INDEX 6.5.4. FORK ASSEMBLY ............................................48 6.5.5. FRONT BRAKE ............................................49 1 . I N T R O D U C T I O N ..............3 6.5.6.
This document is specific to your Turbo Levo SL bicycle and referred to in this manual as the Levo SL. This manual should be read in addition to the Turbo Levo SL User Manual supplied with your bicycle, and the two documents should be kept ASSEMBLY PROCESS ORDER together for future reference.
ASSEMBLY GUIDE VIDEOS PREPARATION To access video content relating to the assembly process of the Turbo Levo SL Carbon, click on the links below to The build starts with a bare 2023 Turbo Levo SL Carbon frame with no components assembled.
2 . F RAME G EO ME TRY 2.1. F RAME AS SOLD ITEM ITEM ITEM A Stack (mm) Fork rake/offset (mm) Handlebar width (mm) B Reach (mm) Front center (mm) Stem length (mm) C Head tube length (mm) K Wheelbase (mm) 1158 1184 1208...
3. TORQUE SPECIF ICAT IONS 3 .1. QUI C K REFERENCE TORQUE TORQUE PART NAME TYPE BOLT SPEC TOOL PART NAME TYPE BOLT SPEC TOOL in-lbf in-lbf 1 TCU screw Screw M4 x 10 mm x 0.7 mm p T10 Torx 9 Non-drive side motor bolts Bolt M10 x 25 mm x 1 mm p...
4 . P IVOT B EAR ING S A ND S PACERS 4.1. P IVOT BEAR ING S AND SPACERS — EXPLO D E D V IEW Q S S Q Apply green Loctite 603 retaining compound to the bearing bore interface surfaces, then press all the bearings into their respective pivot locations. After installing the bearings, allow the Loctite 603 retaining compound to cure 12 hours before riding the bicycle.
4. 2. P IVOT B EARINGS AND SPACERS — SPEC IFICATI ONS SERVICE PART BEARING PIVOT NUMBER MATERIAL Ø OD (mm) Ø ID (mm) WIDTH (mm) THREAD (mm) LENGTH (mm) TOOL NUMBER Main pivot bearing Steel 6901-2RS Horst link bearing Link at seat tube S210600003 Steel...
5. P I VOT BOLTS 5.1. P IVOT BO LTS — EX PLO D ED VIEW All pivot bolts are factory treated with a threadlocker patch on the threads. If it begins to wear off, remove CAUTION: Contaminating the threads of any of the pivot bolts with grease could lead to the Loctite not any remaining threadlocker, then apply a new coat of Loctite 243 or install new bolts with the pre-applied functioning as intended;...
5. 2. P IVOT B OLTS — SPECIF ICAT IO NS TORQUE PIVOT SERVICE PART NUMBER MATERIAL Ø OD (mm) Ø ID (mm) WIDTH (mm) BOLT SIZE LENGTH (mm) TOOL in-lbf Main pivot bolt DS Aluminum M12 left hand 6 mm hex Main pivot bolt NDS Aluminum 6 mm hex...
6. A SSEMBLY PROCES S 6.1. REA R T RI ANG LE ASSEMB LY 6.1.1. SUSPENSION LINK BEARINGS TORQUE PART NAME SERVICE PART NUMBER - CARBON SERVICE PART NUMBER - ALLOY SPEC / DESCRIPTION TOOL in-lbf Shock link — Carbon LINK,MTB,PA TRAIL FSR G1,29F/27.5R,ALY Link forward bore bearing S214300007...
6.1.2. LINK AT SEAT TUBE TORQUE SERVICE PART NUMBER — SERVICE PART NUMBER — PART NAME SPEC / DESCRIPTION TOOL in-lbf CARBON ALLOY Link S214300007 LINK,MTB,PA TRAIL FSR G1,29F/27.5R,ALY Link at seat tube pivot bolt M12 x 17 mm x 1.0 mm p, bolt 6 mm hex Part of suspension bolt kit.
6.1.3. LINK AT SHOCK EXTENSION TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Shock extension — Carbon S216300005 LINK,MTB,PA TRAIL FSR G1,29F/27.5R,ALY Part of suspension bolt kit. Link at extension bolt M12 x 14 mm x 1 mm p, bolt 6 mm hex S210500019 Place a cloth over the frame to prevent the extension arm from damaging the paint.
6.1.4. CHAINSTAY BEARINGS SPEED SENSOR REAR BRAKE GUIDE TUBE DERAILLEUR GUIDE TUBE SERVICE PART TORQUE PART NAME SPEC / DESCRIPTION TOOL NUMBER in-lbf Part of suspension bearing Main pivot bearings — Carbon 12 mm id x 24 mm od x 6 mm w, bearing kit.
6.1.5. MAIN PIVOT TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Main pivot bolt DS M12 x 20 mm x 1 mm p, left hand, bolt 6 mm hex Part of suspension bolt kit. Main pivot bolt NDS M12 x 20 mm x 1 mm p, bolt 6 mm hex S210500019...
6.1.6. DOWN TUBE CHANNEL PLUG < REAR BRAKE GUIDE TUBE DERAILLEUR GUIDE TUBE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION Down tube channel plug S226500009 ICR,CABLE GUIDE,MTB,PA TRAIL FSR G1,29F/27.5R 1: Place a small amount of Loctite 416 at the end of the rear brake guide tube. Briefly allow the glue to spread around the guide tube. ...
CA,SNSR,SPEED,BROSE, AMPHENOL, WERNERWIRTH COPY CON,650MM Speed sensor bolt M4 x 18 mm x 0.7 mm p, bolt 3 mm hex Speed sensor grommet S216800021 ELE TURBO MTB SPEED SENSOR GROMMET 6-Bolt rotor mount speed sensor magnet 6-BOLT VERSION assembly S194200016 Speed sensor magnet bolts M5 x 16 mm x 0.8 mm p, bolt...
6.1.8. LINK AT SEATSTAY PIVOT TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Seatstay S215000005 SS, MTB, PA TRAIL FSR G1, 29F/27.5R, CRBN Link at seatstay bolt M12 x 27 mm x 1.0 mm p, bolt 6 mm hex Part of Carbon suspension bolt kit.
6.1.10. MUD FLAP TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Mud flap kit KIT,MUD FLAP,MTB,PA TRAIL FSR G1 S214200057 Mud flap bolt M4 x 12 mm x 0,7 mm p, bolt 2.5 mm hex This assembly keeps mud and debris from collecting in the gap between the main frame and chainstay. Apply Loctite to the two mud flap bolts and place them in the two holes in the mud flap.
6.1.11. DERAILLEUR HANGER TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf SRAM universal derailleur hanger S202600002 HGR SRAM AC UDH DERAILLEUR HANGER AL BLACK (00.7918.089.000) 8 mm hex (left-hand thread) Use a torque wrench and 8 mm hex bit to torque to specification. ...
6.1.12. DERAILLEUR ASSEMBLY Install the derailleur following the manufacturer’s specifications. Insert the derailleur cable housing into the derailleur. ...
6. 2. REAR CAB LES 6.2.1. REAR BRAKE HOSE REAR BRAKE Feed the rear brake hose into the non-drive side ICR cable port on the inside of the chainstay. Feed the cable though the nylon guide tubes and up the down tube. ...
6.2.2. DERAILLEUR CABLE DERAILLEUR Feed the derailleur cable housing into the drive side ICR port on the bottom of the chainstay. Feed the cable through the derailleur cable guide tube and up the down tube. When the cable housing reaches the ICR port, gently guide it out of the NDS head tube ICR port. ...
6.2.3. NON-DRIVE SIDE ICR PORT REAR BRAKE DERAILLEUR TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf ICR cover — 2 wire ICR CVR,UNIVERSAL RACETRACK, 2 WIRES, 2 CABLES S216500007 ICR base ICR BASE, UNIVERSAL RACETRACK, NYLON, BLK T10 Torx ICR guide screw M3 x 18 mm x 0,5 p, bolt...
6.2.4. DROPPER CABLE DROPPER POST 1. Route the dropper cable up through the integrated cable guide tube inside the down tube until it exits the ICR port on the drive side of the head tube. 2. Guide the other end of the dropper housing up into the seat tube, until it exits the seat tube.Ensure the dropper ...
6.3 . M OTOR AND BAT TERY ASSEMBLY 6.3.1. MAIN HARNESS MAIN HARNESS TCU - MOTOR MOTOR - BATTERY TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Charge port kit MSC SL SELF OPENING CHARGE PORT KIT S209900023 Charge port bolts M2.5 X 14 mm, bolt...
6.3.2. DRIVE SIDE ICR PORT REMOTE - TCU TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf ICR cover — 2 wire ICR CVR,UNIVERSAL RACETRACK,2 WIRES,2 CABLES S216500007 ICR base ICR BASE,UNIVERSAL RACETRACK,NYLON,BLK ICR guide screw M3 x 18 mm x 0,5 mm p, bolt T10 Torx 3.
6.3.3. BATTERY TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Internal battery S196800015 ELE BATTERY SL SYSTEM, INTEGRATED, 320WH, SBC-B15, W/O BOLTS Battery mounting hardware — Carbon BLT MY22 LEVO SL CARBON, BATTERY MOUNTING HARDWARE Battery mounting bolt S210500020 M6 x 14 mm x 1.0 mm p, bolt 4 mm hex...
6.3.4. MOTOR PREPARATION TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Motor MOTOR, M20 S226800001 Removable threaded inserts DS MOTOR MOUNT THREADS Prepare the motor for assembly by placing three motor bolt inserts (A) into the slots on the non-drive side of the ...
6.3.5. MOTOR: STEP 1 TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Motor mounting hardware kit — Carbon BLT MY22 LEVO SL CARBON MOTOR MOUNTING HARDWARE KIT NDS motor bolt M6 x 20 mm x 1.0 mm p, bolt 5 mm hex NDS motor washer S210500018...
6.3.6. MOTOR: STEP 2 CABLE MOTOR CONNECTOR CONNECTOR SPEED SENSOR MAIN HARNESS TCU - MOTOR BATTERY / MAIN CONNECTOR MOTOR - BATTERY SPEED SENSOR TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Motor S226800001 MOTOR, M20 Speed sensor cable S196800019 ELE MY20 MTB SL SYSTEM, SPEEDSENSOR KIT Main harness...
6.3.7. MOTOR: STEP 3 TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Motor mounting hardware kit BLT MY22 LEVO SL CARBON MOTOR MOUNTING HARDWARE KIT NDS motor bolt M6 x 20 mm x 1.0 mm p, bolt 5 mm hex NDS motor washer S210500018...
6.3.8. ROCK GUARD TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Rock guard kit SUB MY22 LEVO SL CARBON ROCK GUARD KIT MOTOR,M20 Rock guard ROCK GUARD,PA TRAIL FSR G1.1 Rock guard / battery bolt M6 x 14 mm x 1 mm p, bolt 4 mm hex S214200058 Rock guard washer...
SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Turbo connect unit (TCU) ELE TURBO CONNECT UNIT DISPLAY (A1.2) WITH GITEKI MARK S216800009 TCU screw M4 x 10 mm bolt T10 Torx WARNING! Always turn the battery off when not in use and/or when working on the bicycle.
MasterMind turbo connect unit (TCU) ELE TURBO CONNECT UNIT 2 S216800020 Turbo connect unit (TCU) mounting bolt M4 x 10 mm bolt T10 Torx MASTERMIND WARNING! Always turn the battery off when not in use and/or when working on the bicycle.
6.4 . DR IVET RAIN ASSEMBLY 6.4.1. REAR WHEEL TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Rear thru-axle S220200002 12 mm x 148 mm x 174.5 mm, axle 6 mm hex Roval traverse 27.5 Rim S193700010 MY19 ROVAL TRAVERSE 27.5 RIM-670, 30 MM WIDTH 28H W/CHARCOAL DECAL RIM Install the rear wheel into the rear frame ensuring the brake disc is between the brake pads.
6.4.2. CHAIN GUIDE Place the chain guide on the frame, then insert the chain guide pin TORQUE SERVICE PART PART NAME SPEC / DESCRIPTION TOOL into the hole in the frame. This prevents the chain guide from rotating NUMBER in-lbf when torquing.
Park Tool BBT-79 Crank arms SEE TABLE CRK TURBO, SL M20, MOUNTAIN, 165 MM - 175 MM, L+R ARMS, CARBON / ALLOY, SRAM 8 mm hex 1. Assemble the chainring to the spider with the four chainring bolts and nuts. Use a torque wrench and a 5 mm...
6.4.4. CHAIN GUIDE ADJUSTMENT SERVICE PART TORQUE PART NAME SPEC / DESCRIPTION TOOL NUMBER in-lbf Chian guide CHG LEVO SL (GEN.2), CARBON FRM, CHAIN GUIDE, MOTOR BOLT MOUNTED, 32-34T S231200005 5 mm hex Chain guide mounting nut M8 x 1 mm p, nut Shift to the smallest cog on the cassette.
6. 5. FR O NT END 6.5.1. HEADSET 0° + .0° -1° +/-1° +1° SERVICE PART Lower bearing cup SPHERICAL ADAPTER 1.5” 45° - 54 MM OD X 52 MM ID PART NAME SPEC / DESCRIPTION NUMBER HEAD TUBE ANGLE ADJUST 0° | 1-1/8” - 41.8 MM ID, 46 PRIME AERO, AC-286-5, CARBON SPACER ,34 MM OD Upper zero offset cup S212500015...
6.5.2. HEADSET CUPS ADJUSTMENT +1° -1° The head tube angle is adjustable via adjustable headset cups. The bicycle ships with the “zero” offset cup and a +/- 1 degree headset cup ships in the small parts box. Adjustable headset cup replacement ...
6.5.4. FORK ASSEMBLY SERVICE PART TORQUE PART NAME SPEC / DESCRIPTION TOOL NUMBER in-lbf Swat™ Conceal carry mtb tool 90 mm S185300020 | 105 mm S185300016 | 120 mm S185300017 Swat™ Bow tie anchor SWAT™ BOW TIE ANCHOR 5 mm hex Swat™...
6.5.5. FRONT BRAKE FRONT BRAKE 1. Install the front brake caliper and brake caliper adaptor to the fork following the manufacturers instructions. Use a torque wrench to torque the brake caliper mounting bolts to the manufacturer’s specification. 2. Thread the front brake hose from the caliper through the cable guide on the fork leg. ...
6.5.6. FRONT WHEEL 1. Use a 6 mm hex key to loosen the pinch bolt (B), then install the front wheel into the fork dropouts. Insert front wheel between the dropouts making sure the brake disc is between the brake caliper pads. Slide the thru-axle (A) through the drive side dropout and hub.
6.5.7. HANDLEBAR SERVICE PART TORQUE PART NAME SPEC / DESCRIPTION TOOL NUMBER in-lbf Trail remote ELE TRAIL REMOTE 2 S216800019 2 mm hex Trail remote bolt Grub screw 1. Install the drive side brake lever and shifter onto the bar and hand tighten only. ...
6.5.8. HANDLEBAR MOUNTING SERVICE PART TORQUE PART NAME SPEC / DESCRIPTION TOOL NUMBER in-lbf Alloy trail stem STEM, JD, JD-ST97Q, 6061-T6, 35 MM,40 MM AND 50 MM, STEEL, ZINC FINISH BOLT, NO THREAD LOCK 5 mm hex Alloy trail stem faceplate bolt upper M5 x 18 mm x 0.8 mm p, bolt / includes spring washer 5 mm hex Alloy trail stem faceplate bolt upper...
6.5.9. DROPPER POST FRAME SIZE MAX INSERTION 180 mm 180 mm 26.982 200 mm 220 mm 240 mm 260 mm MAX INSERTION SERVICE PART TORQUE PART NAME SPEC / DESCRIPTION TOOL NUMBER in-lbf 4 mm hex Seatpost clamp S214700007 STC SPL-SC02-386A-02,38.6MM EXTRUDED,7075-T73, BLACK ZINC BOLT,CLAMP TYPE, W/SKIRT FOR SHIMMED FRAMES Remove the bicycle from the stand and remove the temporary seatpost.
Arrange the cockpit components and torque all the bolts to the manufacturer’s specifications. System power up and registration Connect the charger and charge the battery. Power up the system using the TCU/MasterMind TCU. Connect to Turbo Studio and perform the firmware updates. ...
7. CA BL ING DIAG RAM S 7.1. CABLE ROUT ING 7.1.1. CARBON FRAME — NON AXS MAIN HARNESS / TCU REAR BRAKE DERAILLEUR DROPPER CABLE CONNECTOR MOTOR CONNECTOR BATTERY / MAIN HARNESS SPEED SENSOR CABLE...
7. 2. E LECTRICAL SCHEMATICS 7.2.1. SYSTEM SCHEMATICS — TCU MOTOR CABLE CONNECTOR CONNECTOR Battery / Main Harness MISSION CONTROL Speed Sensor SPEED SENSOR BATTERY REMOTE MOTOR LIGHT SPLITTER MAIN HARNESS FRONT LIGHT RANGE EXTENDER REAR LIGHT CHARGER Main Harness / Battery Main Harness / Motor Main Harness / TCU Speed Sensor...
7.2.2. SYSTEM SCHEMATICS — MASTERMIND TCU MOTOR CABLE CONNECTOR CONNECTOR Battery / Main Harness MISSION CONTROL Speed Sensor SPEED SENSOR TYPE C BATTERY REMOTE MASTERMIND MOTOR LIGHT SPLITTER MAIN HARNESS FRONT LIGHT RANGE EXTENDER REAR LIGHT CHARGER Main Harness / Battery Main Harness / Motor Main Harness / MasterMind TCU Speed Sensor...
8. 2. S ERV IC E PA RTS: C A R B O N F RA M E Rear shock hardware BLT KIT, MY22 LEVO SL (GEN.2) CARBON, REAR SHOCK MOUNTING BOLT KIT kit - Carbon SERVICE Rear shock mounting bolt PART NAME PART PART SPECIFICATION...
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