GEN.0000000003185 REV A8
FORK REMOVAL
If you haven’t done so already, measure and record1.
(in the “Record Your Settings” section) the distance
between the top of the lower crown and the top of
the upper tube just underneath the top cap. This will
make re-installing your fork easier.
Use a 6 mm hex wrench to loosen the Maxle™ DH2.
bolt on the non-drive-side until detent clicks are no
longer felt.
Use a 6 mm hex wrench to unthread and3.
completely remove the Maxle DH from the drive-
side. Pull downward on the wheel to remove it from
the fork.
Remove the brake caliper and disconnect the brake4.
hose from the fork.
Use a 4 mm hex wrench to loosen the four lower5.
crown and two upper crown bolts that clamp the
crowns to the upper tubes. Do not loosen the steerer
tube clamping bolt located on the upper crown.
Slide the upper tubes downward until they are clear6.
of the upper crown enough to be able to remove the
frame bumpers. Lightly re-tighten one of the lower
crown bolts to temporarily hold the fork in place.
Use your thumb and pry the thickest section of each7.
frame bumper away from the upper tube. Spray
isopropyl alcohol or water between each bumper and
upper tube. Twist each bumper back and forth until
it is loose on the upper tube. Slide both bumpers up
and off of the upper tubes.
Loosen the lower crown bolt and slide the fork down8.
through the lower crown and completely remove it
from the bike.
Use isopropyl alcohol and a lint free rag to clean the9.
upper tubes and the crown clamping surfaces.
INTRODUCTION
BOXXER R2C2 TECHNICAL MANUAL
5Copyright © SRAM LLC • 2009
GETTING STARTED (CONTINUED)
RECORD YOUR SETTINGS
Take a moment and record all of your BoXXer fork’s settings in the chart below. This will allow you to return your fork to its original
settings after service. Be sure to record the service date as well, this will help you keep track of service intervals.
To determine your bottom out, compression, and rebound settings perform the following:
Bottom out - Count the number of clicks while turning the bottom out adjuster fully counter-clockwise.
Rebound - Count the number of clicks while turning the rebound adjuster fully counter-clockwise .
Compression - Count the number of clicks while turning the compression adjuster fully counter-clockwise .
Note: Spring preload will be determined later during spring system service.
MY SETTINGS
SERVICE DATE UPPER CROWN
HEIGHT
NUMBER OF
PRELOAD SPACERS
BOTTOM
OUT
LOW SPEED
COMPRESSION
HIGH SPEED
COMPRESSION
BEGINNING
STROKE REBOUND
ENDING
STROKE REBOUND
The following chart lists all of the oil volumes and weights for your BoXXer as well as tool sizes and torque values for all of the
fasteners.
OIL VOLUME CHART
Damper
technology
(drive side)
Volume
(mL)
Height
(mm)
Oil
wt
Volume
(mL)
Oil
wt Spring
technology
(non-drive side)
Volume
(mL) Oil wt Volume
(mL) Oil wt
Upper leg Lower leg Upper leg Lower leg
Boxxer World Cup Mission Control DH 245 153 5 10 15 Coil with Drop Stop - - 40 15
TORQUE CHART
Part/fastener Tool size Torque
Maxle DH ( non drive-si de) 6 mm 8 clicks
Maxle DH (d rive-side) 6 mm 5.7 N·m (50 in-lb)
Crown b olts 4 mm 7.3 N· m (65 in-lb)
Bot tom bolts 5 mm 7.3 N·m ( 65 in-lb)
Top caps 24 mm 7.3 N·m (6 5 in-lb)
BO
XX
ER TEAM TECHNICAL MANUAL
1 2
3 5
6
7
Removing your fork from the bike is the first step required in order to perform service. BoXXer’s dual crown feature allows the
fork to be easily disassembled and removed from the bike. This provides easy access to internal components and is more
convenient than working around a complete bike.
