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Installation Instructions Boxxer AWK

Please read these instructions carefully! In case of doubt do not install the AWK unit.
Improper installation may cause malfunction, resulting in serious injury or death!
Wear safety glasses and protective gloves during installation and maintenance!

Note:
Pike LT for 140-160mm travel (2014-2017, all wheel sizes)
Pike MT for 120-140mm travel (2014-2017, all wheel sizes)
Pike Boost LT for 140-160mm travel (2014-2017, all wheel sizes)

The Pike AWK does not fit in Dual Position forks!

Step 1

Be sure to depressurize your solo air chamber first.
Unscrew the Solo Air top cap as described in the Rock Shox manual.

Step 2

Remove both air valve caps from the AWK unit top cap.
Unscrew the valve-core of the main chamber valve (the unlabeled valve).Use a Schrader valve-core tool.

Step 3

Apply SRAM Butter, r.s.p. SlickKick or similar to the AWK air piston and seal.

Step 4

Apply SRAM Butter, r.s.p. SlickKick or similar to the top cap threads. This is necessary to protect the AWK piston seal ring during installation.

Step 5

Place the AWK piston as shown at the upper end of the top cap threads. Work the top cap in a circular motion while pressing the AWK piston into the stanchion.

Step 6

Lightly press the AWK piston 30-40mm into the stachion. Apply 1.5ml 0W-30 Rock Shox Oil (engine oil 5W-30...40 also possible).
Do not use longlife engine oil!

Step 7

Lightly press the AWK top cap to the beginning of the threads. Ensure that you don't twist the AWK top cap. Use a torque wrench with a 30mm socket to tighten the top cap to 7,3 NM.

Step 8

Reinstall the valve-core and tighten to 0.35-0.55Nm.

Step 9

Pressurize the AWK chamber (marked with 'AK' or '( )' ) according to the pressure chart below.

Rider weight:
60-72kg -> 70psi
70-80kg -> 80psi
80-90kg -> 90psi
90-100kg -> 100psi

Note: This is the AWK pressure pre-setting, not the final AWK pressure! Do not exceed 100psi (aluminium guide rod) or 90psi (steel guide rod, older model) when main air chamber is unpressurized. This could result in damage to the AWK unit.

Step 10

Pressurize the main air chamber (the unlabeled valve). Refer to the pressure chart below.

Rider weight:
60-72kg -> 41-54psi
70-80kg -> 50-60psi
80-90kg -> 58-68psi
90-100kg -> 66-78psi

Note: Ensure that the AWK chamber pressure is higher than the main air chamber pressure.

Step 11

Pressurize the AWK chamber to the final pressure.

Rider weight:
60-72kg -> 88-120psi
70-80kg -> 110-135psi
80-90kg -> 127-150psi
90-100kg -> 145-171psi

Note: A pressure difference between AWK chamber and main air chamber greater than 100psi (current model) is not permitted! Do not exceed 175psi in the AWK chamber!

Step 12

Threads the air valve caps on both valves.

Note: operation without air valve caps is not allowed!

Service

After 10 hours of riding check the main chamber and AWK chamber pressure.
After 150-200 hours of riding/annually visually inspect, clean/grease the AWK internal parts as described below.

Note: muddy, wet and dusty conditions can shorten the service intervals!

Maintenance

Always wear safety glasses and gloces during any maintenance work!
Remove both aur valve caps from the AWK unit.
Use a small hex wrench and start by pressing the labeled valve core. Depressurize until the AWK chamber is at ambient pressure. Continue by pressing the unlabeled valve core until the main air chamber is at the ambient pressure.
If you are unsure whether all air is released use a Schrader valve core tool and unscrew the valve core carefully!

Note: Do not disassemble a pressurized AWK unit!

Use a 30mm socket wrench to unscrew the AWK unit carefully.
(counterclockwise)

Check the internal parts and inspect the top cap treads, guide rod, AWK piston and seals for damage, wear andscratches. In case of mechanical damage, do not reinstall the AWK unit.

Use a clean rag and a small amount of Isopropyl alcohol to clean the AWK unit.
Install a new X-Ring (23,40 x 3,53 NBR 70 Shore) and apply SRAM Butter, r.s.p. SlickKick or similar to the guide rod, deals and piston.

Now reinstall the AWK unit, start with step 2 of the installation instructions.

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