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 manual was drafted in English (original instructions) and may have been translated into other languages as applicable (translation of original instructions). This document is specific to your Turbo Levo SL Alloy frame bicycle and referred to in this manual as the Levo SL. ASSEMBLY PROCESS ORDER This manual should be read in addition to the Levo SL User Manual supplied with your bicycle, and the two documents should be kept together for future reference.
MOTOR AND BATTERY ASSEMBLY GUIDE VIDEOS S C A N M E https://vimeo.com/801053048/f1235102e1 To access video content relating to the assembly process of the Turbo Levo SL Alloy, click on the link next to the PREPARATION video icon to go directly to the assembly video.
2 . F RAME G EOME T RY 2.1. AS SO LD ITEM ITEM ITEM A Stack (mm) I Fork rake/offset (mm) Handlebar width (mm) B Reach (mm) J Front center (mm) Stem length (mm) C Head tube length (mm) K Wheelbase (mm) 1154 1180...
3. TO R Q UE S PECI F IC AT IO NS 3.1. Q U IC K REF ERE N C E TORQUE TORQUE PART NAME TYPE BOLT SPECIFICATION TOOL PART NAME TYPE BOLT SPECIFICATION TOOL in-lbf in-lbf 1 TCU screw Screw M4 x 10 mm x 0.7 mm p T10 Torx...
4. PIVOT B EAR IN G S A N D SPACERS 4.1. P IVOT B EA R I NG S A N D S PAC E RS — EX PLO D ED VI EW R B 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.
5. P IVOT BOLTS 5.1. P IVOT B O LTS — EX PLO D E D V IEW 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 O LTS — A LLOY F RA M E : S PEC IF IC AT I O NS TORQUE PIVOT SERVICE PART NUMBER MATERIAL Ø OD Ø ID WIDTH BOLT SIZE LENGTH TOOL in-lbf Main pivot bolt DS Aluminum...
6. AS SE MB LY PR O CESS 6 .1. REAR T R IA NG L E A S S E M B LY 6.1.1. SUSPENSION LINK BEARINGS TORQUE PART NAME SERVICE PART NUMBER - ALLOY SPEC / DESCRIPTION TOOL in-lbf Shock link LINK,MTB,PA TRAIL FSR G1,29F/27.5R,ALY...
6.1.2. LINK AT SEAT TUBE TORQUE PART NAME SERVICE PART NUMBER — ALLOY SPEC / DESCRIPTION TOOL in-lbf 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 — Alloy S216300004 EXTN,MTB,PA TRAIL FSR G1,AL Part of suspension bolt kit. Link at extension bolt M12 x 14 mm x 1 mm p, bolt 6 mm hex S220500016 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 TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Part of suspension bearing kit. Main pivot bearings — Alloy 15 mm id x 24 mm od x 7 mm w, bearing S220600006 Chainstay kit —...
6.1.5. MAIN PIVOT TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Main pivot bolt DS M14 x 15 mm x 1 mm p, left hand, bolt 6 mm hex Part of suspension bolt kit. Main pivot bolt NDS M14 x 15 mm x 1 mm p, bolt 6 mm hex S220500016...
6.1.6. DOWN TUBE CABLE GUIDE REAR BRAKE GUIDE TUBE DERAILLEUR GUIDE TUBE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION Down tube ICR guide CABLE GUIDE,ICR,QUAD,BOTTLE CAGE MOUNT Down tube ICR guide bolt S226500016 M4 x 12 mm x 0.7 mm p, bolt Down tube ICR guide washer 4.2 mm id x 7 mm od x 0.8 mm thick, washer Thread the derailleur and rear brake guide tube up the down tube to the non-drive side ICR port located in the top 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 — Alloy S225000013 SS,MTB,PA TRAIL FSR G1.2,29F/27.5R,ALY Link at seatstay bolt — Alloy M12 x 27 mm x 1.0 mm p, bolt 6 mm hex Part of Alloy suspension bolt kit.
6.1.10. HORST PIVOT - CHAINSTAY PROTECTOR EXTENSION TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Chainstay protector S216900005 CS PROTECTOR,MTB,PA TRAIL FSR G1.1 Chainstay protector extension — Alloy S226900012 CS PROTECTOR EXTENSION,MTB,PA TRAIL FSR G1.2,29F/27.5R,ALY The alloy chainstay requires an additional chainstay protector extension. Clean the chainstay, remove the adhesive film from the extension, then align and firmly place the chainstay ...
6.1.12. SUSPENSION BOLTS TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Suspension bolt kit my23 Levo SL Alloy S220500016 BLT MY23 LEVO SL, ALLOY FRM, SUSPENSION PIVOT BOLT KIT (W/ PIVOT SPACERS) Use a torque wrench and the appropriate hex bit to torque all rear suspension bolts to specification.
6.1.13. 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.
6.1.14. 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. ...
6.1.15. DERAILLEUR ASSEMBLY Install the derailleur following the manufacturer’s specifications. Insert the derailleur cable housing into the derailleur. ...
6 . 2 . REA R CA BL ES 6.2.1. REAR BRAKE HOSE REAR BRAKE Using a T10 Torx key loosen the screw holding the inner and outer components of the ICR port guide together but do not separate the two components completely. ...
6.2.2. DERAILLEUR CABLE DERAILLEUR Feed the derailleur cable housing into the drive side ICR cable port on top of the chainstay. Feed the cable through the nylon guide tube and up the down tube 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 mm p, bolt frame.
6.2.4. DROPPER CABLE < DROPPER POST TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Dropper cable guide tube — Alloy TUBE,ICR,5.5 X 7,NYLON,BLK - Cut length: S1-720 mm, S2-730 mm, S3-750 mm, S4-760 mm, S5-790 mm, S6-810 mm 1.
6 . 3 . MOTO R AN D BAT T E RY A S S E M B LY 6.3.1. MAIN HARNESS MAIN HARNESS TCU - MOTOR MOTOR - BATTERY TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Main harness S196800021...
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 T10 Torx ICR guide screw M3 x 18 mm x 0,5 mm p, bolt 3.
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 Motor mounting hardware kit MOTOR MOUNTING HARDWARE KIT S194200050 Motor mount nut M10 x 9.5 mm x 0.1 mm p, nut 15 mm open wrench Prepare the motor for assembly by placing the three threaded inserts (A) into the slots on the non-drive side of the ...
6.3.5. MOTOR: STEP 1 CABLE MOTOR CONNECTOR CONNECTOR SPEED SENSOR MAIN HARNESS TCU - MOTOR MOTOR - BATTERY BATTERY / MAIN CONNECTOR SPEED SENSOR TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf S226800001 Motor MOTOR,M20 Motor mounting hardware kit — Alloy KIT,MOTOR,PA TRAIL FSR C1,PLW 4 mm hex Motor mount bolt DS rear —...
6.3.6. MOTOR: STEP 2 TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Motor mounting hardware kit — Alloy KIT,MOTOR,PA TRAIL FSR C1,PLW T30 Torx Motor mount bolt NDS front — Alloy M6 x 28 mm x 1.0 mm p, bolt Motor mount washer NDS —...
6.3.7. MOTOR: STEP 3 TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf Motor mounting hardware kit-Alloy KIT,MOTOR,PA TRAIL FSR C1,PLW T30 Torx Motor mount bolt DS front — Alloy M10 x 258 mm x 1.0 mm p, bolt Motor mount washer DS —...
6.3.8. ROCK GUARD TORQUE PART NAME SERVICE PART NUMBER SPEC / DESCRIPTION TOOL in-lbf T30 Torx Part of Alloy motor mounting Motor mount bolt NDS front — Alloy M6 x 28 mm x 1.0 mm p, bolt hardware kit Motor mount washer NDS — Alloy S194200050 6.4 mm id x 16 mm od x 4 mm thick, washer Rock guard kit —...
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 . D R I V ET RAI N A S S E M B LY 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...
6.4.2. CHAIN GUIDE Place the chain guide on the frame, then insert the chain guide pin SERVICE PART TORQUE PART NAME SPEC / DESCRIPTION TOOL into the hole in the frame. This prevents the chain guide from rotating NUMBER in-lbf when torquing.
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 KIT,CHN GUIDE,PA TRAIL FSR G1.2 S221200012 5 mm hex M8 x 1 mm p, nut Chain guide mounting nut Shift to the smallest cog on the cassette. ...
6 . 5 . F R O NT EN D 6.5.1. HEADSET 0° + .0° -1° +/-1° +1° SERVICE PART Lower bearing cup SPHERICAL ADAPTER 1.5” 45° - 54 OD X 52 PART NAME SPEC / DESCRIPTION NUMBER HEAD TUBE ANGLE ADJUST 0° | 1-1/8” - 41.8 ID, 46 PRIME AERO, AC-286-5, CARBON SPACER ,34 MM OD Upper zero offset cup...
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 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.
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. Complete online registration. Register bicycle here. Perform a test ride.
7. C ABLE DIAG RA MS 7.1. CA B LE R O UT I N G 7.1.1. ALLOY FRAME MAIN HARNESS / TCU DROPPER DERAILLEUR REAR BRAKE CABLE CONNECTOR MOTOR CONNECTOR BATTERY / MAIN HARNESS SPEED SENSOR CABLE...
7. 2. ELECT R I CAL S C H E M AT IC S 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...
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...
8.3. S E RV IC E PARTS : AL LOY 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 PART DESCRIPTION M8 x 25 mm bolt...
Page 60
Do pivot spacer,geo adj 6 mm x 1 mm, flip Horst link inner flip chip SPCR,DO PIVOT,GEO ADJ,M6 X 1,ALY Rock guard kit — Alloy frame MSC MY23 LEVO SL (GEN.2), ALLOY FRM, ROCK GUARD KIT chip Horst link outer flip chip Do pivot spacer,geo adj,6.0 Id, flip chip SPCR,DO PIVOT SPACER,GEO ADJ,6.0 ID,FLAT,ALY Rock guard Alloy...
Need help?
Do you have a question about the LEVO SL 2-ALLOY and is the answer not in the manual?
Questions and answers