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
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 ................................................................................................................................................................... 10
LOWER LEG SEAL SERVICE ........................................................................................................................................................................................................... 13
COIL SPRING SERVICE ....................................................................................................................................................................15
COIL SPRING REMOVAL...................................................................................................................................................................................................................15
COIL SPRING INSTALLATION ........................................................................................................................................................................................................ 18
CHARGER DAMPER™ SERVICE .....................................................................................................................................................20
CHARGER DAMPER REMOVAL ....................................................................................................................................................................................................20
OPTIONAL CHARGER DAMPER™ RE-TUNE ................................................................................................................................30
OPTIONAL REBOUND RE-TUNE .................................................................................................................................................................................................30
OPTIONAL COMPRESSION RE-TUNE ....................................................................................................................................................................................... 33
CHARGER DAMPER™ ASSEMBLY AND BLEED ........................................................................................................................... 37
LOWER LEG ASSEMBLY .................................................................................................................................................................47
FORK INSTALLATION .....................................................................................................................................................................49
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!
BoXXer™ Team Exploded View
Top cap
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
Compression piston assembly
Coupler
Preload spacers (5 maximum)
Upper crown
Spring isolator
Coil spring
Steerer tube
Lower crown
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
Spring perch
Support washer
Wavy washer
Base plate assembly
Spring shaft assembly
Retaining ring
Crush washer
Crush washer retainer
Bottom bolt
Bottom bolt
Set screw
Rebound adjuster knob
5BoXXer™ Team Exploded View
RockShox® Suspension Service
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 dier from the pictures contained in this publication.
Parts and Tools Needed for Service
• 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
SAFETY INSTRUCTIONS
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.
6RockShox® Suspension Service
Record your Settings
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.
Service Interval Information
Maintenance Interval (hours)
Clean dirt and debris from upper tubes Every ride
Inspect upper tubes for scratches Every ride
Check front suspension fasteners for proper torque 25
Remove lowers, clean/inspect bushings and change oil bath 50
Clean and lubricate coil spring assembly 100
Change oil in damping system 100
BoXXer Torque Chart
Part Tool Torque
Maxle Lite DH™ (non-drive side)
Maxle Lite DH (drive side)
Crown bolts
Bottom bolts
Top caps
6 mm hex bit socket
6 mm hex bit socket
4 mm hex bit socket
5 mm hex bit socket
24 mm socket
8 clicks or 3.4 N•m
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)
BoXXer Oil Volume
Part Oil Weight Volume (mL)
Drive side lower leg
Non-drive side lower leg
Drive side upper tube
Non-drive side upper tube
0w-30
3wt Bleed (varies)
Liquid O-Ring® PM600 military grease
10
20
(30 in-lb)
7Record your Settings
Fork Removal
6 mm
6 mm
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
1
the top of the upper tube to the top of the lower crown.
Use a 6 mm hex wrench to loosen the non-drive side bolt of the
2
Maxle Lite DH™ until detent clicks are no longer felt.
Use a 6 mm hex wrench to remove the Maxle Lite DH from the
3
drive side of the fork. Pull the wheel down to remove it from the
fork.
27.5" forks: Use a 2.5 mm hex wrench to remove the brake hose
4
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.
8Fork Removal
Use a 4 mm hex wrench to loosen the four lower crown and two
4 mm Lower crown
4 mm Upper crown
4 mm7 4 mm
5
upper crown pinch bolts clamping the upper tubes.
Do not loosen the steerer tube clamping bolt located on the
upper crown.
Slide the upper tubes down so they clear the upper crown. Leave
6
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.
Use your thumb to pry the thickest section of each frame bumper
away from the upper tube. Spray isopropyl alcohol or water
between each bumper and upper tube. Twist the frame bumpers
back and forth until they are loose on the upper tubes.
Remove the frame bumpers from the upper tubes.
Use a 4 mm hex wrench to loosen the lower crown bolt. Slide
8
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.
9Fork Removal
Lower Leg Removal
Non-drive side
5 mm Loosen 3 to 4 turns
Plastic mallet
5 mm
Clamp the non-drive side upper tube into a bicycle stand.
1
Use a 5 mm hex wrench to loosen the non-drive side bottom bolt
2
3 to 4 turns.
Place an oil pan beneath the fork to catch any draining fluid. Use
3
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.
Firmly pull the lower leg downward until fluid begins to drain.
4
Continue pulling downward to remove the lower leg from the
non-drive side upper tube.
If the lower leg does not slide o 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.
NOTICE
Do not hit the fork arch with any tool when removing the lower leg
as this could damage the lower leg.
10Lower Leg Removal
Clamp the drive side upper tube into a bicycle stand.
Drive side
2.5 mm
5 mm Loosen 3 to 4 turns
Plastic mallet
5 mm
5
Use a 2.5 mm hex wrench to loosen the set screw and remove the
6
rebound adjuster knob located at the bottom of the drive side
lower leg.
Use a 5 mm hex wrench to loosen the drive side bottom bolt 3 to
7
4 turns.
Place an oil pan beneath the fork to catch any draining fluid.
8
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.
11Lower Leg Removal
Firmly pull the lower leg downward until fluid begins to drain.
9
Continue pulling downward to remove the lower leg from the fork.
If the lower leg does not slide o 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.
NOTICE
Do not hit the fork arch with any tool when removing the lower leg
as this could damage the fork.
12Lower Leg Removal
Lower Leg Seal Service
Downhill tire lever
35 mm seal installation tool
Place a rag on top of the dust wiper seal. Insert the tip of a
1
downhill tire lever underneath the lower lip of the lower black oil
seal located above the upper bushing.
NOTICE
If using a flat head screwdriver, make sure it has a round shaft. A
screwdriver with a square shaft will damage the lower leg.
Stabilize the lower leg on a bench top or on the floor. Press down
2
on the downhill tire lever handle to remove both seals at the same
time. Repeat on the other side.
NOTICE
Keep the lower leg assembly stable. Do not allow the lower leg to
twist in opposite directions, compress toward each other, or be
pulled apart. This will damage the lower leg.
Spray isopropyl alcohol on the inside and outside of the lower leg
3
and clean it with a rag.
Wrap a rag around a long dowel and insert it into each lower leg to
clean the inside.
Position the new lower oil seal, with the grooved side visible, onto
4
the stepped side of a 35 mm seal installation tool.
13Lower Leg Seal Service
Hold the lower leg firmly and use the seal installation tool to push
35 mm seal installation tool
35 mm seal installation tool
35 mm seal installation tool
5
the lower oil seal evenly into the leg until the bottom surface of
the seal is flush with the bottom of the seal pocket.
Remove the wire spring from the new dust wiper seal and set the
6
spring aside.
Insert the narrow end of the new dust wiper seal into the recessed
end of the 35 mm seal installation tool.
Hold the lower leg firmly and use the seal installation tool to push
7
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.
14Lower Leg Seal Service
Coil Spring Service
Non-drive side
24 mm
Coil Spring Removal
NOTICE
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.
Clamp the non-drive side upper tube into a bicycle stand.
1
Use a 24 mm socket to remove the top cap.
2
Spray isopropyl alcohol on the upper tube threads and clean the
threads with a rag.
Use your fingers or a pick to remove the top cap o-ring. Use your
3
fingers to install a new o-ring.
15Coil Spring Service
Use your fingers to remove the preload spacer(s). Pull the coil
Snap ring pliers
4
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
5
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.
CAUTION- BURN HAZARD
Do not get the heat gun or hair dryer too close to the isolator.
Failure to do so may result in a burn hole in the isolator. Allow the
isolator to cool down before handling. Failure to do so may result
in burns.
Place the tips of large internal snap ring pliers into the eyelets of
6
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.
Remove the spring shaft assembly from the upper tube.
7
16Coil Spring Removal
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