Cervélo S5 Assembly Manual
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Cervélo S5 Assembly Manual

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2019 S5 DISC RETAILER ASSEMBLY MANUAL
S5_Disc_manual_v5.5.indd 1
2018-08-27 10:55 AM

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  • Page 1 2019 S5 DISC RETAILER ASSEMBLY MANUAL S5_Disc_manual_v5.5.indd 1 2018-08-27 10:55 AM...

  • Page 2: Table Of Contents

    Mechanical Cable Routing ........ 19 IMPORTANT INFORMATION This manual is intended to assist Cervélo retailers in setting up and customizing the 2019 S5 Disc NOTE: Cervélo strongly recommends that bicycle. This manual is not intended for consumer use, and requires the use of the specified tools all assembly and adjustment procedures be performed by an authorized Cervélo...

  • Page 3: List Of Tools & Supplies

    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: 2019 S5 Disc Parts List

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

  • Page 5: Frame Features

    FRAME FEATURES A guide to the 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 S5_Disc_manual_v5.5.indd 4 2018-08-27 10:55 AM...

  • Page 6: Handlebar & Stem Components

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

  • 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 Spacer or Pitch Adjust Wedge kits. 14mm 0˚ Bar Fixing Screw - Handlebar Fixing Nuts (L + R) HBP-AB08-ZERO M5 x 14mm...

  • 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 - 2.5˚ Pitch Adjust Wedge (L + R) HBP-AB08-2.5DEG 16mm - M5 x 16mm Bolts (x4) Bar Fixing Screw 5˚ Pitch Adjust Kit M5 x 16mm Actual Size Complete Handlebar Stack Spacer or...

  • Page 9: Fork & Headset Components

    FORK & HEADSET COMPONENTS NOTE: The S5 Disc headset Fit Top Bearing Dust assembly does not require a Seal to Fork Topper Your Cervélo frame & fork have been compression ring. before installation. designed to work together. 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. Not all parts will be used, depending on the groupset fitted to the bicycle.

  • Page 11: Frame Preparation

    FRAME PREPARATION Apply carbon paste to both frame and Lightly grease Rear Derailleur Hanger Fixing seatpost. Nut and install Rear Derailleur Hanger (DRH- RAT for Cervélo Rapid Axle) finger tight. 2. Insert Seatpost Clamp (SPC-0E0S5) fully into Final tightening will be done after rear wheel frame so it is fully flush with the top tube.

  • Page 12: S5 Disc Assembly Overview

    S5 DISC ASSEMBLY OVERVIEW NOTE: See the following pages for more detailed assembly instructions. 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, apply install bearings. Feed brake hose and derailleur amount of 5mm Stem Spacers. Loctite 242 and secure the stem and stem controls through Preload Cone.

  • Page 14: Before You Build

    • Whenever possible, it is best to establish the correct fit before performing final cabling of the S5. Here are a few t ricks that we have learned along the way that may help with...

  • 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. S5_Disc_manual_v5.5.indd 14 2018-08-27 10:55 AM...

  • Page 16: Mechanical Cable Preparation

    MECHANICAL CABLE PREPARATION Brake Rear Shifter 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. S5_Disc_manual_v5.5.indd 15 2018-08-27 10:55 AM...

  • Page 17: Brake Housing Routing

    BRAKE HOUSING ROUTING It is recommended that the hydraulic brake hoses or brake cable housing is installed first. 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. S5_Disc_manual_v5.5.indd 17 2018-08-27 10:55 AM...

  • 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.

  • 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 Torque fixing Fork Topper complete installation, by performing a trial screw to 5Nm Fixing Screw assembly without hoses or control cables M5 x 16 present.

  • Page 23: Stem Installation

    (Optional) re-cabling. Base position for S5 Disc stem and handlebar matches that of the previous edition S5 with a 6˚ stem Do not exceed six of the 5mm and a 5mm top cap. Stem Spacers. Refer to page 23. NOTE: This diagram is for assembly reference only.

  • Page 24: Stack Adjustment

    STACK ADJUSTMENT 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 stem stack adjustment is 30mm.

  • 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 Using the supplied M5 Handlebar Fixing Screws, attach handlebar to stem with the Handlebar Fixing Nuts. Ensure Complete Handlebar Stack that chosen Fixing Screws and Handlebar Fixing Nut match Spacer or Pitch Adjust Wedge the Stack or Pitch Adjust Wedge chosen. Torque to 6-6.5Nm.   kits must be utilized without substitution or combination 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 (EW- to Left Shifter RS910) to Right shifter. 3.

  • Page 28: Handlebar & Stem - Mechanical Cable Routing

    HANDLEBAR & STEM - MECHANICAL CABLE ROUTING Brake Rear Shifter 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 Blanking Plug With all wires inside, cap the (GR-DRPOUT-CLOSED). Bottom Bracket Cable Port with the BB Cable Guide/Cover (BBG-0E0). S5_Disc_manual_v5.5.indd 29 2018-08-27 10:55 AM...

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

  • Page 33: Seatpost Cutting Instructions

    SEATPOST CUTTING INSTRUCTIONS Note: It is essential that all Cervélo Aero Seatposts, have a 45 degree chamfer cut on the rear 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

    RAPID AXLE WHEEL INSTALLATION To secure the front wheel, install the greased axle, through the drive side drop out, through the wheel hub, aligning the T-End of the axle with the insert. Rotate the axle To ensure rider safety, it is critical to install the Cervelo 90°...
  • 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.
  • Page 38 2019 S5 DISC RETAILER ASSEMBLY MANUAL www.cervelo.com CER-S5-V2 2018-08-24 S5_Disc_manual_v5.5.indd 37 2018-08-27 10:55 AM...

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