SR Suntour V-Boxx FR9 User manual

Owner‘s Manual
V-Boxx FR9

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
English
No. 06
Shifting unit
No. 07
BB shaft
No. 09
Centre bearing
No. 05
Main casting
No. 01
Fixing points
No. 03
Outer casting
xing bolts
No. 02
Output shaft
Gear and suspenion
centre
No. 08
ITM shaft
No. 04
Shifting shaft

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
Caution
WARNING !
Failure to comply with the given warnings and instructions may
cause damage to the product, injuries or even death to the rider.
►Be sure to read this manual carefully before using your V-BOXX. Inappropriate usage of
your V-BOXX may cause damage to the product, serious injuries or even death to the
rider.
►Please note that only certied V-BOXX mechanics are allowed to open, repair, dissamble
or reassemble the V-BOXX. Not following this instruction will void the warranty of your
SR SUNTOUR V-BOXX.
►Only use genuine SR SUNTOUR parts. The use of aftermarket replacement and spare
parts voids the warranty of your fork and might cause failure to the fork. This could
result into an accident, injury or even death.
► This instruction sheet contains important information about the service and
maintenance of your V-BOXX. Nevertheless please be informed that special knowledge
and tools are essential to service and maintain the SR SUNTOUR V-BOXX. Common
mechanical knowledge may not be sucient to service or maintain the V-BOXX.
Therefore we strongly recommend getting your V-BOXX installed, serviced and/or
maintained by a trained and qualied bicycle mechanic. Improper installation, service
or maintenance can result in failure of the product, accident, injury or even death.
►Always be equipped with proper safety gear. This includes a properly tted and fastened
helmet. According to your riding style you should use additional safety protection.
Make sure your equipment is in awless condition.
► Study all other owner’s manuals provided with your bike and make yourself familiar
with the components mounted to your bike.
IMPORTANT SAFETY INFORMATION
14 Nm
43 Nm
11 Nm

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9 SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
English
Caution
GENERLA INFORMATION ON THE X-OFF Vboxx
►When your are changing gears you have to
make sure that the grip shift lever is proper-
ly engaged. If the grip shift lever is placed in
between two gear the clutches inside the box
will not work properly. This will cause the ge-
ars to slip through and fear the risk that the
internals of the box are getting damaged.
►Please note that you should avoid shifting
under load. The interals of your Vboxx whe-
re not constructed for shifting actions under
load. Shifting under load fears the risk that
the clutches inside the V-BOXX are getting
damaged.
►When you are shifting you should decrease
the load on the V-BOXX. If you are shifting
under load the tension of the shifting cable
is too high. As a result of this the shifter can
not be turned. Please do not use any force to
try to shift under load.
►The gear box is a closed and sealed system.
Therefore the gearbox itself is almost main-
tenance free. Please do not try to open the
gearbox by yourself. This will void the war-
ranty of your gearbox. Only certied V-BOXX
menchanics are allowed to open the gear
box. If there is any problem with it, please
contact your local dealer for assistance or
get in contact with one of the V-BOXX SERICE
CENTERS.
►Your dealer might not be allowed/able to re-
pair or maintain the V-BOXX.Therefore we set
up„Vboxx Serive Centers“. For more detailed
information please refer to the„SR SUNTOUR
SERVICE CENTER“ section of this manual.
►Even your V-BOXX casting looks very stab-
le you should avoid sliding over rocks. The
main casting (No. 05) was produce through
a extrusion methode and is made of Alloy.
When sliding over or hitting rocks it might
get damaged.
►While shifting it can happen that you hear
some kind of metallic noises coming from
the boxx. This is mainly caused by the clut-
ches and is not unusual.
►When ridinding in specic gears it may hap-
pen that you can hear some kind of „clip-
clop“ noises coming from the boxx. This is
caused by the clutches which are skiping
over and nothing you should worry about.
The Vboxx system is based on a spline system with three shafts. Inside the Vboxx there are four
clutches which are taking care of the gear switching operations. ....................................

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR - OWNERS MANUAL
GEAR SYSTEM

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9 SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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HOW TO CHANGE THE V-BOXX SHIFTING CABLES
After you have disassambled the shifters
oyour handlebar you have to put the
shifter to gear No. 1
1
PUTTO GEAR1
TAKE OFF
Detach the shifting unit othe boxx.
2.5 mm
Take othe shifting unit (No. 9 page 1)
using a 2.5mm Allen key.
3 mm
Take othe shiting unit (No. 9 page 1)
using a 3mm Allen key.

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
Take othe backside plate by using a Phil-
lips screwdriver No.2.
Unfasten the xing bolts which are xing
the shifting cables by using a 3mm Allen
key.
3 mm
It might be helpfull to mark the position
of the square. When you are going to
reassemble the shifting unit it indicates
the correct position of the square. Use a
screwdrive to draw this line.
Take othe cover plate by using a Phillips
screwdriver No. 2

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9 SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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In order to pull out the shifting cables you
have to put the shifter to gear No. 3.......
GEAR 3
Make sure to install the new shifting cab-
les in the correct position.
WRONG
CORRECT
Make sure to install the new shfting cables
in the correct postion.
GEAR 7
.......and gear No. 7

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
2.5 mm
?? Nm
Put the shifter to position 1. Bring the
cable in at shifting position No. 3. Run
the cable through the casing into the
shifting unit. Bring the cable almost one
tour around the cable ring. Pull the cable
hard and tighten the xing bolts using a
2.5mm Allen key.
2.5 mm
?? Nm
Turn the shifter to position No. 9 and
bring the cable in. Run the cable through
the casing into the shifting unit. Bring the
cable almost one tour around the cable
ring. Pull the cable hard and tighten the
xing bolt using a 2.5mm Allen key. After-
wards cut both cables to a proper length
and turn the shifter back to position No.1.
Reinstall the backside plate by using a
Phillips screwdriver No.2.
PULL
Check if the tension of the shifting cables
is adequate. If the tension is to high the
shifting will beome to hard. Pull the cabels
slightly. You should have 1-2mm space on
both sides.

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9 SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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2.5 mm
??? Nm
Reassemble the shifting unit back again
using a 2.5mm Allen Key
3 mm
??? Nm
Reassemble the shifting unit back again
using a 3mm Allen key.
As already mentioned, the square has to
be in the same position like it was before,
when you were disassembling the shi-
ting unit. If it is not anymore, you have to
turn the shifting shaft counter clockwise
until the stopper. The shifter needs to be
positioned at gear 1.

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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MAINTENANCE
Your SR SUNTOUR V-BOXX is a closed and sealed system, which means that the internals are pro-
tected against outside inuence like moisture and dirt. Therefore the gearbox itself is almost main-
tenance free. Please do not try to open the gearbox by yourself. This will void the warranty of your
gearbox. Only certied V-BOXX mechanics are allowed to open the V-BOXX. If there is any problem
with it, please contact your local dealer for assistance or get directly in contact with one of the SR
SUNTOUR V-BOXX SERVICE CENTER‘s
Nevertheless, you should re-new the grease inside your V-BOXX once in a while to make sure the
system runs nice and smoothly. Grease itself has the characteristic that it will get tough after some
time of using. This is depending on three major facts, the time on the box riding, riding conditions
and total duration. In general SR SUNTOUR recommends to change the grease within the V-Boxx
every 8 month. If your are riding your bike every day you should re-new the grease more often.
Also if your are riding in cold weather conditions the grease of your V-Boxx should be changed
every 6 month.
Unscrew the „Upper
Bolts“ . Pour clean gear
box oil into the V-Boxx.
We recommend to use
oil with a lower visco-
sity. Reassemble the
bolts again.
V-Boxx Service
Center Asia
4 mm
??? Nm
Upper
Bolts
Lower
Bolts
In order to wash the
old grease away from
the sprockets you
should turn you crank
several times.
V-Boxx Service
Center Asia
TURN

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9 SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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LIMITED WARRANTY
SR SUNTOUR warrants its products to be free from defects in material and workmanship under
normal use for a period of two years from the date of original purchase. This warranty is made
by SR SUNTOUR Inc. with only the original purchaser and is not transferable to any third party.
Lodging a claim under this warranty must be made through the dealer where the bicycle or SR
SUNTOUR product was purchased. To prove the original purchase the original retail invoice and a
copy of your X-OFF V-BOXX FR9 Warranty Cards has to be provided.
LOCAL LAW:
This warranty gives you specic legal rights. According to the state (USA) or province (Canada)
or every other country you are living in, you may have other rights than explained within these
warranty regulations. These regulations shall be insofar adapted to the local law to be consistent
with such law.
Unscrew the „Oil Re-
lease Bolt“ and drain
the contaminated oil/
grease out. Afterwards
reassemble the bolt
back again.
Please note that you
can re-use the clea-
ning oil several times.
Therefore keep it for
next time.
??? Nm
4 mm
Oil Release
Bolt
Unscrew the „Upper
and Lower Bolts“. Press
fresh grease through
the holes onto the
lower sprockets. You
have to use grease
with a lower viscosity,
otherwise it get‘s to sti-
cky. Turn your crank‘s
in order to spread the
grease on all other
sprockets. Repeat this
action until there is
enough grease
on all sprockets.V-
1.5mm
0.5 Nm
Upper
Bolts
Lower
Bolts

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
LIMITATION OF WARRANTY
This limited warranty does not apply to any defect of the product caused by improper installation,
disassembling and re-assembling, intentional breakage, alterations or modication to the gear
boxx, any unreasonable use or abuse of the product or any use for which this product was not
intended for, accidents, crashes, improper maintenance, repairs improperly performed.
The obligation of this “Limited Warranty” is restricted to repairs and replacements of the V-BOXX
or any parts of it in which there is a defect in materials or workman-ship within a period of two
years.
SR SUNTOUR makes no express or implied warranties of tness or merchatability of any kind, ex-
cept as set forth above. Under no circumstances will SR SUNTOUR be liable for incidental or con-
sequential damages.
Damages which are caused by the use of other manufacturer‘s replaceements parts or damages
which are caused by the use of parts that are not compatible or suitable to SR SUNTOUR V-BOXX
are not covered by this warranty.
Within this manual you will nd two „X-OFF V-BOXX FR9 Warranty Cards“. Send the card labeled
with „Manufacturer“ back to SR SUNTOUR. Not sending back this card will void the warranty of
your X-OFF V-BOXX FR9. For more detail information please check the„SR SUNTOUR SERVICE CEN-
TER“ section of this manual.
This warranty does not apply to normal wear and tear.
WEAR AND TEAR PARTS:
► Dust Seals
► O-rings
► Rubber Moving Parts
► Stanchion Tubes
SR SUNTOUR V-BOXX SERICE CENTER‘S
According to the complexity of the SR SUNTOUR V-BOXX, special technical knowledge is required
to maintain or repair this product. Therefore we have set up special V-BOXX service centers around
the globe to provide you with the best support we can give you, to make your V-BOXX work again.
Whenever you have a problem with our V-BOXX, you should frist consultate your local dealer. All
inquiries regarding V-BOXX services or repairs need to be done through your local dealer. The dea-
ler should rst get in contact with us by phone or email in order to clarify the situation. When
sendind in your V-BOXX, you should always add a copy of your „X-OFF V-BOXX WARRANTY CARD“.
Included in this manual there are two „warranty cards“. Please ll in both, for European countries
please send the card which is labled as „MANUFACTURER“ back to the V-BOXX Service Center
Europe .For the US and Canada please send it to the V-BOXX Service Center USA&Canada. For all
other countries please send it back to the V-Boxx Service Center Asia. Please keep the„Owners“
version for your reference in a save place.

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR V BOXX SERICE CENTER
V-Boxx Service Center Asia
SR SUNTOUR INC.
#7 Hsing Yeh Road, Fu Hsing Industrial Zone Chang Hua,
Taiwan, R.O.C.
Tel: 886- (0)4-769-5115
Fax: 886- (0)4-769-4028
E-mail: [e-mail]
V- Boxx Service Center Europe
SR SUNTOUR EUROPE GmbH
Am Marschallfeld 6a 83626 Valley, Germany
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
V-Boxx Service Center France
SAV SR Suntour France (Service)
Z.A. Les Meres
F-38850 Chirens, France
TEL.: [phone]
FAX: [phone]
E-MAIL: [e-mail]
V-Boxx Service Center USA & Canada
SR SUNTOUR USA
503 Columbia street, Vancouver, WA 98660, USA
Tel: [phone]
Fax: [phone]
E-Mail: [e-mail]

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR - OWNERS MANUAL
LOCATION OF SERIAL NUMBER

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9 SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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X-OFF V-BOXX FR9 WARRANTY CARD
SERIAL NUMBER
FIRST NAME LAST NAME BOUGHT AT BOUGHT ON BIKE MANUFACTURER MODELL + YEAR eMAIL ADDRESS PHONE NO. STREET ZIP CODE + CITY
OWNER

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
English
SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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X-OFF V-BOXX FR9 WARRANTY CARD MANUFACTURER
SERIAL NUMBER
FIRST NAME LAST NAME BOUGHT AT BOUGHT ON BIKE MANUFACTURER MODELL + YEAR eMAIL ADDRESS PHONE NO. STREET ZIP CODE + CITY

SR SUNTOUR - OWNERS MANUAL X-OFF Vboxx FR 9
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SR SUNTOUR HEADQUATER
SR SUNTOUR INC.
#7 Hsing Yeh Rd
Fu Hsing Industrial Zone
Chang Hua
Twaiwan, R.O.C.
Tel.: [phone]
Fax: [phone]
email: [e-mail]
SR SUNTOUR EUROPE
SR SUNTOUR EUROPE GMB H
Am Marschallfeld 6a
83626 Valley
Germany
Tel.: [phone]
Fax: [phone]
email: [e-mail]
SR SUNTOUR USA
SR SUNTOUR USA
503 Columbia Street,
Vancouver, WA 98660
USA
Tel.: [phone]
Fay: [phone]
email: [e-mail]
www.srsuntour-cycling.com
www.srsuntour-tuning-base.com
August 2008