SRAM 2015 BOXXER TEAM Service Manual Download Page 48

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Lower Leg Assembly

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.

Install a new crush washer retainer and crush washer on the

non-drive side and drive side bottom bolts.

N OT I C E

Dirty or damaged crush washers can cause leaks.

Thread the black bottom bolt into the non-drive side shaft of the

lower leg. Thread the silver bottom bolt 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).

Install the rebound adjuster knob onto the drive side bottom bolt.
Use a torque wrench with a 2.5 mm hex bit socket to tighten the

set screw to 1.1 N·m (10 in-lb).

N OT I C E

Make sure to hold the rebound adjuster knob in place during

installation of the set screw to prevent damage to the bottom bolt.

Spray isopropyl alcohol on the entire fork and clean it with a rag.

Non-drive side

Drive side

5 mm

7.3 N

m (65 in-lb)

5 mm

7.3 N

m (65 in-lb)

2.5 mm

1.1 N

m (10 in-lb)

Summary of Contents for 2015 BOXXER TEAM

Page 1: ...2015 BOXXER TEAM Service Manual ...

Page 2: ...eptable 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 consequential damages LIMITATIONS OF WARRANTY This warranty does not apply to products that ...

Page 3: ...T 7 BOXXER OIL VOLUME 7 FORK REMOVAL 8 LOWER LEG REMOVAL 10 LOWER LEG SEAL SERVICE 13 COIL SPRING SERVICE 15 COIL SPRING REMOVAL 15 COIL SPRING INSTALLATION 18 CHARGER DAMPER SERVICE 20 CHARGER DAMPER REMOVAL 20 OPTIONAL CHARGER DAMPER RE TUNE 30 OPTIONAL REBOUND RE TUNE 30 OPTIONAL COMPRESSION RE TUNE 33 CHARGER DAMPER ASSEMBLY AND BLEED 37 LOWER LEG ASSEMBLY 47 FORK INSTALLATION 49 ...

Page 4: ...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 ...

Page 5: ...h Set screw Rebound adjuster knob Bottom bolt Bottom bolt Spring shaft assembly Retaining ring Retaining ring Lower seal head Bottom out bumper Inner scraper seal Inner scraper seal Rebound damper shaft Spring isolator Support washer Wavy washer Base plate assembly Low speed compression adjuster Compression top cap Bladder and bladder sleeve Low speed compression needle Compression piston assembly...

Page 6: ... Clean lint free rags Oil pan Isopropyl alcohol Bicycle stand Bench vise with aluminum soft jaws RockShox 3wt suspension fluid RockShox 0w 30 suspension fluid SRAM Butter grease Liquid O Ring PM600 military grease Shock pump 35 mm seal installation tool Downhill tire lever Plastic mallet Flat head screwdriver Diagonal cutter 26 Schrader valve core tool 2 21 and 1 25 mm open end wrenches 21 and 25 ...

Page 7: ... n Maintenance Interval hours Clean dirt and debris from upper tubes Every ride Inspect upper tubes for scratches Every ride Check front suspension fasteners for proper torque 25 Remove lowers clean inspect bushings and change oil bath 50 Clean and lubricate coil spring assembly 100 Change oil in damping system 100 B o X X e r T o r q u e C h a r t Part Tool Torque Maxle Lite DH non drive side 6 m...

Page 8: ...he top of the lower crown 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 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 t...

Page 9: ...y 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 Slid...

Page 10: ... mm hex wrench to remove the bottom bolt from the lower leg 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 turns and repeat steps 2 4 N OTI C ...

Page 11: ...oosen the drive side bottom bolt 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 Drive side 5 6 2 5 mm 7 5 mm Loose...

Page 12: ... the lower leg from the fork 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 turns and repeat steps 7 9 N OTI C E Do not hit the fork arch with any tool when removing the lower leg as this could damage the fork 9 ...

Page 13: ...n on the downhill tire lever handle to remove both seals at the same time Repeat on the other side N OTI C E 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 Spray isopropyl alcohol on the inside and outside of the lower leg and clean it with a rag Wrap a rag around a long dowe...

Page 14: ...the spring aside Insert the narrow end of the new dust wiper seal into the recessed end of the 35 mm seal installation tool Hold the lower leg firmly and use the seal installation tool to push the dust 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 on the other side 5 35 mm seal in...

Page 15: ...s 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 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...

Page 16: ... in its position Gradually heat the isolator until it emits a vapor C AU TI O N B U R N H A Z A R D 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 handling Failure to do so may result in burns Place the tips of large internal snap ring pliers into the eyelets of the retaining ring Pre...

Page 17: ...t 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 8 9 ...

Page 18: ...ube until the retaining ring groove is visible 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 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 sha...

Page 19: ... 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 N OTI C E 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...

Page 20: ...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 SRAM Butter to the new seal or o ring Clamp the drive side upper tube into a bicycle stand Use your fingers to remove the bottom out bumper from the rebound damper shaft Use a 2 mm hex wrench to remove the knob...

Page 21: ... with a rag Use a pick or your fingers to remove the compression top cap o ring Install a new compression top cap o ring Use large internal snap ring pliers to remove the retaining ring from the bottom of the upper tube Insert a long dowel into the top of the upper tube and push the lower seal head out the bottom of the upper tube 4 24 mm 5 Snap ring pliers 6 7 ...

Page 22: ...ce and remove the inner scraper seal from the lower seal head Use your fingers to install a new o ring and scraper seal on the lower seal head Remove the drive side upper tube from the bicycle stand Clamp the cartridge tube into a bicycle stand with the rebound damper oriented upward 8 Scraper seal orientation 9 ...

Page 23: ...wrench flats on the cartridge tube Holding the cartridge tube in place turn the rebound damper seal head counter clockwise to loosen and remove the rebound shaft and piston assembly Remove the cartridge tube from the bicycle stand and pour the fluid into an oil pan Remove the rebound damper seal head from the rebound damper shaft 21 mm 21 mm 10 11 12 ...

Page 24: ...to install a new o ring and scraper seal Use your fingers to remove the glide ring from the rebound damper piston Use your fingers to install a new glide ring Set the rebound shaft assembly aside Clamp the wrench flats of the coupler into a vice with the cartridge tube oriented upward N OTI C E Do not clamp the cartridge tube in the vise 13 Scraper seal orientation 14 15 ...

Page 25: ...e aside Remove the coupler bladder and compression top cap assembly from the vise While holding it over an oil pan use needle nose pliers to remove the compression piston assembly Fluid will spill from the coupler Pour the fluid into an oil pan Clamp the wrench flats of the coupler into a vice with the compression top cap oriented upward Use a 6 mm socket to remove the retaining nut from the compr...

Page 26: ...a pick to remove the o ring on the low speed compression adjuster Use your fingers to install a new o ring Use your fingers or a pick to remove the o ring from the compression piston Use your fingers to install a new o ring Use your fingers or a 2 5 mm hex wrench to remove the low speed compression needle 20 Needle nose pliers 21 22 2 5 mm 23 ...

Page 27: ... the o ring from the low speed compression needle Use your fingers to install a new o ring Use a 24 mm socket to loosen and remove either the coupler or the compression top cap from the bladder whichever loosens first Remove the assembly from the vise 24 25 24 mm ...

Page 28: ...o remove the coupler If the coupler came off in step 24 set the bladder on the hex bit socket with the compression top cap oriented upward Use a 24 mm socket wrench to remove the compression top cap Remove the assembly from the vise Use a pick or your fingers to remove the o ring inside the coupler Use your fingers to install a new o ring 26 5 8 5 8 To remove the top cap 24 mm 5 8 To remove the co...

Page 29: ... your fingers to remove the bladder from the bladder sleeve Inspect it for tears or cracks If there are any tears or cracks replace the bladder Spray isopropyl alcohol on the bladder and bladder sleeve and clean them with a rag 28 ...

Page 30: ...ecommend changing to a firm tune on the rebound If your compression setting is one or two clicks from closed we recommend changing to a firm tune on the compression All Charger Dampers in BoXXer ship with the Medium Damper Tune installed O p t i o n a l R e b o u n d R e t u n e Clamp the bottom of the rebound damper shaft into a RockShox Rear Shock Vise Block N OTI C E To prevent damage to the re...

Page 31: ...1 14 0 2 8 0 3 8 0 1 12 0 2 16 Hoop 16 0 1 0 1 14 0 2 16 Hoop Medium Rebound Tune Stock Tune Piston Face Bottom of stack 16 0 1 0 1 0 1 0 1 0 1 0 2 Outer Dimension mm 1 1 Shim Size 1 1 Shim Thickness mm 16 16 0 1 14 14 0 2 8 0 3 8 12 16 Hoop Firm Rebound Tune Piston Face Bottom of stack 0 1 Outer Dimension mm 1 1 Shim Size 1 1 Shim Thickness mm 16 0 1 16 0 1 14 0 2 8 0 3 8 0 1 12 Soft Rebound Tune...

Page 32: ...TI C E Ensure the hoop shim is centered on the shim stack Thread the main piston nut onto the rebound damper piston Use a torque wrench with a 10 mm socket to tighten the nut to 3 7 N m 33 in lb N OTI C E Ensure the check shim is centered and not pinched under the piston Remove the assembly from the vise Centered shim stack Off center hoop shim 5 6 10 mm 3 7 N m 33 in lb Centered check shim Pinche...

Page 33: ...lock N OTI C E To prevent damage to the compression piston position the shaft in the vise so that the piston is clear of the vise block Use a 10 mm socket to remove the piston bolt Use a small wrench to remove the piston assembly from the compression damper shaft Set the shims on a rag in the order they came off of the piston 1 10 mm 2 3 Small wrench ...

Page 34: ... 15 0 15 0 15 0 15 Medium CompressionTune Stock Tune Outer Dimension mm 1 1 Shim Size 1 1 Shim Thickness mm Firm CompressionTune Outer Dimension mm 1 1 Shim Size 1 1 Shim Thickness mm 16 0 3 0 3 8 0 3 8 0 3 8 0 3 8 0 3 8 0 3 8 0 3 8 0 3 8 Soft Compression Tune Piston Face Bottom of stack Piston Face Bottom of stack Piston Face Bottom of stack 16 0 1 18 0 2 18 18 18 18 18 0 15 0 15 0 15 18 0 15 18 ...

Page 35: ...contact with the shims Install the shims on a small wrench in the order of your desired tune Install the piston assembly onto the compression damper shaft Use your fingers to squeeze the shim stack and center the shims N OTI C E Ensure the hoop shim is centered on the rest of the shim stack Loctite Threadlocker Red 2760 5 Centered shim stack Off center hoop shim 6 ...

Page 36: ...sion damper shaft Use a torque wrench with a 10 mm socket to tighten the nut to 3 7 N m 33 in lb N OTI C E Ensure the check shim is centered and not pinched by the piston bolt Remove the assembly from the vise 10 mm 3 7 N m 33 in lb 7 Centered check shim Pinched check shim ...

Page 37: ...ches 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 SRAM Butter to the new seal or o ring Use your fingers to install the bladder onto the bladder sleeve Ensure that it is centered between the ends of the sleeve Apply a liberal amount of SRAM Butter onto both ends of the bladde...

Page 38: ...installation If the bladder starts to twist unthread the compression top cap and coupler and repeat steps 1 4 Spray isopropyl alcohol on the inside and outside of the cartridge tube Clean the outside of the cartridge tube with a rag Wrap a rag around a long dowel and insert it into the cartridge tube to clean inside the cartridge tube Clamp the cartridge tube into a bicycle stand with the threads ...

Page 39: ...rebound damper seal head Place a 21 mm open end wrench on the wrench flats on the damper cartridge tube While holding the damper cartridge tube in place turn the rebound damper seal head clockwise to tighten the rebound assembly to 9 10 N m 80 90 in lb Install the crowfoot onto the torque wrench at a 90 angle to the handle to ensure an accurate torque reading Insert a 2 5 mm hex wrench into the re...

Page 40: ...alf full Use the palm of your hand or a rag to cover the cartridge tube and cycle the damper rebound shaft a few times to help pre bleed air from the damper Pour additional RockShox 3wt suspension fluid into the cartridge tube until the fluid is level with the top of the tube Use your finger to remove any air bubbles from the surface of the fluid C AU TI O N E Y E H A Z A R D Pull the rebound damp...

Page 41: ...l on the threads inside the coupler and clean the threads with a rag Apply a small amount of Loctite Threadlocker Blue 242 on the coupler threads N OTI C E Do not allow the Loctite to come in contact with the o rings or bladder Thread the coupler onto the cartridge tube by hand Place a torque wrench with a 25 mm crowfoot open end wrench on the wrench flats of the coupler Place a 21 mm open end wre...

Page 42: ...r shaft a few times to help pre bleed air from the damper Pour additional RockShox 3wt suspension fluid into the top cap until the fluid is level with the top Use your finger to remove any air bubbles from the surface of the fluid C AU TI O N E Y E H A Z A R D Fluid may be ejected from the damper top cap assembly Wear safety glasses Fully extend the rebound damper shaft by pulling down on the rebo...

Page 43: ...t This will force bubbles out of the damper assembly Pressurize the damper assembly by pushing down on the syringe handle and simultaneously pulling down on the rebound damper shaft Continue to hold down on the syringe handle and simultaneously cycle the rebound damper shaft a few times to purge bubbles The bladder will expand and contract This is normal Repeat pulling a vacuum and pressurizing th...

Page 44: ...rag to cover the syringe tip and compression top cap bleed port then unthread and remove the syringe C AU TI O N E Y E H A Z A R D Fluid may be ejected from the damper top cap assembly if the bladder is not in its resting position Wear safety glasses Install the low speed compression adjuster into the compression top cap by hand Install the compression top cap retaining nut by hand Use a torque wr...

Page 45: ...taining ring N OTI C E Scratches on the rebound 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 groove by using the snap ring pliers to rotate t...

Page 46: ...per Assembly and Bleed Install the low speed compression adjuster knob and knob retaining screw Use a torque wrench with a 2 mm hex bit socket to tighten the screw to 1 1 5 N m 8 13 in lb 2 mm 1 1 5 N m 8 13 in lb 30 ...

Page 47: ... tube N OTI C E 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 at a 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 0w 30 suspension fluid int...

Page 48: ... the lower leg Thread the silver bottom bolt 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 Install the rebound adjuster knob onto the drive side bottom bolt Use a torque wrench with a 2 5 mm hex bit socket to tighten the set screw to 1 1 N m 10 in lb N OTI C E Make sure to hold the rebound adjuster knob in place d...

Page 49: ...pray isopropyl alcohol or water on the inner surfaces of each frame bumper and upper tube Reinstall the frame bumpers onto the upper tubes 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 Measure the distance from the top of the upper tube to the top of the lower crown This distance must be 156...

Page 50: ... with a 4 mm hex bit socket to tighten the two upper crown pinch bolts to 5 N m 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 Position the front wheel in the lower leg dropouts so the hub is seate...

Page 51: ... torque wrench with a 6 mm hex bit socket to tighten the non drive side axle bolt until you hear or feel 8 clicks or reach a torque value of 3 4 N m 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 BoXXer front suspension forks 6 ...

Page 52: ...This publication includes trademarks and registered trademarks of the following companies Loctite is a registered trademark of Henkel Corporation ...

Page 53: ...www sram com GEN 0000000004678 Rev B 2014 SRAM LLC ...

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