Cervélo R5 Disc User manual

R5 DISC MANUAL

1
INTRODUCTION
Welcome to the Cervélo family, and congratulations on your decision to ride an R Series bicycle.
The ultra-lightweight engineering of your Cervélo R Series classic road bikewill help you attackany
climbs,and enjoy speed and control on descents. The understated design allows performance to shine
through with a settled ride that lets you respond to the road.
As with the ownership of any high-performance vehicle, it is important to familiarize yourself with its
features and service requirements. Please read this manual before assembly or use.
This document has been prepared to guide you through the assembly of the unique features of the R
Series, but is intended only as a supplement to the assembly instructions oered by your component
manufacturer.
TABLE OF CONTENTS
Introduction............................................. 1
Frame Features........................................... 2
Fork Preparation......................................... 3
Small Parts.............................................. 5
Frame Preparation........................................ 6
Brake Housing Installation............................... 7
Mechanical Cable Routing................................. 9
Electric Cable Routing.................................. 11
Seatpost Assembly & Installation........................ 13
Frame Protection Installation........................... 15
CS026 Stem.............................................. 16
AB06 Handlebar.......................................... 17
Tire Clearance.......................................... 18
Rapid Axle Wheel Installation........................... 19
Version 2 - 2018-05-07 - CER-R5D-V2

2
FRAME FEATURES
A guide to your Cervélo R5 Disc frame.
Rear dropout cable exit
Front derailleur
wire exit hole,
electric and
mechanical
Bottom bracket cable port
Top tube
internal
cable port

3
FORK PREPARATION
A
B
Max.
4mm
1st Mark 2nd Mark /
Final Cut
C
D
E
F G
H
I
J
A.Stem Caps + 5mm bolt
B.Headset Spacers
C.Bearing Cap
D.Compression Ring
E.Bearings
F.Fork Insert
G.Two-Part Epoxy
H.Mixing Stick
I.Isopropyl Alcohol Wipe
J.Sandpaper (120 Grit)
1. Apply grease to the bearing seats, and Install the upper & lower
headset bearings into the head tube.
2. Fit the fork provided with your frame into the head tube with the
complete headset, required spacers, and the stem.
3. Apply the minimum pressure needed to ensure the assembly is fully
seated. Mark the steerer tube at the top of the stem.
4. Remove fork and clearly mark the fork steerer tube at a point 4mm
below the rst mark. Take care to verify that this measurement is
correct as this denes the cut line for the steerer tube.
Avoid breathing the dust created during cutting carbon
composite materials.
Your Cervélo frame & fork have been designed to work together. Do
not substitute a dierent size fork without rst consulting Cervélo
Customer Service to conrm compatibility with your frame.

4
5. To trim fork steerer, use only a saw suitable for cutting carbon,
and a cutting guide.
6. Carefully sand a bevel to the inside of the cut end of the steerer
tube to t the insert.
7. Dry t insert to check that it is ush with the cut end of the
steerer tube.
8. Use isopropyl alcohol to clean the inside of the steerer tube
and the outside of the insert.
9. Fully mix the two-part epoxy and apply to the outer surface of
the insert with the wooden mixing stick.
10. Slide the insert into the steerer while rotating it slowly until the
ared end sits ush with the top of the steerer.
11. Wipe away any excess glue from the outside surface of the
steerer tube with the isopropyl alcohol wipe.
12. 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.
Improper cutting of the steerer tube could cause a failure that
results in severe injury or death.
Do not exceed 50mm maximum total spacer height,
including the bearing cap.
Insert should be ush
with cut end of the
fork steerer tube

5
Top Tube Cable
Stop (Mechanical)
ICS4-S5D
Bottom Bracket
Cable Guide
(Mechanical)
BBG-R-2013
Front Derailleur
Wire Hole
Blanking Plug
GR-ST-CLOSED
Rear
Derailleur
Hanger
Rear Derailleur
Hanger Fixing Nut
Cover Mount
Cover
R Series Disc Rear Derailleur
Hanger Assembly
DRH-RAT
Seatpost Clamp
Cover Assembly
SPCC
Rear Derailleur
Press-In
Cable Stop
(Mechanical)
CBS-DRPOUT
Rear Derailleur
Wire Guide
(Electric)
GR-DRPOUT-GUIDE
Rear Derailleur
Blanking Plug
(Wireless)
GR-DRPOUT-CLOSED
Seatpost Clamp
SPC-R5-SM (48cm-51cm)
SPC-R5-LG (54cm-61cm)
Bottom Bracket
Access Port
Rubber Blanking
Plug (Electric)
GR-BB-GUIDE
Top Tube Cable
Plug (Wireless)
GR-ICS4TT-CLOSED
Top Tube Cable Stop
Noodle (Mechanical)
CH-TE-TTC-ICS3 x2
Top Tube Cable
Stop (Electric)
GR-TTFILL-S5D
SMALL PARTS
Designed to accommodate electronic, mechanical and hydraulic controls, the R5 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*:
*Complete parts kits are provided with framesets only.

6
FRAME PREPARATION
Lightly grease Rear Derailleur Hanger Fixing
Nut and install Rear Derailleur Hanger, nger
tight. Final tightening will be done after rear
wheel installation.
Install front fork Cervélo Rapid Axle
insert (QRI-RAT). Lightly grease the bolt
and tighten to 3 Nm maximum.
Do not nal tighten rear derailleur hanger assembly
without rear wheel installed. Doing so will result in a
misaligned derailleur and poor shifting.

7
BRAKE HOUSING INSTALLATION
It is recommended that the hydraulic brake hoses or brake cable housing is installed 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.

8
Route hydraulic brake hose or mechanical
brake housing through the frame and
fork. Install and adjust calipers as per
manufacturer’s instructions.
Removing the fork
allows for easier
routing of the rear
hydraulic hose or
brake housing.

9
Insert plastic noodles
into Top Tube Cable
Stop (Mechanical).
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.
Assemble shifter cables (with
ferrules) so that the rear housing
is inserted into the drive-side port
of the Top Tube Cable Stop, and the
front housing into the non-drive side.
The housing should be long enough
that it passes in a smooth arc from
the lower back of the bar, over the
stem cap, and enters perpendicular
to the top tube. The housing nests
in the cable stop, with the cables
continuing into the frame though the
noodles.
Failure to use the cable noodles may
result in damage to the frame.

10
Route gear cables out of the bottom
bracket cable port. Ensure that the
cables are not twisted together.
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 chain stay. When complete, snap
Bottom Bracket Cable Guide into place.
Install Rear Derailleur Press-In Cable Stop. As per manufacturer’s instructions, install rear derailleur on rear
derailleur hanger, cut appropriate housing length, and attach cable.

11
Route the down tube electric wire
to the bottom bracket, through
the Top Tube Cable Stop (Electric).
For wireless shifting systems
use the Top Tube Cable Plug.
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.

12
With all wires inside, cap the bottom bracket
access port with the Bottom Bracket Access
Port Rubber Blanking Plug.
Install the Rear Derailleur Wire Guide.
For wireless shifting systems install the
Rear Derailleur Blanking Plug.

13
SEATPOST ASSEMBLY & INSTALLATION
1. Apply a light coat of carbon
assembly compound to the upper
face of the Seatpost, making
sure to cover area around the
adjustment slots.
2. Locate saddle rail between upper
and lower clamps, and place on
Seatpost.
3. With alignment washers installed,
attach assembly to Seatpost, by
tightening lightly greased xing
bolts, alternating between the two
sides each 1/2 turn. Once saddle is
adjusted, tighten xing bolts to a
maximum of 8 Nm. Zero setback seatpost
Ensure the Seatpost Clamp
Cover and Seatpost Clamp
Cover Mount are placed
onto the seatpost and
lightly tightened before
installing the Di2 battery
or inserting the post into
the frame.
The R5 uses a proprietary shaped
seatpost. Do not attempt to use any
seatpost other than the model provided
by Cervélo.

14
1. Apply carbon paste to frame and insert Seatpost Clamp.
2. Adjust height and torque seat wedge to 8 Nm maximum.
3. Position to Seatpost Clamp Cover Mount at the top of the
frame surface and torque to 1 Nm maximum.
4. Push the Seatpost Clamp Cover down and t over the Cover
Mount.
Press the Di2 battery
into the R-Series Internal
Battery Holder and attach
the cable according to
manufacturers instructions.
Insert the assembled
battery and holder
into the seatpost.

15
FRAME PROTECTION INSTALLATION
Clean the chain stay using
isopropyl alcohol. Install the
Chain Stay Guard by removing
adhesive backing, and xing
the guard to the frame.The
bottom rearward edge should be
12mm from the edge of the Rear
Derailleur Hanger Fixing Nut.
Install chain catcher when installing the front
derailleur. Complete nal adjustment with the
chain in the small chainring and largest cassette
cog.Tighten the connecting bolt to 4 Nm.
12mm
Install the front derailleur
using the bolt provided
with the derailleur.
Torque to the derailleur
specications.

16
CS026 STEM
The Pass-through tting stem cap has been provided for test tting purposes.
Once your stem height has been conrmed and your fork steerer is cut to your
desired length, it should be replaced with the Aero stem cap and the bond-in
fork insert installed.
Should you want your fork steerer to remain long, with the bond-in fork
insert in place you can use the Pass-through tting stem cap as a permanent
solution. Use with spacers placed on top, and a standard top-cap in place to
adjust headset.
Torque to 5 Nm maximum
Torque to 5 Nm maximum
Compatible with Bar Fly Direct
MINI and MAX stem mount.
A.
B.
B. Pass-through stem
tting cap
A. Aero stem cap
The CS026 stem supports internal routing of Di2 wires if used with the Shimano EW-RS910 bar end
junction and a compatible handlebar. Please refer to the component manufacturer’s service center or
website for further information.

17
AB06 HANDLEBAR
EW-JC130
Cable
80mm Reach
Di2 Cable Exit
EW-JC200
Connector
Di2 Cable to
Junction B
Di2 Cable
to Rear Shifter
Brake and mechanical
shifter housing are
routed externally
in pockets on the
underside of the bar.
EW-RS910
Junction A
The AB06 handlebar supports the internal routing of Di2 wires if used with the Shimano EW-RS910
bar end junction and a compatible stem. 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.
128mm Drop

18
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. 1. Measure the space between the chainstays at
the bottom-bracket junction.
2. Measure the space between the seatstays at the
top of the tire.
3. Using the smallest of those two numbers,
subtract 8mm (4mm per side) to determine the
remaining space.
4. With the tire installed and fully inated on your
wheel, measure the tire width to ensure that it
ts.
Failure to follow these guidelines may result in
damage to the frame not covered by Cervélo
Limited Lifetime Warranty.
4mm
minimum
4mm
minimum

19
RAPID AXLE WHEEL INSTALLATION
Put the Cervélo Rapid Axle
lever in the open position.
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 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.
The force required to close the lever should leave a clear imprint in the
palm of your hand, or require wrapping your ngers around the fork leg for
leverage while closing.
Once adjusted,
close lever to lock.
Use the preload nut to
set the desired tension
before closing.
Insert axle. Rotate 90˚ to secure.
When the axle
lever is in the
open position
the arrows are visible.
When the axle lever is
in the closed position the
Cervélo logo is visible.