Step-by-Step: Rebuilding Your Boxxer Select RC Suspension Fork

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The RockShox Boxxer Select RC [paid link] is a premium suspension fork designed for downhill and aggressive riding. Known for its smooth performance and adjustable features, the Boxxer Select RC [paid link] requires regular maintenance to keep it functioning at its peak [paid link]. Rebuilding this fork is an essential task that every mountain biker should learn to master for maintaining the performance and longevity of their bike. This comprehensive guide walks you through the step-by-step process of rebuilding your Boxxer Select RC suspension fork.

Tools Required

  • 8mm, 10mm, and 15mm wrenches
  • T25 and T30 Torx drivers
  • 8mm hex wrench
  • RockShox fluid (recommended for the Boxxer fork)
  • Suspension grease
  • 20mm axle (if applicable)
  • Fork seal press
  • Clean rags or towels
  • Small parts tray for organizing components
  • Oil pan for draining fluids
  • A soft brush for cleaning parts
  • 5mm hex wrench

Preparation for Rebuilding

Before starting, ensure that your workspace is clean and well-organized. Rebuilding a suspension fork requires attention to detail, and having a clean workspace will help avoid contaminating the fork’s internal components.

Step 1: Remove the Fork from the Bike

To begin, you need to remove the Boxxer Select RC fork from your bike. Follow these steps:

  • Use a 15mm wrench to remove the front wheel.
  • Remove the stem and handlebar by loosening the bolts on the stem using a T25 Torx driver.
  • Loosen the crown race bolts, if necessary, to remove the fork from the headset.

Make sure the fork is free of any attached components such as brake calipers and mudguards. Place the fork securely in a workstand for ease of handling during the rebuild.

Step 2: Drain the Oil and Remove the Lowers

After removing the fork, start by draining the oil from the fork. Here’s how:

  • Place the fork upside down over an oil pan to drain the existing oil. Leave it to drain fully for several minutes.
  • Remove the bolts on the bottom of the lowers using the 8mm hex wrench.
  • Gently tap the lowers with a soft mallet to loosen them from the stanchions.
  • Carefully slide the lowers off the fork. At this stage, you can also inspect the fork seals and bushings for any wear or damage.

Step 3: Clean and Inspect the Fork

Now that the lowers are removed, it’s time to clean all parts thoroughly. Use a soft brush and clean rags to remove dirt and debris from the stanchions and other components. Inspect the internal components for wear, cracks, or damaged seals. If any part appears worn out or damaged, it’s essential to replace it before proceeding with the rebuild.

Pay close attention to the following areas:

  • The fork seals for any signs of leaks or excessive wear.
  • The bushings for smooth operation.
  • The oil levels in the damper and spring systems.

Step 4: Rebuild the Damper Cartridge

The Boxxer Select RC fork features an adjustable damper that controls the compression and rebound settings. Rebuilding the damper is a crucial step to maintain the fork’s performance. Follow these steps:

  • Using the appropriate Torx driver (T30), remove the top cap from the damper.
  • Carefully slide the damper out of the stanchion tube and place it on a clean surface.
  • Inspect the damper for any signs of damage. If needed, replace the oil inside the damper cartridge. Refer to the RockShox manual for the recommended fluid type and volume.
  • Reinstall the damper, ensuring the oil level is correct and the seals are in place.

Step 5: Replace the Seals

Fork seals wear out over time and can lead to oil leakage and decreased performance. Replace the seals on the Boxxer Select RC as part of your rebuild. Here’s how:

  • Use the fork seal press to remove the old seals from the lowers.
  • Clean the seal seating area thoroughly, removing any dirt or debris.
  • Install the new seals using the seal press, ensuring they are seated properly.

Step 6: Reassemble the Lowers

Once you’ve replaced the seals, it’s time to reassemble the lowers. Apply suspension grease to the stanchions and the inner surface of the lowers before sliding them back onto the stanchions. This helps prevent friction and ensures smooth operation.

  • Carefully slide the lowers onto the stanchions, aligning them properly.
  • Secure the lowers by tightening the bolts on the bottom of the fork. Be sure to torque these bolts to the manufacturer’s recommended settings.

Step 7: Fill with Fresh Oil

With the fork reassembled, it’s time to refill the fork with fresh oil. The Boxxer Select RC fork requires both a damper and a spring oil. Follow these guidelines:

  • Refer to the RockShox service manual for the exact oil volumes and weights for your specific fork model.
  • Pour the correct oil into the damper and spring system, filling it to the recommended level.
  • Be cautious not to overfill the fork, as this can lead to improper suspension performance.

Step 8: Reinstall the Fork on the Bike

Now that the fork has been rebuilt, it’s time to reinstall it onto your bike. Reverse the steps you followed to remove the fork:

  • Slide the fork back into the headset and tighten the crown race bolts.
  • Reattach the stem and handlebars, making sure everything is aligned and tightened to the proper torque specifications.
  • Install the front wheel using the 15mm wrench and make sure the axle is properly secured.

Step 9: Set Suspension Settings

Once the fork is back on the bike, it’s time to adjust the suspension settings. The Boxxer Select RC fork offers several adjustments, including compression and rebound settings. Adjust the settings based on your riding style and terrain. Start by setting the rebound to a medium position and adjust the compression to suit your riding preferences.

Perform a few test rides to fine-tune the settings, ensuring optimal performance for your needs.

Troubleshooting Common Issues

While rebuilding your Boxxer Select RC, you may encounter some common issues. Here are some troubleshooting tips:

  • Leaking Oil: If you notice oil leaking from the fork after the rebuild, check the seals and replace any worn parts. Ensure that the seals were installed correctly.
  • Poor Rebound Performance: If the rebound feels too fast or too slow, adjust the rebound settings. If the issue persists, inspect the damper and replace it if necessary.
  • Fork Sticking or Binding: If the fork feels sticky or binds during travel, it could indicate an issue with the bushings or the lower leg assembly. Clean and lubricate the parts thoroughly, and replace any damaged components.

Customization and Optimization for Better Performance

For riders looking to optimize their Boxxer Select RC for specific riding styles, there are several options to consider:

  • Adjust Spring Rate: Consider changing the air spring or coil spring depending on your riding weight and style. A stiffer spring may provide better performance for aggressive downhill riding.
  • Upgrade the Damper: Upgrading to a higher-end damper cartridge can provide additional adjustability and smoother performance, especially for riders who require precise control on technical terrain.
  • Fine-Tune Oil Levels: Experimenting with different oil weights and levels in both the damper and spring systems can also help tailor the fork’s feel to your preferences.

Compatibility with Other Drivetrain Components

The Boxxer Select RC is designed to integrate seamlessly with most modern mountain bike drivetrains, especially those used in downhill or enduro riding. It is crucial to ensure that the fork is compatible with your bike’s geometry, axle type, and brake system. Always verify the fork’s specifications, such as axle diameter and brake mount type, to ensure compatibility with your bike’s components.

By following this guide and regularly maintaining your Boxxer Select RC, you can keep your suspension fork in excellent condition, ensuring optimal performance on even the most challenging rides.