2006 BOXXER SERVICE GUIDE

For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at
www.rockshox.com.

Information contained in this publication is subject to change at anytime without prior notice.
For the latest technical information, visit our website at www.rockshox.com.
Names used in this manual may be trademarks or registered trademarks of others.

© SRAM Corporation • July 2005 PN 95.4311.775.000, Rev. A

2006 Boxxer Service Guide

• Perform service every 100 hours of riding (less depending on riding conditions and riding style).
• Regular maintenance will ensure your RockShox suspension fork performs as it should.
• For dust seal, foam ring, oil seal, and bushing removal and installation, please reference the Bushing Service Guide.
• Right side equals rider’s right; left side equals rider’s left.

G E T T I N G S TA R T E D
1. Remove fork from bicycle.
2. Spray entire fork with isopropyl alcohol and wipe all dirt and mud from fork. Clean around dust seals and upper tubes.
3. Lay tools out on work bench, and create a clean work area for internal's service.
4. Place oil pan under fork on floor.

TOOLS
• Safety Glasses • Long and Short Plastic or Wood
• Clean Rags Dowel, 3/4" diameter (non-metallic)
• Oil Pan or Bucket • Torque Wrench
• Bicycle Stand/Clean Work • Sharp Pick/Dental Pick
Table/Area • Oil Mixing Syringe and Measuring
• 24mm and 10mm 6-point Socket Cup
• Plastic-Faced Mallet • Isopropyl Alcohol/Spray Bottle
• Snap Ring Pliers (internal and • 5wt and 15wt Suspension Oil
external) • Suspension Oil Height Tool
• Shock Pump
• 2, 2.5 and 5mm Hex Wrench

PROCEDURES FOR 2006 BOXXER RACE, RIDE, TEAM AND WORLD CUP LOWER LEG REMOVAL AND INSTALLATION ARE
THE SAME FOR EACH MODEL. BOXXER TEAM LOWER LEGS PICTURED HERE.

L O W E R L E G R E M O VA L

1. Loosen upper crown bolts with a 5mm hex wrench (fig 1a).
1a 1b 1c
Remove upper crown (figs 1b/1c).

BOXXER RIDE PICTURED. Be sure to flip the U-Turn

travel adjuster knob to the position pictured when
removing crowns.

2. Spray isopropyl alcohol onto upper tube, under upper

tube/frame bumpers (fig 2a). 2a 2b 2c

Twist and pull up to remove (figs 2b/2c).

2 © SRAM Corporation • 2006 BOXXER SERVICE GUIDE

 2006 Boxxer Service Guide

3. BOXXER RIDE: Using a 2.5mm hex wrench, remove U-Turn travel adjuster knob
screw. (fig 3a). 3a 3b

Remove knob (fig 3b).

Using a magnet, remove detent ball bearings and detent springs.

4. Using a 5mm hex wrench loosen

lower crown bolts (fig 4a). 4a 4b 4c 4d
Jeremiah

Using a twisting motion, slide

each upper down and out of
crown (figs 4b/4c/4d).

5. BOXXER WORLD CUP (SOLO AIR): Remove air cap. Press schrader valve and release all air pressure (fig 5).
5
ALL 2006 BOXXER MODELS: It is not necessary to remove Motion Control knob at this point.

6. Pull to remove external rebound adjuster knob (fig 6a).

Using a 5mm hex wrench, loosen 6a 6b 6c 6d

left and right shaft bolts about 3
turns (figs 6b/6c).

Using a plastic mallet, tap each

shaft bolt until you feel the shaft
break free from the lower leg
internally (fig 6d). Each shaft is
seated tightly inside the bolt hole shaft bore inside the lower leg.
7. Hold the bottom of the lower legs
over an oil pan to allow oil to 7a 7b 7c 7d
drain.

Pull each upper tube/shaft

assembly out of lower leg (figs
7a/7b).

Allow all oil to drain into oil pan.

(figs 7c/7d).

Spray isopropyl alcohol inside each lower leg. Wrap a clean rag around a long wooden or plastic dowel, insert into each lower leg side
and clean thoroughly. Spray each dust seal and clean with a rag. Replace if worn or leaking oil. See the ‘Bushing Service Guide’ for
procedures.

PN 95.4311.775.000, REV. A 3
2006 Boxxer Service Guide

BOXXER RIDE, RACE, TEAM, WORLD CUP MOTION CONTROL DAMPING

(RIGHT UPPER TUBE)

Disassembly and service should be performed on a clean work surface.

8. MOTION CONTROL COMPRESSION DAMPER REMOVAL AND SERVICE
Using a 24mm socket wrench, loosen compression damper top cap (figs 8a/8b). 8a 8d

There is no need to remove the blue compression adjuster knob.

9. Slowly pull compression damper out of upper tube (figs 9a/9b/9c). You may need to twist from side to side to ease the compression
damper from upper tube.
9a 9b 9c
Spray compression damper with isopropyl alcohol and
wipe all grease and oil clean.

10. Remove and replace lower and upper Motion Control compression damper o-rings
(figs 10a/10b). 10a 10b

11. Pour damping oil into an oil pan (fig 11).

11

12. REBOUND DAMPER REMOVAL

AND SERVICE Using snap ring 12a 12b 12c
pliers remove rebound damper
seal head retaining ring. (fig 12a)

Pull rebound damper shaft and

seal head out of upper tube (figs
12b/12c).

4 © SRAM Corporation • 2006 BOXXER SERVICE GUIDE

 2006 Boxxer Service Guide

13. Remove and replace rebound damper piston glide ring (fig 13a).

Slide rebound damper seal head

13a 13b 13c 13d
from damper shaft (fig 13b).
Using a pick, carefully remove
and replace the inner seal head o-
ring seal (fig 13c).

Remove and replace the outer

seal head o-ring (fig 13d).

IMPORTANT! DO NOT SCRATCH O-RING GROOVES WHEN REMOVING O-RINGS. DAMAGE CAUSES PERMANENT AIR LEAK.

14. Apply fresh grease to the inner seal head o-ring (fig 14a).
14a 14b 14c
Slide seal head/upper tube ring and seal head back onto
rebound damper shaft. (fig 14b)

Apply fresh grease to the outer seal head o-ring (fig 14c).

15. Spray the upper tube (inner and outer surfaces) with
isopropyl alcohol or degreaser and wipe with a clean rag 15a 15b 15c
(fig 15a).

Wrap a clean rag around the end of a wood or plastic

dowel and insert into upper tube to clean (figs 15b/15c).

16. Insert rebound damper piston into bottom of upper tube

(fig 16a). 16a 16b 16c

Slide rebound damper seal head/upper tube ring and seal

head up rebound damper shaft and insert into the upper
tube seal head step. Gently press into place with your
thumb (fig 16b).

Using snap ring pliers, reinstall retaining ring (sharp end

facing out) (fig 16c). Set upper tube aside.

Insert rebound adjuster knob into bottom of rebound damper shaft and turn counterclockwise to open rebound damper valve. This
ensures proper oil flow when filling damping system with suspension oil.
17. Turn the compression adjuster knob to the open position (fig 17a). Open Position
17a 17b
Opening the compression piston window eases installation (fig 17b).

PN 95.4311.775.000, REV. A 5
2006 Boxxer Service Guide

18. Hold upper tube upright and pour 150ml/cc of 5wt

suspension oil into upper tube (fig 18a). 18a 18b 18c

OPTIONAL PROCEDURE:
If you choose to measure oil height using a suspension oil
height tool, use the following steps:
a. Measure and set the syringe needle stop to 205mm (fig
18b)
b. Insert the syringe needle into the upper tube, resting the
stop flat on upper tube (fig 18c).
c. Pull out excess oil with syringe plunger (fig 18c).
d. Remove oil height tool from upper tube.
19. Gently insert the Motion Control compression damper into upper tube. Press down and gently ease the piston o-ring past the upper
tube/top cap threads (figs 19a/19b).
19a 19b 19c
Press down and slowly twisti side to side to ease the
damper into the upper tube. Hand-thread the
compression damper top cap into the upper tube threads.

Using a 24mm socket wrench tighten the top cap to 60in-

lb (fig 19c). Set upper tube/damper assembly aside for
now.

BOXXER RIDE U-TURN SPRING (LEFT UPPER TUBE)

R E M O VA L
20. Clamp U-Turn spring upper tube into bicycle stand clamp.
20a 20b 20c
Using a 24mm socket wrench, loosen and remove U-Turn
spring top cap (figs 20a/20b). The spring is attached to
the top cap and spring shaft. Pull and lift entire spring
assembly from upper tube (fig 20c).

IMPORTANT! PRESS DOWN FIRM WHEN LOOSENING

TOP CAPS.

21. Spray entire spring assembly with isopropyl alcohol and wipe all grease and oil from top cap, spring and spring shaft. Apply grease to
outside of entire coil spring and spring isolators.
I N S TA L L AT I O N
22. Insert spring assembly into left upper tube, through crown (fig 22a). Align and seat
the spring shaft through shaft guide/base plate. 22a 22b

Press down on U-Turn spring top cap and hand-thread into upper tube/crown.
Using a 24mm socket wrench, tighten to 60 in-lb (fig 22b).

6 © SRAM Corporation • 2006 BOXXER SERVICE GUIDE

 2006 Boxxer Service Guide

BOXXER RACE/TEAM SPRING (LEFT UPPER TUBE)

R E M O VA L
23. Using a 24mm socket wrench, loosen and remove spring spring top cap (figs 23a/23b).

23a 23b 23c 23d 23e

Remove spring pre-load spacers (fig 23c). Pull spring from upper tube (fig 23d). Spray isopropyl alcohol onto spring and spring
isolators. Apply fresh grease (oil soluble) to spring and spring isolators (fig 23e).

IMPORTANT! PRESS DOWN SQUARE AND FIRM WHEN LOOSENING TOP CAPS.

24. Using snap ring pliers remove the spring shaft base plate retaining ring (fig 24a).

Pull spring shaft and base plate from upper tube (figs 24a 24b 24c
24b/24c).

Spray isopropyl alcohol onto spring shaft and wipe clean.

Check for any damaged parts, and replace assembly if

necessary.

25. Spray the upper tube (inner and outer surfaces) with
isopropyl alcohol or degreaser and wipe with a clean rag 25a 25b 25c
(figs 25a/25b).

Wrap a clean rag around the end of a wood or plastic

dowel and insert into upper tube to clean (figs 25c).

I N S TA L L AT I O N
26. Insert spring shaft assembly back into bottom of upper tube (fig 24c/24b).

Seat base plate assembly into upper tube step and secure with retaining ring (sharp end out) (fig 24a).
27. Insert spring back into upper tube (fig 23d).

Place spring preload spacer(s) on top of spring inside upper tube (fig 23c).

Clean top cap with a clean rag. Apply a thin amount grease to top cap threads.

Hand-thread the top cap back into upper tube (fig 23b). Using a 24mm socket wrench, tighten to 60 in-lb (fig 23a). Wipe away any
excess grease.

PN 95.4311.775.000, REV. A 7
2006 Boxxer Service Guide

BOXXER WORLD CUP SOLO AIR SPRING (LEFT UPPER TUBE)

R E M O VA L
28. Using a small hex wrench press
schrader air valve and release all 28a 28b 28c 28d
air pressure (fig 28a).

Using a 24mm socket wrench,

loosen and remove Solo Air top
cap (figs 28b/28c/28d).

29. Pour any air seal lubrication oil from air spring upper tube into an oil pan.

Use your finger to press the air 29a 29b 29c 29d
seal head into upper tube. You
will feel it break free and slide
into the tube about 3mm
(fig 29a). Using snap ring pliers
remove spring shaft seal head
retaining ring from upper tube
(fig 29b).

Pull Solo Air spring shaft assembly out of upper tube (figs 29c/29d).
30. Spray Solo Air spring assembly
with isopropyl alcohol and wipe 30a Main Air Piston
O-ring
30b 30c 30d
clean. (fig 30a) Negative Piston
O-ring

Pinch the main air seal o-ring

and remove. Replace with new a
o-ring (fig 30b).
Inner Sleeve
O-ring

Slide negative air seal/sleeve off

air spring shaft. (fig 30c).

Pinch the negative air seal o-ring and remove. Use a sharp pick to remove inner sleeve o-ring. Replace with new o-rings (fig 30d).

31. Inspect the Solo Air retaining ring

and spring washer to ensure fit is 31a 31b 31c 31d
secure (fig 31a).

Apply fresh grease to the new

inner sleeve o-ring (fig 31b), the
new main air seal o-ring (fig 31c)
and negative air seal o-ring
(fig 31d).

8 © SRAM Corporation • 2006 BOXXER SERVICE GUIDE

 2006 Boxxer Service Guide

32. Spray the upper tube (inner and outer surfaces) with
isopropyl alcohol or degreaser and wipe with a clean rag 32a 32b 32c
(figs 32a/32b).

Wrap a clean rag around the end of a wood or plastic

dowel and insert into upper tube to clean (figs 32c).

33. Slide negative sleeve back onto air shaft assembly.

33a 33b
Insert air piston into upper tube. Slide assembly into upper tube. Press seal head
with your thumb into upper tube (fig 33a).

Using snap ring pliers, install retaining ring, sharp side out (fig 33b).

34. Holding the upper tube, pour 3-5 cc/ml of 5wt suspension
oil into the upper tube (fig 34a). This oil will lubricate the 34a 34b 34c
air piston o-rings during suspension movement.

Clean the air top cap and upper tube threads. Hand-thread
the air top cap into upper tube (fig 34b).

Using a 24mm socket wrench, tighten to 60 in-lb (fig 34c).

B O X X E R L O W E R L E G I N S TA L L AT I O N ( A L L M O D E L S )
35. Thoroughly clean each foam ring and dust seal in the lower legs. If extremely worn
or contaminated, replace both. Refer to the ‘Bushing Service Guide’ for 35a 35b
procedures.

Pour 15wt suspension oil onto each foam ring and saturate (fig 35a).

Apply fresh grease to the inside surface of each dust seal (fig 35b.).

36. Insert the spring (left) and damping (right) upper tube assemblies into the lower legs. Ensure the dust seal lip does not fold under and
is seated correctly around upper tube (figs 36a/36b).
36a
SPRING SIDE (LEFT): Slide the spring assembly/upper tube completely into the left lower leg until the
spring shaft stops and rests in the lower leg shaft bore hole. Look through the bolt hole in the bottom
of the lower leg to make sure the shaft is aligned and seated in the center of the bolt hole.

DAMPER SIDE (RIGHT): Slide the damper/upper tube assembly about half way into the right lower leg.
Do not seat completely into bottom of lower leg. The shaft end should not be visible in the bolt hole.
36b
Pour or inject (an oil syringe works best) 15cc/ml of 15wt suspension oil into the bottom of the lower
leg through the bolt hole. This lubricates the bushing.

2006 Boxxer forks feature Motion Control damping, which is considered a ‘closed’ system. A ‘closed’
damping system refers to sealed damping fluid inside the upper tube. Sealed damping is not an ‘open
bath’ damping/lubrication system. Therefore, suspension oil is added to the bottom of the lower leg for
bushing lubrication using the ‘closed’ system.

PN 95.4311.775.000, REV. A 9
2006 Boxxer Service Guide

37. Slide the damper/upper tube completely into the right lower leg until the damper shaft stops and rests in the lower leg shaft bore hole.
Look through the bolt hole in the bottom of the lower leg to make sure the shaft is aligned and seated in the center of the bolt hole.
38. Inspect each black shaft bolt crush washer and crush washer retainer. Clean and replace if damaged.

38a 38b 38c

Insert the damper (right) shaft bolt (hollow) into the right
shaft through the lower leg bolt hole (fig 38a). Insert the
spring (left) shaft bolt (solid) into the left shaft through the
lower leg bolt hole.

Using a 5mm hex wrench, tighten each shaft bolt to 60in-lb

(figs 38b/38c). Wipe away any excess oil from bolts and
lower leg.

39. BOXXER RACE/TEAM: With fork clamped in bicycle stand, use a 24mm socket wrench to loosen and remove spring top cap.
(fig 39a).
39a 39b 39c
Gently slide upper down until spring preload spacer is
exposed. Remove preload spacer. (fig 39b).

Pull upper tube back up. Measure and pour 30cc/ml of

5wt suspension into upper tube. (fig 39c)

Reinstall top cap, and tighten to 60in-lb.

40. BOXXER RIDE: With fork clamped in bicycle stand, use a 24mm socket wrench to loosen U-Turn spring top cap (fig 40a).

40a 40b 40c

Gently slide upper down until top cap and U-Turn spring
are exposed. Measure and inject/pour 50cc/ml of 5wt
suspension into upper tube, through the spring (fig 40b).

Pull upper tube back up. Press top cap into threads and
tighten by hand (fig 40c). Use a 24mm socket wrench and
tighten to 60in-lb (fig 40a).

41. BOXXER RIDE: Insert detent springs and ball bearings into top cap detent holes,
evenly spaced. Install U-Turn adjuster knob onto top cap (fig 41a). 41a 41b

Using a 2.5mm hex wrench, install and tighten U-Turn travel adjuster knob screw.
(fig 41b).

B O X X E R C R O W N I N S TA L L AT I O N ( A L L M O D E L S )
42. Clean the inside of each crown/upper tube hole in the
lower crown with isopropyl alcohol and a clean rag. 42a 42b 42c

Insert each upper tube evenly into each hole in the lower
crown (fig 42a).

Pull upper tubes up and into the crown, twisting gently as

the upper tubes ease into the hole (figs 42b/42c).

10 © SRAM Corporation • 2006 BOXXER SERVICE GUIDE

 2006 Boxxer Service Guide

43. Pull each upper tube up to the fully extended position.

43
Measure, from the dust/lower leg to the bottom of the lower crown hole, 205mm and tighten each crown
bolt to 65in/lb. (fig 43) Make sure upper tubes are positioned at an even height. Refer to the diagram below
for crown measurements.

44. Slide each upper tube/frame bumper onto BOXXER CROWN

each upper tube (figs 44a/44b). 44a 44b HEIGHTS

SHORT UPPER CROWN

152mm (+/-2mm)
Frame/
Upper TALL UPPER CROWN
Tube 182mm (+/-2mm)
Bumper

45. Install upper crown onto upper tubes and

steerer tube (fig 45a). 45a 45b LOWER CROWN
205mm (+/-2mm)

Refer to the diagram at the right for

measurements. Tighten with a 5mm hex
wrench to 65in-lb (fig 45b).

Spray isopropyl alcohol onto entire fork

and wipe with a clean rag.

BOXXER MAXLE (RIDE)

46. Disassemble Boxxer Ride Maxle and replace any damaged or worn parts. See diagram for orientation of parts.

BOXXER RIDE MAXLE BOXXER DH MAXLE

Lever/Axle Assembly
Axle

Axle Nut

Spring Nut

Spring
Nut
Axle Wedge
Lever Wedge
20
Nut Wedge Nut Wedge

PN 95.4311.775.000, REV. A 11
2006 Boxxer Service Guide

OIL
RIGHT LEG
RIGHT LEG TOP RIGHT LEG BOTTOM
OIL WEIGHT OIL WEIGHT
(VOLUME) (VOLUME)
BOXXER RIDE 150cc/ml 5wt 15cc/ml 15wt (stock)
BOXXER RACE/TEAM 150cc/ml 5wt 15cc/ml 15wt (stock)
BOXXER WORLD CUP 150cc/ml 5wt 15cc/ml 15wt (stock)
LEFT LEG
LEFT LEG BOTTOM
LEFT LEG TOP (VOLUME) OIL WEIGHT OIL WEIGHT
(VOLUME)
BOXXER RIDE 50 cc/ml 15wt x x
BOXXER RACE/TEAM 30 cc/ml 15wt x x
BOXXER WORLD CUP 3 - 5 cc/ml 15wt 15cc/ml 15wt (stock)

SPRINGS - BOXXER RIDE (U-TURN)

* RIDER WEIGHT SPRING COLOR SPRING ASSEMBLY PART #
>150 lb (68 kg) Yellow 11.4309.240.000
150-175 lb (68-79 kg) Yellow/Red 11.4309.241.000
175-200 lb (79-91 kg) Red (Std) 11.4309.242.000
>200 lb (91 kg) Black 11.4309.870.000

SPRINGS - BOXXER RACE/TEAM (SINGLE-SIDED)

* RIDER WEIGHT SPRING COLOR SPRING ASSEMBLY PART #
<120 lb (55 kg) White 11.4311.490.000
120-150 lb (55-68 kg) Silver 11.4311.489.000
150-180 lb (68-82kg) Yellow 11.4311.488.000
>180 lb (82 kg) Red 11.4311.487.000

AIR PRESSURE SETTINGS - BOXXER WORLD CUP (SOLO AIR)

RIDER WEIGHT POSITIVE AIR PRESSURE
<120 lb (55 kg) 100-110 psi
120-140 lb (55- 63 kg) 110-120 psi
140-160 lb (63-72 kg) 120-140 psi
160-180 lb (72-81 kg) 140-160 psi
180-200 lb (81-91 kg) 160-180 psi
>200 lb (91 kg) 180+ psi

12 © SRAM Corporation • 2006 BOXXER SERVICE GUIDE

 2006 Boxxer Service Guide

TROUBLE-SHOOTING
AIR LOSS (WORLD CUP)
• Inspect air piston o-rings and replace if necessary.
• To avoid air loss, deflate positive air chamber, remove air top cap every month and pour 3 to 5cc 15wt suspension oil into air
spring chamber. This keeps air seal lubricated.
• Maximum air pressure may have been exceeded. Do not exceed recommended air pressures!

L O S S O F / O R VA R I A N C E I N D A M P I N G
• Inspect all damper o-rings. Replace and grease.
• Inspect damper oil volume. Remove damper top cap/compression damper assembly. Using a thin ruler, measure the oil height.
Correct height is five inches from the top of the upper tube (when fork is set at 140mm travel). Add or remove oil as needed.

COMPRESSION STROKE NOT SMOOTH

• Remove both shaft bolts. Pull lowers down about an inch. Allow oil to drain. Refill fork with fresh suspension oil (follow the
steps in this guide).
• Lubricate upper tubes near dust seals. Push down on fork a few times. Wipe away excess lubricant.

B U S H I N G P L AY
• Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced after approximately 100-200 riding
hours, depending your riding style, condition, riding time and body weight. If you ride a lot, check those bushings!

SEE THE 'BUSHING INSTALLATION' GUIDE AT WWW.ROCKSHOX.COM FOR PROCEDURES.

OIL LOSS
• Inspect the air piston o-rings for air bypass. Air pressure can force oil out of the left dust seal.
• Inspect your shaft bolt crush washers. Replace if worn or damaged.
• Inspect your top cap o-rings. Replace if torn or knicked.

PN 95.4311.775.000, REV. A 13