GEN.0000000003185 REV A
13
Coil spring insTallaTion
make sure the base plate is installed on the
9.
spring shaft so that the small top out spring is
oriented toward the spring perch.
Insert the spring perch, spring shaft, and base
10.
plate assembly completely into the bottom of the
upper tube so that the retaining ring groove is
visible.
Use large internal snap ring pliers to secure the
11.
snap ring into the snap ring groove.
Make sure the snap ring is securely fastened
in the snap ring groove. You can check this by
using the snap ring pliers to rotate the snap ring
back and forth a couple of times, then firmly
pulling down on the damper shaft.
snap rings have two unique sides. one side
is flat edged, while the other is round edged.
installing snap rings with the flat edge facing
the tool will allow for easier removal and
installation.
Apply fresh grease liberally to the drop Stop
12.
bumper, spring and spring isolators. Identify the
larger diameter end of the of the coil spring and
push the drop Stop bumper into the coil from
that end.
Use a grease brush and apply a generous
13.
amount of grease to the entire length of the coil
spring. Install the coil spring, with the smaller
diameter end first, into the upper tube.
Use a ruler to measure the distance from the top
14.
of the coil spring to the top of the upper tube.
This distance should be at least 14 mm but not
more than 16 mm. If the measurement is greater
than 16 mm, add preload spacers until the
measurement falls between 14-16 mm (each
preload spacer is 2 mm thick).
if the distance measures greater than 16 mm and
is not corrected, the coil spring will experience
up/down play in the upper tube and the fork
will make a ‘knocking’ noise. if the distance is
less than 14 mm, the coil spring will bind in the
upper tube which can lead to damage of the coil
spring.
clean the top cap, then apply grease to the
15.
top cap threads and o-ring. Insert the top cap
into the upper tube/crown and hand thread into
upper tube. Be careful not to damage the top
cap o-ring upon installation. Use a 24 mm socket
wrench to tighten to 7.3 N
·
m (65 in-lb).
Re-install the bottom out adjuster cap onto the
16.
top cap. Tighten the pinch bolts to
.2-.6 N·m (2-5 in-lb).
bo
XX
er r2C2 TeChniCal Manual
9
10
12
11
13
14
15
16
spring
perCh
Top ouT
spring
base
plaTe
supporT
washer
wavY
washer
Summary of Contents for BoXXer R2C2
Page 1: ...2011 Technical Manual ...