Cervélo PX Series User manual

PX-SERIES RETAILER ASSEMBLY MANUAL

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This manual is intended to assist Cervélo retailers in setting up and customizing the PX-Series bicycle.This manual is not
intended for consumer use, and requires the use of the specied tools to ensure proper assembly. This manual also references
proprietary parts available only to retailers through direct ordering from Cervélo.
Failure to use the specied parts and to follow the supplied assembly instructions may result in a loss of control while riding and
serious injury. This manual is an overview of the steps required to assemble this bicycle and to make any desired modications
as set forth in this manual. This manual assumes that the retailer has the minimum required background and skill level required
of all professional bicycle mechanics. See https://www.probma.org/
Important Information .................. 1
List of Tools & Supplies. . . . . . . . . . . . . . . . . 2
PX-Series Parts List................... 3
Small Parts ....................... 4
Frame & Fork Preparation. . . . . . . . . . . . . . . . . 5
Fork Installation .................... 7
Brake Housing Routing .................. 9
Electric Wire Routing ..................11
Mechanical Cable Routing. . . . . . . . . . . . . . . . . 12
Riser Post Cutting Instructions .............13
Riser Post Pad Mount Installation ............14
Extension Assembly. . . . . . . . . . . . . . . . . . . . 15
Extension Angle Adjustment................16
Arm Cup & Pad Installation................17
Arm Cup Positions ....................18
Split Basebar Wiring...................19
Split Basebar Installation................20
One-Piece Basebar Wiring. . . . . . . . . . . . . . . . . 21
One-Piece Basebar Installation..............22
Riser Post Wiring ....................23
Riser Post Assembly Installation.............24
Extension & Basebar - Di2 Wire Routing .........25
Extension & Basebar - eTap Wire Routing .........26
Extension & Basebar - Mechanical Cable Routing .....27
Stem Cover Installation . . . . . . . . . . . . . . . . . 28
Di2 Battery Installation. . . . . . . . . . . . . . . . . 30
Electric Wire Installation................31
Mechanical Cable Installation ..............32
SmartPak Installation ..................33
StealthBox Installation .................34
SpeedCase Installation. . . . . . . . . . . . . . . . . . 35
Seatpost Assembly . . . . . . . . . . . . . . . . . . . . 36
Seatpost Cutting Instructions ..............37
Tire Clearance. . . . . . . . . . . . . . . . . . . . . . 38
Aero Thru-Axle Installation ...............39
CER-PX-V2 - 2020-01-31
TABLE OF CONTENTS
IMPORTANT INFORMATION
LIST OF TOOLS & SUPPLIES
NOTE: This manual was developed to
compliment the Cervélo General User
Manual, and is intended as a supplement
to the assembly and installation
instructions supplied by the component
manufacturers (provided with this
bicycle). If you are a Cervélo PX-Series
consumer/purchaser reading this manual
we suggest that before attempting to
undertake any of the procedures in this
manual that you consult your authorized
Cervélo retailer, or visit us at
www.cervelo.com/support.
NOTE: All non-proprietary components are
available from your local distributor.
This manual outlines a number of procedures for
making optional adjustments to the PX-Series
bicycles.The following tools and parts listed are
required for these adjustments. Cervélo strongly
recommends that all assembly and adjustment
procedures be performed by an authorized
Cervélo retailer.
Tools
Bicycle workstand (types which
secure bike by the seatpost, or
pro-type stand with fork mount)
Torque wrench(es) with 2.5Nm to
15Nm range and adaptors:
Allen (Hex) head inserts:
2mm, 2.5mm, 3mm, 4mm, 5mm,
6mm, 8mm, 10mm
Open ended wrenches:
7mm, 8mm, 10mm, 17mm
Cable cutters
Pliers
Phillips-head screwdriver
Slot-head screwdriver
Tools
Pedal wrench
Brake rotor lockring tools
Hydraulic bleed kit
Isopropyl alcohol
Di2 wire tool – Shimano
Good quality bicycle grease &
carbon assembly compound
Saw cutting guide (Park Tool SG-7.2
or equivalent)
Hacksaw (with carbon specic
blade)

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PX-SERIES PARTS LIST
Item Description Cervélo Part No.
PX Riser Post Clamp HBP-P3XCLP
SpeedCase Assembly ASY-P5X-DTBOX
SmartPak 600 w/ Pill
Tray SB-SB02-TT
StealthBox 300 w/
Fixing Screws SB-SB01-DT
EX10 Riser Post HBP-EX10-RISER
EX10 Pad Mount w/
Fixing Screws HBP-EX10-PADMT
EX10 Tilt Adjust Plate
w/ Fixing Screws HBP-EX10-ADJPL
EX10 Bottle Mount HBP-EX10-BOTMT
Front Derailleur
Mount w/ Fixing
Screws
FDM-0E0
Front Derailleur
Mount Blanking Plate
(1x)
FDM-CVR
Item Description Cervélo Part No.
SP21 Carbon Seatpost
w/ Head SP-SP21
P3X/P5X Seatpost
Plug SPP-PX
ST30 Stem Cover
for PX HBP-HB10-CVR
HB10 Basebar HB-HB10
HB10 Basebar
Mounting Plate HBP-HB10-BMP
ST30 Stem ST-ST30
BB Grommet PX GR-BB-129
Threaded Fork Insert QRI-THD
Derailleur Hanger w/
Mounting Nut DRH-WMN112
Cervélo Front Aero
Through Axle QRA-AERO-F
Seat Post Clamp SPC-148A
Item Description Cervélo Part No.
Cervélo Rear Aero
Through Axle QRA-AERO-R
Basebar Grips L/R HBP-GRIPS
EX11 Di2 Riser Post
Plug MT-EX11-DI2
EX11 Riser Post Rests
w/ Fixing Screws HBP-EX11-RESTS
EX11 Riser Post Pads HBP-EX11-PADS
Disc Brake Hose
Guide 0E0 CBG-DBH
Seatpost Water Bottle
Mount MT-WB-SP
SP21/SP23 Saddle
Clamp Slug SPS-SP2123
Stem Cover Access
Cap w/ Window HBP-MPXSCC
Internal Battery Mount
Assembly MT-BINT
Threaded Fork
Insert w/Fixing
Screw
QRI-THD
BB Cable
Guide w/
Fixing Screw
BBG-PX110
Front Derailleur Wire
Hole Blanking Plug
GR-ST-CLOSED
E-Wire Grommet
Open Type
GR-BEC-OPEN
BB Grommet
GR-BB-129
Disc Hose Bushing x3
CBG-DBH
Rear Derailleur
Hanger Assembly
DRH-WMN112
Internal Battery Mount Kit
MT-BINT
Rear Derailleur
Wire Guide
(Electric)
GR-DRPOUT-GUIDE
Rear Derailleur
Blanking Plug
(Wireless)
GR-DRPOUT-CLOSED
Designed to accommodate electronic, mechanical and hydraulic controls, the PX-Series 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 tted to the bicycle.
SMALL PARTS
Riser Post Clamp
HBP-P3XCLP
Seatpost Clamp
SPC-148A

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Clean chainstay with isopropyl
alcohol and apply chainstay
protector.
Lightly grease Rear Derailleur Hanger
Fixing Nut and install Rear Derailleur
Hanger (DRH-WMN112) nger tight. Final
tightening will be performed after rear
wheel installation.
Install Front Derailleur Mount
(FDM-0E0), and ensure xing
screws are torqued to 3Nm.
For 1x systems replace with
the Front Derailleur Mount
Blanking Plate (FDM-CVR).
Do not nal tighten rear derailleur hanger
assembly without rear wheel installed.
Doing so may result in a misaligned
derailleur and poor shifting.
FRAME & FORK PREPARATION
Hold the frame using a secured seatpost only.
Clamping the top tube can damage the frame
and void your warranty.
1. Apply carbon assembly compound to both
frame and seatpost.
2. Insert Seatpost Clamp (SPC-148A) in frame so
it is ush with the top tube.
3. Adjust height and torque to 8Nm maximum.
1. Lightly grease supplied M4 xing screw.
Install the Threaded Fork Insert (QRI-THD)
and xing screw, tightening only lightly.
2. Without wheel in place, install the axle
and tighten until the ange meets the fork
dropout face, but does not compress the
fork blades.
3. Tighten the xing screw to 3Nm.
4. Remove the axle and install wheel.
Reinstall axle and tighten to 12-15Nm.
5. Remove axle and wheel, and re-torque the
xing screw to 3Nm.

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FORK INSTALLATION
Note: It is recommended that you familiarize
yourself with the steering system before
complete installation, by performing a trial
assembly without hoses or control cables
present.
Fork Insert
1. To prepare fork for the glue in Fork Insert, carefully sand a bevel to
the inside of the end of the circular steerer tube to t the insert.
2. Dry t Fork Insert to check that it is ush with the end of the steerer
tube.
3. Use isopropyl alcohol to clean the inside of the steerer tube and the
outside of the Fork Insert.
4. Fully mix the two-part epoxy and apply to the outer surface of the
Fork Insert with the wooden mixing stick.
5. Slide the Fork Insert into the steerer while rotating it slowly until the
ared end sits ush with the top of the steerer.
6. Wipe away any excess glue from the outside surface of the steerer
tube with the isopropyl alcohol wipe.
7. Set the fork aside and allow it to sit undisturbed for the full curing
period.
Do not attempt to t the fork into a bike prior to
the completion of the full curing period.
NOTE: This diagram is for assembly reference
only. During complete assembly, hoses and
control cables will be present.
Preload Fixing
Screw M6 x 30mm
Stem Cap
1 1/8" Upper
Bearing
(36˚x 45˚)
1 1/2" Lower
Bearing
(36˚x 45˚)
Stem Steerer
Clamp (ST-ST30)
Steerer Clamp Screws
Compression Ring
1. Check the Stem Steerer Clamp and headset components to make sure there are no sharp or
rough edges on any of the surfaces which could cut or damage the steerer tube. If any rough
edges are detected, have the components repaired (sharp edges removed) or replaced before
proceeding.
2. Press the upper and lower headset bearings into the frame, and insert the fork into the head
tube.
3. Slide the compression ring onto the steerer, and down until it fully seats in the top of the
upper headset bearing. The split in the compression ring must be oriented toward to the left or
right side of the steerer – never towards the front or back.
4. Slide the Stem Steerer Clamp onto the fork steerer oriented as shown. Note the Stem Steerer
Clamp must engage both the fork steerer and the external steerer. Do not use grease on the
fork steerer. The use of Tacx Carbon Assembly Compound™ or equivalent friction paste is
recommended to help secure the Stem Steerer Clamp.
5. Lightly grease the threads of the Preload Fixing Screw, and the Steerer Clamp screws.
6. Place the Stem Cap on top of the Stem Steerer Clamp and insert the greased M6 bolt through
the cap to engage with the star nut. Tighten the bolt only enough to remove all play from the
headset, and ensure that the fork still rotates freely.
7. Tighten the 2 greased Steerer Clamp Screws to the steerer using a torque wrench. Tighten to a
maximum of 5Nm.
8. As a nal check ensure that the fork rotates freely in the head tube without any play or
binding. If any problem is detected, loosen the bolts and perform steps 6) to 7) again.
Do not exceed the maximum torque specication for the stem. Correct tightening force on
fasteners – nuts, bolts, screws – on your bicycle is very important. Too little force, and the
fastener may not hold securely. Too much force, and the fastener can strip threads, stretch,
deform or break. Either way, incorrect tightening force can result in component failure,
which can cause you to loose control and fall.

Chainstay
height: 35mm
910
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.
BRAKE HOUSING ROUTING
Run brake hose
from bottom of
fork up through
top.
Route brake hose
from chainstay through
Top Tube Internal Cable
Port.
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.

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It is recommended that electric wiring 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.
ELECTRIC WIRE ROUTING
Brake E-Wire
Route 1000mm Di2 E-Wire
from Top Tube Internal
Cable Port out through
Bottom Bracket Cable Port.
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.
MECHANICAL CABLE ROUTING
Brake Rear Shifter Front Shifter
Route shifter housing
from Top Tube Internal
Cable Port out through
Bottom Bracket Cable
Port.
1000mm
E-Wire
600mm
E-Wire
300mm
E-Wire
300mm
E-Wire

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RISER POST PAD MOUNT INSTALLATION
Setback Position
Forward Position
Attach Riser Pad Mount and Riser Post toTilt Adjust Plate using
two lightly greased M6 xing screws. Torque to 6Nm.
EX10 Riser Pad Mount
(HBP-EX10-PADMNT)
EX10 Riser Post
(HBP-EX10-RISER)
Tilt Adjust Plate
(HBP-EX10-ADJPL)
Tilt Adjust Fixing
Screws M6 x 20mm
The Riser Pad Mount can be
attached in two positions:
RISER POST CUTTING INSTRUCTIONS
1. Use a light coloured grease pencil to accurately mark the cut-o location
on the Riser Post. See table below for the exact number based on frame
size.
2. Insert the Riser Post in the Park Tool SG-7.2 Saw Guide (or equivalent) so
that the cut-o line can be seen clearly through the blade guide in the tool.
3. Using a blade designed specically for cutting carbon; proceed with
cutting the stem steerer (as per Park Tool’s instructions).
4. Carefully le the cut end removing any rough edges.
Achieving the lowest possible stack may require trimming
the Riser Post. If using a cut Riser Post ensure there is always
a minimum of 70mm inserted inside the frame.
Frame Size
Trim Amount for
Lowest Stack
(w/ riser plug)
S81mm
M61mm
L33mm
XL 3mm
Max. 81mm
Cut Line
If trimming is required, nal length should allow for a minimum
70mm of Riser Post remaining in the frame. Failure to meet this
requirement, may result in damage to the frame not covered by
warranty policy, or serious injury to rider.

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EXTENSION ANGLE ADJUSTMENT
0˚
0˚
5˚
5˚
10˚
10˚
15˚
15˚
Tilt Adjust Plate
Position 1: 0˚, 10˚
Bottom View
Forward
Tilt Adjust Plate
Position 2: 5˚, 15˚
The Riser Pad Mount and Extensions can be set in one
of four discrete angles: 0˚, 5˚, 10˚, 15˚.
1. Remove both Tilt Adjust Fixing Screws and
Tilt Adjust Plate.
2. Position Tilt Adjust Plate in one of two
orientations, and install lightly greased
xing screws in appropriate holes.
3. Torque to 6Nm.
EXTENSION ASSEMBLY
NOTE: This diagram is for assembly reference
only. During complete assembly, hoses and
control cables will be present.
Install and adjust extensions.
Torque to 3Nm.
Extensions should be ush with
bottom edge Riser Pad Mount
for internal Di2 routing.
Extension Plugs
(HBP-PXBP)
EX10 Riser Pad Mount
(HBP-EX10-PADMNT)
Bottle Boss
(HBP-EX10-BOTMT)
Extensions
Aerobar water bottle mount,
torque M5 x 8mm xing screws
to 2Nm.
Extension Fixing
Screws M5 x 18mm

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ARM CUP POSITIONS
Failure to use the specied parts and to
follow the supplied assembly instructions
may result in a loss of control while
riding and potentially serious injury.
Position: Farthest
outside,farthest
forward.
Position: Farthest
outside,farthest
back.
Two xing screws must always be
installed per arm cup. The xing
screws must be installed in fore-aft
xing position, and not diagonal.
ARM CUP & PAD INSTALLATION
M5 x 12mm
Fixing Screws
1. Clean Arm Cups with isopropyl alcohol and
apply Velcro sheets.
2. Attach Arm Cups to the Riser Post using two
lightly greased M5 Fixing Screws.
3. Torque Fixing Screws to 4Nm.
4. Align the Arm Pads with the Arm Cups and
press to secure them to the Velcro sheets.
Arm Pad (pair)
(HBP-EX11-PADS)
Arm Cup (pair)
(HBP-EX11-RESTS)
Adhesive
Velcro