advertisement
2015
BO
XX
ER™ TEAM
Service Manual
SRAM LLC WARRANTY
EXTENT OF LIMITED WARRANTY
Except as otherwise set forth herein, SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after original purchase.
This warranty only applies to the original owner and is not transferable. Claims under this warranty must be made through the retailer where the bicycle or the SRAM component was purchased. Original proof of purchase is required.
Except as described herein, SRAM makes no other warranties, guaranties, or representations of any type (express or implied), and all warranties (including any implied warranties of reasonable care, merchantibility, or fitness for a particular purpose) are hereby disclaimed.
LOCAL LAW
This warranty statement gives the customer specific legal rights. The customer may also have other rights which vary from state to state (USA), from province to province (Canada), and from country to country elsewhere in the world.
To the extent that this warranty statement is inconsistent with the local law, this warranty shall be deemed modified to be consistent with such law, under such local law, certain disclaimers and limitations of this warranty statement may apply to the customer. For example, some states in the United States of America, as well as some governments outside of the United States (including provinces in
Canada) may: a. Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer
(e.g. United Kingdom).
b. Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations.
For Australian customers:
This SRAM limited warranty is provided in Australia by SRAM LLC, 1333 North Kingsbury, 4th floor, Chicago, Illinois, 60642, USA. To make a warranty claim please contact the retailer from whom you purchased this SRAM product. Alternatively, you may make a claim by contacting SRAM Australia, 6 Marco Court, Rowville 3178, Australia. For valid claims SRAM will, at its option, either repair or replace your SRAM product. Any expenses incurred in making the warranty claim are your responsibility. The benefits given by this warranty are additional to other rights and remedies that you may have under laws relating to our products. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable 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 have been incorrectly installed and/or adjusted according to the respective SRAM user manual. The SRAM user manuals can be found online at sram.com, rockshox.com, avidbike.com, truvativ.com, or zipp.com.
This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance with manufacturers specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design.
This warranty does not apply when the product has been modified, including, but not limited to any attempt to open or repair any electronic and electronic related components, including the motor, controller, battery packs, wiring harnesses, switches, and chargers.
This warranty does not apply when the serial number or production code has been deliberately altered, defaced or removed.
This warranty does not apply to normal wear and tear. Wear and tear parts are subject to damage as a result of normal use, failure to service according to SRAM recommendations and/or riding or installation in conditions or applications other than recommended.
Wear and tear parts are identified as:
• Dust seals
• Bushings
• Air sealing o-rings
• Glide rings
• Rubber moving parts
• Foam rings
• Rear shock mounting hardware and main seals
• Upper tubes (stanchions)
• Stripped threads/bolts
(aluminium, titanium, magnesium or steel)
• Brake sleeves
• Brake pads
• Chains
• Sprockets
• Cassettes
• Shifter and brake cables (inner and outer)
• Handlebar grips
• Shifter grips
• Jockey wheels
• Disc brake rotors
• Wheel braking surfaces
• Bottomout pads
• Bearings
• Bearing races
• Pawls
• Transmission gears
• Spokes
• Free hubs
• Aero bar pads
• Corrosion
• Tools
• Motors
• Batteries
Notwithstanding anything else set forth herein, this warranty is limited to one year for all electronic and electronic related components including motors, controllers, battery packs, wiring harnesses, switches, and chargers. The battery pack and charger warranty does not include damage from power surges, use of improper charger, improper maintenance, or such other misuse.
This warranty shall not cover damages caused by the use of parts of different manufacturers.
This warranty shall not cover damages caused by the use of parts that are not compatible, suitable and/or authorised by SRAM for use with SRAM components.
This warranty shall not cover damages resulting from commercial (rental) use.
TABLE OF CONTENTS
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!
B o X X e r ™ T e a m E x p l o d e d V i e w
Knob retaining screw
Low speed compression adjuster knob
Retaining nut
Low speed compression adjuster
Compression top cap
Bladder and bladder sleeve
Low speed compression needle
Top cap
Preload spacers (5 maximum)
Upper crown
Spring isolator
Coil spring
Steerer tube
Lower crown
Compression piston assembly
Coupler
Cartridge tube
Upper tube
Rebound damper piston assembly
Lower leg
Inner scraper seal
Rebound damper seal head
Inner scraper seal
Lower seal head
Bottom out bumper
Retaining ring
Rebound damper shaft
Crush washer
Bottom bolt
Set screw
Rebound adjuster knob
Spring perch
Support washer
Wavy washer
Base plate assembly
Spring shaft assembly
Retaining ring
Crush washer
Crush washer retainer
Bottom bolt
BoXXer™ Team Exploded View 5
R o c k S h o x ® S u s p e n s i o n S e r v i c e
We recommend that you have your RockShox suspension serviced by a qualified bicycle mechanic. Servicing RockShox suspension requires knowledge of suspension components as well as the special tools and fluids used for 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.
Your product's appearance may differ from the pictures contained in this publication.
P a r t s a n d T o o l s N e e d e d f o r S e r v i c e
• Safety glasses
• Nitrile gloves
• Apron
• 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 mm crowfoot wrenches
• 2, 2.5, 4, 5, 6, and 8 mm hex wrenches
• 5/8", 2, 2.5, 4, 5, and 6 mm hex bit sockets
• 6, 10, 15, and 24 mm socket wrenches
• Torque wrench
• Needle-nose pliers
• Large internal snap ring pliers
• Pick
• Long plastic or wooden dowel
• RockShox syringe with Charger™ bleed tip
• Loctite® Threadlocker Blue 242™
• Loctite® Threadlocker Red 2760™
• Metric calipers (for re-tuning shim stacks)
• Ruler
• RockShox Rear Shock Vise Block (for re-tuning shim stacks)
• Cable tie (26")
• Heat gun or hair dryer
S A F E T Y I N S T R U C T I O N S
Always wear nitrile gloves when working with suspension fluid and bicycle grease.
Place an oil pan on the floor underneath the area where you will be working on the fork.
RockShox® Suspension Service 6
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.
Service date - helps you keep track of service intervals.
Dual Crown height - measure the distance from the top of the upper to tube to the top of the lower crown (see figure in Step 1).
Rebound setting - count the number of clicks while turning the rebound adjuster fully counter-clockwise.
Compression setting - count the number of clicks while turning the compression adjuster fully counter-clockwise.
S e r v i c e I n t e r v a l I n f o r m a t i o n
Maintenance
Clean dirt and debris from upper tubes
Inspect upper tubes for scratches
Check front suspension fasteners for proper torque
Remove lowers, clean/inspect bushings and change oil bath
Clean and lubricate coil spring assembly
Change oil in damping system
B o X X e r T o r q u e C h a r t
Interval (hours)
Every ride
Every ride
25
50
100
100
Part Tool
Maxle Lite DH™ (non-drive side)
6 mm hex bit socket
Maxle Lite DH (drive side)
6 mm hex bit socket
Crown bolts
4 mm hex bit socket
Bottom bolts
5 mm hex bit socket
Top caps
24 mm socket
B o X X e r O i l V o l u m e
Part
Drive side lower leg
Non-drive side lower leg
Drive side upper tube
Non-drive side upper tube
Torque
8 clicks or 3.4 N•m (30 in-lb)
5.7 N•m (50 in-lb)
5 N•m (44 in-lb)
7.3 N•m (65 in-lb)
7.3 N•m (65 in-lb)
Oil Weight
0w-30
3wt
Volume (mL)
10
20
Bleed (varies)
Liquid O-Ring® PM600 military grease
Record your Settings 7
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.
1
To assist you with post-service assembly, record the distance from the top of the upper tube to the top of the lower crown.
2
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.
3
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.
6 mm
4
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 to cut the cable tie holding the brake hose to the fork arch.
Remove the brake caliper according to the brake manufacturer's instructions.
6 mm
Fork Removal 8 space between frames space between steps
5
Use a 4 mm hex wrench to loosen the four lower crown and two upper crown pinch bolts clamping the upper tubes.
Do not loosen the steerer tube clamping bolt located on the upper crown.
6
Slide the upper tubes down so they clear the upper crown. Leave enough clearance between the upper tube and upper crown to remove 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 remove the frame bumpers.
4 mm Lower crown
4 mm
7
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.
4 mm Upper crown
8
Use a 4 mm hex wrench to loosen the lower crown bolt. Slide the tubes through the lower crown and remove the fork from the bicycle.
Spray isopropyl alcohol on the upper tubes and crown clamping surface and clean them with a rag.
4 mm
Fork Removal 9
L o w e r L e g R e m o v a l
1
Clamp the non-drive side upper tube into a bicycle stand.
Non-drive side
2
Use a 5 mm hex wrench to loosen the non-drive side bottom bolt
3 to 4 turns.
3
Place an oil pan beneath the fork to catch any draining fluid. Use a plastic mallet to firmly strike the non-drive side bottom bolt to dislodge the spring shaft from the lower leg.
Use a 5 mm hex wrench to remove the bottom bolt from the lower leg.
5 mm Loosen 3 to 4 turns
5 mm
4
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 OT I C E
Do not hit the fork arch with any tool when removing the lower leg as this could damage the lower leg.
Plastic mallet
Lower Leg Removal 10
5
Clamp the drive side upper tube into a bicycle stand.
6
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.
7
Use a 5 mm hex wrench to loosen the drive side bottom bolt 3 to
4 turns.
2.5 mm
Drive side
8
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.
5 mm Loosen 3 to 4 turns
5 mm
Plastic mallet
Lower Leg Removal 11
9
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.
N OT I C E
Do not hit the fork arch with any tool when removing the lower leg as this could damage the fork.
Lower Leg Removal 12
L o w e r L e g S e a l S e r v i c e
1
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.
N OT I C E
If using a flat head screwdriver, make sure it has a round shaft. A screwdriver with a square shaft will damage the lower leg.
2
Stabilize the lower leg on a bench top or on the floor. Press down on the downhill tire lever handle to remove both seals at the same time. Repeat on the other side.
N OT I 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.
3
Spray isopropyl alcohol on the inside and outside of the lower leg and clean it with a rag.
Wrap a rag around a long dowel and insert it into each lower leg to clean the inside.
Downhill tire lever
4
Position the new lower oil seal, with the grooved side visible, onto the stepped side of a 35 mm seal installation tool.
35 mm seal installation tool
Lower Leg Seal Service 13
5
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.
6
Remove the wire spring from the new dust wiper seal and set the spring aside.
Insert the narrow end of the new dust wiper seal into the recessed end of the 35 mm seal installation tool.
35 mm seal installation tool
7
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.
35 mm seal installation tool
35 mm seal installation tool
Lower Leg Seal Service 14
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 OT I C E
Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your 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 grease to the new seal or o-ring.
1
Clamp the non-drive side upper tube into a bicycle stand.
2
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.
3
Use your fingers or a pick to remove the top cap o-ring. Use your fingers to install a new o-ring.
24 mm
Non-drive side
Coil Spring Service 15
4
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.
5
Verify the three isolators are evenly spaced along the coil spring with approximately 50 mm of exposed coil at each end.
To reposition an isolator, thread it along the coil by hand. Use a heat gun or hair dryer to shrink and secure the isolator in its position. Gradually heat the isolator until it emits a vapor.
C AU T I 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.
6
Place the tips of large internal snap ring pliers into the eyelets of the retaining ring. Press firmly on the pliers to push the base plate into the upper tube enough to compress and remove the retaining ring.
Slide the retaining ring onto your finger and release the spring shaft.
7
Remove the spring shaft assembly from the upper tube.
Snap ring pliers
Coil Spring Removal 16 space between frames space between steps
8
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.
9
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.
Coil Spring Removal 17
C o i l S p r i n g I n s t a l l a t i o n
1
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.
2
Firmly push the spring shaft assembly into the bottom of the upper tube until the retaining ring groove is visible.
3
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 shaft.
Retaining rings have a sharper-edged side and a rounder-edged side. Installing retaining rings with the sharper-edged side facing the tool will allow for easier installation and removal.
Coil Spring Installation 18 space between frames space between steps
4
Apply a generous amount of Liquid O-Ring® PM600 military 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.
Small diameter first
5
Use a measuring device to measure 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 OT I C E
Installing more than five preload spacers into the upper tube will cause damage to your fork.
< 16 mm
6
Insert the top cap into the top of the upper tube.
Use a torque wrench with a 24 mm socket to tighten the top cap to 7.3 N·m (65 in-lb).
5 max
24 mm 7.3 N•m (65 in-lb)
Coil Spring Installation 19
C h a r g e r D a m p e r ™ S e r v i c e
C h a r g e r D a m p e r R e m o v a l
N OT I C E
Use aluminum soft jaws to protect the Charger Damper assembly when using a vice.
Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your 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.
1
Clamp the drive side upper tube into a bicycle stand.
Drive side
2
Use your fingers to remove the bottom out bumper from the rebound damper shaft.
3
Use a 2 mm hex wrench to remove the knob retaining screw.
Remove the low speed compression adjuster knob.
2 mm
Charger Damper™ Service 20
4
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.
5
Use a pick or your fingers to remove the compression top cap o-ring. Install a new compression top cap o-ring.
24 mm
6
Use large internal snap ring pliers to remove the retaining ring from the bottom of the upper tube.
7
Insert a long dowel into the top of the upper tube and push the lower seal head out the bottom of the upper tube.
Snap ring pliers
Charger Damper Removal 21
8
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.
9
Remove the drive side upper tube from the bicycle stand.
Clamp the cartridge tube into a bicycle stand with the rebound damper oriented upward.
Scraper seal orientation
Charger Damper Removal 22
10
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.
21 mm 21 mm space between frames space between steps
11
Remove the cartridge tube from the bicycle stand and pour the fluid into an oil pan.
12
Remove the rebound damper seal head from the rebound damper shaft.
Charger Damper Removal 23
13
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.
14
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.
15
Clamp the wrench flats of the coupler into a vice with the cartridge tube oriented upward.
N OT I C E
Do not clamp the cartridge tube in the vise.
Scraper seal orientation
Charger Damper Removal 24
16
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.
17
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.
21 mm
18
Pour the fluid into an oil pan.
Needle-nose pliers
19
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 compression top cap.
6 mm
Charger Damper Removal 25 space between frames space between steps
20
Use needle-nose pliers to remove the low speed compression adjuster from the compression top cap.
21
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.
22
Use your fingers or a pick to remove the o-ring from the compression piston.
Use your fingers to install a new o-ring.
23
Use your fingers or a 2.5 mm hex wrench to remove the low speed compression needle.
2.5 mm
Needle-nose pliers
Charger Damper Removal 26
24
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.
25
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 mm
Charger Damper Removal 27
26
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. Use a
24 mm socket wrench to remove the compression top cap.
Remove the assembly from the vise.
5/8"
5/8" To remove the top cap 24 mm
27
Use a pick or your fingers to remove the o-ring inside the coupler.
Use your fingers to install a new o-ring.
5/8" To remove the coupler 25 mm
Charger Damper Removal 28
28
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 29
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.
If your rebound setting is one or two clicks from open, we recommend changing to a soft tune on the rebound. If your compression setting is one or two clicks from open, we recommend changing to a soft tune on the compression.
Conversely, if your rebound setting is one or two clicks from closed, we recommend 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
1
Clamp the bottom of the rebound damper shaft into a RockShox
®
Rear Shock Vise Block.
N OT I C E
To prevent damage to the rebound damper shaft, do not clamp the middle of the shaft in the vise.
2
Use a 10 mm socket to remove the piston nut. Use your hand to stabilize the rebound damper shaft.
3
Use a small wrench or pick to slide the shims off of the rebound damper piston. Set the shims on a rag in the order they came off of the piston.
10 mm
Small wrench
Optional Charger Damper™ Re-tune 30
4
Use the chart below to layout the shim stack for your desired tune 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™ in BoXXer™ ship with the Medium Damper
Tune installed.
100 mm
*Print this page at 100% scale and use the chart to layout your desired rebound tune.
Soft Rebound Tune
1:1* Shim Size
Outer Dimension
(mm)
1:1* Shim
Thickness
(mm)
8
0.3
12
0.1
14
0.1
16
0.1
8
0.2
16
Piston Face
Bottom of stack
0.1
16
0.1
Shim diameter
Medium Rebound Tune
(Stock Tune)
1:1* Shim Size
Outer Dimension
(mm)
1:1* Shim
Thickness
(mm)
16
0.1
Firm Rebound Tune
1:1* Shim Size
Outer Dimension
(mm)
1:1* Shim
Thickness
(mm)
8
0.3
14
0.1
14
8
8
12
0.1
0.2
0.3
0.1
16
8
12
0.1
0.2
0.1
16
16 Hoop
0.1
0.2
16
Shim thickness
16 Hoop
0.1
0.2
14
0.1
14
0.1
14
0.1
16
Piston Face
Bottom of stack
0.1
16
Piston Face
Bottom of stack
0.1
16 Hoop
0.2
If using the soft tune,
16 x 6 x 0.1, 14 x 6 x 0.1, and
16 x 14 x 0.2 are not used.
Save them so they can be reinstalled if you change your tune to Medium or
Firm.
Optional Rebound Re-tune 31
5
Install the shims on a small wrench or pick in the order of your desired tune. Slide the shim stack onto the piston face. Use your fingers to squeeze the stack and center the shims.
N OT I C E
Ensure the hoop shim is centered on the shim stack.
Off center hoop shim
6
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 OT I C E
Ensure the check shim is centered, and not pinched under the piston.
Remove the assembly from the vise.
Centered shim stack
10 mm 3.7 N•m (33 in-lb)
Pinched check shim
Centered check shim space between frames space between steps space between frames space between steps
Optional Rebound Re-tune 32
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
1
Clamp the compression piston shaft into a RockShox® Rear Shock
Vise Block.
N OT 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.
2
Use a 10 mm socket to remove the piston bolt.
3
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.
10 mm
Small wrench
Optional Compression Re-tune 33
4
Use the chart below to layout the shim stack for your desired tune 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™ in BoXXer™ ship with the Medium Damper
Tune installed.
100 mm
*Print this page at 100% scale and use the chart to layout your desired rebound tune.
Soft Compression Tune
1:1* Shim Size
Outer Dimension
(mm)
1:1* Shim
Thickness
(mm)
16
0.1
Shim thickness
Medium CompressionTune
(Stock Tune)
1:1* Shim Size
Outer Dimension
(mm)
1:1* Shim
Thickness
(mm)
Shim diameter
Firm CompressionTune
1:1* Shim Size
Outer Dimension
(mm)
1:1* Shim
Thickness
(mm)
16
0.1
16
0.15
18
18
8
8
8
8
18
0.2
0.15
0.3
0.3
0.3
0.3
0.15
18
8
8
8
8
18
18
0.2
0.3
0.3
0.3
0.3
0.15
0.15
18
8
8
8
8
18
18
0.15
0.3
0.3
0.3
0.3
0.2
0.15
18
0.15
18
0.15
18
0.15
18
0.15
18 Hoop
0.3
16
0.15
18
0.1
Piston Face/Bottom of stack
18
0.15
18 Hoop
0.3
16
0.15
18
0.1
Piston Face/Bottom of stack
18
0.15
18 Hoop
0.3
16
0.1
18
0.1
Piston Face/Bottom of stack
5
Apply a small amount of Loctite® Threadlocker Red 2760™ on the compression shaft threads.
N OT I C E
Do not allow the Loctite to come in contact with the shims.
6
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 OT I C E
Ensure the hoop shim is centered on the rest of the shim stack.
Loctite Threadlocker Red 2760
Off center hoop shim
Centered shim stack space between frames space between steps
Optional Compression Re-tune 35
7
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 OT I 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)
Pinched check shim
Centered check shim space between frames space between steps
Optional Compression Re-tune 36
C h a r g e r D a m p e r ™ A s s e m b l y a n d B l e e d
N OT I C E
Use aluminum soft jaws to protect the Charger Damper assembly when using a vice.
Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your 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.
1
Use your fingers to install the bladder onto the bladder sleeve.
Ensure that it is centered between the ends of the sleeve.
2
Apply a liberal amount of SRAM Butter onto both ends of the bladder.
3
Thread the compression top cap and coupler into either side of the bladder assembly.
Charger Damper™ Assembly and Bleed 37
4
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 OT I C E
Ensure the bladder does not twist during installation. If the bladder starts to twist, unthread the compression top cap and coupler and repeat steps 1-4.
5
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.
24 mm 4.5-5.5 N•m (40-50 in-lb)
6
Clamp the cartridge tube into a bicycle stand with the threads at the bottom and the wrench flats at the top.
Charger Damper™ Assembly and Bleed 38
7
Install the rebound damper seal head onto the rebound damper shaft with the threads oriented toward the piston.
8
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.
9
Place a torque wrench with a 21 mm crowfoot open end wrench on the wrench flats on the 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.
21 mm 9-10 N•m (80-90 in-lb) 21 mm
10
Insert a 2.5 mm hex wrench into the rebound shaft until it contacts the rebound adjuster screw. Turn the hex wrench counter-clockwise until it stops. The rebound adjuster is now in the open position.
2.5 mm
Charger Damper™ Assembly and Bleed 39 space between frames space between steps
11
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.
12
Pour RockShox® 3wt suspension fluid into the cartridge tube until it is approximately half full.
13
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 T I O N - E Y E H A Z A R D
Pull the rebound damper shaft down slowly. Failure to do so can result in fluid ejecting from the cartridge tube. Wear safety glasses.
3wt
3wt
Charger Damper™ Assembly and Bleed 40
14
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.
N OT I C E
Failure to unthread the needle a 1/2 turn will prevent the fork from performing properly.
2.5 mm
15
Spray isopropyl alcohol on the cartridge tube threads and clean the threads with a rag.
Spray isopropyl alcohol on the threads inside the coupler and clean the threads with a rag.
16
Apply a small amount of Loctite® Threadlocker Blue 242™ on the coupler threads.
N OT I C E
Do not allow the Loctite to come in contact with the o-rings or bladder.
17
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 wrench on the wrench flats on the damper cartridge tube.
While holding the damper cartridge tube in place, tighten the coupler 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.
Loctite Threadlocker Blue 242
25 mm 9-10 N•m (80-90 in-lb) 21 mm
Charger Damper™ Assembly and Bleed 41
18
Pour RockShox® 3wt suspension fluid into the compression top cap until it is approximately half full.
19
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.
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 T I O N - E Y E H A Z A R D
Fluid may be ejected from the damper top cap assembly. Wear safety glasses.
3wt
20
Fully extend the rebound damper shaft by pulling down on the rebound damper shaft.
3wt
Charger Damper™ Assembly and Bleed 42 space between frames space between steps
21
Fill the bleed syringe 1/3 full with 3wt suspension fluid and thread the syringe into the compression top cap assembly.
22
Create a vacuum in the damper assembly by pulling up on the syringe handle and simultaneously pushing up on the rebound damper shaft. 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 the damper assembly until only very small bubbles emerge from the damper assembly.
3wt
Charger Damper™ Assembly and Bleed 43
23
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.
C AU T I 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.
24
Install the low speed compression adjuster into the compression top cap by hand.
25
Install the compression top cap retaining nut by hand. Use a torque wrench with a 6 mm socket to tighten to 4.8 N•m
(42 in-lb).
6 mm 4.8 N•m (42 in-lb)
Charger Damper™ Assembly and Bleed 44
26
Spray isopropyl alcohol on the Charger Damper™ assembly and clean it with a rag.
27
Insert the Charger Damper assembly into the top of the upper tube that has the BoXXer™ graphic printed on it.
Use a torque wrench with a 24 mm socket to tighten the compression top cap to 7.3 N•m (65 in-lb).
28
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. Push the lower seal head into the bottom of the upper tube.
Push the rebound damper shaft into the upper tube to prevent it from getting scratched while installing the retaining ring.
N OT I 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 the retaining ring and seal head back and forth a few times, then firmly pull down on the rebound shaft.
Retaining rings have a sharper-edged side and a rounder-edged side. Installing retaining rings with the sharper-edged side facing
the tool will allow for easier installation and removal.
29
Use your fingers to install the bottom out bumper onto the rebound damper shaft with the smaller end pointed away from the top.
24 mm 7.3 N•m (65 in-lb)
Charger Damper™ Assembly and Bleed 45
30
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 46
L o w e r L e g A s s e m b l y
1
Spray isopropyl alcohol on the upper tubes and clean them with a rag.
2
Apply a liberal amount of SRAM® Butter to the inner surfaces of the lower oil seals and dust wiper seals.
3
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.
Slide the upper tube with the coil spring into the non-drive side lower leg just enough to engage the upper bushing with the upper tube.
N OT I C E
Make sure both dust wiper seals slide onto the tubes without folding the outer lip of either seal.
4
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 into the drive side lower leg, and 20 mL of RockShox 0w-30 suspension fluid into the non-drive side lower leg.
N OT I C E
Do not exceed the recommended fluid volume per leg as this can damage the fork. Do not let fluid fill the rebound shaft.
DS: 10 mL NDS: 20 mL RockShox 0w-30 suspension fluid
Lower Leg Assembly 47
5
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.
6
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.
Drive side
7
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).
Non-drive side
5 mm 7.3 N·m (65 in-lb)
8
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.
5 mm 7.3 N·m (65 in-lb)
2.5 mm 1.1 N·m (10 in-lb)
9
Spray isopropyl alcohol on the entire fork and clean it with a rag.
Lower Leg Assembly 48
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 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.
2
Spray isopropyl alcohol or water on the inner surfaces of each frame bumper and upper tube. Reinstall the frame bumpers onto the upper tubes.
4 mm
3
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 mm (+/- 2 mm).
4
Align the BoXXer™ logo on the drive side upper tube with the
RockShox ® logo on the lower leg.
156 mm (+/- 2 mm)
Fork Installation 49 space between frames space between steps space between frames space between steps
5
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). Tighten the top bolt to torque once more, and then tighten the bottom to torque again.
Repeat this tightening procedure for the bolts on the other side of the lower crown.
6
Use a torque wrench with a 4 mm hex bit socket to tighten the two upper crown pinch bolts to 5 N•m (44 in-lb).
4 mm 5 N•m (44 in-lb)
7
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.
4 mm 5 N•m (44 in-lb)
8
Position the front wheel in the lower leg dropouts so the hub is seated in the dropouts.
N OT I C E
Verify no parts interfere with the lower leg. Consult your brake manufacturer's instructions if you need to adjust your disc brakes.
Fork Installation 50
9
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).
10
Use a 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).
6 mm 5.7 N•m (50 in-lb)
11
Refer to your pre-service recorded settings to adjust the rebound and compression settings on the fork.
6 mm 8 clicks or 3.4 N•m (30 in-lb)
12
Spray isopropyl alcohol on the entire fork and clean it with a rag.
This concludes the service for RockShox® BoXXer™ front suspension forks.
Fork Installation 51
This publication includes trademarks and registered trademarks of the following companies:
Loctite® is a registered trademark of Henkel Corporation
www.sram.com
GEN.0000000004678 Rev B © 2014 SRAM, LLC
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project