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Installation • Tuning
Installation
It is extremely important that your Boxxer fork is installed correctly by a qualified technician with proper tools.
Improperly installed forks are extremely dangerous and can result in severe and/or fatal injuries.
1. Remove the existing fork from the bicycle and the headset crown race from the fork. The RockShox steerer
tube may need cutting to the proper length. On threadless steerers (Aheadset design), make sure there is
sufficient length to properly clamp the stem (refer to stem manufacturer's instructions). Make sure to install
upper crown when taking the steerer tube measurements. Use a short upper crown for head tube and headset
stack heights of less than 160 mm, or a medium upper crown for stack heights 160 to 183 mm, and a tall
upper crown for stack heights of more than 183 mm.
Important: Do not add threads to RockShox steerers. The steerer tube crown assembly is a one
time press fit. Replacement of the assembly must be done to change length. Do not remove or
replace the steerer tube, because this could result in loss of control of the bicycle with possible
serious and/or fatal injuries.
2. Install the headset crown race firmly against the top of the lower fork crown. Install the fork assembly on the
bike. Adjust the headset so you feel no play or drag. D D o o n n o o t t e e x x c c e e e e d d 1 1 6 6 0 0 m m m m o o f f e e x x p p o o s s e e d d u u p p p p e e r r t t u u b b e e a a b b o o v v e e t t h h e e
l l o o w w e e r r c c r r o o w w n n . .
3. Install the brakes according to the manufacturer's instructions and adjust brake pads properly.
4. Forks with hangerless braces were designed for 'V'-type, hydraulic cantilever, or disc brakes. Do not route the
cable through the stem or any other mounts or cable stops. The cable should make a direct route from the
brake lever to the brake and be able to freely move up and down with the suspension movement. It may be
necessary to install a whole new cable.
5. Apply grease or anti-seize to the axle. Set the wheel in the recesses of the dropouts and insert 20mm axle.
Torque the axle bolt to a maximum of 25 in-lb. Tighten clamp bolts to 40 to 60 in-lb.
6. Keep in mind tire clearance as you choose tires. Maximum tire size is 2.35" wide or 337mm radius. Be sure to
check this radius whenever you change tires. To do this, remove the spring stack (per the instructions on the
following pages), and compress the fork c c o o m m p p l l e e t t e e l l y y to verify at least 5 mm of clearance exists between the top
of the tire and the bottom of the crown. Exceeding this maximum will cause the tire to jam against the
crown when the fork is fully compressed. The upper tubes must always be fully engaged in the crown with no
more than 160 mm of exposed upper tube above the lower crown.
Tuning
The Boxxer fork is designed as a high performance, world class downhill fork. Our forks are factory tuned for the
150-180 lbs. (65-85 kg.) downhill racer and can be tuned to many different rider weights or riding styles. You can
tune this fork to benefit your needs by changing preload, internal coil springs, rebound damping, and low or high
speed compression damping.
C
HANGING THE
If you are bottoming out too often or not using all the available travel then the overall spring rate should be changed.
The standard spring rate (medium) is designed for the 150-180 lbs. (65-85 kg.) downhill racer. You may change the
overall spring rate by changing the main coil spring in each leg with one that is softer or firmer than the standard
spring. By changing the coil springs, you alter the overall spring rate.
RockShox has designed nine spring configurations for the Boxxer. By changing the springs in either one or both legs
you can tune the bike to your specific needs. Below is a table that breaks down the spring rates into rider weight
ranges. Use this table as a guide when choosing a different spring rate than the one provided in the fork.
Color
Spring Rate (lb-in.)
Silver
Extra Soft (10 lb-in.)
Orange
Soft (15 lb-in.)
Yellow
Medium (20 lb-in.) - Standard
Red
Firm (25 lb-in.)
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S
R
PRING
ATE
PN 950-004836-00, Rev. A
The Boxxer is built standard with two medium springs (20 lb-in.). Also included in the package is one extra soft
spring and one extra firm spring. These extra springs may help more closely meet your needs. The following is how
these spring may be interchanged:
Rate
Rider Weight
Soft (17.5 lb.)
120 to 150 lb.
Standard (20 lb.) 150 to 180 lb.
Firm (22.5 lb.)
180 to 210 lb.
S
ETTING
The Boxxer is designed to compress (sag) when you are sitting on the bike. This sag allows the front wheel to stay
in contact with the ground when braking and cornering over rough and uneven terrain. Optimum sag is between 35
and 60 mm of total fork travel.
To measure sag, install a zip tie on the upper tube so that it is flush against the seal; sit on the bike in normal riding
position; then step off the bike and measure from the bottom of the zip tie to the top of the wiper. This measurement
is sag. Changing the preload alters the sag and firmness of the initial fork movement. A heavier, more aggressive
riders need more spring preload to maintain proper ride height and allow more of the fork's travel to be used during
bump impact.
The preload can be changed by adding or removing preload spacers into the main coil spring stack.
Important: No more than eight preload spacers should be added to either side of the fork. More
than eight spacers can cause the spring to be damaged. If you can not achieve the proper
preload, you may need to install softer or firmer coil springs.
T
:
O CHANGE THE PRELOAD
1. Remove the top caps with a 22mm six-point socket wrench.
2. Inspect the O-rings for damage and replace if necessary.
3. Slightly compress the fork to get access to the preload spacers, which sit on top of the spring stacks.
4. Add or remove preload spacers and/or springs as necessary.
5. Re-install top caps and torque to 30 to 40 in-lb.
E
R
XTERNAL
EBOUND
Rebound damping should be adjusted any time the spring rate or preload have been changed. The rebound adjuster
is located in the lower right leg and is accessible with a 3mm Allen wrench inserted through the hollow shaft bolt.
Clockwise rotation of the adjuster results in more rebound damping. Proper rebound depends on rider style, weight,
preference and fork setup. This adjuster is indexed.
E
L
S
XTERNAL
OW
PEED
Low speed compression damping controls pedal bob and fork sensitivity. The adjuster is located in the lower left leg
and is accessible with a 3mm Allen wrench inserted through the hollow shaft bolt. Clockwise rotation of the adjuster
results in more low speed compression damping. Compression damping should be adjusted any time the springs or
preload have been changed. Proper compression damping depends on rider style, weight, preference and fork setup.
This adjuster is n n o o t t indexed.
PN 950-004836-00, Rev. A
English
Fork Leg #1
Fork Leg #2
15 lb-in.
20 lb-in.
20 lb-in.
20 lb-in.
20 lb-in.
25 lb-in.
S
AG
A
DJUSTMENT
C
A
OMPRESSION
DJUSTMENT
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