Insert the spring (left) and damping (right) upper tube assemblies into the lower legs. Ensure the dust seal lip does not fold under andis seated correctly around upper tube (figs 36a/36b).

SPRING SIDE (LEFT): Slide the spring assembly/upper tube completely into the left lower leg until thespring shaft stops and rests in the lower leg shaft bore hole. Look through the bolt hole in the bottomof the lower leg to make sure the shaft is aligned and seated in the center of the bolt hole.

DAMPER SIDE (RIGHT): Slide the damper/upper tube assembly about half way into the right lower leg.Do not seat completely into bottom of lower leg. The shaft end should not be visible in the bolt hole.Pour or inject (an oil syringe works best) 15cc/ml of 15wt suspension oil into the bottom of the lowerleg through the bolt hole. This lubricates the bushing.

2006 Boxxer forks feature Motion Control damping, which is considered a ‘closed’ system. A ‘closed’damping system refers to sealed damping fluid inside the upper tube. Sealed damping is not an ‘openbath’ damping/lubrication system. Therefore, suspension oil is added to the bottom of the lower leg forbushing lubrication using the ‘closed’ system.

36b

36a



37. Slide the damper/upper tube completely into the right lower leg until the damper shaft stops and rests in the lower leg shaft bore hole.Look through the bolt hole in the bottom of the lower leg to make sure the shaft is aligned and seated in the center of the bolt hole.

38. Inspect each black shaft bolt crush washer and crush washer retainer. Clean and replace if damaged.

Insert the damper (right) shaft bolt (hollow) into the rightshaft through the lower leg bolt hole (fig 38a). Insert thespring (left) shaft bolt (solid) into the left shaft through thelower leg bolt hole.

Using a 5mm hex wrench, tighten each shaft bolt to 60in-lb(figs 38b/38c). Wipe away any excess oil from bolts andlower leg.

38b 38c38a

39. BOXXER RACE/TEAM: With fork clamped in bicycle stand, use a 24mm socket wrench to loosen and remove spring top cap.(fig 39a).

Gently slide upper down until spring preload spacer isexposed. Remove preload spacer. (fig 39b).

Pull upper tube back up. Measure and pour 30cc/ml of5wt suspension into upper tube. (fig 39c)

Reinstall top cap, and tighten to 60in-lb.

39b 39c39a

40. BOXXER RIDE: With fork clamped in bicycle stand, use a 24mm socket wrench to loosen U-Turn spring top cap (fig 40a).

Gently slide upper down until top cap and U-Turn springare exposed. Measure and inject/pour 50cc/ml of 5wtsuspension into upper tube, through the spring (fig 40b).

Pull upper tube back up. Press top cap into threads andtighten by hand (fig 40c). Use a 24mm socket wrench andtighten to 60in-lb (fig 40a).

40b 40c40a

41. BOXXER RIDE: Insert detent springs and ball bearings into top cap detent holes,evenly spaced. Install U-Turn adjuster knob onto top cap (fig 41a).

Using a 2.5mm hex wrench, install and tighten U-Turn travel adjuster knob screw.(fig 41b).

41a 41b

B O X X E R C R O W N I N S TA L L AT I O N ( A L L M O D E L S )

42. Clean the inside of each crown/upper tube hole in thelower crown with isopropyl alcohol and a clean rag.

Insert each upper tube evenly into each hole in the lowercrown (fig 42a).

Pull upper tubes up and into the crown, twisting gently asthe upper tubes ease into the hole (figs 42b/42c).

42b 42c42a

PN 95.4311.775.000, REV. A 11


43. Pull each upper tube up to the fully extended position.

Measure, from the dust/lower leg to the bottom of the lower crown hole, 205mm and tighten each crownbolt to 65in/lb. (fig 43) Make sure upper tubes are positioned at an even height. Refer to the diagram belowfor crown measurements.

43

44. Slide each upper tube/frame bumper ontoeach upper tube (figs 44a/44b). 44a 44b

45. Install upper crown onto upper tubes andsteerer tube (fig 45a).

Refer to the diagram at the right formeasurements. Tighten with a 5mm hexwrench to 65in-lb (fig 45b).

Spray isopropyl alcohol onto entire forkand wipe with a clean rag.

45a 45b

Frame/UpperTube

Bumper

SHORT UPPER CROWN152mm (+/-2mm)

TALL UPPER CROWN182mm (+/-2mm)

LOWER CROWN205mm (+/-2mm)

BOXXER CROWNHEIGHTS

B O X X E R M A X L E ( R I D E )

46. Disassemble Boxxer Ride Maxle and replace any damaged or worn parts. See diagram for orientation of parts.

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Spring

Nut Wedge

Nut

Spring

Lever Wedge

Lever/Axle AssemblyAxle

Nut Wedge

Nut

Axle Wedge

Axle Nut

BOXXER RIDE MAXLE BOXXER DH MAXLE



O I L

A I R P R E S S U R E S E T T I N G S - B O X X E R W O R L D C U P ( S O L O A I R )

RIDER WEIGHT POSITIVE AIR PRESSURE

<120 lb (55 kg) 100-110 psi120-140 lb (55- 63 kg) 110-120 psi140-160 lb (63-72 kg) 120-140 psi160-180 lb (72-81 kg) 140-160 psi180-200 lb (81-91 kg) 160-180 psi

>200 lb (91 kg) 180+ psi

RIGHT LEG

RIGHT LEG TOP(VOLUME) OIL WEIGHT

RIGHT LEG BOTTOM(VOLUME) OIL WEIGHT

BOXXER RIDE 150cc/ml 5wt 15cc/ml 15wt (stock)BOXXER RACE/TEAM 150cc/ml 5wt 15cc/ml 15wt (stock)BOXXER WORLD CUP 150cc/ml 5wt 15cc/ml 15wt (stock)

LEFT LEG

LEFT LEG TOP (VOLUME) OIL WEIGHTLEFT LEG BOTTOM

(VOLUME) OIL WEIGHT

BOXXER RIDE 50 cc/ml 15wt x xBOXXER RACE/TEAM 30 cc/ml 15wt x xBOXXER WORLD CUP 3 - 5 cc/ml 15wt 15cc/ml 15wt (stock)

S P R I N G S - B O X X E R R I D E ( U - T U R N )

* RIDER WEIGHT SPRING COLOR SPRING ASSEMBLY PART #

>150 lb (68 kg) Yellow 11.4309.240.000

150-175 lb (68-79 kg) Yellow/Red 11.4309.241.000

175-200 lb (79-91 kg) Red (Std) 11.4309.242.000

>200 lb (91 kg) Black 11.4309.870.000

S P R I N G S - B O X X E R R A C E / T E A M ( S I N G L E - S I D E D )

* RIDER WEIGHT SPRING COLOR SPRING ASSEMBLY PART #

<120 lb (55 kg) White 11.4311.490.000

120-150 lb (55-68 kg) Silver 11.4311.489.000

150-180 lb (68-82kg) Yellow 11.4311.488.000

>180 lb (82 kg) Red 11.4311.487.000

PN 95.4311.775.000, REV. A 13


T R O U B L E - S H O O T I N G

AIR LOSS (WORLD CUP)• Inspect air piston o-rings and replace if necessary.• To avoid air loss, deflate positive air chamber, remove air top cap every month and pour 3 to 5cc 15wt suspension oil into air

spring chamber. This keeps air seal lubricated.• Maximum air pressure may have been exceeded. Do not exceed recommended air pressures!

LOSS OF/OR VARIANCE IN DAMPING• Inspect all damper o-rings. Replace and grease.• Inspect damper oil volume. Remove damper top cap/compression damper assembly. Using a thin ruler, measure the oil height.

Correct height is five inches from the top of the upper tube (when fork is set at 140mm travel). Add or remove oil as needed.

COMPRESSION STROKE NOT SMOOTH• Remove both shaft bolts. Pull lowers down about an inch. Allow oil to drain. Refill fork with fresh suspension oil (follow the

steps in this guide).• Lubricate upper tubes near dust seals. Push down on fork a few times. Wipe away excess lubricant.

BUSHING PLAY• Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced after approximately 100-200 riding

hours, depending your riding style, condition, riding time and body weight. If you ride a lot, check those bushings!

SEE THE 'BUSHING INSTALLATION' GUIDE AT WWW.ROCKSHOX.COM FOR PROCEDURES.

OIL LOSS• Inspect the air piston o-rings for air bypass. Air pressure can force oil out of the left dust seal.• Inspect your shaft bolt crush washers. Replace if worn or damaged.• Inspect your top cap o-rings. Replace if torn or knicked.

Documents

Boxxer 2006 Service Guide