2015-Present BoXXer RC
Contents
1. e Glide rings e Brake pads e 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 e 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 BOXXER ed Dae pd VIEW EE EE OE EE EE EE NE EE N EE EE 5 ROCKSHOX SUSPENSION SERVICE eee de ee ee de ee doe Os oe 6 PARTS AND TOOLS NEEDED FOK SERVIEE RE nr eer Re De cr errr Ge ee OE EG ee er Ee ee ea Ge ee be Ge ee rr 6 RECORDO 8 de SANG EA RE AE AO EE 7 SERVICE INTERVAL INFORMATION da ese nana E Es Gee ee IG eo E jac ee eke ree ed Oe ee ee Gee SE De ee ten 7 28 OE Me SAUK AE AN AE AE T CR a 7 P AER ANE ieke Is AE EA OE AE OR AE N OE AE ER ER 7 FORK REMOVAL cusin e el de vu ie Ge ewe da ee eu ee eens de dd We Ge GE Re eN ee de es de Ede n oe ee el2. BoXXer Oil Volume Ow 30 Non drive side lower leg 20 Non drive side upper tube Liquid O Ring PM600 military grease 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 2 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 from 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 t
3. Ci Melelelelelelelelef tra Ed 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 o
4. a 8 LOWER LEG REMOVAE EE EE EE EE N EE EE EE Ee 10 OPERA SERVICE TO EA EE EO EA AR EE EE 15 COIL SPRING SERVICE ee eed de ee oe WE EE sane RD Me Re RE RE ee we 15 CONS lI bie E E 3 AL sd ee ene ee ed ee Te ee ede ee Ee ee Dee ener ee ree eo ee es 15 CONS PERI IG IN RATIO ee eas ee EE nee nie ee ee Ee Ee EE ee ge ee oe EE 18 D AMPER SERVICE ie ss dor ce es dos du eie ee ei ee ee de ee ee ew de acts de ELKE ce de oe ec ew ee n cates ee dee ee id de ee ed ie ee 20 COMPRESSION DAMFER REMOVAL oi 20 REBOUND DAMPER REMOVA LC crrr ER E E 22 REBOUND DAMPER INSTALLATION see a reer ee ee GE EE 24 COMPRESSION DAMPER HINSTALLA TIG Ni ana eie De EE ae GP ere SE EE EE ee 26 LOWER CEG ASSEMBLY esse disse see sei we we de n vi ge Ede ed ee He Ge Gee ee ee ee ee ew ei Ge Wee ee se Rd ee ee ge ee ee Eie ie ee ie Di oe ee ie ee de 28 FORK INSTALLATION sessies sides eds osse sv RM Ee ow od dose Ede ve we Gee nee dune nos Vi de We we NG oe se do ee ee ed we ed EE WE EN ge 30 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 RC Exploded View Top cap Preload spacers 5 maximum Coil spring Low speed compression adjuster knob retaining screw Low speed compression Spring isolator adjuster knob Compression top cap Compression damper Upper crown Compression valve Steerer tube Lower crow
5. consequential 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 e Air sealing o rings e Brake sleeves e Jockey wheels e Free hubs
6. turns and repeat steps 2 4 NOTICE Do not hit the fork arch with any tool when removing the lower leg as this could damage the lower leg Lower Leg Removal 10 Clamp the drive side upper tube into a bicycle stand Drive side Remove the rebound adjuster knob located at the bottom of the drive side lower leg 7 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 Lower Leg Removal 11 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 7 10 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 the tip of a downhill tire lever underneath the lower lip of the dust r seal NOTICE If using a flat blade screwdriver make sure it has a round shaft A screwdriver with a square shaft will damag
7. 4 Align the BoXXer logo on the drive side upper tube with the RockShox logo on the lower leg Fork Installation 31 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 Nem 44 lb Tighten the top bolt to torque once more and then tighten the bottom to torque 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 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 7 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 Fork Installation 32 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 bi
8. ated 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 firmly pull down on the spring 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 Coil Spring Installation 19 4 Apply a generous amount of Liquid O Ring PM6OO military EER N grease to the coil spring Use a measuring device to Identify the end of the coil spring with a smaller diameter Install the smaller end of the coil spring into the top of the upper tube Use a measuring device to measure the distance from the top of the coil spring to the top of the upper tube The distance should be less than 16 mm Add up to five preload spacers to achieve a distance of 16 mm or your desired preload setting NOTICE Installing more than five preload spacers into the upper tube will cause damage to your fork 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 Nm 65 in Ib 7 3 Nem 65 in Ib Coil Spring Installation 20 Damper Service Compression Damper Removal NOTICE 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
9. bes and clean them with a rag 2 Apply a liberal amount of SRAM Butter to the inner surfaces of the lower oil seals and dust wiper seals Slide the upper tube with the damper into the drive side lower leg just enough to engage the upper bushing with the upper tube Slide the upper tube with the coil spring into the non drive side lower leg just enough to engage the upper bushing with the upper tube NOTICE 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 ata slight angle with the lower leg bolt holes oriented upward Angle a syringe fitting in each lower leg bolt hole so the fluid will only contact the inside of the lower leg Inject 10 mL of RockShox Ow 30 suspension fluid into the drive side lower leg and 20 mL of RockShox Ow 30 suspension fluid into the non drive side lower leg NOTICE Do not exceed the recommended fluid volume per leg as this can damage the fork Do not let fluid fill the rebound shaft NW DS 10 mL NDS 20 mL RockShox Ow 30 suspension fluid Lower Leg Assembly 29 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 leg SS S e Install anew crush washer retainer and crush washer on the non drive side and drive si
10. de bottom bolts NOTICE Dirty or damaged crush washers can cause leaks Drive side Non drive side 7 Thread the black bottom bolt into the non drive side shaft of the lower leg Thread the bottom bolt with the large washer crush washer retainer and crush washer 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 Nm 65 in lb EJ Install the rebound adjuster knob onto the drive side bottom bolt 9 Spray isopropyl alcohol on the entire fork and clean it with a rag Lower Leg Assembly 30 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 dr hr Qu me NEE EE EE Weeds 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 ey an rar ar ar er a ed PEL CT PEL 156 mm 2 mm
11. e by using the snap ring pliers to rotate the retaining ring and seal head back and forth a few times 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 Rebound Damper Installation 25 5 Pull the rebound damper shaft down to the fully extended position Rebound Damper Installation 26 Compression Damper Installation Pour 290 mL RockShox 5wt suspension fluid in the drive side upper tube Suspension fluid volume is critical Too much suspension fluid reduces available travel too little suspension fluid decreases damping performance 2 Use your fingers to turn the compression valve at the bottom of the compression damper to the open position Z Insert the compression damper into the upper tube Press down and rock side to side until the damper is installed 4 Use a torque wrench with a 24 mm socket to tighten the compression top cap to 7 3 Nem 65 in lb 7 3 Nem 65 in Ib Compression Damper Installation 27 5 Install the low speed compression adjuster knob and low speed 1 1 5 Nem 8 13 in Ib compression adjuster knob retaining screw K Use a torque wrench with a 2 mm hex bit socket to tighten the low compression adjuster knob retaining screw to 1 1 5 Nem 8 13 in lb Compression Damper Installation 28 Lower Leg Assembly Spray isopropyl alcohol on the upper tu
12. e the fork leg 2 W the lower leg on a bench top or on the floor Press down on the ever handle to remove the dust wiper seal Repeat on the other side NOTICE Keep the lower leg assembly stable Do not allow the lower leg to twist in opposite directions compress toward each other or be pulled apart This will damage the lower leg 3 ad fingers to remove and discard the foam rings inside the lower 4 the new foam rings in RockShox Ow 30 suspension fluid Lower Leg Seal Service 13 y isopropyl alcohol on the inside and outside of the lower leg Clean utside 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 new foam rings on the top bushings in the lower leg 7 ih the wire spring from the new dust wiper seal and set it aside EX the narrow end of a new dust wiper seal into the recessed end of eal installation tool Lower Leg Seal Service 14 the lower leg steady and use the seal installation tool to press the 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 t
13. f this warranty 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
14. handling Failure to do so may result in burns 6 Place the tips of large internal snap ring pliers into the eyelets of the retaining ring Press firmly on the pliers to push the base plate into the upper tube enough to compress and remove the retaining ring Slide the retaining ring onto your finger and release the spring shaft Snap ring pliers Remove the spring shaft assembly from the upper tube Coil Spring Removal 17 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 base plate assembly wavy washer and support washer from the spring shaft Spray isopropyl alcohol on the spring shaft spring perch and base plate assembly and clean them with a rag Coil Spring Removal 18 Coil Spring Installation Install a new support washer and a new wavy washer on the spring shaft so that the support washer is closest to the spring perch Install the base plate assembly onto the spring shaft so that the small top out spring is oriented toward the spring perch os Firmly push the spring shaft assembly into the bottom of the upper tube until the retaining ring groove is visible Z 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 se
15. he foam rings Lower Leg Seal Service 15 Coil Spring Service Coil Spring Removal NOTICE 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 grease to the new seal or o ring Clamp the non drive side upper tube into a bicycle stand Non drive side 2 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 Use your fingers or a pick to remove the top cap o ring Use your fingers to install a new o ring Coil Spring Service 16 Use your fingers to remove the preload spacer s Pull the coil spring from the upper tube Spray isopropyl alcohol on the preload spacer s coil spring and upper tube threads and clean them with a rag with approximately 50 mm of exposed coil at each end Verify the three isolators are evenly spaced along the coil spring Aa a To reposition an isolator thread it along the coil by hand Use a heat gun or hair dryer to shrink and secure the isolator in its position Gradually heat the isolator until it emits a vapor Do not get the heat gun or hair dryer too close to the isolator Failure to do so may result in a burn hole in the isolator Allow the isolator to cool down before
16. n Upper tube 7 Spring perch Lower leg Support washer Wavy washer Base plate assembly Rebound damper piston assembly Spring shaft assembly Seal head Retaining ring Retaining ring Crush washer Crush washer retainer Rebound damper shaft assembly Bottom bolt Crush washer Crush washer retainer Washer Bottom bolt Rebound adjuster knob BoXXer RC 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 Your 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 5wt suspension fluid RockShox Ow 30 suspension fluid SRAM Butter grease Liquid O Ring PM6OO military grease Shock pump 35 mm seal i
17. nstallation tool Diagonal cutter 26 Service Schrader valve core tool 2 2 5 4 5 and 6 mm hex wrenches 2 2 5 4 5 and 6 mm hex bit sockets 24 mm socket wrench Torque wrench Needle nose pliers Large internal snap ring pliers Pick Long plastic or wooden dowel Ruler Cable tie 26 Heat gun or hair dryer Downhill tire lever Plastic mallet Flat head screwdriver 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 BoXxXer fork settings to return your fork to its pre service settings Service date helps you keep track of service intervals 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 Clean dirt and debris from upper tubes Inspect upper tubes for scratches Check front suspension fasteners for proper torque Remove lowers clean inspect bushings and change oil bath 50 Clean and lubricate coil spring assembly BoXXer Torque Chart Part foot e S
18. o 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 Fork Removal 9 Lower Leg Removal 2 5 Clamp the non drive side upper tube into a bicycle stand i Non drive side Use a 5 mm hex wrench to loosen the non 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 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
19. t socket to tighten the non drive side axle bolt to 3 4 Nem 30 in lb 3 4 Nem 30 in lb Refer to your pre service recorded settings to adjust the rebound and compression settings on the fork Spray isopropyl alcohol on the entire fork and clean it with a rag This concludes the service for RockShox BoXxXer front suspension forks Fork Installation 33 LI dale WwWw 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 1000 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
20. 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 Use a 2 mm hex wrench to remove the low speed compression adjuster knob retaining screw Remove the low speed compression adjuster knob Z Use a 24 mm socket to loosen the compression top cap Remove the compression damper from the upper tube Clean the upper tube threads with a rag Damper Service 21 Use your fingers or a pick to remove the compression top cap o ring Install a new compression top cap o ring 5 Use your fingers or a pick to remove the compression damper piston o ring Install a new o ring Compression Damper Removal 22 Rebound Damper Removal Pour the suspension fluid into an oil pan Place your finger over the end of the rebound damper shaft to prevent it from getting scratched while removing the retaining ring NOTICE Scratches on the rebound damper shaft will allow oil to bypass the seal head into the lower leg resulting in reduced spring performance Use large internal snap ring pliers to remove the retaining ring from the bottom of the upper tube Remove the rebound damper shaft assembly from the upper tube Z 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
21. upper tube 4 Remove the seal head from the rebound damper shaft Spray isopropyl alcohol on the rebound damper shaft and clean it with a rag Rebound Damper Removal 23 5 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 Use your fingers to install the new o rings Use your fingers to remove the glide ring from the rebound damper piston Use your fingers to install a new glide ring Rebound Damper Removal 24 Rebound Damper Installation 7 Install the seal head on the rebound damper shaft with the narrow end facing the rebound damper piston 2 Insert the rebound damper piston into the bottom of the upper tube at an angle with the side opposite the glide ring split entering first Continue to angle and rotate the piston until the glide ring is in the upper tube 4 Use your finger to push the rebound seal head into the upper tube until the retaining ring groove is visible Push the rebound damper shaft into the upper tube to prevent it from getting scratched while installing the retaining ring NOTICE Scratches on the rebound damper 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 groov
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