USER MANUAL
Contents
1. F Rebound Damper G Axle e J Lower Leg H Rebound Adjuster I Axle Pinch Bolts 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 DECEMBER 2004 3 ENGLISH SRAM CORPORATION BOXXER USER MANUAL SRAM CORPORATION BOXXER USER MANUAL ENGLISH BoxxER WoRLD CUP TEAM 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 A Steerer Tube Q Top Cap GI J4 P Upper Crown short shown Li 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 lo2. Rear shock mounting hardware Upper tubes stanchions and main seals Stripped threads bolts aluminium titanium magnesium or steel Brake pads Chains Sprockets Cassettes Shifter and brake cables inner and outer Handlebar grips Shifter grips Jockey wheels Disc brake rotors Tools Brake sleeves 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 SRAM CORPORATION DECEMBER 2004 11
3. 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 SRAM CORPORATION DECEMBER 2004 9 ENGLISH SRAM CORPORATION BOXXER USER MANUAL Torque Tightening Values Bottom shaft bolt 45 75 in Ib 5 1 8 5 Nm Top caps 55 75 in b 6 2 8 5 Nm Threaded rod plug compression 30 40 in Ib 3 5 4 5 Nm Axle clamp bolts 20 30 in Ib 2 3 3 4 Nm Axle bolt 40 60 in Ib 4 5 6 8 Nm Crown bolts 45 80 in Ib 5 1 9 0 Nm Judy XC GPS Metro Judy TT C Pilot C SERVICE INTERVALS Check top caps brake posts and shaft bolts for proper torque heck air pressure Remove lowers clean inspect bushings and change oil bath hange oil in Pure system hange oil in Motion Control System Clean and lubricate Air U Turn Dual Air Air Assist assembly lean and lubricate coil spring or coil U Turn spring assembly Clean and lubricate PopLoc cable and housing Reba SL Race SID Race SL Pike SL Race amp Team amp World Cup amp Team lean dirt and debris from upper tubes nspect upper tubes for scratches Lubricate dust seals tubes Check top caps brake posts and shaft bolts for proper torque heck air pressure Remove lowers clean inspect bushings and change oil bath Notes E Every ride Numeric values represent hours of riding time Increase service intervals based on rider weight aggressive
4. ssssovoktes 233330320030 peesaceses doesesshes thesccestteces 4900300008 poeoosesete 009033334 beteeccset 043300000 3332333432 023343 122112224 22222 EEIM 333313153443 settecseetee bkrttas Steccettes seeceeettee 4331305 4 2 22222 bogseenetd 1222221 1211112222 tte 2990070202941 pO F09998 29990990 9 00909402 571 thttesceceee sethtecceeseee 241114142401 22201 200222 besecceses UsEeR MANUAL esccesi 2222922 d seceettl eposoo00 00 I 40000909 04 BoxxER RIDE A Steerer Tue R U Turn Adjustment Q Top Cap Knob P Upper Crown short shown O Lower Crown B Coil Spring B C Upper Tube 4 y N Wiper Seal M Oil Seal AR F Rebound Damper K Topout Assembly J Lower Leg JA G Axle H Rebound Adjuster I Axle Pinch Bolts SRAM CORPORATION BOXXER USER MANUAL ENGLISH BoxxER RAcE SET AT 178MM A Steerer Tube gt short shown ae Co P Upper Crown O Lower Crown B Coil Spring C Upper Tube gt js D Topout Spring E All Travel Spacer set at 178mm N Wiper Seal M Oil Seal L All Travel Spacer set at 178mm K Topout Assembly
5. 178 mm of travel To determine the travel on your fork use the travel gradients on the upper tube Changing Travel Ride Only Turning the U turn adjuster knob counterclockwise increases travel From minimum travel there are approximately six turns to achieve maximum travel 178 mm Each turn increases or decreases the travel by 7 5 mm fig 2 IMPORTANT STOP TURNING THE U TURN ADJUSTER KNOB AFTER YOU VE REACH 178 MM OF TRAVEL MAXIMUM TRAVEL TURNING THE KNOB PAST THIS POINT MAY CAUSE DAMAGE TO THE U TURN FEATURE Spring Rate Increase 3 a o c o o o o 2 o aa o c x 133 140 5 148 155 5 163 170 5 178 U Turn Travel Adjustment mm Fig 2 Boxxer Ride Changing the Spring Rate Spring rate is the amount of force needed to compress a spring one inch Changing your fork s coil spring for a spring of a higher or lower rate will alter the overall feel of your fork Higher spring rates make the fork feel more stiff while lower spring rates make the fork more supple Contact your local RockShox dealer to order replacement springs NoTE WHEN DECREASING TRAVEL SEE U TURN TRAVEL ADJUST YOU INCREASE THE SPRING RATE MAINTENANCE 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 WE RECOMMEND THIS
6. LE 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 Note all upper crown pinch bolts and stem steerer pinch bolts must be loose to adjust headset properly Make sure that the minimum distance of exposed upper tube between the fork s dust wiper and bottom of lower crown is the same as the fork s maximum travel Fork Model Minimum Upper Tube Exposure World Cup Team 203 mm Race 203 mm 203 mm Race 178 mm 178 mm Ride 178 mm Note For BoxxER RIDE THE U TURN KNOB MUST BE TURNED FULL COUNTERCLOCKWISE UNTIL THE GRADIENT MARKED AS 178MM IS EXPOSED 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 en Keep in mind tire clearance as you choose tires Maximum size is 2 7 x 26 wide or 710 mm diameter installed Be sure to check this diameter whenever 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 clear
7. Ne D Topout Spring 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 F S Compression Damper 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 possible serious and or fatal injuries 6 Only mount cantilever type brakes to the existing brake posts Forks with J Lower Leg 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 i T High Speed not route the front brake cable and or cable housing through the stem or F Rebound Damper Compression Damper any other mounts or cable stops Do not use a front brake cable leverage device mounted to the brace T Observe all owner s manual instructions for care and service of this product Axle Pinch Bolts e 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 H Rebound Adjuster U Compression TO MEET THE CONSUMER PRODUCT SAFETY COMMISSION S CPSC Adjuster REQUIREMENTS FO
8. R BICYCLE STANDARDS IF THE FORK IS GOING TO BE USED ON PUBLIC ROADS AT ANY TIME 4 95 4309 223 000 REV D SRAM CORPORATION DECEMBER 2004 5 ENGLISH SRAM CORPORATION BOXXER USER MANUAL 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 length to clamp the stem refer to the stem manufacturer s instructions Install the upper crown when taking the steerer tube measurements If using a direct mount stem make sure the steerer is exposed 5mm above the upper crown Use a short upper crown for head tube and headset stack heights of less than 150 mm or a tall upper crown for stack heights up to 180mm 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 BICYC
9. ance exists between the top of the tire and the bottom of the crown Exceeding maximum tire 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 forks is designed as a high performance world class downhill and freeride fork Our Downhill forks Race Team and World Cup are factory tuned for a 73 to 83 kg 160 to 180 Ib rider The Boxxer Ride is factory tuned for a 68 to 79 kg 150 to 175 Ib rider These 6 95 4309 223 000 REv D SRAM CORPORATION BOXXER USER MANUAL ENGLISH forks can be 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 Race Team and World Cup 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 yellow is designed for the 160 180 lbs 72 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 o
10. ection indicated by the rebound speed decal The adjuster has a 90 degree range of adjustment 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 NOTE THIS ADJUSTER IS NOT INDEXED 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 fork to follow the contours of the trail maximizing stability traction and control NOTE THE 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 brake dive and fork sensitivity The adjuster is located in the lower left leg and is accessible with a 2 5mm hex key inserted through the hollow shaft bolt The adjuster has eight full turns of adjustment 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 prefe
11. ne or both legs you can tune the bike to your specific needs Below is a table 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 BoxxER DOWNHILL SPRING RATES 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 lb in BoxxER DOWNHILL SPRING RATE TUNING RATES BASED ON A DOWNHILL RACING APPLICATION Rate Rider Weight Fork Leg 1 Fork Leg 2 Extra Soft 20 Ib lt 45 kg lt 100 Ib White White Soft Extra Soft 25 Ib 45 to 54 kg 100 to 120 Ib White Silver Soft 30 Ib 54 to 63 kg 120 to 140 Ib Silver Silver Medium Soft 35 Ib 63 to 72 kg 140 to 160 Ib Silver Yellow Medium standard 40 Ib 73 to 82 kg 160 to 180 Ib Yellow Yellow Medium Firm 45 Ib 82 to 91 kg 180 to 200 Ib Yellow Red Firm 50 Ib 91 to 100 kg 200 to 220 Ib Red Red BoxxER RIDE SPRING RATE TUNING Color Rider Weight Yellow 57 to 68 kg 125 to 150 Ib Yellow Red 68 to 79 kg 150 to 175 Ib Red standard 79 to 91 kg 175 to 200 Ib Black 9 to 102 kg 200 to 225 Ib 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 te
12. rence and fork setup High Speed Note THIS ADJUSTER IS NOT INDEXED Compression Adjuster Nut Internal High Speed Compression Adjustment World Cup l and Team This adjuster controls high speed compression blow off while leaving your low speed compression adjustment virtually unchanged The high speed compression adjuster is located inside the left leg To adjust the high speed compression you must follow instructions available in the Boxxer Service Guide available on our website at www rockshox com With the assembly removed use a 5mm wrench turn the compression nut clockwise to increase high speed compression 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 Fg 1 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 8 95 4309 223 000 REv D SRAM CORPORATION BOXXER USER MANUAL ENGLISH U turn Travel Adjust Ride Only Boxxer Ride forks can be adjusted from 133 to
13. rer to enforce such disclaimers or limitations 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 supplies be liable for direct indirect special incidental or consequential damages Limitations of Warranty This warranty does not apply to products that have not been incorrectly installed and or adjusted according to the respective SRAM technical installation manual The SRAM installation manuals can be found online at www sram com or www rockshox com This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturets 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 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 Dust seals Bushings Air sealing o rings Glide rings Rubber moving parts Foam rings
14. riding style conditions inclement weather and racing Pilot Judy SL XC SL Boxxer Ride Race Team amp World Cup 10 95 4309 223 000 REv D SRAM CORPORATION BOXXER USER MANUAL ENGLISH SRAM CORPORATION WARRANTY Extent of Limited Warranty 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 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 warranty statement from limiting the statutory rights of the consumer e g United Kingdom b Otherwise restrict the ability of a manufactu
15. rrain Optimum sag is between 15 and 25 percent 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 The preload can be changed by adding or removing preload spacers into the main coil spring stack NOTE THERE SHOULD BE A MINIMUM OF 2MM OF PRELOAD ON EACH SPRING 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 SRAM CORPORATION DECEMBER 2004 7 ENGLISH SRAM CORPORATION BOxxER USER MANUAL 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 Re install top caps and torque to 55 to 75 in lb pONr Sai 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 dir
16. ss of oil collision or other activity bending or Td i O Lower Crown breaking the fork s components or parts and extended periods of non use j S Fork failure may not be visible Do not ride the bicycle if you notice 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 B Coil Spring injury may result Q Always use genuine RockShox parts Use of aftermarket replacement parts voids the warranty and could cause structural failure to the shock EN Structural failure could result in loss of control of the bicycle with possible C Upper Tube e 7 serious and or fatal injuries N Wiper Seal 5 Use extreme caution not to tilt the bicycle to either side when mounting the gy bicycle to a carrier by the fork drop outs front wheel removed The fork E M Oil Seal legs may suffer structural damage if the bicycle is tilted while the drop outs i raga are in the carrier Make sure the fork is securely fastened down with a D Topout 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 Spring can allow the bike s mass to side load the drop outs causing them to
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