2015-Present BoXXer World Cup
Contents
1. Manufacturing date code after 26T5 Place a 2 mm open end wrench on the wrench flats of the cartridge tube Place a 23 mm open end wrench on the damper seal head Holding the cartridge tube in place turn the damper seal head counter clockwise to loosen and remove the rebound assembly NOTICE Forks with a manufacturing date code after 26T5 have the most recent performance upgrades and it is not necessary to replace the damper components unless they are damaged or worn Remove the cartridge tube from the bicycle stand and pour the 10 fluid into an oil pan Charger Damper Removal 26 emove the rebound damper seal head from the rebound damper 77 R th b dd I head f h b dd shaft NOTICE The damper seal head will be replaced in the Assembly and Bleed section Use your fingers to remove the glide ring from the rebound damper piston Use your fingers to install a new glide ring Set the rebound shaft assembly aside 13 Clamp the wrench flats of the coupler into a vice with the cartridge tube oriented upward NOTICE Do not clamp the cartridge tube in the vise ZZZZZ 74 Place a 2 mm open end wrench on the wrench flats of the cartridge tube Hold the coupler in place with the vise and turn the wrench counter clockwise to loosen and remove the cartridge tube from the coupler Set the cartridoe tube aside oS SS Charger Damper Removal 27 15 Remove the coupler bla2. 23 mm 9 10 Nem 80 90 in Ib 21mm Charger Damper Assembly and Bleed 41 10 Insert a 2 5 mm hex wrench into the rebound shaft until it contacts the rebound adjuster screw Turn the hex wrench counter clockwise until it stops The rebound adjuster is now in the open position 77 Remove the cartridge tube assembly from the bicycle stand turn it over and clamp the cartridge tube assembly in the bicycle stand so the rebound shaft is oriented downward Pull down on the rebound shaft 72 Pour RockShox 3wt suspension fluid into the cartridge tube until it is approximately half full Charger Damper Assembly and Bleed 42 13 Use the palm of your hand or a rag to cover the cartridge tube and cycle the damper rebound shaft a few times to help pre bleed air from the damper Pour additional RockShox 3wt suspension fluid into the cartridge tube until the fluid is level with the top of the tube Use your finger to remove any air bubbles from the surface of the fluid Pull the rebound damper shaft down slowly Failure to do so can result in fluid ejecting from the cartridge tube Wear safety glasses 74 Insert the low speed compression needle into the compression piston assembly Use your hand or a 2 5 mm hex wrench to turn the needle clockwise until it stops and then unthread it a 1 2 turn Wrap a rag around the cartridge tube Insert the compression piston assembly into the cartridge tube NOTICE Failure to unt
3. Retaining nut Bottomless Token 4 maximum Low speed compression adjuster Compression top cap Bladder and bladder sleeve Steerer tube Lower crown Low speed compression needle Upper tube Compression piston assembly Lower leg Coupler Cartridge tube je h Rebound damper piston assembly Lower leg K M L K S Rebound damper seal head Lower seal head a 2 Retaining ring Rebound damper shaft Crush washer retainer Bottom bolt Set screw NR Rebound adjuster knob a _ e 4 Air piston Inner o ring Seal head assembly Inner scraper seal Wavy washer Top out spacer Retaining ring Air shaft Crush washer Crush washer retainer lt Bottom bolt 2 BoXXer World Cup Exploded View 5 RockShox Suspension Service We recommend that you have your RockShox suspension serviced by a qualified bicycle mechanic Servicing RockShox suspension requires knowledge of suspension components as well as the special tools and fluids used for service For exploded diagram and part number information please refer to the Spare Parts Catalog available on our website at sram com service For order information please contact your local SRAM distributor or dealer Information contained in this publication is subject to change at any time without prior notice For the latest technical information please visit our website at sram com service Yo
4. Clamp the non drive side upper tube into a bicycle stand i i Non drive side 2 Remove the air valve cap from the top cap located on the non drive side fork leg Use a small hex wrench to depress the Schrader valve and release all air pressure from the air chamber Verify all pressure is removed from the fork before proceeding Failure to do so can result in injury and or damage to the fork Wear safety glasses Small hex wrench 4 Use a 5 mm hex wrench to loosen the non drive side bottom bolt 3 to 4 turns Loosen 3 to 4 turns Lower Leg Removal 10 5 Clamp the drive side upper tube into a bicycle stand Place an oil pan beneath the fork to catch any draining fluid Use a plastic mallet to firmly strike the non drive side bottom bolt to dislodge the air shaft from the lower leg Use a 5 mm hex wrench to remove the bottom bolt from the lower leg Plastic mallet Firmly pull the lower leg downward until fluid begins to drain Continue pulling downward to remove the lower leg from the non drive side upper tube If the lower leg does not slide off of the upper tube then the press fit of the shaft to the lower leg may still be engaged Reinstall the bottom bolt 2 to 3 turns and repeat steps 4 6 NOTICE Do not hit the fork arch with any tool when removing the lower leg as this could damage the lower leg Drive side Use a 2 5 mm hex wrench to loosen the set screw and remove the rebound ad
5. ring 5 Use large internal snap ring pliers to remove the retaining ring from the bottom of the upper tube Snap ring pliers Insert a long dowel into the top of the upper tube and push the lower seal head out the bottom of the upper tube Charger Damper Removal 24 7 Use your fingers to remove the outer o ring on the lower seal head Use a pick to pierce and remove the inner scraper seal from the lower seal head Use your fingers to install a new o ring and scraper seal on the lower seal head Scraper seal orientation Remove the drive side upper tube from the bicycle stand Clamp the cartridge tube into a bicycle stand with the rebound damper oriented upward Charger Damper Removal 25 Identify the manufacturing date code on your fork by looking on the back side of the crown The code is broken up into sections the first two numbers are the week the fork was made the letter is the factory code the following number is the last digit of the year and the rest of the code is the serial number for the fork Only the first four digits are important to this step 2 6 53038937 AD A E Week Factory Year Serial Number Manufacturing date code before 26T5 Place a 21 mm open end wrench on the wrench flats of the cartridge tube Place another 21 mm open end wrench on the damper seal head Holding the cartridge tube in place turn the damper seal head counter clockwise to loosen and remove the rebound assembly
6. shim is centered on the rest of the shim stack Off center hoop shim Centered shim stack Thread the piston bolt onto the compression damper shaft Use a torque wrench with a 10 mm socket to tighten the nut to 3 7 Nem 33 in Ib NOTICE Ensure the check shim is centered and not pinched by the piston bolt Remove the assembly from the vise Centered check shim Optional Compression Re tune 58 Charger Damper Assembly and Bleed NOTICE Use aluminum soft jaws to protect the Charger Damper assembly when using a vice Inspect each part for scratches Do not scratch any sealing surfaces when servicing your suspension Scratches can cause leaks When replacing seals and o rings use your fingers or a pick to remove the seal or o ring Spray isopropyl alcohol on each part and clean with a rag Apply SRAM Butter to the new seal or o ring Use your fingers to install the bladder onto the bladder sleeve Ensure that it is centered between the ends of the sleeve 2 Apply a liberal amount of SRAM Butter onto both ends of the bladder z Thread the compression top cap and coupler into either side of the bladder assembly Charger Damper Assembly and Bleed 39 4 Clamp the wrench flats on the coupler into a vise with the compression top cap facing up Use a torque wrench with a 24 mm socket to tighten the compression top cap to 4 5 5 5 Nem 40 50 in lb NOTICE Ensure the bladder does not twis
7. side lower leg NOTICE Do not exceed the recommended fluid volume per leg as this can V damage the fork Do not let fluid fill the rebound shaft RockShox Ow 30 suspension fluid Lower Leg Assembly 49 5 Slide the lower leg assembly along the upper tubes until it stops and the spring and damper shafts are visible through the lower leg bolt holes Use a rag to clean the outer surface of the lower leo d SS SS v Install a new crush washer retainer and crush washer on the Drive Side non drive side and drive side bottom bolts NOTICE Dirty or damaged crush washers can cause leaks Non drive Side Thread the black bottom bolt into the non drive side shaft of the 7 3 N m 65 in Ib lower leg Thread the silver bottom bolt into the drive side shaft of the lower leg Use a torque wrench with a 5 mm hex bit socket to tighten the bolts to 7 3 N m 65 in lb 7 3 N m 65 in lb EJ Install the rebound adjuster knob onto the drive side bottom bolt 11 N m 10 in Ib Use a torque wrench with a 2 5 mm hex bit socket to tighten the set screw to 1 1 N m 10 in Ib Make sure to hold the rebound adjuster knob in place during installation of the set screw to prevent damage to the bottom bolt Lower Leg Assembly 50 Refer to your pre service recorded settings to pressurize your air spring or use the air chart on the fork s lower leg and pressurize the air spring to the appropriate pressure fo
8. solo air seal head assembly into the upper tube enough to compress and remove the retaining ring Slide the retaining ring onto your finger and release the air spring shaft 6 Use your fingers to install tne bottom bolt in the air shaft Firmly pull on the bottom bolt to remove the air shaft assembly from the upper tube Unthread and remove the bottom bolt from the air shaft Air Spring Removal 17 7 Spray isopropyl alcohol on the inside and outside of the upper tube and clean it with a rag Wrap a rag around a long dowel and insert it into the upper tube to clean inside the upper tube Remove the top out spacer wavy washer and seal head assembly from the air shaft Spray isopropyl alcohol on the seal head assembly and air shaft and clean it with a rag Use your fingers or a pick to remove the outer seal head o rings Use a pick to pierce and remove the inner o ring and scraper seal Use your fingers to install the new o rings and scraper seal Air Spring Removal 18 Use your fingers or a pick to remove the air piston quad ring and backup rings Use your fingers to install a new quad ring and backup rings Air Spring Removal 19 Bottomless Token Installation Bottomless Tokens reduce the air volume in your fork to create oreater ramp at the end of the fork travel Add up to four tokens to maintain your BoXXer s bottomless feel For ordering information please contact your local SRAM distributor or d
9. used Save them so they can be reinstalled if you change your tune to Medium or Firm N W SN Shim thickness Firm Rebound Tune 1 1 Shim Size 1 1 Shim Outer Dimension Thickness mm mm O 0 2 16 Hoop 0 2 Piston Face Bottom of stack Optional Rebound Re tune SS 5 Install the shims on a small wrench or pick in the order of your Off center hoop shim desired tune Slide the shim stack onto the piston face Use your fingers to squeeze the stack and center the shims NOTICE Ensure the hoop shim is centered on the shim stack Centered shim stack Thread the main piston nut onto the rebound damper piston Use a torque wrench with a 10 mm socket to tighten the nut to 3 7 Nem 33 in lb NOTICE Ensure the check shim is centered and not pinched under the piston Remove the assembly from the vise Pinched check shim Centered check shim Optional Rebound Re tune 34 Optional Compression Re tune Clamp the compression piston shaft into a RockShox Rear Shock Vise Block NOTICE To prevent damage to the compression piston position the shaft in the vise so that the piston is clear of the vise block Use a 10 mm socket to remove the piston bolt U nt BS N soa iii Use a small wrench to remove the piston assembly from the compression damper shaft Set the shims on a rag in the order they came off of the piston OoOo
10. GEN OOOOOOOO04665 Rev C 2015 SRAM LLC SRAM LLC WARRANTY EXTENT OF LIMITED WARRANTY Except as otherwise set forth herein SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after original purchase This warranty only applies to the original owner and is not transferable Claims under this warranty must be made through the retailer where the bicycle or the SRAM component was purchased Original proof of purchase is required Except as described herein SRAM makes no other warranties guaranties or representations of any type express or implied and all warranties including any implied warranties of reasonable care merchantibility or fitness for a particular purpose are hereby disclaimed LOCAL LAW This warranty statement gives the customer specific legal rights The customer may also have other rights which vary from state to state USA from province to province Canada and from country to country elsewhere in the world To the extent that this warranty statement is inconsistent with the local law this warranty shall be deemed modified to be consistent with such law under such local law certain disclaimers and limitations of this warranty statement may apply to the customer For example some states in the United States of America as well as some governments outside of the United States including provinces in Canada may a Preclude the disclaimers and limitations of this w
11. Nem 44 lIb Tighten the top bolt to torque once more and then tighten the bottom to toraue again Repeat this tightening procedure for the bolts on the other side of the lower crown 5 Nem 44 in lb Use a torque wrench with a 4 mm hex bit socket to tighten the two upper crown pinch bolts to 5 Nem 44 in lb 5 Nem 44 in lb 7 27 5 fork Use a 2 5 mm hex wrench to install the brake hose in the hose brace on the fork arch 26 5 fork Use a cable tie to connect the brake hose to the fork arch Install the brake caliper according to the brake manufacturer s instructions Fork Installation 55 Position the front wheel in the lower leg dropouts so the hub is seated in the dropouts NOTICE Verify no parts interfere with the lower leg Consult your brake manufacturer s instructions if you need to adjust your disc brakes Install the threaded end of the Maxle Lite DH through the drive side of the hub until it engages the threads of the lower leg dropout Use a torque wrench with a 6 mm hex bit socket to tighten the drive side axle bolt to 5 7 Nem 50 in Ib 5 7 Nem 50 in lb Use a torque wrench with a 6 mm hex bit socket to tighten the non drive side axle bolt to 3 4 Nem 30 in lb 3 4 Nem 30 in Ib 7 Refer to your pre service recorded settings to adjust the rebound and compression settings on the fork Fork Installation 54 72 Spray isopropyl alcohol on the entire fork and clean it with a r
12. ag This concludes the service for RockShox BoXXer front suspension forks Fork Installation 55 This publication includes trademarks and registered trademarks of the following companies Loctite is a registered trademark of Henkel Corporation fF FIEER WWW Sram com We will revolutionize the relationship that our users have with SRAM products cultivating a bond between the rider and bicycle Our technical communication will be delivered in innovative and exciting ways with deliberation and accuracy that inspires loyalty and trust across the globe SRAM TechCom Vision Statement ASIAN HEADQUARTERS WORLD HEADQUARTERS EUROPEAN HEADQUARTERS SRAM Taiwan SRAM LLC SRAM Europe No 1598 8 Chung Shan Road 1OOO W Fulton Market 4th Floor Paasbosweg 14 16 Shen Kang Hsiang Taichung City Chicago Illinois 60607 3862ZS Nijkerk Taiwan R O C USA The Netherlands
13. arranty statement from limiting the statutory rights of the consumer e g United Kingdom b Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations For Australian customers This SRAM limited warranty is provided in Australia by SRAM LLC 1000 W Fulton Market 4th Floor Chicago IL 60607 USA To make a warranty claim please contact the retailer from whom you purchased this SRAM product Alternatively you may make a claim by contacting SRAM Australia 6 Marco Court Rowville 3178 Australia For valid claims SRAM will at its option either repair or replace your SRAM product Any expenses incurred in making the warranty claim are your responsibility The benefits given by this warranty are additional to other rights and remedies that you may have under laws relating to our products Our goods come with guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure LIMITATIONS OF LIABILITY To the extent allowed by local law except for the obligations specifically set forth in this warranty statement in no event shall SRAM or its third party suppliers be liable for direct indirect special incidental or consequ
14. atch any sealing surfaces when servicing your suspension Scratches can cause leaks When replacing seals and o rings use your fingers or a pick to remove the seal or o ring Spray isopropyl alcohol on each part and clean with a rag Apply SRAM Butter to the new seal or o ring Clamp the non drive side upper tube into a bicycle stand Non drive side Use a small hex wrench to depress the Schrader valve and verify all air pressure is removed from the air chamber Verify all pressure is removed from the fork before proceedino Failure to do so can cause the top cap to eject forcefully from the upper tube which can result in injury Wear safety glasses Small hex wrench 3 Use a 24 mm socket to remove the top cap Spray isopropyl alcohol on the upper tube threads and clean the threads with a rag Solo Air Spring Service 16 4 Use your fingers or a pick to remove the top cap o ring Use your fingers to install a new o ring Use a flat head screwdriver to push the seal head tab under the retaining rino Snap ring pliers Place your finger over the end of the air spring shaft to prevent it from getting scratched while removing the retaining ring NOTICE Scratches on the air shaft will allow air to bypass the seal head into the lower leg resulting in reduced spring performance Place the tips of large internal snap ring pliers into the eyelets of the retaining ring Press firmly on the pliers to push the
15. bound Re tune Clamp the bottom of the rebound damper shaft into a RockShox Rear Shock Vise Block NOTICE To prevent damage to the rebound damper shaft do not clamp the middle of the shaft in the vise jo Use a 10 mm socket to remove the piston nut Use your hand to stabilize the rebound damper shaft Z Use a small wrench or pick to slide the shims off of the rebound damper piston Set the shims on a rag in the order they came off of the piston mi pe oko Kokoro OO o Qo Optional Charger Damper Re tune 52 Use the chart below to layout the shim stack for your desired tune on your rebound damper piston Use a metric caliper to verify the shim outer diameter and shim thickness or print the page at 100 scale to arrange the shim stack using the outlines on the page All Charger Dampers in BoXXer ship with the Medium Damper Tune installed 100 mm Print this page at 100 scale and use the chart to layout your desired rebound tune Shim diameter Medium Rebound Tune Stock Tune 1 1 Shim Size 1 1 Shim Outer Dimension Thickness mm mm Soft Rebound Tune 1 1 Shim Size 1 1 Shim Outer Dimension Thickness mm mm 0 3 m o 0 1 o o 0 1 0 2 01 0 3 0 1 O 0 1 0 1 Piston Face Bottom of stack 16 Hoop 0 2 Piston Face Bottom of stack If using the soft tune 16 x 6 x 0 1 14 x 6 x O 1 and 16 x 14 x O 2 are not
16. cooO Oo o Optional Compression Re tune 55 Use the chart below to layout the shim stack for your desired tune on your compression piston Use a metric caliper to verify the shim outer diameter and shim thickness or print the page at 100 scale to arrange the shim stack using the outlines on the page All Charger Dampers in BoXXer ship with the Medium Damper Tune installed 100 mm Print this page at 100 scale and use the chart to layout your desired rebound tune Shim diameter Soft Compression Tune Medium CompressionTune Firm CompressionTune Stock Tune 1 1 Shim Size 1 1 Shim 1 1 Shim Size 1 1 Shim 1 1 Shim Size 1 1 Shim Outer Dimension Thickness Outer Dimension Thickness Outer Dimension Thickness mm mm mm mm mm mm 01 01 nej 0 15 03 03 0 15 0 3 0 3 s Z C3 3 os O lt 0 15 0 2 03 18 Hoop 0 5 18 Hoop 0 3 18 Hoop 0 3 Piston Face Bottom of stack Piston Face Bottom of stack POtatnorhat lt Boutborssodrstaektune 36 5 Apply a small amount of Loctite Threadlocker Red 2760 on the compression shaft threads NOTICE Do not allow the Loctite to come in contact with the shims Install the shims on a small wrench in the order of your desired tune Install the piston assembly onto the compression damper shaft Use your fingers to squeeze the shim stack and center the shims NOTICE Ensure the hoop
17. dder and compression top cap assembly from the vise While holding it over an oil pan use needle nose pliers to remove the compression piston assembly Fluid will spill from the coupler Needle nose pliers P h id i i I our the fluid into an oil pan 77 Clamp the wrench flats of the coupler into a vice with the compression top cap oriented upward Use a 6 mm socket to remove the retaining nut from the compression top cap Use needle nose pliers to remove the low speed compression adjuster from the compression top cap Needle nose pliers Charger Damper Removal 28 19 Use your fingers or a pick to remove the o ring on the low speed compression adjuster Use your fingers to install a new o ring Use your fingers or a pick to remove the o ring from the compression piston Use your fingers to install a new o ring 21 Use your fingers or a 2 5 mm hex wrench to remove the low speed compression needle 2 Use your fingers or a pick to remove the o ring from the low speed compression needle Use your fingers to install a new o ring Charger Damper Removal 29 23 Use a 24 mm socket to loosen and remove either the coupler or the compression top cap from the bladder whichever loosens first Remove the assembly from the vise Clamp a 5 8 hex bit socket into a vise If the compression top cap came off in step 24 set the bladder on the hex bit socket with the coupler oriented upward Use a 25 mm open
18. ealer Please refer to the Spare Parts Catalog available on our website at sram com service for further information Use an 8 mm hex wrench to thread up to four Bottomless Tokens onto the bottom of the top cap to 1 1 2 3 Nem 10 20 in b 1 1 2 3 Nem 10 20 in lb Bottomless Token Installation 20 Air Spring Installation Apply a liberal amount of SRAM Butter to the inner o rings and scraper seal Install the seal head assembly wavy washer and top out spacer onto the air shaft 2 Apply a liberal amount of SRAM Butter to the air piston and seal head Firmly push the air shaft and seal head assembly into the bottom of the upper tube while gently rocking the air shaft side to side Install the wavy washer and top out spacer inside the upper tube Air Spring Installation 21 Use your finger to push the air shaft in to prevent it from getting scratched while installing the retaining ring NOTICE Scratches on the air shaft will allow air to bypass the seal head into the lower leg resulting in reduced spring performance Place the tips of large internal snap ring pliers into the eyelets of the retaining ring and install the retaining ring into the groove The tab of the seal head should be positioned between the retaining ring eyelets Check that the retaining ring is properly seated in the retaining ring groove by using the snap ring pliers to rotate the retaining ring and seal head back and forth a few tim
19. end wrench to remove the coupler If the coupler came off in step 24 set the bladder on the hex bit socket with the compression top cap oriented upward Use a 24 mm socket wrench to remove the compression top cap Remove the assembly from the vise To remove the top cap To remove the coupler Charger Damper Removal 30 25 Use a pick or your fingers to remove the o ring inside the coupler Use your fingers to install a new o ring Use your fingers to remove the bladder from the bladder sleeve Inspect it for tears or cracks If there are any tears or cracks replace the bladder Spray isopropyl alcohol on the bladder and bladder sleeve and clean them with a rag Charger Damper Removal 31 Optional Charger Damper Re tune The Charger Damper in BoXXer comes with additional shims installed on the piston to allow the rider to modify the compression and or rebound tunes If your rebound setting is one or two clicks from open we recommend changing to a soft tune on the rebound If your compression setting is one or two clicks from open we recommend changing to a soft tune on the compression Conversely if your rebound setting is one or two clicks from closed we recommend changing to a firm tune on the rebound If your compression setting is one or two clicks from closed we recommend changing to a firm tune on the compression All Charger Dampers in BoXXer ship with the Medium Damper Tune installed Optional Re
20. ential damages LIMITATIONS OF WARRANTY This warranty does not apply to products that have been incorrectly installed and or adjusted according to the respective SRAM user manual The SRAM user manuals can be found online at sram com rockshox com avidbike com truvativ com or zipp com This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturers specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design This warranty does not apply when the product has been modified including but not limited to any attempt to open or repair any electronic and electronic related components including the motor controller battery packs wiring harnesses switches and chargers This warranty does not apply when the serial number or production code has been deliberately altered defaced or removed This warranty does not apply to normal wear and tear Wear and tear parts are subject to damage as a result of normal use failure to service according to SRAM recommendations and or riding or installation in conditions or applications other than recommended Wear and tear parts are identified as e Dust seals e Stripped threads bolts aluminium Handlebar grips e Transmission gears e Bushings titanium magnesium or steel e Shifter grips e Spokes Air sealing o rings e Brake sleeves e Jockey wheels e Free hubs Gl
21. er leg to twist in opposite directions compress toward each other or be pulled apart This will damage the lower leg 3 Use your fingers to remove and discard the foam rings inside the lower leg Soak the new foam rings in RockShox Ow 30 suspension fluid Lower Leg Seal Service 13 5 Spray isopropyl alcohol on the inside and outside of the lower leg Clean the outside of the lower leg with a rag Wrap a rag around a long dowel and insert it into each lower leg to clean the inside of the lower leg 6 Reinstall new foam rings on the top bushings in the lower leg Remove the wire spring from the new dust wiper seal and set it Z aside Insert the narrow end of a new dust wiper seal into the recessed end of the seal installation tool Lower Leg Seal Service 14 Hold the lower leg steady and use the seal installation tool to press the dust wiper seal evenly into the lower leg until the seal surface is flush with the top of the lower leg surface Reinstall the wire spring onto the dust wiper seal Repeat steps 7 8 and 9 for the other side of the lower leg NOTICE Only press the dust wiper seal into the lower leg until it is flush with the top surface of the lower leg Pressing the dust wiper seal past the top surface of the lower leg can damage the foam rings Lower Leg Seal Service 15 Solo Air Spring Service Air Spring Removal NOTICE Inspect each part for scratches Do not scr
22. es Retaining rings have a sharper edged side and a rounder edged side Installing retaining rings with the sharper edged side facing the tool will allow for easier installation and removal Insert the top cap into the top of the upper tube Use a torque wrench with a 24 mm socket to tighten the top cap to 7 3 Nem 65 in Ib Use a shock pump to pressurize the air spring to 30 psi 2 1 bar to push the air shaft out of the upper tube 30 psi 2 1 bar 7 3 Nem 65 in Ib Air Spring Installation 22 Charger Damper Service Charger Damper Removal NOTICE Use aluminum soft jaws to protect the Charger Damper assembly when using a vice Inspect each part for scratches Do not scratch any sealing surfaces when servicing your suspension Scratches can cause leaks When replacing seals and o rings use your fingers or a pick to remove the seal or o ring Spray isopropyl alcohol on each part and clean with a rag Apply SRAM Butter to the new seal or o ring Clamp the drive side upper tube into a bicycle stand Drive side 2 Use a 2 mm hex wrench to remove the knob retaining screw Remove the low speed compression adjuster knob 3 Use a 24 mm socket to loosen the compression top cap Remove the Charger Damper assembly from the upper tube Clean the upper tube threads with a rag Charger Damper Service 25 Use a pick or your fingers to remove the compression top cap o ring Install a new compression top cap o
23. ety glasses Charger Damper Assembly and Bleed 46 24 Install the low speed compression adjuster into the compression top cap by hand 25 Install the compression top cap retaining nut by hand Use a torque wrench with a 6 mm socket to tighten to 4 8 Nem 42 in lb Spray isopropyl alcohol on the Charger Damper assembly and clean it with a rag Insert the Charger Damper assembly into the top of the upper tube that has the BoXXer graphic printed on it Use a torque wrench with a 24 mm socket to tighten the compression top cap to 7 3 Nem 65 in b 24 mm 7 3 Nem 65 in Ib Charger Damper Assembly and Bleed 47 Apply SRAM Butter to the scraper in the lower seal head and install it onto the rebound shaft with the flat side of the lower seal head facing the upper tube Push the lower seal head into the bottom of the upper tube Push the rebound damper shaft into the upper tube to prevent it from getting scratched while installing the retaining ring Scratches on the rebound shaft will allow oil to bypass the seal head into the lower leg resulting in reduced performance Place the tips of large internal snap ring pliers into the eyelets of the retaining ring and install the retaining ring into the groove Check that the retaining ring is properly seated in the retaining ring groove by using the snap ring pliers to rotate the retaining ring and seal head back and forth a few times then firm
24. hread the needle a 1 2 turn will prevent the fork from performing properly 5 Spray isopropyl alcohol on the cartridge tube threads and clean the threads with a rag Spray isopropyl alcohol on the threads inside the coupler and clean the threads with a rag Charger Damper Assembly and Bleed 43 Apply a small amount of Loctite Threadlocker Blue 242 on the coupler threads NOTICE Do not allow the Loctite to come in contact with the o rings or bladder Loctite Threadlocker Blue 242 Thread the coupler onto the cartridge tube by hand je Place a torque wrench with a 25 mm crowfoot open end wrench on the wrench flats of the coupler Place a 21 mm open end wrench on the wrench flats on the damper cartridge tube While holding the damper cartridge tube in place tighten the coupler to 9 10 Nem 80 90 in lb Install the crowfoot onto the torque wrench at a 90 angle to the handle to ensure an accurate torque reading CHARGER 25 mm 9 10 Nem 80 90 in Ib 21 mm Pour RockShox 3wt suspension fluid into the compression top cap until it is approximately half full Charger Damper Assembly and Bleed 44 Use the palm of your hand or a rag to cover the compression top cap and cycle the rebound damper shaft a few times to help pre bleed air from the damper Pour additional RockShox 3wt suspension fluid into the compression top cap until the fluid is level with the top Use your finger to remo
25. ide rings e Brake pads Disc brake rotors e Aero bar pads e Rubber moving parts e Chains e Wheel braking surfaces e Corrosion e Foam rings e Sprockets e Bottomout pads Tools e Rear shock mounting hardware e Cassettes e Bearings e Motors and main seals e Shifter and brake cables inner e Bearing races e Batteries e Upper tubes stanchions and outer e Pawls Notwithstanding anything else set forth herein the battery pack and charger warranty does not include damage from power surges use of improper charger improper maintenance or such other misuse This warranty shall not cover damages caused by the use of parts of different manufacturers This warranty shall not cover damages caused by the use of parts that are not compatible suitable and or authorised by SRAM for use with SRAM components This warranty shall not cover damages resulting from commercial rental use TABLE OF CONTENTS POXXER WORLD CUP EXPLODED VIEW uuu u u uuu aaa AAEE EAR aE 5 ROCKSHOX SUSPENSION SERYICE uu x u 2 2 s Z uu uu E EaR a RA 6 PARTS AND TJOCS NEEDED SOR ER E ua ee er eee ce ee er rere eee eer et ee ere rrr 6 RECORD YOUR SET PING tacts eect o ee 7 GERVICE INTERVAL INFORMATIKAI ere een eo ne p ee 7 F G4 we TOROUE C FHAR uuu er ee o ee eer eer ree ren ere 7 zle AER ANE Ee o 7 FORK REMOVAL uuu usss m do u a na an n ae ln obe 8 LOWER LEG REMOVAL uu uuu uu musu akussssssussassupaspasasssius ssssapasssqaqasiswaqhaqastayusistusassqassnatussausstusszuqau
26. juster knob located at the bottom of the drive side lower leg Lower Leg Removal 11 Use a 5 mm hex wrench to loosen the drive side bottom bolt 3 to 4 turns Loosen 3 to 4 turns Place an oil pan beneath the fork to catch any draining fluid Use a plastic mallet to firmly strike the drive side bottom bolt to dislodge the rebound damper shaft from the lower leg Use a 5 mm hex wrench to remove the bottom bolt from the lower leg Do not dislodge the silver casting plug from the drive side lower leg Plastic mallet Firmly pull the lower leg downward until fluid begins to drain Continue pulling downward to remove the lower leg from the fork If the lower leg does not slide off of the upper tube then the oress fit of the shaft to the lower leg may still be engaged Reinstall the bottom bolt 2 to 3 turns and repeat steps 9 11 NOTICE Do not hit the fork arch with any tool when removing the lower leg as this could damage the fork Lower Leg Removal 12 Lower Leg Seal Service 7 Place the tip of a downhill tire lever underneath the lower lip of the dust wiper seal NOTICE If using a flat blade screwdriver make sure it has a round shaft A screwdriver with a square shaft will damage the fork leg 2 Stabilize the lower leg on a bench top or on the floor Press down on the tire lever handle to remove the dust wiper seal Repeat on the other side NOTICE Keep the lower leg assembly stable Do not allow the low
27. ly pull down on the rebound shaft Retaining rings have a sharper edged side and a rounder edged side Installing retaining rings with the sharper edged side facing the tool will allow for easier installation and removal Install the low speed compression adjuster knob and knob retaining screw Use a torque wrench with a 2 mm hex bit socket to tighten the screw to 1 1 5 Nem 8 13 in lb CHARGER 2mm 1 1 5 Nem 8 13 in Ib Charger Damper Assembly and Bleed 48 Lower Leg Assembly l 2 S NOTICE Spray isopropyl alcohol on the upper tubes and clean them with a rag Apply a liberal amount of SRAM Butter to the inner surfaces of the dust wiper seals Slide the upper tube with the Charger Damper into the drive side lower leg just enough to engage the upper bushing with the upper tube Slide the upper tube with the air spring into the non drive side lower leg just enough to engage the upper bushing with the upper tube Make sure both dust wiper seals slide onto the tubes without folding the outer lip of either seal Clamp the upper tube into a bicycle stand Position the fork at a slight angle with the lower leg bolt holes oriented upward Angle a syrinoe fitting in each lower leg bolt hole so the fluid will only contact the inside of the lower leo Inject 10 mL of RockShox Ow 30 suspension fluid into the drive side lower leg and 10 mL of RockShox Ow 30 suspension fluid into the non drive
28. qaspaspaqustustaytaq uqas aqusussca 10 LOWER LES SEAL SERVICE s iu anna T N dne pahandp htas k k sz Ada Ra R R E 15 SOLO AR SPRING SERVICE uu uu uuu uuu u Jnd uu sat asus end a ud r Sud Aeg dada ae E Ka saun dH a Nena Sub U acc 16 AIR PILI PEB T U uu R ERO ese REMO PE OE ONO S E OAO AAE EEE O S P OE OOM OLP S PO PE RY MOP PO POR 16 BOTTOMLESS TOKEN SAE A PON o u u u u u u aus assasi Qusaqa nika ETECO EEA ip eee 20 AIR SP po TINS VAT KIN O 21 GRIAR GEE DAMPER SERVICE uu u u E ons oct soon a la nao daN da NS sa Ado SNO eau ce acer asa S and aa 23 H eS PEP DAMPER eal A LZS sua ern ete eee E ner rr eee A E ete 23 OPTIONAL CHARGER DAMPERTIRE TUNE uuu uuu lll l lli ll l B o il ii iii a sla le n 32 OPTONAELREBOUND RET UNE stahu u eee EE uu a las kaa see ea reccomended cane 52 OPTIONALCONMPPEESSPONTETUND 22 a EE REET a E o ada A OE E E NA A AEGEE RAA AE A E EOE 55 CHARGER DAMPER ASSEMBLY AND BLEED iscrisse add ud cda S Has usa e la dod nani sena da hadi aa anoda 39 LOWER LEG ASSEMBLY uu uuu u uuu E E ks a nec 49 POR INSTALEA ON u nem te E E REA use deda c E S u Ven n dk ak 52 SAFETY FIRST We care about YOU Please always wear your safety glasses and protective gloves when servicing RockShox products Protect yourself Wear your safety gear BoXXer World Cup Exploded View Knob retaining screw _ Z Air valve cap Low speed compression VA Upper crown adjuster knob J N Air top cap
29. r your rider weight You may see a drop in the indicated air pressure on the pump gauge while filling the air spring this is normal Continue to fill the alr spring to the recommended air pressure Thread the air valve cap onto the top cap of the non drive side fork leg until it stops Spray isopropyl alcohol on the entire fork and clean it with a rag Lower Leg Assembly 51 Fork Installation Slide each upper tube through the lower crown Leave enough clearance between the upper tube and the upper crown to install the frame bumpers Use a 4 mm hex wrench to tighten one of the lower crown bolts to temporarily hold the tubes in place while you install the bumper 2 Spray isopropyl alcohol or water on the inner surfaces of each frame bumper and upper tube Reinstall the frame bumpers onto the upper tubes 3 Push and twist the upper tubes through the upper crown until both upper tubes extend past the top of the upper crown by an equal amount and at least 2 mm Measure the distance from the top of the upper tube to the top of the lower crown This distance must be 156 mm 2 mm 156 mm 2 mm 4 Align the BoXXer logo on the drive side upper tube with the RockShox logo on the lower leg Fork Installation 52 5 Use a torque wrench with a 4 mm hex bit socket to tighten the top bolt on the lower crown to 5 Nem 44 in lb Use a 4 mm hex bit socket to tighten the bottom bolt on the lower crown to 5
30. rom the drive side of the fork Pull the wheel down to remove it from the fork 4 27 5 forks Use a 2 5 mm hex wrench to remove the brake hose from the hose brace on the fork arch 26 forks Use a diagonal cutter to cut the cable tie holding the brake hose to the fork arch Remove the brake caliper according to the brake manufacturer s instructions Fork Removal 8 5 Use a 4 mm hex wrench to loosen the four lower crown and two upper crown pinch bolts clamping the upper tubes Do not loosen the steerer tube clamping bolt located on the upper crown Lower crown Slide the upper tubes down so they clear the upper crown Leave enough clearance between the upper tube and upper crown to remove the frame bumpers Use a 4 mm hex wrench to tighten one of the lower crown bolts to temporarily hold the tubes in place while you remove the frame bumpers Use your thumb to pry the thickest section of each frame bumper away from the upper tube Spray isopropyl alcohol or water between each bumper and upper tube Twist the frame bumpers back and forth until they are loose on the upper tubes Remove the frame bumpers from the upper tubes Use a 4 mm hex wrench to loosen the lower crown bolt Slide the tubes through the lower crown and remove the fork from the bicycle Spray isopropyl alcohol on the upper tubes and crown clamping surface and clean them with a rag Upper crown Fork Removal 9 Lower Leg Removal
31. t during installation If the bladder starts to twist unthread the compression top cap anq coupler and repeatsteps14 O3O gt R X wk 4 5 5 5 Nem 40 50 in lb 5 Spray isopropyl alcohol on the inside and outside of the cartridge tube Clean the outside of the cartridge tube with a rag Wrap a rag around a long dowel and insert it into the cartridge tube to clean inside the cartridge tube Clamp the cartridge tube into a bicycle stand with the threads at the bottom and the wrench flats at the top Charger Damper Assembly and Bleed 40 7 Install the new seal head assembly onto the rebound damper shaft with the threads oriented toward the piston NOTICE Failure to replace the old seal head with the new seal head may result in reduced fork performance New Seal Head Lightly clamp the cartridge tube into a bicycle stand with the threads at the bottom and wrench flats at the top Thread the rebound assembly into the cartridge tube by hand Place a torque wrench with a 23 mm crowfoot open end wrench on the wrench flats on the rebound damper seal head Place a 21 mm open end wrench on the wrench flats on the damper cartridge tube While holding the damper cartridge tube in place turn the rebound damper seal head clockwise to tighten the rebound assembly to 9 10 Nem 80 90 in Ib Install the crowfoot onto the torque wrench at a 90 angle to the handle to ensure an accurate torque reading
32. ur product s appearance may differ from the pictures contained in this publication Parts and Tools Needed for Safety glasses Nitrile gloves Apron Clean lint free rags Oil pan Isopropyl alcohol Bicycle stand Bench vise with aluminum soft jaws RockShox 3wt suspension fluid RockShox Ow 30 suspension fluid SRAM Butter suspension grease Shock pump 35 mm seal installation tool Downhill tire lever Plastic mallet Flat head screwdriver Diagonal cutter 26 fork Service Schrader valve core tool 2 21 23 and 25 mm open end wrenches 21 23 and 25 mm crowfoot wrenches 2 2 5 4 5 6 and 8 mm hex wrenches 5 8 2 2 5 4 5 and 6 mm hex bit sockets 6 10 15 and 24 mm socket wrenches Torque wrench Needle nose pliers Large internal snap ring pliers Pick Long plastic or wooden dowel RockShox syringe with Charger bleed tip Loctite Threadlocker Blue 242 Loctite Threadlocker Red 2760 Metric calipers for re tuning shim stacks RockShox Rear Shock Vise Block for re tuning shim stacks Cable tie 26 fork SAFETY INSTRUCTIONS Always wear nitrile gloves when working with suspension fluid and bicycle grease Place an oil pan on the floor underneath the area where you will be working on the fork RockShox Suspension Service 6 Record your Settings Use the charts below to record your BoXXer fork settings to return your fork to its pre service settings Record your service date to track ser
33. ve any air bubbles from the surface of the fluid Fluid may be ejected from the damper top cap assembly Wear safety glasses Fully extend the rebound damper shaft by pulling down on the rebound damper shaft 2 Fill the bleed syringe 1 3 full with 3wt suspension fluid and thread the syringe into the compression top cap Charger Damper Assembly and Bleed 45 Create a vacuum in the damper assembly by pulling up on the syringe handle and simultaneously pushing up on the rebound damper shaft This will force bubbles out of the damper assembly Pressurize the damper assembly by pushing down on the syringe handle and simultaneously pulling down on the rebound damper shaft Continue to hold down on the syringe handle and simultaneously cycle the rebound damper shaft a few times to purge bubbles The bladder will expand and contract This is normal Repeat pulling a vacuum and pressurizing the damper assembly until only very small bubbles emerge from the damper assembly 23 Make sure the rebound damper shaft is fully extended by pulling down on the shaft Push the syringe handle down and release it Allow the bladder to come to its natural resting position by waiting a few moments until the syringe stops filling Use a rag to cover the syringe tip and compression top cap bleed port then unthread and remove the syringe Fluid may be ejected from the damper top cap assembly if the bladder is not in its resting position Wear saf
34. vice intervals Service date helps you keep track of service intervals x Air pressure use a shock pump to determine how much air pressure is in your air spring Dual Crown height measure the distance from the top of the upper to tube to the top of the lower crown see figure in Step 1 Rebound setting count the number of clicks while turning the rebound adjuster fully counter clockwise Compression setting count the number of clicks while turning the compression adjuster fully counter clockwise Service Interval Information BoXXer Torque Chart pt RA O BoXXer Oil Volume Oil Weight Volume mL Drive side lower leg Ow 30 10 Non drive side lower leg Drive side upper tube Bleed varies Non drive side upper tube SRAM Butter Record your Settings 7 Fork Removal We recommend the following steps to remove your BoXXer fork from the bicycle Removing the fork from the bicycle provides easy access to internal components and is more convenient than working around a complete bicycle To assist you with post service assembly record the distance from the top of the upper tube to the top of the lower crown Vid Znam TEE PV JM Mo Bs amea we s ap p PSP p 100W POV bisa rarer er ar wiwa kana wana JD Mani o Use a 6 mm hex wrench to loosen the non drive side bolt of the Maxle Lite DH until detent clicks are no longer felt Use a 6 mm hex wrench to remove the Maxle Lite DH f
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