User Manual - BoXXer
Contents
1. BOX XER SRAM Corporation 2004 Boxxer User MANUAL ENGLISH Steerer Tube Gabelschaftrohr Potencia tubo de direcci n Tube pivot Cannotto di sterzo RATITO Fa Stuurbuis Coluna de direc o Fork Stop Anschlag f r Gabel Tope de la horquilla Arr t de fourche Arresto forcella TAO Aby7 Voorvork stop Stop da forqueta Upper Tube Oberes Rohr Tubo superior Tube sup rieur Stelo FIN Pa Bovenbuis Tubo superior Conjunto de bra o inferior Through axle Shaft Hole Orificio para el eje pasante Trou pour la tige de l axe transversal Durch Wellenbohrung Foro perno passante MELIA RAIL Asopening Orificio de pist o para atravessamento do eixo Top Cap Obere Abdeckkappe Tapa superior Capuchon Sup rieur Tappo superiore Ky 7 w 71 h Protec es superiores Upper Crown Obere Gabelkopf Corona superior Couronne sup rieure Piastra superiore PES DD Bovenkroon Coroa superior Lower Crown Unterer Gabelkopf Corona inferior Couronne inferieure Piastra inferiore Ondefkroon 7 2 22 Coroa inferior Lower Leg Assembly Conjunto del brazo inferior Assemblage des tubes inf rieurs Montage des unteren Gabelbeins Gruppo Monopezzo A 7 Ly TETU Montage onderste poot Suporte de trav o de disco Disk Brake Mount Soporte de freno de disco Monture du frein disque Befestigung f r Scheibenbremsen Supporto per freno a disco UND Ribas Installatie2. Riding 1 With a 24mm six point wrench remove the top caps Inspect the O ring and replace if necessary 2 Push the lower legs up and remove the spring stacks Note orientation of parts spring spring spacer and preload spacers Wipe clean 3 Place an oil pan underneath the fork Reinstall top caps invert the fork and remove the top caps Oil will pour out of the fork from the upper tubes 4 Cycle lower legs up and down to pump out remaining oil SRAM Corporation May 2003 7 6 ENGLISH SRAM Corporation 2004 Boxxer User MANUAL 5 Return the fork to an upright position Pour oil into the upper tubes while slowly cycling the lower fork leg up and down With the fork leg fully compressed without springs the oil level should be approximately 120 mm from the top of upper tube Approximately 195 cc of oil based on a dry fork is required for each fork leg IMPORTANT SETTING THE OIL ABOVE THIS SPECIFICATION MAY RESTRICT THE TRAVEL Completely extend the fork Install the spring stacks into the leg Install top cap and torque to 55 75 in Ib Torque Tightening Values Bottom shaft bolt 45 75 in lb 5 1 8 5 Nm Top caps 55 75 in lb 6 2 8 5 Nm Threaded rod plug compression 30 40 in lb 3 5 4 5 Nm Axle clamp bolts 20 30 in lb 2 3 3 4 Nm Axle bolt 40 60 in lb 4 5 6 8 Nm Crown bolts 45 80 in lb 5 1 9 0 Nm 95 4307 865 000 Rev B SRAM Corporation 2004 Boxxer User MANUAL ENGLISH WARRANTY SRAM Corporatio
3. common wear and tear parts which are subject to damage as a result of normal use failure to service product according to SRAM recommendations wet conditions racing use of disc brakes rider weight riding or installation in conditions or applications other than recommended Wear and Tear parts are identified as External dust seals bushings foam rings rubber moving parts such as air sealing o rings and glide rings stripped threaded shafts or bolts upper tubes stanchions rear shock mounting hardware and springs and fork drop outs Pioneer Support Program In the event parts are unavailable at the time of your repair at the option of SRAM or its authorized agent a replacement fork may be provided at a determined discount price Warranty Expenses Incurred The SRAM warranty policy excludes expenses incurred as a result of transportation of product from a SRAM dealer to SRAM or its authorized distributor labor performed by a SRAM dealer for removal of RockShox product or warranty repair work performed by a SRAM dealer Warranty work performed by a SRAM dealer is voluntary Warranty Repair Tf for any reason it should be necessary to have warranty work done return the product to a SRAM dealer In the USA dealers are required to call for a Return Authorization number RA prior to returning product Outside the USA dealers are required to call an authorized SRAM Distributor For more technical information visit our website a
4. into the main coil spring stack IMPORTANT NO MORE THAN EIGHT PRELOAD SPACERS SHOULD BE ADDED TO EITHER SIDE OF THE FORK MORE THAN EIGHT SPACERS CAN CAUSE THE SPRING TO BE DAMAGED IF YOU CAN NOT ACHIEVE THE PROPER PRELOAD YOU MAY NEED TO INSTALL SOFTER OR FIRMER COIL SPRINGS To change the preload Remove the top caps with a 24mm six point socket wrench Inspect the O rings for damage and replace if necessary Slightly compress the fork to get access to the preload spacers which sit on top of the spring stacks Add or remove preload spacers and or springs as necessary 5 Re install top caps and torque to 55 to 75 in Ib Penn External Rebound Adjustment Rebound damping controls the speed at which a fork returns to its full extension following compression Located at the bottom of the right fork leg is the rebound adjuster Using the 2 5mm hex key that came with your fork turn the adjuster in the direction indicated by the rebound speed decal Turning the adjuster toward the rabbit decreases rebound damping causing the fork to return to full extension faster Turning the adjuster in the direction indicated by the turtle increases rebound damping slowing the return of the fork to full extension Excessive rebound damping will cause the fork to pack up over successive bumps reducing travel and causing the fork to bottom out Set your fork to rebound as fast as possible without topping out or kicking back This allows your fo
5. er you change tires To do this remove the top caps and spring stack assemblies and compress the fork completely to make sure at least 5 mm of clearance exists between the top of the tire and the bottom of the crown Exceeding maximum tite size will cause the tire to jam against the crown when the fork is fully compressed The upper tubes must always be fully engaged in the crown with no more than 160 mm of exposed upper tube above the lower crown PERFORMANCE TUNING The Boxxer fork is designed as a high performance world class downhill fork Our forks are factory tuned for the 150 180 lbs 65 85 kg downhill racer and can be tuned to many different rider weights or riding styles You can tune this fork to benefit your needs by changing preload internal coil springs rebound damping and low or high speed compression damping Changing the Spring Rate If you are bottoming out too often or not using all the available travel then the overall spring rate should be changed The standard spring rate medium is designed for the 150 180 lbs 65 85 kg downhill racer You may change the overall spring rate by changing the main coil spring in each leg with one that is softer or firmer than the standard spring By changing the coil springs you alter the overall spring rate RockShox has designed nine spring configurations for the Boxxer By changing the springs in either one or both legs you can tune the bike to your specific needs Below is a table
6. gth to clamp the stem refer to the stem manufacturer s instructions Install the upper crown when taking the steerer tube measurements Use a short upper crown for head tube and headset stack heights of less than 160 mm or a tall upper crown for stack heights of more than 160 mm DO NOT ADD THREADS TO ROCKSHOX THREADLESS STEERERS THE STEERER TUBE CROWN ASSEMBLY IS A ONE TIME PRESS FIT REPLACEMENT OF THE ASSEMBLY MUST BE DONE TO CHANGE THE LENGTH DIAMETER OR HEADSET TYPE THREADED OR THREADLESS DO NOT REMOVE OR REPLACE THE STEERER TUBE THIS COULD RESULT IN THE LOSS OF CONTROL OF THE BICYCLE WITH POSSIBLE SERIOUS AND OR FATAL INJURIES 2 Install the headset crown race 29 9mm for 1 1 8 steerers firmly against the top of the fork crown Install the fork assembly on the bike Adjust the headset until you feel no play or drag Do not exceed 160 mm of exposed upper tube above the lower crown 3 Install the brakes according to the manufacturer s instructions and adjust brake pads properly Use the fork only with disc style brakes mounted through the provided mounting holes 4 Apply grease or anti seize to the axle Set the wheel in the recesses of the dropouts and insert the 20 mm axle Torque the axle bolt to a maximum of 40 to 60 in Ib Tighten axle clamp bolts to 20 to 30 in Ib max 5 Keep in mind tire clearance as you choose tires Maximum size is 2 4 x 26 wide or 696 mm diameter installed Be sure to check this diameter whenev
7. n warrants its products for a period of two years from original date of purchase to be free from defects in materials or workmanship SRAM or an authorized SRAM Agent must inspect all SRAM products If a product is found by SRAM or its authorized agent to be defective in materials or workmanship replacement or repair is at the option of SRAM This warranty is the sole and exclusive remedy SRAM shall not be held liable for any indirect special or consequential damages Exclusions of Warranty This warranty does not apply to products which have not been properly installed and adjusted according to RockShox installation instructions The warranty does not cover any product that has been subject to misuse or whose serial number has been altered defaced or removed This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturer s specifications or any other circumstances in which the product has been subjected to forces or loads beyond its design This warranty does not cover paint damage or modifications to the product Original proof of purchase is required Warranty repair replacement is only valid upon presentation of proof of purchase directly submitted to SRAM at the time of warranty evaluation Warranty repair or replacement is at the discretion of SRAM or its authorized agent upon physical product evaluation and proof of purchase This warranty does not include or cover
8. ression nut clockwise to increase high speed compression y damping and counterclockwise to decrease high speed compression damping Fig 1 Note the location of the low speed adjuster prior to making the high speed adjustment CAUTION ENSURE THE END OF THE COMPRESSION ADJUSTER ROD DOES NOT BECOME RECESSED INTO THE NUT THE NUT MAY BECOME DISENGAGED DURING OPERATION IF THE ADJUSTER IS NOT FULLY THREADED INTO THE NUT Changing Travel Race Only To change the travel of your fork you must perform a full service on your fork To obtain service information or instructions visit our website at www rockshox com or contact your local RockShox dealer or distributor Fig 1 MAINTENANCE 9 To maintain the high performance safety and long life of your fork periodic maintenance is required If you ride in extreme conditions maintenance should be performed more frequently ES e ES Maintenance 4 Clean dirt and debris from upper tubes x Check upper tubes for seratches sv Check top caps crown axle and shaft bolts for proper torque Y Inspect top cap o rings spring stacks change oil Banks Remove lower casting clean bushings and change oil ve Rebuild fork lvl WE RECOMMEND THIS SERVICE BE PERFORMED BY A QUALIFIED BICYCLE MECHANIC TO OBTAIN SERVICE INFORMATION OR INSTRUCTIONS VISIT OUR WEBSITE AT WWW ROCKSHOX COM OR CONTACT YOUR LOCAL ROCKSHOX DEALER OR DISTRIBUTOR After Twenty Five Hours of
9. rk to follow the contours of the trail maximizing stability traction and control NOTE ALL MODELS NOW INCLUDE A 2 5MM HEX KEY THIS HEX KEY MAY BE USED ON BOTH REBOUND AND COMPRESSION DAMPING ADJUSTMENTS FOR ON THE TRAIL USE THE HEX KEY MAY BE STORED BY CAREFULLY SLIDING IT IN BETWEEN THE UPPER TUBE AND RUBBER FORK STOP External Low Speed Compression Adjustment World Cup and Team Low speed compression damping controls pedal bob and fork sensitivity The adjuster is located in the lower left leg and is accessible with a 2 5mm Allen wrench inserted through the hollow shaft bolt Clockwise rotation of the adjuster results in more low speed compression damping Compression damping should be adjusted any time the springs or preload have been changed Proper compression damping depends on rider style weight preference and fork setup This adjuster is not indexed 6 95 4307 865 000 Rev B SRAM CORPORATION 2004 Boxxer USER MANUAL ENGLISH Internal High Speed Compression Adjustment World Cup and Team This adjuster controls high speed compression blow off while leaving your low speed compression adjustment virtually unchanged The high speed compression High Speed adjuster is located inside the left leg To adjust the high speed compression you Compression must follow instructions available in the Boxxer Service Guide available on our Adjuster Nut website at www rockshox com With the assembly removed use a 5mm wrench turn the comp
10. schijfremmen Rebound Adjuster P I Regulador de rebote Bouton de r glage du rebond Regolazione del ritorno UN gt KERBhEE Afstelling terugvering Regulador de recupera o Note YOUR FORK S APPEARANCE MAY VARY FROM THE ILLUSTRATIONS PHOTOS IN THIS MANUAL FOR THE LATEST INFORMATION ABOUT YOUR FORK VISIT OUR WEBSITE AT WWW ROCKSHOX COM SRAM Corporation May 2003 ENGLISH SRAM Corporation 2004 Boxxer User MANUAL Congratulations You have the best in suspension components on your bicycle This manual contains important information about the safe operation and maintenance of your fork To ensure that your RockShox fork performs properly we recommend that you have your fork installed by a qualified bicycle mechanic We also urge you to follow our recommendations to help make your riding experience more enjoyable and trouble free The fork on your bicycle is designed for use by a single or tandem bicycle on mountain trails and similar off road conditions Before riding the bicycle be sure the brakes are properly installed and adjusted If the brakes do not work properly the rider could suffer serious and or fatal injuries Your fork may fail in certain circumstances including but not limited to any condition that causes a loss of oil collision or other activity bending or breaking the fork s components or parts and extended periods of non use Fork failure may not be visible Do not ride the bicycle if you no
11. sible serious and or fatal injuries Only mount cantilever type brakes to the existing brake posts Forks with hangerless style braces are only designed for V style or hydraulic cantilever brakes Do not use any cantilever brake other than those intended by the brake manufacturer to work with a hangerless brace Do not route the front brake cable and or cable housing through the stem or any other mounts or cable stops Do not use a front brake cable leverage device mounted to the brace 7 Observe all owner s manual instructions for care and service of this product ROCKSHOX FORKS ARE DESIGNED FOR COMPETITIVE OFF ROAD RIDING AND DO NOT COME WITH THE PROPER REFLECTORS FOR ON ROAD USE YOUR DEALER SHOULD INSTALL PROPER REFLECTORS TO MEET THE CONSUMER PRODUCT SAFETY COMMISSION S CPSC REQUIREMENTS FOR BICYCLE STANDARDS IF THE FORK IS GOING TO BE USED ON PUBLIC ROADS AT ANY TIME 4 95 4307 865 000 Rev B SRAM Corporation 2004 Boxxer User MANUAL ENGLISH INSTALLATION It is extremely important that your RockShox fork is installed correctly by a qualified bicycle mechanic Improperly installed forks are extremely dangerous and can result in severe and or fatal injuries 1 Remove the existing fork from the bicycle and the crown race from the fork Measure the length of the fork steerer tube against the length of the RockShox steerer tube The RockShox steerer tube may need cutting to the proper length Make sure there is sufficient len
12. t www rockshox com Dealers outside the USA must contact their local distributor For a complete list of Authorized Distributors outside the USA visit www rockshox com SRAM Corporation May 2003 9
13. that breaks down the spring rates into rider weight ranges Use this table as a guide when choosing a different spring rate than the one provided in the fork SRAM Corporation May 2003 5 ENGLISH SRAM Corporation 2004 Boxxer USER MANUAL Color Spring Rate Ib in White Extra Soft 10 Ib in Silver Soft 15 Ib in Yellow Medium 20 Ib in Standard Red Firm 25 Ib in The Boxxer is built standard with two medium springs 20 Ib in Rate Rider Weight Fork Leg 1 Fork Leg 2 Soft 17 5 Ib 120 to 150 Ib 15 Ib in 20 Ib in Standard 20 Ib 150 to 180 Ib 20 Ib in 20 Ib in Firm 22 5 lb 180 to 210 Ib 20 Ib in 25 Ib in Setting Sag The Boxxer is designed to compress sag when you are sitting on the bike This sag allows the front wheel to stay in contact with the ground when braking and cornering over rough and uneven terrain Optimum sag is between 35 and 60 mm of total fork travel To measure sag install a zip tie on the upper tube so that it is flush against the seal sit on the bike in normal riding position then step off the bike and measure from the bottom of the zip tie to the top of the wiper This measurement is sag Changing the preload alters the sag and firmness of the initial fork movement A heavier more aggressive riders need more spring preload to maintain proper ride height and allow more of the fork s travel to be used during bump impact The preload can be changed by adding or removing preload spacers
14. tice bent or broken fork parts loss of oil sounds of excessive topping out or other indications of a possible fork failure such as loss of shock absorbing properties Instead take your bike to a qualified dealer for inspection and repair In the event of a fork failure damage to the bicycle or personal injury may result Always use genuine RockShox parts Use of aftermarket replacement parts voids the warranty and could cause structural failure to the shock Structural failure could result in loss of control of the bicycle with possible serious and or fatal injuries Use extreme caution not to tilt the bicycle to either side when mounting the bicycle to a carrier by the fork drop outs front wheel removed The fork legs may suffer structural damage if the bicycle is tilted while the drop outs are in the carrier Make sure the fork is securely fastened down with a quick release Make sure the rear wheel is fastened down when using ANY bike carrier that secures the fork s drop outs Not securing the rear can allow the bike s mass to side load the drop outs causing them to break or crack If the bicycle tilts or falls out of its carrier do not ride the bicycle until the fork is properly examined for possible damage Return the fork to your dealer for inspection or call RockShox if there is any question of possible damage See the International Distributor List A fork leg or drop out failure could result in loss of control of the bicycle with pos
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