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MY2017
Technical Manual
32 pgs5.53 Mb0

Levo MY2017 Technical Manual

Levo Retailer Technical Guide
MY2017
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Levo Retailer Technical Guide
TABLE OF CONTENTS
Requirements & Recommendations ............................................................................................................................ 3
Optional Service Parts Inventory .................................................................................................................................................................................................... 10
Build, Setup, & Maintenance ....................................................................................................................................... 13
New Bike Build Checklist .................................................................................................................................................................................................................. 13
Setup Checklist for Test Rides, Demos, and Sale s................................................................................................................................................................... 14
First Ride Tips ........................................................................................................................................................................................................................................ 15
Maintenance Details - Bicycle ..........................................................................................................................................................................................................16
Maintenance Details - Motor ............................................................................................................................................................................................................16
Unlocking or De-restricting the Motor ........................................................................................................................................................................................... 16
Glossary ........................................................................................................................................................................ 17
Troubleshooting & Diagnosis Guide - Fundamentals ................................................................................................ 19
Troubleshooting & Diagnosis Guide - Performance Issues ....................................................................................... 21
Symptom Category - Noise .............................................................................................................................................................................................................. 21
Symptom Category - Control .......................................................................................................................................................................................................... 22
Symptom Category - Communications ........................................................................................................................................................................................23
Symptom Category - Expectations ............................................................................................................................................................................................... 24
Troubleshooting & Diagnosis Guide - Function Issues ............................................................................................. 25
Diagnose Hardware Using Visual Inspection ............................................................................................................................................................................. 25
Diagnose System Connection Using the Mission Control App ........................................................................................................................................... 25
Diagnose Motor Harness & Plug Connections Using Substitute Components ............................................................................................................. 26
Warranty ....................................................................................................................................................................... 27
Introduction
This guide provides important technical information and recommendations about Specialized Levo bicycles. It is for use by USA Authorized Specialized Retailers only. If you have any questions please contact Retail Care at 1-800-722-4423.
Please consult the Service Site at service.specialized.com or linked from B2B for any updates to this and any other technical documents before starting work. The Service Site is always has the latest technical information.
Available Resources
This guide is intended to be used in conjunction with other Specialized resources:
• Levo Owner's Manual - The Levo Owner's Manual has information useful to retailers as well as riders.
• Rider/Retail Care Rep - The Rider/Retail Care teams have hands-on experience in riding, customizing, and servicing Levos. They often can provide assistance or advice that comes from personal experience.
• SBCU and SBCU.com - Check with SBCU for Turbo and Levo content currently offered. Visit SBCU.com often for product specific videos, tutorials, and quizzes.
• Service Site - The Service Site is the central location for all technical documents, Technical Bulletins, service procedures, manuals, product service item information, and software resources. Information on the Service Site is frequently updated. Please check frequently to ensure you are using the latest information available.
• The Service Site can be accessed directly at service.specialized.com or linked through the B2B site.
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Levo Retailer Technical Guide
Requirements & Recommendations
This section outlines the various tools and service parts inventory retailers will need to invest in to be able to provide professional level support to Levo riders. Levo support at retail means retailers will be able to perform the following activities with confidence and expertise:
• Execute all firmware and hardware updates
• Quickly and accurately diagnose and resolve issues
• Demonstrate working knowledge of Levo bikes and show how their expertise contributes to the Turbo Ride Experience
• Communicate ride and maintenance details to Levo riders in a knowledgeable manner
Tools & Service Parts Inventory at a Glance
REQUIRED TOOLS
• Turbo PC Connect and Diagnostic Tool (version 4.2 or later) : 989E-5610
• 98916-5646 : Levo Diagnosis Tool adapter
• 3" 2-jaw pulley and gear puller
• Brose cap puller tool : S175300006
• Smartphone or tablet : Android or iOS
• Octalink/Isis bottom bracket tool : Shimano® TL-UN98, Park BBT-18, or equivalent
RECOMMENDED TOOLS
• Counterweighted or powered repair stand
• Handlebar/stem mounted phone holder
RECOMMENDED SERVICE PARTS INVENTORY
• Magnet holder including magnet plate, anodized black : S166800012, recommended inventory 2-3
• Motor-to-battery harness : S176800002, recommended inventory 1
• Speed Sensor : S16680018, recommended inventory 1-2
• Chainring Steel, 104 BCD: S161400009, recommended inventory 1
• Amazinger 2.0 derailleur hanger : S162600002
• Battery mounting thru axle : S166800004, recommended inventory 2
• Battery : 98916-5617, recommended inventory 1-2
• Battery pin w/o hardware : S166800005, recommended inventory 3
• Battery rock guard w/o hardware: S169900019, recommended inventory 3
• Bolt kit for battery : S170500004, recommended inventory 1
OPTIONAL SERVICE PARTS INVENTORY
• Bearing kit, Levo FSR : S160600004
• Bolt kit for Levo FSR : S160500007
• Crank, custom alloy arm for MTB, 165 mm : S161600013
• Crank, custom alloy arm for MTB, 170 mm : S161600015
• Spider, Levo Fat, 104 BCD : S161600017
• Spider, 104 BCD : S161600018
• Chain guide Fat : S161200002
• Chain guide 29 and 6Fattie : S161200001
• Chain stay protector mastic tape Levo Fat : S166900002
• Chain stay protector mastic tape Levo Hardtail : S166900004
• Chain stay protector FSR : S166900003
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Levo Retailer Technical Guide
Requirements & Recommendations
Required Tools
Turbo PC Connect and Diagnostic Tool, version 4.2 or later : 989E-5610
This is an updated version of the existing Turbo PC Connector (aka Turbo Diagnostic Tool). This tool is used exclusively to update the Levo system firmware of the motor and battery. All system diagnosis can be performed electronically with the Mission Control App or manually with the diagnosis techniques outlined in the Troubleshooting Guide section of this guide.
To update the motor firmware, the Levo Diagnosis Tool Adapter must be used in conjunction with Turbo PC Connect and Diagnostic Tool.
Note: previous versions of the Turbo PC Connect and Diagnostic Tool will only update the battery firmware. The previous versions will not update the motor firmware.
Levo Diagnosis Tool Adapter : 98916-5646
The adapter must be used with the Turbo PC Connect and Diagnosis Tool to update the motor firmware. In addition, the battery must be connected to the motor while the Turbo PC Connect performs the update.
3" 2-jaw pulley and gear puller
These tools are typically available at auto parts and/or hardware stores.
The ends of the jaws must be thin enough to fit between the chainring spider and motor cover. The force required to pull the spider is low. Therefore, if the ends of the jaws need to be modified or ground down to fit between the spider and motor, that is acceptable.
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Levo Retailer Technical Guide
Requirements & Recommendations
Brose spindle cover : S175300006
This tool holds the threaded plunger of the gear puller stable. It applies force to the driver when the spider is pressed on which helps to prevent damage to the torque sensor.
Smartphone or tablet : Android or iOS
System requirements: Android 4.3 (Jellybean) or later, iOS 8.1 or later.
All Levo system diagnosis and user customization is performed through the Mission Control App. Unlike the Turbo, system diagnosis and user customization is not possible through the Turbo PC Connect and Diagnostic Tool.
Octalink/Isis bottom bracket tool
Use Shimano®® TL-UN98, Park BBT-18, or an equivalent bottom bracket tool.
This tool is used to tighten or loosen the spider lockring.
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Levo Retailer Technical Guide
Requirements & Recommendations
Recommended Tools
Counterweighted or powered repair stand
EVT E-Z Lift and Park PRS-33 Powered Lift Stand are two options for counterweighted or powered repair stands.
While these stands are expensive, they are a worth the investment. E-bikes are considerably heavier than standard bicycles. A counterweighted or powered stand minimizes the physical effort required to position the bike and reduces the potential for injury to retailer staff when they lift the bike. The bikes can be easily maneuvered in the stand which reduces the potential for damage to the bike while showcasing to Levo riders a level of professionalism that inspires confidence in the retailer.
Handlebar/stem mounted phone holder
Hondo Garage Perfect Squeeze, Ram Mounts, and Rokform Mounts are three options for handlebar/stem mounted phone holders.
Remember, all Levo system based diagnosis and user customization is performed through the Mission Control App. The best diagnostic method is to use the app's real time data display while riding the bike. Using a handlebar or stem mounted phone holder allows the mechanic to ride safely, with both hands on the handlebar, and view the app at the same time to compare the motor performance with respect to speed and rider input.
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Levo Retailer Technical Guide
Requirements & Recommendations
Recommended Service Parts Inventory
This section outlines a small inventory of critical replacement parts that a retailer should keep in stock to help diagnose issues effectively and efficiently. Diagnosis of a Levo drive system issue typically requires the replacement of various components of the system with known functional parts to determine which components are functional or non-functional through a process of elimination. It is much like finding a creak in a bike. A small inventory of parts will save considerable time and money on ordering and shipping replacement parts individually for diagnosis purposes. In addition, some components are wear items that a Levo retailer will want to have in stock to perform service for their customers.
Magnet holder including magnet plate, anodized black : S166800012
The drive system must recognize the bike is in motion before it can activate the motor. Motion is detected when the magnet mounted on the rear brake rotor passes a reed switch in the speed sensor. The speed sensor then sends a signal to activate the motor. The motor will not provide power if the magnet is not attached to the rotor. Riders with multiple wheel sets will need a magnet on each wheel that is used with the Levo or the rider will need to transfer the magnet to the other rear wheel rotor.
Recommended inventory: 2-3
Motor-to-battery harness : S176800002
Specification change - S176800002 replaces S166800008 and is backward compatible. S176800002 is a longer harness length of 180 mm versus the original 165 mm length.
Riders who frequently unplug the battery from the system will wear out the connector which will require replacement.
Remember, to diagnose system issues, various parts, including wire harnesses, must be replaced with a known functional part to eliminate it as a source of the issue.
Recommended inventory: 1
Speed Sensor : S166800018
The speed sensor, much like a traditional cycle computer, is a wire with a reed switch at the end. While a reed switch rarely fails, if it does, or if a rider damages the speed sensor, the motor will not receive a signal to activate and will not operate.
Recommended inventory: 1-2
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Levo Retailer Technical Guide
Requirements & Recommendations
Chainring steel, 104 BCD : S161400009
This is a 104 mm BCD chainring made specifically for Levo by Praxis Works. There are two features that make the chainring ideal for Levo:
• It is made of steel for durability.
• It has internal threads for the chainring bolts which eliminates the need for backing nuts. If the chainring had backing nuts, the spider would have to be removed to install the chainring.
While standard 104 mm BCD chainrings are compatible with the Levo spider, performance could be compromised because:
• Most standard chainrings are made of aluminum and will wear more quickly than a steel chainring.
• Most standard chainrings do not have internal threads for the chainring bolts so the spider must be removed to install the chainring.
• Use of a chainring larger than the stock 32T may inhibit climbing and make larger gears less useful because the larger gears will be difficult to engage until the speed is above the speed limiter (i.e. the speed is above the limit where the motor is required to turn off). Refer to the First Ride Tips later in this guide for climbing tips.
Max chainring: 36T with chain guide; 38T without chain guide
Recommended inventory: 1
Amazinger 2.0 Derailleur Hanger : S162600002
A straight, aligned derailleur hanger is more critical to shift performance on a Levo bicycle versus a traditional bicycle because the motor applies more torque through the rear of the bike. Any misalignment of the derailleur hanger can cause shifting issues.
Retailers should encourage Levo riders to purchase a spare hanger and keep it on hand in case the hanger is bent during a ride.
Battery mounting thru axle : S166800004
Levo riders who frequently remove the battery from the bike to charge the system will most likely need to replace the thru axle because of increased wear, damage, and/or loss of the axle.
Recommended inventory: 2
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Levo Retailer Technical Guide
Requirements & Recommendations
Battery : 98916-5616
The MY16 Aftermarket Levo battery is only offered in a 504 Wh capacity.
The battery requires the additional service item SKUs that follow for installation and use.
Recommended inventory: 1-2
Battery pin w/o hardware : S166800005
Recommended inventory: 3
Battery rock guard w/o hardware : S169900019
Recommended inventory: 3 (in locations with loose rocky trails)
Bolt kit for battery : S170500004
Recommended inventory: 1
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Levo Retailer Technical Guide
Requirements & Recommendations
Optional Service Parts Inventory
This section outlines optional replacement parts that a retailer might choose to keep in stock.
Bearing kit, Levo FSR : S160600004
Bolt kit for Levo FSR : S160500007
Crank, custom alloy arm for MTB, 165 mm : S161600013
Crank, custom alloy arm for MTB, 170 mm : S161600015
Crank, custom alloy arm for Levo Fat, 170 mm : S161600016
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