RockShox Boxxer 2000 Mode D'emploi page 5

Service
Service
D
ISASSEMBLING
1. With a 22mm six-point socket wrench, remove the top caps. Inspect top cap O-rings and replace if necessary.
2. Push the lower leg assembly up and remove the spring stacks. Note orientation of parts (spring, spring spacer,
and preload spacers). Wipe clean.
3. Place an oil pan underneath the fork. Partially loosen shaft bolts with a 6mm hex wrench, tap bolts firmly
with a soft mallet to break shafts free from lower tubes (Fig. 2), and remove
bolts completely.
4. Slide the lower leg assembly down several inches and allow the oil to drain
out of the fork.
5. Remove the lower tube assembly from the fork and clean the internals by
wrapping a socket extension in a lint-free rag and twirling it inside each leg.
6. Visually inspect the upper tubes for wear or damage.
7. The fork has a black damper rod in the right leg (rebound) and a silver
damper rod in the left leg (compression). With snap ring pliers, remove the
damper rod retaining rings from the bottom of both upper tubes and slide the
damper rods out. Clean the inside of the upper tubes.
B R
LACK EBOUND
1. Slide the glide ring off the damper rod and inspect for cracks, scratches or wear. Replace if necessary.
2. Slide the upper tube base valve off the damper rod. Note orientation of the check valve, check plates, wavy
washer, and carrier.
3. Remove top out spring.
4. Clean all parts.
5. Remove the spring retainer.
6. With a pick tool, remove the snap ring at the top of the damper
rod.
7. Carefully remove the index plate, wavy washer, index pin and
index ball. The index ball is located underneath the index plate
(Fig 3). Take care not to lose the index ball, it is small and can
be lost easily.
8. Place a 22mm wrench on the top of the damper rod.
9. Use a 14mm wrench to remove the threaded end plug from the
damper rod. Inspect the internal and external O-rings for wear
and replace if necessary.
10. Carefully slide the rebound adjuster out of the damper rod.
11. Inspect the four O-rings on the rebound adjuster for wear (three are on the outside and one is on the end).
Replace if necessary.
12. Degrease and clean all parts.
B R
LACK EBOUND
1. Grease the rebound adjuster and O-rings with a small amount of
Judy butter. Carefully slide them into the rebound damping rod
from the bottom.
2. Apply a small amount of thread locking fluid onto the end plug
thread. Install threaded end plug (Fig. 4), using a 14mm
wrench. Torque to 30 to 40 in-lb.
3. Put a small amount of grease on the bottom of the index plate.
Place the index ball into the recess of the index plate.
4. Align the groove in the index plate with the finger on the rebound
adjuster and place the index plate into the damper rod.
5. In the bottom of the rebound damper, use a 3mm Allen wrench to rotate the damping adjuster until the
index plate slot aligns with the damper rod slot.
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T F
HE ORK
Fig. 2
D D
AMPER ISASSEMBLY
Fig. 3
D A
AMPER SSEMBLY
Fig. 4
PN 950-004836-00, Rev. A
6. Insert the index pin and reinstall the wavy washer and snap ring.
7. Grease the top-out spring, base valve and glide ring and install them onto the damper rod.
Important: The upper tube rebound base valve is black. Insure that this valve is not installed in
the compression side!
S C
ILVER OMPRESSION
1. Slide the glide ring off the damper rod. Inspect for cracks,
scratches or wear and replace if necessary.
2. Slide the base valve off the damper rod. Note orientation of the
check valve, check plate, wavy washer, and carrier. (Fig. 5)
3. Remove top out spring.
4. Remove spring retainer.
5. Place a 22mm wrench on the top of the damper rod.
6. Use a 14mm wrench to remove the high speed compression
assembly.
7. Clean assembly.
8. Make the internal high speed compression adjustment n n o o w w .
Important: When turning the nut, insure the end of the compression adjuster rod does not
become less than fully engaged on the thread. The nut is self-locking and can become
disengaged during operation if the adjuster is not fully threaded.
S C
ILVER OMPRESSION
Important: When turning the nut, insure the end of the compression adjuster rod does not
become less than fully engaged on the thread. The nut is self-locking and can become
disengaged during operation if the adjuster is not fully threaded.
1. Apply a small amount of thread locking fluid to the threads of the compression adjuster assembly. Install the
compression adjuster assembly into the compression damper rod. Torque to 30 to 40 in-lb.
2. Grease the top-out spring, base valve, and glide ring and install them onto the damper rod.
Important: The compression base valve is white. Insure this valve is not installed in the rebound
side.
A
SSEMBLING
1. Carefully install the damper rods into the upper tubes. The black rebound damper goes on the right and the
silver compression damper goes on the left (rider's perspective).
2. Insure the glide rings are properly seated on the dampers.
3. Install the snap ring, square edge face down, into the base of the upper tubes.
4. Lightly oil the bushings in the lower assembly and apply a thin coat of oil on the upper tubes. Grease sealing
O-rings at bottom of each damper.
5. Slide the lower tubes onto the fork.
6. Install the spring stack in each upper tube and hand tighten the top caps in place.
7. Seat the damper rods into the lower assembly and install the bottom shaft bolts.
Torque to 50 to 55 in-lb.
8. Remove the top cap and spring assemblies.
9. Fill fork with the desired oil by following steps 6 and 7 from "After Twenty-Five Hours of Riding."
10. Install the spring stack and top caps and torque to 30 to 40 in-lb.
PN 950-004836-00, Rev. A
English
D D
AMPER ISASSEMBLY
Fig. 5
/D A
AMPER SSEMBLY
T F
HE ORK
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