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Rock Shox BoXXer R2C2, Technical Manual, Page: 15 / 21

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Rock Shox BoXXer R2C2 Technical Manual Download Page 15

GEN.0000000003185 REV A

15

bo

XX

er r2C2 TeChniCal Manual

daMper  insTallaTion

Spray isopropyl alcohol on the rebound damper 

10. 

shaft and clean it with a lint free rag.

Remove the glide ring from the rebound shaft 

11. 

assembly.  Apply grease to the new glide ring 

and install it.

Apply grease to the seal head inner o-ring.  Slide 

12. 

the rebound seal head onto the rebound damper 

shaft with the flat side of the seal head facing 

away from the piston. 

it is normal for some of the seal head bushing 

material to come off as the damper shaft is 

pushed through the seal head.  once the seal 

head is installed on the shaft, slide the seal 

head back and forth on the damper shaft three 

to four times to help clear bushing material from 

the seal head area.  remove any loose bushing 

material before re-installing the rebound 

assembly into the fork.

Spray isopropyl alcohol into the upper tube.  

13. 

wrap a clean, lint free rag around a dowel and 

clean the inside of the upper tube.

Apply grease to the seal head outer o-ring.  

14. 

Insert the rebound damper piston into the bottom 

of the upper tube at an angle, with the side of the 

glide ring opposite the split entering the upper 

tube first.  continue to angle and rotate until 

the glide ring is in the upper tube.  Push the seal 

head firmly into the bottom of the upper tube 

until the retaining ring groove is visible.

Push the rebound damper shaft into the seal 

15. 

head, leaving just enough shaft exposed to hold 

onto with your fingers.  Use large internal snap 

ring pliers to secure the snap ring into the snap 

ring groove. 

Snap rings have a sharper-edged side and a 

rounder-edged side.  Installing snap rings with 

the sharper-edged side facing the tool will allow 

for easier installation and removal. 

 

 

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.

13

11

14

15

pisTon

seal head

daMper shafT

Summary of Contents for BoXXer R2C2

Page 1: ...2011 Technical Manual ...

Page 2: ...5 service intervals 5 anatomy 6 FORK removal 8 lower leg removal 9 seal service 11 wiper oil seal removal 11 wiper oil seal installation 11 coil spring service 12 coil spring removal service 12 coil spring installation 13 damper service 14 damper removal service 14 damper installation 15 lower leg installation 17 FORK installation 19 ...

Page 3: ...r R2C2 technical manual TOOLS LOWER LEG REMOVAL OIL AND DUST seal Service DAMPER Service SPRING Service LOWER LEG INSTALLATION FORK WHEEL REMOVAL INSTALLATION SAFETY STARTING EQUIPMENT SAFETY GLASSES X X X X X X APRON X X X X X X RUBBER GLOVES X X X X X X CLEAN RAGS LINT FREE X X X X X X OIL PAN X X X X X X CLEAN WORK AREA X X X X X X BICYCLE STAND X X X X X X WRENCHES PLIERS 1 5 mm HEX X 4 mm HEX...

Page 4: ...perform the following Bottom out Count the number of clicks while turning the bottom out adjuster fully counter clockwise Rebound Count the number of clicks while turning the rebound adjuster fully counter clockwise Compression Count the number of clicks while turning the compression adjuster fully counter clockwise Spring preload will be determined later during spring system service MY SETTINGS s...

Page 5: ... 5 mm 7 3 N m 65 in lb Top caps 24 mm 7 3 N m 65 in lb service intervals The following chart is a summary of the maintenance service intervals for BoXXer forks Following this schedule is important to ensure the consistent performance and longevity of your fork Some of the information listed may not be applicable to your fork Maintenance Interval Hours Clean dirt and debris from upper tubes Every r...

Page 6: ...per Tube Steerer Tube Maxle Lite DH Brake Hose Guides BoXXer R2C2 technical manual High Speed Compression Adjuster Knob Low Speed Compression Adjuster Knob Bottom Out Adjuster Knob Beginning Stroke Rebound Adjuster Knob Ending Stroke Rebound Adjuster Knob Drive Side non Drive Side anatomy ...

Page 7: ...5 REV A 7 BoXXer R2C2 technical manual SAFETY FIRST At SRAM we care about YOU Please always wear your safety glasses and protective gloves when servicing your RockShox suspension Protect yourself Wear your safety gear ...

Page 8: ... record all of your BoXXer fork s settings in the chart below This will allow you to return your fork to its original settings after service Be sure to record the service date as well this will help you keep track of service intervals To determine your bottom out compression and rebound settings perform the following Bottom out Count the number of clicks while turning the bottom out adjuster fully...

Page 9: ...ped around the upper tube may be used to protect the tube surface Use a 2 mm hex key to remove the rebound adjuster 2 knob retaining bolt Remove the beginning stroke rebound knob washer and ending stroke rebound knob Use a 24 mm flat wrench to loosen and remove the 3 rebound shaft bolt Remove the crush washer and retainer from the bolt then re install the bolt two to three turns Place a 12 mm sock...

Page 10: ... from the fork by firmly pulling 8 each upper tube out of the lower leg assembly Do not hit the brake arch with any tool when removing the lower leg as this could damage the fork If an upper tube does not slide out of the lower leg the press fit on that side may not be completely released Re install the shaft bolt two to three turns and strike it again Allow any remaining oil in the lower leg to d...

Page 11: ...s toward each other or be pulled apart This will damage the lower leg Spray isopropyl alcohol on and into the lower leg 3 Wipe the lower legs clean then wrap a clean lint free rag around a dowel and clean the inside of each lower leg wiper oil seal installation Position the oil seal with the grooved side 1 visible onto the stepped side of the 35 mm seal installation tool Hold one of the lower legs...

Page 12: ...pring spring 7 isolators spring shaft base plate and the outside of the upper tube and wipe dry with a clean rag Inspect the spring shaft assembly for damage Replace entire assembly if necessary Check the position of the spring isolators There should be three isolators evenly spaced along the coil spring with approximately 50 mm of exposed coil at each end If any of the isolators needs to be re po...

Page 13: ...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...

Page 14: ...ll it Pour any remaining oil from the upper tube into 6 the oil pan Push the rebound damper shaft into the seal 7 head leaving just enough shaft exposed to hold onto with your fingers Use large internal snap ring pliers to remove the seal head snap ring from the snap ring groove Do not scratch or damage the surface of the damper shaft during removal of the snap ring Any damage will allow oil to by...

Page 15: ...lint free rag around a dowel and clean the inside of the upper tube Apply grease to the seal head outer o ring 14 Insert the rebound damper piston into the bottom of the upper tube at an angle with the side of the glide ring opposite the split entering the upper tube first Continue to angle and rotate until the glide ring is in the upper tube Push the seal head firmly into the bottom of the upper ...

Page 16: ... the fork is still on the bike you will need to unweight the front of the bike to allow the fork to fully extend Measure from the top of the upper tube to the top of the oil level The measurement should be 173 mm Add or remove oil as necessary Apply grease to the compression damper top 17 cap threads and top cap o ring Insert the compression damper into the top of the upper tube and push downward ...

Page 17: ...n pull the upper tubes back out a few centimeters to provide clearance for oil lubrication installation Make sure both dust seals slide onto the tubes correctly without folding the seals lip Invert the fork to about 45 5 degrees with the fork legs pointing upward Measure and inject pour 10 mL of RockShox 15wt suspension oil into both sides of the lower leg through the shaft bolt holes Slowly slide...

Page 18: ...by the washer onto the rebound adjuster shaft Apply a small amount of threadlock to the 10 rebound knob retaining bolt Install the beginning stroke rebound knob and retaining bolt onto the rebound adjuster shaft Use a 2 mm hex wrench to tighten the bolt to 0 6 1 N m 5 9 in lb Spray isopropyl alcohol on entire fork and wipe 11 with a clean rag 9 10 ...

Page 19: ...he distance from the top of the upper tube to the top of lower crown This distance must be 156 mm 2 mm Align the logo on the drive side upper tube with the logo on the lower leg Refer to the BoXXer crown heights diagram for proper crown height dimensions Improper crown height placement can cause a reduction in handling performance travel and or cause fork damage Re installing the fork onto the bik...

Page 20: ...ub nor rotor bolts interfere with the lower legs If you are unfamiliar with adjusting your disc brakes see your brake manufacturer s instructions Slide the externally threaded end of the Maxle DH 7 through the drive side of the hub until it engages the threads of the lower leg dropout Use a 6 mm hex wrench to turn the drive side axle bolt and tighten the axle into the dropout Torque to 5 7 N m 50 ...

Page 21: ...ax 1 312 664 8826 european headquarters SRAM Europe Paasbosweg 14 16 3862ZS Nijkerk The Netherlands Phone 31 33 450 6060 Fax 31 33 457 0200 ASIAN HEADQUARTERS SRAM Taiwan No 1598 8 Chung Sahn Rd Shen Kang Hsiang Taichung County 429 Taiwan R O C Phone 886 4 2564 3678 Fax 886 4 2561 3686 www sram com ...

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