03-04 Boxxer Service Guide_RevC.qxp
Contents
1. For exploded diagram and part number information refer to the Spare Parts Catalog available on our website at www rockshox com Contact your local distributor or visit the RockShox website at www rockshox com for ordering information Information contained in this publication is subject to change at anytime without prior notice For the latest technical information visit our website at www rockshox com Names used in this manual may be trademarks or registered trademarks of others SRAM Corporation December 2003 PN 95 4308 635 000 Rev C 2003 2004 BOXXER SERVICE GUIDE 2003 2004 Boxxer Service Guide TooL_s NEEDED Torque Wrench Plastic Faced Mallet 3 8 Ratchet Snap Ring Pliers Small Flat Blade Screwdriver Large Flat Blade Screwdriver 24mm Socket 32mm Socket 3 and 5mm Hex Wrench Adjustable Open End Wrench Dental Pick or Sharp Pick Safety Glasses Oil Pan Judy Butter RockShox 5wt oil NoTE THOROUGHLY READ THIS GUIDE BEFORE PERFORMING SERVICE ON YOUR PRODUCT NOTE WHAT KIND OF KITS PARTS YOU MAY NEED TO REPLACE REMOVING TOP CAPS AND COIL SPRINGS 1 Loosen the crown bolts and slide the upper and lower crown up to remove from the upper tubes 2 Remove top caps using a 24mm socket wrench 3 Compress the fork upper tubes into the lower legs and remove white spring spacers All Travel spacers from top of each spring Boxxer Race 7 travel configuration See fig 3a Boxxer Race For 62. TRAVEL CONFIGURATION THE SPRINGS ARE DIRECTLY UNDER THE TOP CAPS FIG 3B 4 Remove springs from upper tubes 100 SRAM Corporation 2003 2004 Boxxer SERVICE GUIDE 2003 2004 Boxxer Service Guide REMOVING OIL FROM THE FORK Invert the fork into a large oil pan Cycle compress the upper tubes until oil has drained from fork Note JUST UNDER THE SPRING IS A WHITE SPRING PERCH SPACER For BOXXER RACE THE SPRING PERCH IS ON BOTH SIDES FOR BOXXER TEAM WorLD Cup THE SPRING PERCH IS ON THE REBOUND SIDE ONLY THIS MAY SLIDE OUT OF THE FORK WHEN THE FORK IS INVERTED 6 Using a 5mm hex wrench unscrew both shaft bolts three turns Leave bolts in the shafts 7 With a mallet tap the shaft bolts to release the internal shafts from the lower legs After both shafts have been tapped free of the lower legs completely unthread and remove the shaft bolts Inspect the nylon crush washers and crush washer retainers Replace if necessary Note EARLY BOXXER RACE FORKS WERE ASSEMBLED WITH TWO WHITE CRUSH WASHERS ON THE REBOUND DAMPER SHAFT BOLT SIDE THE 03 BoxxXER RACE EXTERNAL HARDWARE KIT INCLUDES CRUSH WASHER CRUSH WASHER RETAINERS AND SHAFT BOLTS FOR BOTH PRODUCTION VERSIONS OF THE 03 BoxxeR RACE 8 Pull apart the lower leg from each upper tube over the oil pan Norte THERE MAY BE SOME OIL STILL INSIDE THE LOWER LEG IMPORTANT THE INITIAL VERSION OF THE 03 BOoxxER RACE FORK INCL
3. UDED BRAKE BOSS HOLES IN THE LOWER LEG ASSEMBLY IF YOUR FORK HAS BRAKE BOSSES THE FOLLOWING KITS MUST BE USED TO SERVICE THE INTERNALS THESE KITS ARE SPECIFIC TO BOSSED LOWER LEGS e 11 4307 311 002 03 Boxxer Race HC2 Rebound Damper Assy Boss Lower Leg e 11 4307 663 000 03 Boxxer Race Compression Rod Kit Boss Lower Leg e 11 4307 664 000 03 Boxxer Race Shaft Bolt Kit Boss Lower Leg PN 95 4308 635 000 Rev C 101 2003 2004 Boxxer Service Guide 9 With snap ring pliers remove the rebound damper assembly and the neutral shaft assembly Race compression damper Team and World Cup BoxxER RACE BoxxER TEAM AND WoRLD Cup 2003 Boxxer Race 2003 04 Boxxer Race 2003 Boxxer WC Rebound 2003 04 Boxxer Team and WC Rebound Damper Neutral Shaft Damper Compression Damper REBOUND BASE VALVE ALL 2004 MODELS 10 Inspect the damper piston o ring or glide ring and replace if worn cut or torn 03 04 Boxxer Damper Service Kit 11 4308 333 000 Note BASE VALVE APPEARANCE AND CONFIGURATION MAY VARY 11 Inspect the rebound damper adjuster window for proper function with the rebound adjuster or 3mm hex key The window should open and close smoothly If the window does not open and close smoothly replace HC2 rebound damper assembly Travel Configuration Travel Configuration inch Boxxer Race T inch Boxxer Race A a 1 1 e 10a Q Damper Window O 10b Ribaund Mewbral Bo
4. ft bolts into the bottom of the lower legs using a 5mm hex wrench Torque shaft bolts to 60 in lbs BoxXER RACE INSTALLING THE SPRINGS AND OIL 25 Clamp the right upper tube into a fork stand 26 Pour 190cc ml of 5wt oil into the top of the right rebound damper upper tube Pour 190cc ml of 5wt oil into the top of the left neutral shaft upper tube Cycle the upper tubes slowly five or six times to circulate the oil through the damper circuits 27 Pull lower leg assembly down to full extended position 28 Insert the spring perch spacers into each upper tube so they rest into the neutral shaft and rebound damper assemblies To insert drop each spring perch narrow end down into the top of the upper tube figure 30a and b 29 Insert each coil spring adding preload spacers as needed 30 7 inch Travel Only Insert the All Travel spring spacer white on the top of the coil spring one on each side In the 6 inch travel setting the All Travel spacer will be located on the rebound and neutral shaft assemblies See fig 30b for correct spacer orientation 31 Install each top cap with a 24mm socket wrench and torque to 60 in lbs 32 Install the lower crown steerer tube assembly and upper crown Torque crown bolts to 65 in lbs 33 Wipe the fork clean BoxxER TEAM AND WORLD Cup INSTALLING THE SPRINGS AND OIL 34 Clamp the right upper tube into a fork stand 35 Pour 190cc ml of 5wt oil into the top of the right rebound dam
5. g Pull un snap to remove the spring cap Snap the white All Travel spring spacer onto the bottom of the top out spring aan Slide the base valve assembly onto the rebound damper shaft and rest just under the All Travel spacer e Install damper and base valve assembly into upper tube Neutral Shaft Left Side 43b a Remove the neutral base plate assembly from the neutral shaft b Remove the small black spring cap from the top of the top out spring Set this aside in your tool box It is not used in the fork in 6 inch travel setting c Snap the white spring spacer onto the gold top out spring on the neutral base plate assembly d Slide the neutral base plate assembly white all travel spacer first onto neutral shaft White all travel spacer should be just under the neutral shaft head e Install neutral shaft and base plate assembly into bottom of upper tube and secure with snap ring 43a 43b 106 SRAM Corporation 2003 2004 Boxxer SERVICE GUIDE
6. nd damper piston o ring or glide ring Insert the HC2 rebound damper assembly into the bottom of the right rider s right upper tube BoxxXeER Race BEFORE INSTALLING THE REBOUND DAMPER ASSEMBLY SEE PAGES 1 AND 8 FOR ALL TRAVEL CONFIGURATIONS 19 Slide the rebound base valve assembly over the rebound damper shaft and into upper tube Secure with a snap ring 104 SRAM Corporation 2003 2004 Boxxer SERVICE GUIDE 2003 2004 Boxxer Service Guide 20 Race Insert neutral shaft upper tube adapter sleeve and base plate assembly into left upper tube and fix with snap ring fig 20a 6 inch shown For Boxxer race All Travel configuration see figs 43a and 43b Team World Cup Insert compression damper and base plate assembly into left upper tube and fix with snap ring fig 20b INSTALLING THE LOWER LEGS 21 Using Judy Butter lubricate the inside of the dust wiper seals and main oil seals 22 Slide the lower leg assembly over the damper shafts and onto the upper tubes Make sure the dust wiper seals do not roll over when engaging the upper tubes 23 Install new crush washers if damaged into the crush washer retainers Boxxer Race may use two crush washers on the rebound damper shaft bolt Be sure to note the number of crush washers befor dissassembling and make sure you install it with the same number that they came off with 24 Slide crush washer retainer with crush washers onto the shaft bolts Install the sha
7. per upper tube Pour 190cc ml of 10wt oil into the top of the left upper tube Compression Damper Cycle the upper tubes slowly five or six times to circulate the oil through the damper circuits 36 Pull lower leg assembly down to fully extended position 37 Insert the spring perch spacer into the right upper tube so it rests onto the rebound damper assembly To insert just drop perch into top of upper tube PN 95 4308 635 000 Rev C 6 inch Boxxer Race 0b i 7 inch Boxxer Race 105 2003 2004 Boxxer Service Guide narrow end down 38 Insert each coil spring Insert the small white spring spacer on top of the right side spring Insert the longer spring spacer on top of the left side spring See fig 38 for correct parts orientation 38 Install each top cap with a 24mm socket tool and torque to 60 in lbs 39 Torque crown bolts to 65 in lbs 40 Wipe the fork clean Boxxer Race All Travel Configuration 7 inch 41 An All Travel spring spacer should be located on top of each spring and just under each top cap fig 30b See fig 43a for damper base plate assembly parts configuration Boxxer Race Six Inch Travel Configuration 42 The spring is located just under each top cap fig 30a 43 Rebound Damper Right Side fig 43a a Remove base valve assembly from rebound damper shaft b Remove the small black spring cap from the bottom of the top out sprin
8. ring from the end plug and replace it with a new o ring 11 4304 700 000 Re install the compression valve assembly into the compression damper rod TUNING TIP HIGH SPEED COMPRESSION DAMPING ADJUSTMENT High speed compression adjustment can alter the rate at which your Boxxer compresses at high shaft speeds High speed compression results from large hits and drops as well as high speed consecutive obstacles Depending on your preference the terrain and your riding style adjustments may be made to control the rate of compression stroke With the internal compression valve assembly removed from the compression damper shaft you may make adjustments as follows e To increase the amount of high speed compression slower compression at high shaft speeds use an open end adjustable wrench on the high speed preload nut and insert a 2 5 mm hex wrench 3mm hex for 1998 2002 into the threaded shaft end Turn the high speed preload nut clockwise Two full turns will make a noticeable difference in high speed compression fig A and B e To decrease the amount of high speed compression faster compression at high shaft speeds turn the high speed preload nut counterclockwise Two full turns will make a noticeable difference in high speed compression fig A and C wi SS REBOUND AND COMPRESSION DAMPER NEUTRAL SHAFT INSTALLATION 18 Add a light coating of 5wt oil to the rebou
9. xxer Team and World Cup Damper Shaft intr rE Rebound and Compression Dampers 102 SRAM Corporation 2003 2004 Boxxer SERVICE GUIDE 2003 2004 Boxxer Service Guide SERVICING THE SEALS 12 Use a large sharp flat blade screwdriver to gently pry the dust wiper seals from the lower leg Note 03 04 BoxxER FORKS DO NOT USE THE SNAP RING AND FLAT WASHER IN THE SEALING SYSTEM 13 With the large sharp flat blade screwdriver remove the main oil seals from the lower leg Clean the area of the lower leg with a rag 14 Lubricate the new main oil seals with a light coating of Judy Butter Then place a1 1 4 32mm socket tool on top of the seal Firmly press on the socket with the palm of your hand to install the oil seal Ensure the seal is completely seated inside the lower leg 15 Lubricate the inside of the new dust wiper seals and press them firmly into the lower leg by hand Ensure they fit flush with the top of the lower leg PN 95 4308 635 000 Rev C 12 103 2003 2004 Boxxer Service Guide TEAM AND Wor Lp Cup Forks ONLY SERVICING THE COMPRESSION DAMPER 16 Clamp the compression damper rod into a soft jaw alum vice clamp Remove the compression damper end plug from the compression rod assembly using a flat adjustable wrench 17 Remove the compression valve assembly from the compression damper rod Using a small flat blade screwdriver remove the large o
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