SRAM BOXXER TEAM 2015 Service Manual
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SRAM BOXXER TEAM 2015 Service Manual

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2015
XX
BO
ER™ TEAM
Service Manual

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Summary of Contents for SRAM BOXXER TEAM 2015

  • Page 1 2015 ER™ TEAM Service Manual...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS BOXXER™ TEAM EXPLODED VIEW ..............................5 ROCKSHOX® SUSPENSION SERVICE ............................. 6 PARTS AND TOOLS NEEDED FOR SERVICE ................................... 6 RECORD YOUR SETTINGS ..........................................7 SERVICE INTERVAL INFORMATION ......................................7 BOXXER TORQUE CHART ..........................................7 BOXXER OIL VOLUME............................................7 FORK REMOVAL ....................................8 LOWER LEG REMOVAL ...................................
  • 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: Boxxer™ Team Exploded View

    B o X X e r ™ T e a m E x p l o d e d V i e w Top cap Knob retaining screw Preload spacers (5 maximum) Low speed compression adjuster knob Upper crown Retaining nut Spring isolator Low speed compression adjuster Compression top cap...

  • Page 6: Rockshox® Suspension Service

    For exploded diagram and part number information, please refer to the Spare Parts Catalog available on our website at sram.com/service. For order information, please contact your local SRAM® distributor or dealer. Information contained in this publication is subject to change at any time without prior notice. For the latest technical information, please visit our website at sram.com/service.

  • Page 7: Record Your Settings

    R e c o r d y o u r S e t t i n g s Use the charts below to record your BoXXer™ fork settings to return your fork to its pre-service settings. Record your service date to track service intervals.

  • Page 8: Fork Removal

    F o r k R e m o v a l We recommend the following steps to remove your BoXXer™ fork from the bicycle. Removing the fork from the bicycle provides easy access to internal components and is more convenient than working around a complete bicycle. To assist you with post-service assembly, record the distance from the top of the upper tube to the top of the lower crown.
  • Page 9 Use a 4 mm hex wrench to loosen the four lower crown and two 4 mm Upper crown upper crown pinch bolts clamping the upper tubes. Do not loosen the steerer tube clamping bolt located on the upper crown. 4 mm Lower crown Slide the upper tubes down so they clear the upper crown.

  • Page 10: Lower Leg Removal

    L o w e r L e g R e m o v a l Clamp the non-drive side upper tube into a bicycle stand. Non-drive side Use a 5 mm hex wrench to loosen the non-drive side bottom bolt 3 to 4 turns.
  • Page 11 Clamp the drive side upper tube into a bicycle stand. Drive side Use a 2.5 mm hex wrench to loosen the set screw and remove the rebound adjuster knob located at the bottom of the drive side lower leg. 2.5 mm Use a 5 mm hex wrench to loosen the drive side bottom bolt 3 to 4 turns.
  • Page 12 Firmly pull the lower leg downward until fluid begins to drain. Continue pulling downward to remove 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.

  • Page 13: Lower Leg Seal Service

    L o w e r L e g S e a l S e r v i c e Place a rag on top of the dust wiper seal. Insert the tip of a downhill tire lever underneath the lower lip of the lower black oil seal located above the upper bushing.
  • Page 14 Hold the lower leg firmly and use the seal installation tool to push the lower oil seal evenly into the leg until the bottom surface of the seal is flush with the bottom of the seal pocket. 35 mm seal installation tool Remove the wire spring from the new dust wiper seal and set the spring aside.

  • Page 15: Coil Spring Service

    C o i l S p r i n g S e r v i c e C o i l S p r i n g R e m o v a l N O T I C E Inspect each part for scratches.

  • Page 16: Coil Spring Removal

    Use your fingers to remove the preload spacer(s). Pull the coil spring from the upper tube. Spray isopropyl alcohol on the preload spacer(s), coil spring, and upper tube threads and clean them with a rag. Verify the three isolators are evenly spaced along the coil spring with approximately 50 mm of exposed coil at each end.
  • Page 17 Spray isopropyl alcohol on the inside and outside of the upper tube and clean it 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.

  • Page 18: Coil Spring Installation

    C o i l S p r i n g I n s t a l l a t i o n Install a new support washer and a new wavy washer on the spring shaft so that the support washer is closest to the spring perch. Install the base plate assembly onto the spring shaft so that the small top out spring is oriented toward the spring perch.
  • Page 19 Apply a generous amount of Liquid O-Ring® PM600 military Small diameter first grease to the coil spring. Use a measuring device to Identify the end of the coil spring with a smaller diameter. Install the smaller end of the coil spring into the top of the upper tube.

  • Page 20: Charger Damper™ Service

    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.
  • Page 21 Use a 24 mm socket to loosen the compression top cap. Remove the Charger Damper assembly from the upper tube. Clean the upper tube threads with a rag. 24 mm Use a pick or your fingers to remove the compression top cap o-ring.
  • Page 22 Use your fingers to remove the outer o-ring on the lower seal head. Use a pick to pierce 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.
  • Page 23 Place a 21 mm open end wrench on the wrench flats on the rebound damper seal head. Place another 21 mm open end wrench on the 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.
  • Page 24 Use your fingers or a pick to remove the rebound damper seal head outer o-ring. Use a pick to pierce and remove the scraper seal. Use your fingers to install a new o-ring and scraper seal. Scraper seal orientation Use your fingers to remove the glide ring from the rebound damper piston.
  • Page 25 Place a 21 mm open end wrench on the wrench flats of the cartridge tube. Hold the coupler in place with the vise and turn the wrench counter-clockwise to loosen and remove the cartridge tube from the coupler. Set the cartridge tube aside. 21 mm Remove the coupler, bladder, and compression top cap assembly from the vise.
  • Page 26 Use needle-nose pliers to remove the low speed compression adjuster from the compression top cap. Needle-nose pliers Use your fingers or 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.
  • Page 27 Use your fingers or a pick to remove 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.
  • Page 28 Clamp a 5/8" hex bit socket into a vise. If the compression top cap came off in step 24, set the bladder on the hex bit socket with the coupler oriented upward. Use a 25 mm open end wrench to 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.
  • Page 29 Use 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. Charger Damper Removal...

  • Page 30: Optional Charger Damper™ Re-Tune

    O p t i o n a l C h a r g e r D a m p e r ™ R e - t u n e The Charger Damper in BoXXer™ comes with additional shims installed on the piston to allow the rider to modify the compression and/or rebound tunes.
  • Page 31 Use the chart below to layout the shim stack for your desired tune Shim thickness on your rebound damper piston. Use a metric caliper to verify the shim outer diameter and shim thickness or print the page at 100% scale to arrange the shim stack using the outlines on the page. All Charger Dampers™...
  • Page 32 Install the shims on a small wrench or pick in the order of your Off center hoop shim desired tune. Slide the shim stack onto the piston face. Use your fingers to squeeze the stack and center the shims. N O T I C E Ensure the hoop shim is centered on the shim stack.

  • Page 33: Optional Compression Re-Tune

    O p t i o n a l C o m p r e s s i o n R e - t u n e Clamp the compression piston shaft into a RockShox® Rear Shock Vise Block. N O T I 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.
  • Page 34 Use the chart below to layout the shim stack for your desired tune Shim thickness on your compression piston. Use a metric caliper to verify the shim outer diameter and shim thickness or print the page at 100% scale to arrange the shim stack using the outlines on the page. All Charger Dampers™...
  • Page 35 Apply a small amount of Loctite® Threadlocker Red 2760™ on the compression shaft threads. N O T I C E Do not allow the Loctite to come in contact with the shims. Loctite Threadlocker Red 2760 Install the shims on a small wrench in the order of your desired tune.
  • Page 36 Thread the piston bolt onto the compression damper shaft. Use a torque wrench with a 10 mm socket to tighten the nut to 3.7 N•m (33 in-lb). N O T I C E Ensure the check shim is centered, and not pinched by the piston bolt.

  • Page 37: Charger Damper™ Assembly And Bleed

    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.
  • Page 38 Clamp the wrench flats on the coupler into a vise with the compression top cap facing up. Use a torque wrench with a 24 mm socket to tighten the compression top cap to 4.5-5.5 N•m (40-50 in-lb). N O T I C E Ensure the bladder does not twist during installation.
  • Page 39 Install the rebound damper seal head onto the rebound damper shaft with the threads oriented toward the piston. Install the rebound damper, piston side first, into the top of the cartridge tube. Use your fingers to thread the rebound damper seal head into the top of the cartridge tube.
  • Page 40 Remove the cartridge tube assembly from the bicycle stand, turn it over, and clamp the cartridge tube assembly in the bicycle stand so the rebound shaft is oriented downward. Pull down on the rebound shaft. Pour RockShox® 3wt suspension fluid into the cartridge tube until it is approximately half full.
  • Page 41 Insert the low speed compression needle into the compression piston assembly. Use your hand or a 2.5 mm hex wrench to turn the needle clockwise until it stops, and then unthread it a 1/2 turn. Wrap a rag around the cartridge tube. Insert the compression piston assembly into the cartridge tube.
  • Page 42 Pour RockShox® 3wt suspension fluid into the compression top cap until it is approximately half full. Use the palm of your hand or a rag to cover the compression top cap, and cycle the rebound damper shaft a few times to help pre-bleed air from the damper.
  • Page 43 Fill the bleed syringe 1/3 full with 3wt suspension fluid and thread the syringe into the compression top cap assembly. Create a vacuum in the damper assembly by pulling up on the syringe handle and simultaneously pushing up on the rebound damper shaft.
  • Page 44 Make sure the rebound damper shaft is fully extended by pulling down on the shaft. Push the syringe handle down and release it. Allow the bladder to come to its natural resting position by waiting a few moments until the syringe stops filling. Use a rag to cover the syringe tip and compression top cap bleed port, then unthread and remove the syringe.
  • Page 45 Use a torque wrench with a 24 mm socket to tighten the compression top cap to 7.3 N•m (65 in-lb). Apply SRAM® Butter to the scraper in the lower seal head and install it onto the rebound shaft with the flat side of the lower seal head facing the upper tube.
  • Page 46 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) Charger Damper™ Assembly and Bleed...

  • Page 47: Lower Leg Assembly

    Spray isopropyl alcohol on the upper tubes and clean them with a rag. Apply a liberal amount of SRAM® Butter to the inner surfaces of the lower oil seals and dust wiper seals. Slide the upper tube with the Charger Damper™ into the drive side lower leg just enough to engage the upper bushing with the upper tube.
  • Page 48 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 Drive side non-drive side and drive side bottom bolts.

  • Page 49: Fork Installation

    F o r k I n s t a l l a t i o n Slide each upper tube through the lower crown. Leave enough 10 1 clearance between the upper tube and the upper crown to install the frame bumpers. Use a 4 mm hex wrench to tighten one of the lower crown bolts to temporarily hold the tubes in place while you install the bumper.
  • Page 50 Use a torque wrench with a 4 mm hex bit socket to tighten the top bolt on the lower crown to 5 N•m (44 in-lb). Use a 4 mm hex bit socket to tighten the bottom bolt on the lower crown to 5 N•m (44-lb).
  • Page 51 Install the threaded end of the Maxle Lite DH™ through the drive side of the hub until it engages the threads of the lower leg dropout. Use a torque wrench with a 6 mm hex bit socket to tighten the drive side axle bolt to 5.7 N•m (50 in-lb).
  • Page 52 This publication includes trademarks and registered trademarks of the following companies: Loctite® is a registered trademark of Henkel Corporation...
  • Page 53 GEN.0000000004678 Rev B © 2014 SRAM, LLC...

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2015 boxxer team

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