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06-09 32mm Boxxer Bushings

ridea

ridea

Monkey
Oct 30, 2006
354
1
south west of England
Does anybody know the dimensions and type of bushings used in the old style 203mm travel 32mm moco boxxers. Mine need replacing but the kits are either non-existent or around £90. I was thinking about going direct as they're only a few pounds each.

Cheers
 
Udi

Udi

RM Chief Ornithologist
Mar 14, 2005
4,915
1,200
RS forks aren't really designed for bushing replacements and you'll more than likely do a bad job if you're doing it yourself. I'm not sure how to put it politely but it's a 32mm Boxxer, just throw it in the bin and buy a new stiffer fork.

Alternatively, I'm sure you'd find someone who'll give you a non-worn set for cheap or free. That's your best bet.
 
peecee

peecee

Monkey
Apr 27, 2012
232
42
Australia
You can find 32mm lowers all over the net if you get your search on, I managed to pick up a pair of 06-09 32mm boxers for a carton of beer. See what eBay can do for you and then try rideio and other UK forums theres plenty of stuff over there.
 
ridea

ridea

Monkey
Oct 30, 2006
354
1
south west of England
Udi said:
RS forks aren't really designed for bushing replacements and you'll more than likely do a bad job if you're doing it yourself. I'm not sure how to put it politely but it's a 32mm Boxxer, just throw it in the bin and buy a new stiffer fork.

Alternatively, I'm sure you'd find someone who'll give you a non-worn set for cheap or free. That's your best bet.
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Aha I love the throw away mentality of the mountain bike industry. If I rode them in 2009 without problems, may I add doing a season in the Alps where I was riding tracks like Champery on a regular basis, just because there's something better about does that really mean I need to drop a G on a new pair of forks because some bushings worth £1 a pop have worn?

peecee said:
You can find 32mm lowers all over the net if you get your search on, I managed to pick up a pair of 06-09 32mm boxers for a carton of beer. See what eBay can do for you and then try rideio and other UK forums theres plenty of stuff over there.
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Yeah good point but the bushings on those will more than likely be half worn at best so I will be back where I started with a second pair of lowers

I was really hoping that someone could just give me the dimensions, perhaps if somebody had a spare pair sitting around that had come out already to measure otherwise the bike will be out of action between removing and sourcing a replacement.
 
ridea

ridea

Monkey
Oct 30, 2006
354
1
south west of England
Yeah sorry i'm in the UK found them but the P&P makes them 45pounds.

Its not too difficult you just have to buy or fashion a tool for removal and then you can use an old bush and station to make a second tool to drift them in.
 
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Udi

Udi

RM Chief Ornithologist
Mar 14, 2005
4,915
1,200
ridea said:
Aha I love the throw away mentality of the mountain bike industry. If I rode them in 2009 without problems, may I add doing a season in the Alps where I was riding tracks like Champery on a regular basis, just because there's something better about does that really mean I need to drop a G on a new pair of forks because some bushings worth £1 a pop have worn?
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I expected a reply like this but I didn't write what I did without reason.
RS distributors here would often replace the entire lower leg unit rather than changing bushings, and on the few occasions I saw it done, there were issues with play developing soon after or excessive stiction at points in the travel. Anyway if you want to put in the effort then by all means do - it may go just fine - just saying there's a good reason this isn't done often on this particular fork.

Also I've never been to the Alps or Champery so I have no idea what you're talking about. ;)
 
iRider

iRider

Turbo Monkey
Apr 5, 2008
5,653
3,092
Udi is right. I talked to a SRAM mechanic at a race and he told me that they stopped replacing bushings because that weakened the lowers. He said in a couple of instances they had seen failures of the lowers after bushing swaps although it was done by a certified mechanic.
 
ridea

ridea

Monkey
Oct 30, 2006
354
1
south west of England
iRider said:
Udi is right. I talked to a SRAM mechanic at a race and he told me that they stopped replacing bushings because that weakened the lowers. He said in a couple of instances they had seen failures of the lowers after bushing swaps although it was done by a certified mechanic.
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Yeah fair enough. In terms of ability I'm a qualified mechanical engineer so I'm competent enough to handle it hopefully ;). If they're weakened they're weakened, they'd end up in the bin anyway so nothing ventured nothing gained. All the more reason to source cheap off the shelf bushings.

sooooooo back to the original question......anybody have dimensions to hand? I'm going to go on a limb and say that if they are standard its likely that a 32mm ID would be a 36mm OD. Can anyone confirm and give me the upper and lower bushing lengths.

edit: 10mm upper and 75mm lower is listed somewhere could anyone confirm?

Cheers
 
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