Rock shox boxxer 2008 service manual

Rear Shock Service Ario, Bar, MC, Pearl For explo de d diagrams and part number information, please refer to the Spare Parts. For or de ring information, please contact your local distributor or visit our website at.

Product names used in this manual may be tra de marks or registered. It de tails the fork mo de l and corresponding damper. It is important to de termine the. While this chart is inten de d. Removing the lower legs of your fork is the first step in servicing your fork. It allows you access to your fork bushings, damper. Suspension fork bushings are consi de red "wear and tear" parts and require regular maintenance, de pending on the frequency.

At this point you should already have the lowers removed from your fork. If not, you will need to return to the Lower Leg.

Complete the bushing service of your fork by de tailing the lower legs. Spray isopropyl alcohol on entire lower leg assembly and. Check the de cals on your fork and replace if necessary. Switching from a remote compression adjust to a crown mounted compression adjust requires only the removal of the remote.

Control compression dampers, the 07 SID Motion Control compression damper remote return spring is not integrated into the. All travel spacers are located just above the air seal head. If you want to change the travel of your fork, snap the travel spacer.

All travel spacers are located just above the bottom out bumper washer. If you want to change the travel of your fork, snap the. All travel spacers are located just above the negative sleeve top out bumper. At this point you should already have already servised your fork bushings, damper system, and spring system. While this chart is. Prior to servicing your rear shock, you will first need to remove it from your bicycle frame according to your bicycle.

All content inclu de d in this catalog, including but not limited to text, graphics or images is copyrighted as a collective. Isis Drive de sign , Wavo, X. Insert air piston bac. For in- de pth service information on SRAM products, refer to our website at www. Contact your local SRAM distributor or de aler for or de ring information. Information contained in this publication is subject to change at any time without prior notice. Protect your eyes! Wear your safety glasses!

Information contained in this publication is subject to change at anytime without prior notice. For the latest technical information, please visit our website at www.

Product names used in this manual may be tra de marks or registered tra de marks of others. It de tails the fork mo de l and corresponding damper and spring technology specific to each fork, and the oil volume and weight for each fork leg. It is important to de termine the technology used in your fork in or de r to successfully service it, as this manual is sectioned by technology, rather than forks.

If you are unsure of the technology used in your fork, consult your local RockShox de aler for assistance. While this chart is inten de d to be comprehensive, it is still only a gui de. Keep in mind your specific fork may not require every tool listed. Remove the air chamber valve cover cap from the left fork leg top cap. If fork has a negative air chamber, remove the negative air chamber valve cover cap from the bottom of the left fork leg.

Depress schra de r valve and release all air from the air chamber. If fork has a negative air chamber, start with the negative air chamber first, then proceed to the positive air chamber. Pull external rebound adjuster knob and remove from the right shaft bolt. For Dual Air equipped forks, use a 10mm socket or open end wrench to loosen and unthread the Dual Air shaft nut just past the threa de d shaft end.

Remove the lower leg assembly from fork by firmly pulling it downward, holding onto both legs or the brake arch. Spray isopropyl alcohol on and into the lower leg assembly. Wipe the lower legs clean, then wrap a clean rag around a dowel and clean the insi de of each lower leg not pictured.

It allows you access to your fork bushings, damper system and spring system. If not, you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lowers. Method 1: on- Bike check 1. Compress fork 5 times to circulate lower leg lube not pictured.

Hold the front brake lever tight and rock the bike back and forth. If the fork feels like it's "knocking", or the headset feels loose, proceed to steps 2 and 3. Check the fork: wrap your fingers around the dust seal and upper tube area. Rock the bike back and forth again. Listen and feel if there is any play between the upper tube and the dust seal. If so, the bushings are loose. Holding the brake, rock the bike back and forth and feel if the headset is loose.

If so, tighten the headset and check again. Method 2: off- Bike check 1. Hold the fork crown tight in one hand and the brake arch in the other hand.

If you can feel any play, or if the fork feels like it's "knocking", the bushings are loose. Remove the dust seal using a medium to large flat-head screwdriver to carefully pry it from the lower leg. Remove the oil foam ring with your fingers.

Remove the inner oil seal, located just below the dust seal using a flat head screwdriver. Install the correct bushing removal plate onto handle end and secure with handle plate screw. Pull lower leg away from puller tool and hook the flat end of the plate secure un de r the bushing.

When the plate is secure un de r bushing, begin to remove. Again, firmly and squarely hit the top of the lower leg on the flat dust seal surface area until the lower bushing pulls free. Longer lower bushings may require more force. Return to Step 3 and repeat for the other fork leg. Spray isopropyl alcohol insi de lower legs. Wrap a clean rag around a dowel and clean the insi de of the lower legs not pictured. Sli de the lower bushing sleeve Sli de lower bushing onto top of lower bushing installation sleeve.

Sli de lower leg over installation post and rest on top of lower bushing. Insert the mallet drift tool into the lower leg shaft hole and hold in place with one hand. Continue to hit the mallet drift tool until the lower leg dust seal ridge is level with the top of the installation post spacer. Remove lower leg from tool and inspect the fit of the lower bushing by sliding one upper tube into the lower leg. Hold lower leg horizontally and release. Return to step 1 and repeat for other leg.

Sli de 10mm then 5mm upper bushing installation spacers onto bushing installation post. Sli de upper bushing onto bushing installation post, on top of the 5mm spacer. Sli de lower leg over installation post and rest on top of upper bushing. Insert mallet drift tool into the lower leg shaft hole and hold in place. Continue to hit the mallet drift tool until the lower leg stops moving. Remove lower leg from tool and inspect the fit of the upper bushing by sliding one upper tube into the lower leg.

Return to Step 9 and repeat for other leg. Sli de lower bushing installation spacer onto bushing installation post. Sli de the lower bushing sleeve onto bushing installation post. Recon, Revelation, tora only: Sli de the tall lower bushing spacer onto the bushing installation post.

Sli de lower bushing onto the top of the lower installation sleeve. Continue to hit the mallet drift tool, until the lower leg dust seal ridge is level with the top of the installation post spacer. You will feel it stop as the bushing is "set" in the lower leg. Return to Step 1 and repeat for other leg. Leave only the lower bushing spacer on bushing installation tool. Sli de upper bushing onto bushing installation post. Sli de lower leg over installation post, and rest on top of the upper bushing.

Continue to hit the mallet drift tool until the lower leg rests flush on top of the install spacer. Return to Step 11 and repeat for other leg. Sli de bushing installation tool adapter over bushing installation post. Sli de lower bushing sleeve onto the adapter.

Sli de lower bushing onto the adapter. You will feel the stopping point as the bushing is "set" into the lower leg. Return to Step 10 and repeat for other leg. Sli de dust seal installation tool over the 28mm bushing installation tool.

It should sit flush with the base of the installation tool. Sli de new dust seal over bushing installation tool and fit on top of dust seal installation tool.

Sli de oil-saturated foam ring over bushing installation tool and fit on top of dust seal. Seat the foam ring insi de the un de r cavity of the dust seal. Wipe excess oil off the dust seal with a clean rag.

Sli de lower leg onto bushing installation tool, on top of new dust seal. Dust seal should be press-fit snug into the lower leg, with little to no gap showing. Insert new oil-saturated foam ring into lower leg. Insert dust seal into lower leg and press straight down and evenly to seat into lower leg. Dust seal should be press-fit snug and flush into lower leg. Apply pressure on all si de s of the oil seal to seat it into place. Soak new foam rings in suspension oil. Insert new oil-saturated foam ring into lower leg on top of oil seal.

Apply pressure on all si de s of the dust seal to seat it into place. Spray isopropyl alcohol on entire lower leg assembly and wipe with a clean rag. Remove external snap ring from compression adjuster knob using external snap ring pliers and remove compression adjuster knob and o-ring. Remove compression damper by pulling up and gently rocking si de to si de.

If fork is equipped with a remote lockout feature, be sure to remove the remote compression damper cable-stop clamp; which is located un de r the compression damper top cap. Replace compression damper top cap o-ring by gently pinching o-ring to remove. Apply a few drops of suspension oil to new o-ring and re-install. Remove fork from bicycle stand and pour remaining oil into pan. Remove rebound damper o-ring and damper inner seal-head o-ring located in the bottom of the upper tube.

Apply fresh grease to new o-rings and re-install. Clamp fork back into bicycle stand and apply a light film of grease to upper tube threads. Insert rebound damper back into right si de of upper tube, shaft first and press piston into upper tube past tube threads. Push rebound damper into upper tube using a long dowel rod. Gui de rebound damper shaft through damper seal head at the bottom of the upper tube and pull shaft through by hand into the fully exten de d position. Measure and pour 5wt suspension oil into the upper tube using the volumes listed in the chart at right.

Remote only: Position cable-stop clamp in the 10 o'clock position around the upper tube hole on the crown prior to inserting compression damper. Grease upper tube threads liberally then insert compression damper into upper tube. Press down and twist to work damper into upper tube.

Be careful not to damage o-ring seals on upper tube threads. Press top cap down into upper tube threads and hand tighten.

Place compression adjuster knob onto compression damper top cap with the knob dial set in the 3 o'clock position. Remove external snap ring from compression adjuster knob using external snap ring pliers and remove compression adjuster knob and o-ring seal.

Remove compression adjuster knob not pictured. If fork is equipped, be sure to remove the remote compression damper cable-stop clamp; which is located un de r the compression damper top cap. With a sharp pick, remove the compression damper top cap o-ring located at the top of the damper and the compression damper seal located at the bottom of the damper.

Apply a few drops of suspension oil to the new o-ring and seal and install. Remove rebound damper gli de ring and inner seal head o-ring. Clamp fork back into bicycle stand. Insert rebound damper back into right si de of upper tube, shaft first. Gui de rebound damper through damper seal head at bottom of upper tube and pull through. Remote only: Sli de compression damper through cable-stop clamp prior to insertion.

Position the cable-stop clamp in the 10 o'clock position on the crown. Grease upper tube threads liberally, then insert compression damper into upper tube. As soon as the damper seal passes through the upper tube threads, pull the damper up slightly, then push back down. Repeat procedure until the compression damper sli de s up and down easily. Be careful not to damage the upper damper o-ring.

Continue to thread top cap down into upper tube threads and hand tighten. With a sharp pick, remove compression damper o-rings located at the top and bottom of the damper. Apply a few drops of suspension oil to new o-rings and re-install. Remove rebound damper seal head retaining ring located insi de the bottom of the right upper tube , using external snap ring pliers.

Pull down and remove the rebound damper and seal head assembly from the upper tube. Sli de seal head off damper shaft and remove inner and outer seal head o-rings. Apply a few drops of suspension oil to new o-rings and reinstall. Spray isopropyl alcohol on rebound damper shaft, and clean with a rag not pictured.

If damaged, replace rebound damper piston gli de ring. Position upper tube base ring on top of seal head step and sli de rebound seal head assembly onto rebound damper shaft. Spray isopropyl alcohol into the upper tube. Wrap a clean rag around a dowel and clean the insi de of the upper tube not pictured. Insert rebound damper piston into the bottom of the upper tube at an angle, with the open-en de d si de of the gli de ring face outward. Continue to angle and rotate until gli de ring is in the upper tube.

Position the upper tube base ring seal and seal head into the upper tube. Position the upper tube base ring seal and seal head into the upper tube and press into the upper tube with your thumb. Pull rebound damper shaft down, into the fully exten de d position. Measure and pour 5wt suspension oil into the upper tube, through the crown, using the volumes listed in the chart at right.

Insert compression damper into upper tube. Remove remote cable stop clamp using a 2mm hex wrench. Remove Floodgate adjuster knob using a 1. Remove external snap ring from compression adjuster spool using external snap ring pliers and remove compression adjuster spool and return spring.

Clean upper tube threads with a rag. Be sure to wrap a rag around the damper tube, as oil will drain from the assembly. Pour remaining oil from damper tube into oil pan. Remove compression damper from damper tube by pulling up gently. Allow any excess oil to drain into oil pan. Pull straight out; don't twist. Spray compression damper assembly and damper tube insi de and out with isopropyl alcohol. Wipe grease and oil from damper assembly and outsi de of damper tube. Wrap a clean rag around a dowel and clean the insi de of the damper tube not pictured.

Sli de seal head off rebound damper shaft and remove inner and outer seal head o-rings. Apply a few drops of suspension oil to new o-rings and install. Spray rebound damper shaft with isopropyl alcohol, and clean with a rag not pictured. Inspect rebound damper piston gli de ring and damper shaft. Replace either, if damaged. Sli de rebound damper seal head back onto rebound damper shaft. Insert a 2. Lubricate rebound damper and seal head by submerging in a container of suspension oil.

Remove compression damper o-rings lower, internal floating piston - IFP, and primary. Apply a few drops of suspension oil to new orings and install. Place gold Floodgate adjuster knob back onto the compression damper and tighten with a 1.

Apply suspension oil to both the main piston and IFP o-rings of the compression damper. Insert the compression damper back into the damper tube and sli de entire damper assembly into the tube. Press top cap firmly into place. Holding damper tube with the open end up, pour 5wt suspension oil into the damper tube until tube is approximately half-full. Pour additional 5wt suspension oil into damper tube until completely full. Remove rebound damper and seal head from the oil container in which it was submerged.

Wrap a rag around the damper tube to catch displaced oil. With the seal head bottomed out, slowly insert rebound piston into the damper tube, by pushing on the seal head, until it is fully seated. Wipe all oil from damper tube.

Ensure the o-ring is positioned flat on the threa de d upper tube base retainer. If the o-ring came out with the damper tube assembly, apply a small amount of grease to the o-ring and re-position it on the bottom of the rebound damper seal head. Insert the damper assembly back into the upper tube, rebound shaft first. Gui de the end of the rebound damper through the center of the threa de d base retainer, sliding the damper completely into the upper tube.

Hand thread the compression damper top cap into the upper tube. Insert the rebound damper external adjuster knob into the bottom of the rebound damper shaft and turn clockwise until damper is in the full closed position. Remove Floodgate adjuster knob again, using a 1.

Place the remote spool onto the compression spool adjuster shaft and turn clockwise until it stops, in the closed lockout position. Hold the remote spool in the closed position and use your free hand to rotate the cable stop clamp counter-clockwise until it touches the remote spool stop. My question is, first do most boxxers have the same problem with the last two compression clicks, and second do you think Rock Shox just have him Race lowers with the old Team uppers and that is why I have the floodgate control?

Thanks for the help. The compression nob is just for LSC, i. What your experiencing is not enough HSC which is unadjustable. The only thing you can do is order a heavier spring and I would advise this. Get a heavier spring or adjust the preload, I don't know how, consult the manual which can be found on their site.

AqueousBeef wrote:. Probably find used ones for 30 bucks. If the floodgate does anything, try closing the floodgate completely then making your compression slow, then just work backwards to how soft you want the suspension. I will definitely look into a heavier spring, also I have a race but it has the floodgate adjustment knob on it.

Do you guys know if when Rock Shox warrantees their forks if they would just send new lowers and internals, hence the floodgate knob on mine? I have tried adjusting it but it doesn't seem to do anything. This adjustment helped at speed on the faces of jumps and launching big drops onto choppy landings. We mounted the World Cup to our Intense Socom downhill racer. The Boxxer always took the brunt of the impacts and reliably returned to position ready for more.

With many downhill forks, there are some flaws in performance that once noticed will change how you ride them. The Boxxer World Cup impressively handled all aspects of technical downhill riding. Its agile feel made it fun to launch high-speed jumps and lean into corners, while the superb damping performance gave us assurance in rocky and very technical terrain.

The air-sprung Boxxer World Cup has been in development since and debuted in Some of the most talented riders in the world have given their feedback, making the World Cup what it is today. We have yet to ride another eight-inch slider with such a simple setup procedure, easy tuning, and consistent performance.

The sweet science of the BlackBox program has developed a top-performing downhill fork, and the technology has trickled down to the consumer. The RockShox Boxxer World Cup tops the list of our race-ready premium downhill forks and is ideal for serious racers. RockShox , Fine tuned: The incremental clicks of the Motion Control knob provided plenty of high-speed compression tuning options for gnarly terrain.

What Are Wide Trail Tires? No fork has won more downhill championships than the RockShox Boxxer. Crown jewel: The top crown of the Boxxer is capable of using a direct-mount or steerer clamp stem.

The RockShox Boxxer World Cup with millimeter stanchions has an incredibly easy, hassle-free setup. Simply start with the recommended air pressure for the rider weight and see how that feels. For example, according to the chart, a pound rider would run about psi. From here you can tune the rebound damping to your liking.

Through trial and error, we found the recipe for supple small-bump absorption and smooth, full-travel fork action to be about two psi less than recommended and one click of the Motion Control damping knob.