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  1. #1
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    2010 Boxxer Worldcup rebound knob keeps coming loose

    Hey everyone, last time I was up in Whistler I had a little problem with my rebound knob on the bottom of my Boxxer Worldcup. The whole assembly kept coming loose, to the point where I was really worried about the whole thing falling off. I finally just took it off and rode with it in my pocket the rest of the day.

    There are 2 dials / adjusters that sit mostly flush with the bottom of the fork leg, and then thereís a rod that slides up through the washer-like adjusters into the bottom of the fork leg. Itís a snug fit, but the pressure alone doesnít appear to be enough to hold everything together while riding. Thereís a little c-clip, but that doesnít seem like itís holding it together either. Maybe Iím doing it wrong?

    2 questions: 1- is it safe to ride with the rebound adjust off. I think it is but wanted to check with the collective. 2. Am I missing a part that holds everything together tight? Am I not putting it together correctly? I have some pictures on my phone I can add later when I get a chance, if that helps. Thanks!

  2. #2
    Huffy Rider
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    Are you talking about the 2.5mm hex key with the red knob on it? If so, I always remove those when riding and carry them in my pack. Less stuff to hang down and get caught on rocks.

  3. #3
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    This is not uncommon with the 2010 WC.
    If the rebound knobs are rattling and loose, odds are that you are missing the tiny c clip that sits on top of the rebound assembly inside the fork leg.
    There are two c clips-one that you can see on the bottom of the low speed rebound dial that is external, and a tiny c clip that sits on top of the rebound assembly inside the fork leg( just a few mm in diameter) that serves to keep the rebound knobs compressed in place.
    If you don't see a tiny c clip on the shaft of the rebound dials assembly when you remove it, you'll know you are missing it.
    Flip the fork upside down and completely remove the rebounds assembly/foot nut.
    You'll see the small groove at the base of the shaft where a c clip should go.
    Easy fix usually-takes about 5 minutes and you can find the tiny c clips at auto parts and hobby stores.

  4. #4
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    I've got the same issue with my 2010 Boxxer Team. The washer that goes between the beginning and ending rebound control knobs somehow fell off. I think it was made of nylon if I remember right? It was definitely on there when I replaced the seals. Anyways, The knobs are still hanging on by the C clip, there's just play within the knobs now. I've been meaning to get to a hardware store to look for a similar washer figuring that would take care of the problem.

  5. #5
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    Here's how to tell if it's just the missing washer or the c clip:
    Pull down on the low speed rebound adjuster.
    If it moves 1/4" or more, the c clip on the upper portion of the adjuster shaft is missing or has slipped out of it's groove.

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