Cervelo S5 Disc User Manual
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Cervelo S5 Disc User Manual

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S5 DISC MANUAL

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Summary of Contents for Cervelo S5 Disc

  • Page 1 S5 DISC MANUAL...

  • Page 2: Table Of Contents

    This manual is intended to assist Cervélo retailers in setting up and customizing the NOTE: Cervélo strongly recommends that 2019 S5 Disc bicycle. This manual is not intended for consumer use, and requires the all assembly and adjustment procedures use of the specified tools to ensure proper assembly. This manual also references be performed by an authorized Cervélo...
  • Page 3 LIST OF TOOLS & SUPPLIES This manual outlines a number of procedures for Tools Tools making optional adjustments to the S5 Disc which differ from the way the bicycle is originally sold Bicycle workstand (types which by Cervélo.The following tools and parts listed...

  • Page 4: Introduction

    2019 S5 DISC PARTS LIST Item Description Cervélo Part No. Item Description Cervélo Part No. Item Description Cervélo Part No. AB08 Carbon S5 Stack Adjustment Aftermarket FK60 Fork HB-AB08-40 KP-0E0S5 FKA-FK60-LG Assembly Kit 54-58 Handlebar 400mm Dealer Kit AB08 Carbon Conventional 1 1/8"...

  • Page 5: Frame Features

    FRAME FEATURES A guide to your Cervélo S5 Disc frame. Front Derailleur Wire Exit Hole, electric and mechanical Internal Di2 Battery Mount Holes Rear Dropout Cable Exit Bottom Bracket Cable Port...

  • Page 6: Handlebar & Stem Components

    HANDLEBAR & STEM COMPONENTS WARNING Only use the components specifi ed in this manual for Cervélo AB08 Handlebar handlebar and stem assembly. Failure to use the specifi ed 38cm HB-AB08-38 parts and to follow the supplied 40cm HB-AB08-40 assembly instructions may result 42cm HB-AB08-42 in a loss of control while riding 44cm HB-AB08-44...

  • Page 7: Handlebar Components - Stack

    HANDLEBAR COMPONENTS – STACK The AB08 handlebar stack can be increased by 2.5mm or 0mm Stack Kit rotated in increments of 2.5˚ or 5˚ by the use of specific Stack or Pitch Adjust Wedge kits. 14mm 0˚ HBP-AB08-ZERO - Handlebar Fixing Bar Fixing Screw M5 x 14mm Nuts (L + R) for...

  • Page 8: Handlebar Components - Pitch Adjust

    HANDLEBAR COMPONENTS – PITCH ADJUST 2.5˚ Pitch Adjust Kit 2.5˚ - Handlebar Fixing Nut (L + R) for 2.5˚ rotation HBP-AB08-2.5DEG - 2.5˚ Pitch Adjust Wedge (L + R) 16mm - M5 x 16mm Bolts (x4) 5˚ Pitch Adjust Kit Bar Fixing Screw M5 x 16mm Actual Size...

  • Page 9: Fork & Headset Components

    FORK & HEADSET COMPONENTS WARNING NOTE: The S5 Disc headset Fit Top Bearing Dust Your Cervélo frame & fork have assembly does not require Seal to Fork Topper been designed to work together. a compression ring. before installation. Do not attempt to install an alternative fork.

  • Page 10: Small Parts

    SMALL PARTS Designed to accommodate electronic, mechanical and hydraulic controls, the S5 Disc frame is engineered to provide seamless integration of all shifting systems, regardless of method or brand. In order to do so, you will require the parts shown below:...

  • Page 11: Frame Preparation

    FRAME PREPARATION Apply carbon paste to both frame and seatpost. Lightly grease Rear Derailleur Hanger Fixing Nut and install Rear Derailleur Hanger 2. Insert Seatpost Clamp (SPC-0E0S5). (DRH-RAT for Cervélo Rapid Axle) finger 3. Adjust height and torque to 8Nm maximum. tight.

  • Page 12: S5 Disc Assembly Overview

    NOTE: See the following pages for more detailed assembly instructions. S5 DISC ASSEMBLY OVERVIEW Prepare the frame by installing the rear brake Prepare the fork by installing the brake hose Prepare the handlebar by installing the shift/ hose and derailleur controls, exiting the frame from the lower leg hose passage, exiting brake levers.
  • Page 13 Grease the bearing cups in the frame, then Feed cables and hoses through desired Ensure you have the correct length bolts, install bearings. Feed brake hose and amount of 5mm Stem Spacers. apply Loctite 242 and secure the stem and derailleur controls through Preload Cone.

  • Page 14: Before You Build

    BEFORE YOU BUILD • While the two-piece 5mm Stem Spacers allow for addition/removal without re-cabling the bike, the length of the cables used during fi rst assembly will dictate how much adjustment is possible later on. • After fi rst assembly it is simpler to remove Stem Spacers (go lower) and trim the hydraulic brake hose at the brake lever as required.

  • Page 15: Electric Cable Preparation

    ELECTRIC CABLE PREPARATION Brake E-Wire Run 750mm Di2 E-Wire cable through stem blades. Run brake hose from bottom of fork up through top. Route brake hose from chainstay through head tube. Route 1400mm Di2 E-Wire cable from bottom bracket through headtube.

  • Page 16: Mechanical Cable Preparation

    MECHANICAL CABLE PREPARATION Brake E-Wire Front Shifter Run brake hose from bottom of fork up through top. Route brake hose from chainstay through head tube. Route shifter housing from bottom bracket through headtube.

  • Page 17: Brake Housing Routing

    BRAKE HOUSING ROUTING It is recommended that the hydraulic brake hoses or brake cable housing is installed fi rst. These routing illustrations are intended as a supplement to the manufacturer’s installation instructions only. For both hydraulic and mechanical disc brakes, please refer to the component manufacturer’s service center or website for further information.
  • Page 18 BRAKE HOUSING ROUTING Route hydraulic brake hose or mechanical brake housing through the frame and fork with the Disc Hose Bushings (CBG-DBH). Install and adjust calipers as per manufacturer’s instructions.

  • Page 19: Electric Cable Routing

    ELECTRIC CABLE ROUTING It is recommended that electric cabling and junction points be installed after the brake hose has been installed. These routing illustrations are intended as a supplement to the manufacturer’s installation instructions only. Please refer to the component manufacturer’s service center or website for further information. Brake E-Wire Route rear brake hose...

  • Page 20: Mechanical Cable Routing

    MECHANICAL CABLE ROUTING It is recommended that front and rear derailleur cables be installed after the brake hose has been installed. These routing illustrations are intended as a supplement to the manufacturer’s installation instructions only. Please refer to the component manufacturer’s service center or website for further information.

  • Page 21: Fork Installation

    2. Install upper bearing on Preload Cone, and press bearing into lightly greased upper bearing pocket. NOTE: The S5 Disc headset assembly 3. Press lower bearing into lightly greased lower bearing does not require a pocket.

  • Page 22: Fork Topper Installation

    FORK TOPPER INSTALLATION NOTE: It is recommended that you familiarize yourself with the steering system before complete installation, by performing a trial Torque fixing Fork Topper assembly without hoses or control cables screw to 5Nm Fixing Screw present. M5 x 16 Locate Fork Topper on fork, so that the Preload Cone is captured and the three forward fixing screw holes align with the threaded fork inserts. Note, if...

  • Page 23: Stem Installation

    M6 Stem Fixing Screws. Refer to pages 23-24 Two-piece Stem Spacers allow for 5mm Stem Spacer Base position for S5 Disc stem installation or (Optional) and handlebar matches that of the removal without previous edition S5 with a 6˚ stem re-cabling.

  • Page 24: Stack Adjustment

    STACK ADJUSTMENT WARNING To ensure rider safety, it is critical that the supplied fixing screws be used, and matched to the indicated spacer size and configuration. Failure to do so may result in catastrophic failure of the steering mechanism, and injury to rider. NOTE: Maximum stack adjustment is 32.5mm.

  • Page 25: Stem Fixing Screw Guide

    STEM FIXING SCREW GUIDE Stem Fixing Screws Actual Size 45mm 40mm 35mm 30mm 25mm 20mm 14mm M6 x 14mm M6 x 20mm M6 x 25mm M6 x 30mm M6 x 35mm M6 x 40mm M6 x 45mm No Spacers 5mm (1 Spacer) 10mm (2 Spacers) 15mm (3 Spacers) 20mm (4 Spacers)

  • Page 26: Handlebar Installation

    HANDLEBAR INSTALLATION WARNING Complete Handlebar Stack Spacer or Pitch Adjust Wedge Using the supplied M5 Handlebar Fixing Screws, attach kits must be utilized without handlebar to stem with the Handlebar Fixing Nuts. Ensure substitution or combination that chosen Fixing Screws and Handlebar Fixing Nut match of parts.

  • Page 27: Handlebar & Stem - Electric Cable Routing

    HANDLEBAR & STEM – ELECTRIC CABLE ROUTING Brake E-Wire Install shifters on handlebar and connect Left and Right using the 750mm E-Wire A A. 750mm E-Wire 2. Install 300mm E-Wire B connecting Junction A to Left Shifter (EW-RS910) to Right shifter. 3.

  • Page 28: Handlebar & Stem - Mechanical Cable Routing

    HANDLEBAR & STEM – MECHANICAL CABLE ROUTING Brake E-Wire Front Shifter Install shifters on handlebar. 2. Thread exposed shifter housing through the appropriate blades of the stem. (right/rear, left/front). 3. Thread brake hoses through the appropriate blades of the stem. 4.

  • Page 29: Di2 Battery Installation

    DI2 BATTERY INSTALLATION The battery for your Shimano Di2 system mounts inside the down tube using the Internal Battery Mount (MT-BINT) designed to fit this frame. As this is a sealed location, it is important to test the system prior to final installation. Ensure Loctite 242 is applied to the M3 fixing screws.

  • Page 30: Electric Cable Installation

    ELECTRIC CABLE INSTALLATION Install the Rear Derailleur Wire Guide (GR-DRPOUT-GUIDE). For wireless shifting systems install the Rear Derailleur With all wires inside, cap the Blanking Plug Bottom Bracket Cable Port with the (GR-DRPOUT-CLOSED). BB Cable Guide/Cover (BBG-0E0).

  • Page 31: Mechanical Cable Installation

    MECHANICAL CABLE INSTALLATION Ensure ferrules Install Rear Derailleur Press-In Cable Stop are used to cap (CBS-DRPOUT). shifter housing at BB Cable Guide/Cover. The front cable travels across the non-drive side slot, and in the direction of the seat tube. The rear cable travels along the drive side slot, and along the chainstay.

  • Page 32: Seatpost Assembly

    SEATPOST ASSEMBLY Ensure Loctite 242 is applied to threads below the head of the 45mm M5 Seatpost Screws button head cap screw. Install cross Actual Size bar on 45mm button head cap screw and torque to 3Nm. 2. Ensure Loctite 242 is applied to both 35mm fixing screw threads.

  • Page 33: Seatpost Cutting Instructions

    SEATPOST CUTTING INSTRUCTIONS It is essential that all Cervélo Aero Seatposts, have a 45 degree chamfer cut on the trailing edge of the post. If trimming is required after fitting, the following method is recommended: Taking care to maintain the minimum required seatpost insertion of 6.5cm and maximum of 8.5cm, carefully measure and use a light coloured grease pencil to accurately mark the cut-off location on the seatpost.

  • Page 34: Frame Protection Installation

    FRAME PROTECTION INSTALLATION Install the front derailleur using the bolt provided with the derailleur. Torque to the derailleur specifications. Clean the chainstay using isopropyl alcohol. Install the Chainstay Guard by removing adhesive backing, Install chain catcher when installing the front and fixing the guard to the frame.

  • Page 35: Tire Clearance

    TIRE CLEARANCE Your Cervélo bicycle complies with the ISO 4210-2:4.10.2 standard for tire clearance. In order to comply with these safety standards and maintain your Limited Lifetime Warranty, a minimum of 4mm of clearance must remain between the tire and any frame element. Due to the growing complexity of tire and rim interfaces, Cervélo recommends identifying the available space before choosing a tire.

  • Page 36: Rapid Axle Wheel Installation

    To ensure rider safety, it is critical to insert. Rotate the axle 90° clockwise until the T-End is stopped by the insert. install the Cervelo Rapid Axle correctly. If the lever is clamping too much/less adjust the preload nut until the lever Failure to do so may result in a crash, is clamping securely.
  • Page 37 To secure the rear wheel, install the greased axle, through the non-drive side drop out, through the wheel hub, aligning the T-End of the axle with the derailleur hanger insert. Rotate the axle 90° clockwise until the T-End is stopped by the insert. If the lever is clamping too much/less adjust the preload nut until the lever is clamping securely.
  • Page 38 MANUAL S5 DISC www.cervelo.com 1973K3418005...

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