SRAM LEVEL TL Service Manual Download Page 35

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Lever Blade Installation

Cut the hose to install a new barb and compression fitting.

NOTICE

You must install a new hose barb and compression fitting before recon-

necting the brake lever to the hose.

Apply DOT grease to the hose barb threads. Thread the hose barb into

the hose until it is flush with the end of the hose.

NOTICE

Do not overtighten the hose barb. Overtightening may cause damage

to the hose liner.

Install the compression nut onto the hose.

Thread the compression fitting over the hose barb, counter-clockwise,

until it is flush or slightly lower than the hose barb.

The compression fitting is reverse threaded.

Apply DOT grease to the outside of the compression fitting and the

threads of the compression nut.

SRAM Hydraulic Hose Cutter

DOT Grease

Summary of Contents for LEVEL TL

Page 1: ...1 GEN 0000000005086 Rev E 2017 SRAM LLC Level Ultimate TLM TL Service Manual...

Page 2: ...also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure LIMITATIONS OF LIABILITY To the extent allowed by...

Page 3: ...TON INSTALLATION 13 SRAM LEVEL TL CALIPER SERVICE 16 PARTS AND TOOLS NEEDED FOR SERVICE 16 SRAM LEVEL TL CALIPER EXPLODED VIEW 16 CALIPER BRAKE PAD REMOVAL 17 CALIPER PISTON REMOVAL 18 CALIPER PISTON...

Page 4: ...4 Table of Contents SAFETY FIRST We care about YOU Please always wear your safety glasses and protec tive gloves when servicing SRAM products Protect yourself Wear your safety gear...

Page 5: ...brakes after you service the brake caliper and or lever Always wear safety glasses and nitrile gloves when working with DOT fluid Place an oil pan on the floor where you will be working on the brake U...

Page 6: ...until the brake pads nearly contact one another 4 Insert the Level pad spreader between the brake pads to spread the pads to the full width of the clip 5 Remove the Level pad spreader 6 Repeat steps...

Page 7: ...sit our website at sram com service Your product s appearance may differ from the pictures contained in this publication P a r t s a n d T o o l s N e e d e d f o r S e r v i c e Safety glasses Nitril...

Page 8: ...or a 5 mm hex wrench to remove the brake caliper from the fork or frame Remove the caliper mounting bracket and hardware from the caliper then set them aside in the order that they were removed Use n...

Page 9: ...DOT fluid is not covered under warranty Use a T25 TORX wrench to remove the banjo bolt and hose Insert the SRAM monoblock caliper 21 mm piston removal tool then use a 2 5 mm hex wrench to install the...

Page 10: ...ston may dislodge rapidly from the caliper which can lead to bodily injury or damage to the parts Point the caliper piston toward a rubber surface to prevent the piston from becoming a projectile Remo...

Page 11: ...anjo port then place a towel over the caliper to contain any dislodged fluid CAUTION Wear safety glasses The caliper piston may dislodge rapidly from the caliper which can lead to bodily injury or dam...

Page 12: ...de each piston bore the inside and the outside of the caliper and all of the removed parts and clean them with a shop towel NOTICE If the system has been contaminated with mineral oil or DOT 5 fluid f...

Page 13: ...bore Inspect the caliper pistons for damage and replace the pistons if necessary Use your gloved finger to apply a small amount of SRAM DOT 5 1 fluid to each piston then install each piston into each...

Page 14: ...loosening the banjo bolt adjusting it to the desired position and then retightening the banjo bolt to 4 4 5 4 N m 39 48 in lb Insert the Level bleed block into the caliper Use a 2 5 mm hex wrench to i...

Page 15: ...from the banjo fitting or banjo bolt remove and replace the o ring then repeat the installation process CAUTION Servicing your brakes removes all of the fluid from the system You must bleed the brake...

Page 16: ...at blade screwdriver Torque wrench Air compressor with a rubber tipped chuck nozzle 5 mm hex bit socket 2 5 mm and 5 mm hex wrenches Pick Clean lint free shop towel Isopropyl alcohol Soft rubber or pi...

Page 17: ...e a 5 mm hex wrench to remove the brake caliper from the fork or frame Remove the caliper mounting bracket and hardware from the caliper then set the bracket and hardware aside in the order they were...

Page 18: ...d or printed surfaces by DOT fluid is not covered under warranty Use an 8 mm flare nut crowfoot wrench to remove the crimped hose fitting Pull the brake hose and crimped hose fitting from the caliper...

Page 19: ...e piston is dislodged Remove the piston from the caliper Place the outboard caliper body half piston side down on a soft rubber mat or a small section of inner tube on a flat surface Insert a rubber t...

Page 20: ...and outboard half of the caliper body Spray isopropyl alcohol into the caliper piston bores and clean them with a shop towel then install a new seal inside each caliper body half NOTICE Do not scratch...

Page 21: ...stons if necessary Use your gloved finger to apply a small amount of SRAM DOT 5 1 fluid to each piston then install each piston into each piston bore NOTICE For the best braking performance use only S...

Page 22: ...new o ring and install it Align the caliper body halves together then thread the caliper body bolts into the caliper by hand Use a torque wrench with a 5 mm hex bit socket to tighten each bolt to 9 8...

Page 23: ...nate the brake pads and could lead to a brake failure Spray isopropyl alcohol on the caliper and clean it with a shop towel Visually check your work If an o ring protrudes from the crimped hose fittin...

Page 24: ...ervoir bolts 2 Piston assembly L e v e r S e r v i c e P a r t s a n d T o o l s N e e d e d f o r S e r v i c e Safety glasses Nitrile gloves Oil pan Isopropyl alcohol Clean lint free shop towel SRAM...

Page 25: ...v e r E x p l o d e d V i e w Hose boot Bleed port screws 2 Bladder Reservoir cap Lever body Compression nut SwingLink push rod Lever blade Washer Snap ring Piston assembly Hose Reservoir bolts 2 Lev...

Page 26: ...h or a 4 mm hex wrench to remove the brake clamp bolt from the discrete clamp MMX or XLoc XLoc requires removal of the shifter and remove the brake lever from the handlebar Pull the hose boot away fro...

Page 27: ...he parts to dry prior to rebuilding Install all new seals and a new brake hose For the best braking performance use only SRAM DOT 5 1 fluid If SRAM fluid is not available use only DOT 5 1 fluid or 4 f...

Page 28: ...ng TLM TL Place the lever body on the edge of a table allowing the pivot pin to hang off of the side of the table then insert the SRAM aftermarket lever pivot tool into the pivot pin slot TLM TL Use a...

Page 29: ...rom the lever body TLM TL The spring and spring bushing will separate from the lever blade Insert a new spring bushing into the spring TLM TL Remove the lever blade bushings from the lever body and re...

Page 30: ...he piston assembly into the lever body as you remove the snap ring Remove the washer located beneath the snap ring Remove the piston assembly Spray isopropyl alcohol on and in the lever body the lever...

Page 31: ...rinted surfaces by DOT fluid is not covered under warranty Submerge the new piston assembly in SRAM DOT 5 1 fluid If SRAM fluid is not available only use DOT 5 1 or 4 fluid Insert the piston assembly...

Page 32: ...de so that one end of the spring is braced against the lever blade and the other extended beyond the blade Hold the spring and bushing in place throughout the lever installation process Insert the pus...

Page 33: ...OOL LEVER PIVOT Tool through the lever body bushings lever spring and the spring bushing Insert the pin on the AM SRAM TOOL LEVER PIVOT Tool onto the pivot pin Push the pivot pin through the lever bod...

Page 34: ...to be properly installed Place the reservoir cap bladder assembly onto the lever body Use a torque wrench and a T10 TORX bit socket to tighten each reservoir cap bolt to 1 1 1 3 N m 10 12 in lb Spray...

Page 35: ...sh with the end of the hose NOTICE Do not overtighten the hose barb Overtightening may cause damage to the hose liner Install the compression nut onto the hose Thread the compression fitting over the...

Page 36: ...on nut CAUTION Servicing your brakes removes all of the fluid from the system You must bleed the brakes after you service the brake caliper and or lever For brake bleed brake hose shortening and brake...

Page 37: ...37 This publication includes trademarks and registered trademarks of the following companies TORX is a registered trademark of Acument Intellectual Properties LLC...

Page 38: ...Chung Shan Road Shen Kang Hsiang Taichung City Taiwan R O C WORLD HEADQUARTERS SRAM LLC 1000 W Fulton Market 4th Floor Chicago Illinois 60607 USA EUROPEAN HEADQUARTERS SRAM Europe Paasbosweg 14 16 386...

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