2005-Boxxer.pdf

U SER M ANUAL

SRAM C ORPORATION • B OXXER U SER M ANUAL

E NGLISH

B O X X E R R I D E

B O X X E R R A C E ( S E T A T 1 7 8 M M )

A. Steerer Tube

R. U-Turn

Adjustment

Knob

A. Steerer Tube

Q. Top Cap

P. Upper Crown

(short shown)

P. Upper Crown

(short shown)

O. Lower Crown

B. Coil Spring

C. Upper Tube

N. Wiper Seal

C. Upper Tube

N. Wiper Seal

M. Oil Seal

F. Rebound Damper

D. Topout Spring

E. All Travel Spacer

(set at 178mm)

L. All Travel Spacer

(set at 178mm)

K. Topout Assembly

J. Lower Leg

F. Rebound Damper

G. Axle

J. Lower Leg

H. Rebound Adjuster

I. Axle Pinch

Bolts

I. Axle Pinch

Bolts

N OTE : Y OUR FORK ’ S APPEARANCE MAY VARY FROM THE ILLUSTRATIONS / PHOTOS IN THIS MANUAL .

F OR THE LATEST INFORMATION ABOUT YOUR FORK VISIT OUR WEBSITE AT WWW . ROCKSHOX . COM .

SRAM C ORPORATION .• D ECEMBER 2004

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SRAM C ORPORATION • B OXXER U SER M ANUAL

E NGLISH

B O X X E R W O R L D C U P / T E A M

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

P. Upper Crown

(short shown)

IMPORTANT

Consumer Safety Information

1.The fork on your bicycle is designed for use by a single or tandem bicycle,

on mountain trails, and similar off-road conditions.

2.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 loss of oil; collision or other activity bending or

breaking the fork's components or parts; and extended periods of non-use.

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

injury may result.

4.Always use genuine RockShox parts. Use of aftermarket replacement parts

voids the warranty and could cause structural failure to the shock.

Structural failure could result in loss of control of the bicycle with possible

serious and/or fatal injuries.

5. Use extreme caution not to tilt the bicycle to either side when mounting the

bicycle to a carrier by the fork drop-outs (front wheel removed). The fork

legs may suffer structural damage if the bicycle is tilted while the drop-outs

are in the carrier. Make sure the fork is securely fastened down with a

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

can allow the bike’s mass to side-load the drop-outs, causing them to

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

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

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

not route the front brake cable and/or cable housing through the stem or

any other mounts or cable stops. Do not use a front brake cable leverage

device mounted to the brace.

7. Observe all owner's manual instructions for care and service of this product.

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

TO MEET THE CONSUMER PRODUCT SAFETY COMMISSION’S (CPSC)

REQUIREMENTS FOR BICYCLE STANDARDS IF THE FORK IS GOING TO

BE USED ON PUBLIC ROADS AT ANY TIME.

O. Lower Crown

B. Coil Spring

C. Upper Tube

N. Wiper Seal

M. Oil Seal

D. Topout

Spring

D. Topout Spring

S. Compression Damper

F. Rebound Damper

J. Lower Leg

G. Axle

T. High Speed

Compression Damper

I. Axle Pinch Bolts

H. Rebound Adjuster

U. Compression

Adjuster

95.4309.223.000, R EV .D

SRAM C ORPORATION .• D ECEMBER 2004

E NGLISH

SRAM C ORPORATION • B OXXER U SER M ANUAL

E NGLISH

I N S T A L L A T I O N

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.

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.

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 one 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.

WARNING

B OXXER D OWNHILL S PRING R ATES

Color Spring Rate (lb-in.)

White Extra Soft (10 lb.-in.)

Silver Soft (15 lb.-in.)

Yellow Medium (20 lb.-in.) - standard

Red Firm (25 lb.-in.)

The Boxxer is built standard with two medium springs (20 lb-in.).

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 BICYCLE WITH POSSIBLE

SERIOUS AND/OR FATAL INJURIES.

B OXXER D OWNHILL S PRING R ATE TUNING

*( RATES BASED ON A DOWNHILL RACING APPLICATION )

Rate

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

Rider Weight

Fork Leg #1 Fork Leg #2

Extra Soft (20 lb.)

<45 kg.(<100 lb.)

White

Soft/Extra Soft (25 lb.)

45 to 54 kg. (100 to 120 lb.)

White

Silver

Minimum Upper Tube Exposure

Soft (30 lb.)

54 to 63 kg. (120 to 140 lb.)

Silver

Medium/Soft (35 lb.)

63 to 72 kg. (140 to 160 lb.)

Silver

Yellow

World Cup/Team

203 mm

Medium - standard (40 lb) 73 to 82 kg. (160 to 180 lb.)

Yellow

Race (203 mm)

203 mm

Medium/Firm (45 lb.)

82 to 91 kg.(180 to 200 lb.)

Yellow

Red

Race (178 mm)

178 mm

Firm (50 lb.)

91 to 100 kg.(200 to 220 lb.)

Red

Ride*

178 mm

B OXXER R IDE S PRING R ATE TUNING

Color

* N OTE : F OR B OXXER R IDE , THE U-T URN KNOB MUST BE TURNED FULL COUNTERCLOCKWISE

UNTIL THE GRADIENT MARKED AS 178 MM IS EXPOSED .

Rider Weight

Yellow

57 to 68 kg.(125 to 150 lb.)

Yellow/Red

68 to 79 kg (150 to 175 lb.)

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-lb. Tighten axle clamp bolts to 20 to 30

in-lb max.

5. 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 clearance 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.

Red (standard)

79 to 91 kg (175 to 200 lb.)

Black

91 to 102 kg (200 to 225 lb.)

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 terrain. 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.

N OTE :T HERE SHOULD BE A MINIMUM OF 2 MM OF PRELOAD ON EACH SPRING .

I MPORTANT : N O MORE THAN EIGHT PRELOAD SPACERS SHOULD BE ADDED TO EITHER SIDE OF THE FORK . M ORE

THAN EIGHT SPACERS CAN CAUSE THE SPRING TO BE DAMAGED . I F YOU CAN NOT ACHIEVE THE PROPER

PRELOAD , YOU MAY NEED TO INSTALL SOFTER OR FIRMER COIL SPRINGS .

P E R F O R M A N C E T U N I N G

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 lb.) rider. The Boxxer Ride is factory tuned for a 68 to 79 kg. (150 to 175 lb.) rider. These

95.4309.223.000, R EV .D

SRAM C ORPORATION .• D ECEMBER 2004

E NGLISH

SRAM C ORPORATION • B OXXER U SER M ANUAL

E NGLISH

To change the preload:

1. Remove the top caps with a 24mm six-point socket wrench.

2. Inspect the O-rings for damage and replace if necessary.

3. Slightly compress the fork to get access to the preload spacers, which sit on top of the spring stacks.

4. Add or remove preload spacers and/or springs as necessary.

5. Re-install top caps and torque to 55 to 75 in-lb.

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

direction 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.

N OTE : 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.

N OTE : T HE HEX KEY MAY BE USED ON BOTH REBOUND AND COMPRESSION DAMPING ADJUSTMENTS . F OR ON -

THE - TRAIL - USE , THE HEX KEY MAY BE STORED BY CAREFULLY SLIDING IT IN BETWEEN THE UPPER TUBE AND

RUBBER FORK STOP .

U-turn Travel Adjust (Ride Only)

Boxxer Ride forks can be adjusted from 133 to 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).

I MPORTANT : S TOP TURNING THE U- TURN ADJUSTER KNOB AFTER YOU ’ VE REACH 178 MM OF TRAVEL

( MAXIMUM TRAVEL ). T URNING THE KNOB PAST THIS POINT MAY CAUSE DAMAGE TO THE U- TURN FEATURE .

Spring Rate Increase

30.0%

25.0%

20.0%

15.0%

10.0%

5.0%

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, preference and

fork setup.

N OTE : T HIS ADJUSTER IS NOT INDEXED .

0.0%

133

140.5

148

155.5

163

170.5

178

U-Turn Travel Adjustment (mm)

Fig. 2

High Speed

Compression

Adjuster Nut

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.

N OTE : W HEN DECREASING TRAVEL ( SEE “U- TURN T RAVEL A DJUST ”), YOU INCREASE THE SPRING RATE .

Internal High Speed Compression Adjustment (World Cup

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.

C AUTION : E NSURE THE END OF THE COMPRESSION ADJUSTER ROD DOES NOT BECOME

RECESSED INTO THE NUT . T HE NUT MAY BECOME DISENGAGED DURING OPERATION IF THE

ADJUSTER IS NOT FULLY THREADED INTO THE NUT .

M A I N T E N A N C E

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.

* W E RECOMMEND THIS SERVICE BE PERFORMED BY A QUALIFIED BICYCLE MECHANIC .

T O OBTAIN SERVICE INFORMATION OR INSTRUCTIONS , VISIT OUR WEBSITE AT WWW . ROCKSHOX . COM OR

CONTACT YOUR LOCAL R OCK S HOX DEALER OR DISTRIBUTOR .

Changing Travel (Race Only)

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.

Fig. 1

95.4309.223.000, R EV .D

SRAM C ORPORATION .• D ECEMBER 2004

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