Rock Shox Boxxer World Cup: Air cartridge maintenance

In this video we will show how to maintain your Rock Shox Boxxer World Cup air cartridge and how to grease internals to achieve a soft and nice fork travel.
Today we are going to show how to maintain your Rock Shox Boxxer World Cup. We are going to dissasemble lower leg, upper air tube, lube it all and change lower leg oil. By this way we will obtain a soft and sensitive fork behaviour.
To do that we will use a 2mm hex. key, a 1.5mm, a 4mm, a 5mm and a 24mm spanner or an adjustable spanner, a nylon hammer, a syringe to measure the suspension oil, suspension oil itself, oil seal grease and a jar.
First thing is to loosen lower legs from upper tubes. It’s nice to use a socket to avoid hitting the lower end directly.
We will use a tray just in case oil leaks.

Once there is no oil inside, we can clean oil seals. Although this Boxxer fork is almost new it is recommended to clean and grease oil seals because they are almost dry from Factory and suspension stroke is not as soft and nice as it should be.

To open the air tube remove the air cap, release air pressure and remove the bottom rebound regulator. If you can’t loosen it because all the tube is turning around use temporally the fork lower crown and tighten the tube at this distance. Tighten the clamp bolt a little bit and undo the bottom bolt.
It’s important to lower the front end of the 24mm socket with a lathe or similar so to keep it totally flat. Standard sockets have a step and it’s posible to dent the tube cap if it the socket slips while loosening.
Now you can remove the lower crown.
Now remove the piston from underside. Clean it thoroughly, inspect all o-rings are in good condition and apply a little bit of grease to them and to the piston seal. After that, apply suspension oil to the piston seal again.
Install the piston carefully into the tube, check everything is okay and install the snap ring.
Once the snap ring is installed you will notice it has a position. Place it correctly so it can’t turn and jump out.
Spill 5ml of suspension oil into the air camber and now it’s ready to be closed.

Tighten the tube cap and install the compression regulator.
Now we are going to grease the seals and spill oil into the lower tubes.

Grease the seals thoroughly. It’s a good advice to apply oil between the dust seal and the oil seal.
Now, being careful not to pinch the seals, install the tube.

Before closing it we are going to spill oil into the lower tubes. Rock Shox recommends 15ml of SAE 15W. Once done, compress the lower tube so to approach the thread to install both bolts.
Tighten them and install rebound regulators. Install the red one, the small black plastic washer and the small regulator. Check both regulators turn correctly.

Now you know how to service your Rock Shox Boxxer World Cup fork and make it work really smoothly.
Hope it helps and see you on next video!

Well, hope it has been useful, And remember that all of your component and bicycle manipulation is under your responsability. We are not responsible of it, so take care :D

Translation & voice dubbing Goose Alvaro (Gassattack.com).
Cheers!

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