Cervélo S5 2023 User manual

2023 S5 RETAILER ASSEMBLY MANUAL

1 2
This manual is intended to assist Cervélo retailers in setting up and customizing the 2023 S5 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
2023 S5 Parts List. . . . . . . . . . . . . . . . . . . . 3
Small Parts . . . . . . . . . . . . . . . . . . . . . . . 4
Fork & Headset Components ................ 6
Handlebar & Stem Components ............... 7
Frame & Fork Preparation. . . . . . . . . . . . . . . . . 9
Fork Installation ....................11
Brake Hose Routing. . . . . . . . . . . . . . . . . . . . 13
Headset Assembly.....................15
Di2 Battery Installation. . . . . . . . . . . . . . . . . 16
Electric Wire Routing & Installation. . . . . . . . . . . 17
Stack Adjustment.....................19
Stem Installation ....................20
Handlebar Installation. . . . . . . . . . . . . . . . . . 21
Before Final Fitting...................23
Seatpost Assembly . . . . . . . . . . . . . . . . . . . . 24
Seatpost Cutting Instructions ..............25
Compatible Parts - HB14 Tri Extension Mount Assembly...26
Aero Thru-Axle Installation ...............27
Tire/Rim Clearance. . . . . . . . . . . . . . . . . . . . 29
Intended Use of the S5 Bicycle..............30
S5 Torque Specications .................31
Cervélo Customer Support. . . . . . . . . . . . . . . . . 33
CER-S5F-V1 - 2021-12-22
IMPORTANT INFORMATION
NOTE: Cervélo strongly recommends that
all assembly and adjustment procedures
be performed by an authorized Cervélo
retailer.If you are a Cervélo S5
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: 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).
NOTE: All non-proprietary components
such as those from Shimano or SRAM are
available from your local distributor.
LIST OF TOOLS & SUPPLIES
This manual outlines a number of procedures
for making optional adjustments to the S5 which
dier from the way the bicycle is originally sold
by Cervélo.The following tools and parts listed
are required for these adjustments. These parts
are not available for consumer purchase and are
only available for purchase by Cervélo retailers.
Cervélo strongly recommends that all assembly
and adjustment procedures be performed by an
authorized Cervélo retailer.
All parts available for separate purchase are noted
in this manual with Cervélo part numbers listed
in ALL- CAPS FORMAT, with a full listing provided
on page 3. These parts are available by visiting
the Cervélo Customer Portal https://dealers.
cervelo.com
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
Torx head inserts:
T25
Open ended wrenches:
7mm, 8mm, 10mm, 17mm
Cable cutters
Pliers
Philips-head screwdriver
Tools
Slot-head screwdriver
Pedal wrench
Brake rotor lockring tools
Hydraulic bleed kit
Isopropyl alcohol
Di2 wire tool – Shimano
Good quality bicycle grease
Saw cutting guide (Park Tool SG-7.2
or equivalent)
Hacksaw (with carbon specic
blade)
TABLE OF CONTENTS

3 4
2023 S5 PARTS LIST
Item Description Cervélo Part No.
S5 Seatpost Clamp
Assembly SPC-0E0S5
Front Derailleur
Mount w/Fixing
Screws
FDM-0E0
FDM Blanking Plate FDM-CVR
Rear Derailleur
Hanger w/Fixing Nut DRH-WMN112
Shimano Direct Mount
RDH w/Fixing Nut DRH-SDM
Threaded Fork Insert
w/Fixing Screw QRI-THD
Disc Brake Hose
Guide CBG-DBH
BB Blanking Plug GR-BB-140
6mm Blanking Plug
for Front & Rear
Derailleur
GR-576
Internal Battery Mount
Assembly BTM-705
Upper Bearing Gap
Spacer w/Fixing
Screws
FKI-GPSP
Item Description Cervélo Part No.
Preload Cone HS-S5F-CN
Tension Rod w/
Bumper for 48cm HS-TR48
Tension Rod w/
Bumper for 51cm HS-TR51
Tension Rod w/
Bumper for 54cm HS-TR54
Tension Rod w/
Bumper for 56cm HS-TR56
Tension Rod w/
Bumper for 58cm HS-TR58
Tension Rod Bumper HS-581
HB14 Handlebar see page 7
HB14 Mounting Kit HBP-HB14
HB14 Extension
Mounts w/ Pads and
Fixing Screws
HBP-HB14-EXTMT
ST35 Stem see page 8
ST35 Stem Mounting
Hardware Kit SK-ST35
Item Description Cervélo Part No.
ST35 Stem Bolt Cover
Kit GR-C035
ST35 Headset Spacer
Kit HSS-S5F-KT
SP20 Carbon Post 0mm
Oset w/Head SP-SP20-ZERO
SP20 Carbon Post
15mm Oset w/Head SP-SP20-15MM
Cervélo Front
Aero Thru Axle w/
Removable Handle
QRA-AERO2-F
Cervélo Rear AeroThru
Axle w/Removable
Handle
QRA-AERO2-R
Removable Handle for
Cervélo Aero Thru Axle QRA-AERO2-HNDL
S5 Chainstay Protector PRO-CS-508
Two-Bolt Mount
Accessory Kit-Front MT-LM-F-371
Accessory Mount-Rear MT-LM-R-003
Internal Battery
Mount Kit
BTM-705
Front/Rear
Derailleur Wire
Hole Blanking
Plug(6mm) x2
GR-576
Disc Hose
Bushing x2
CBG-DBH
Seatpost Clamp
SPC-0E0S5
The S5 frame is engineered to provide seamless integration of electronic
shifting systems. In order to do so, you may require the parts shown below:
Direct Mount
Derailleur
Hanger
DRH-SDM
Derailleur
Hanger
DRH-WMN112
Derailleur
Hanger Fixing
Nut
Front Derailleur
Mount w/ Fixing
Screws FDM-OEO
Front
Derailleur
Mount Blanking
Plate (1x)
FDM-CVR
BB Blanking
Plug
GR-BB-140
Threaded Fork
Insert w/Fixing
Screw
QRI-THD
SMALL PARTS

5 6
SMALL PARTS FORK & HEADSET COMPONENTS
Your Cervélo frame & fork have been
designed to work together. Do not
attempt to install an alternative fork.
Preload Cone
HS-S5F-CN
Tension Rod
Bumper
HS-581
Tension Rod
48cm-HS-TR48
51cm-HS-TR51
54cm-HS-TR54
56cm-HS-TR56
56cm-HS-TR58
Upper Bearing
1-1/8", 36° x 45°
Lower Bearing
1-3/8", 36° x 45°
Upper Bearing
Gap Spacer
FKI-GPSP
S5 Fork
48cm FK147-2464
51cm FK147-2465
54cm FK147-2466
56cm FK147-2467
58cm FK147-2468
M3x8mm Fixing
Screws x3
NOTE: The S5 headset
assembly does not
require a split ring.
Use M4x16mm
xing screws
if mounting a
single accessory
plate. Torque
to 2Nm
Torque
M5x20mm
to 2.5Nm
Use M4x22mm
xing screws
if mounting
dual accessory
plates. Torque
to 2Nm
Torque
M3x6mm
to 1Nm
Torque
M5x20mm
to 2.5Nm
Includes
inserts
for Garmin
& Wahoo
computers.
To install Two-Bolt Mount Accessory
Kit - Front (MT-LM-F-371) use the
appropriate length xing bolts
and mount to the underside of
the handlebar. Tighten to 2Nm
maximum.
For use without
accessory, clip may be
hidden, by reversing
the upper clamp.
To install Accessory Mount
- Rear (MT-LM-R-003),
replace the rear upper
clamp of the seatpost with
the kit version.Tighten to
maximum 8Nm.

7 8
HANDLEBAR & STEM COMPONENTS
80mm
380mm
400mm
420mm
440mm
128mm
Only use the components specified in this manual
for handlebar and stem assembly. Failure to use the
specified parts and to follow the supplied assembly
instructions may result in a loss of control
while riding and serious injury.
Cervélo HB14
Handlebar
38cm HB-HB14-38
40cm HB-HB14-40
42cm HB-HB14-42
44cm HB-HB14-44
Brake hoses
run in the
channels on
underside of
handlebar.
Brake hoses
run through
the arms of
the C035 stem.
Cervélo C035 Stem
CO35 Stem Spacers
HSS-S5F-KT
5mm spacers x3
7.5mm spacers x2
Handlebar Mounting
Inserts(Right & Left)
Kit w/ Fixing Screws
HBP-HB14
T25 Torx Fixing Screws
M5x20mm x4
Stem Fixing
Screws
M6x50mm w/ M6
Ribbed Lock
Washers x3
SK-ST35
Rear Bolt Cover
Front Bolt Cover
Stem Bolt Covers are
included with stem.
Stem Bolt Covers
also available as
kit GR-C035.
80mm ST-C035-80
90mm ST-C035-90
100mm ST-C035-100
110mm ST-C035-110
120mm ST-C035-120
130mm ST-C035-130
Two-piece Stem
Spacers allow for
installation or
removal without
re-cabling.

FRAME & FORK PREPARATION
910
1. Apply carbon paste to both frame and
seatpost.
2. Insert the seatpost and the Seatpost Clamp
(SPC-0E0S5) fully into frame so it is fully
ush with the top tube.
3. Adjust height and torque to 8Nm maximum.
Hold the frame
using a secured
seatpost only.
Clamping the top tube
can damage the frame
and void your warranty.
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.
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).
Lightly grease Rear Derailleur Hanger Fixing
Nut and install either Rear Derailleur Hanger
(DRH-WMN112) or Direct Mount Rear
Derailleur Hanger (DRH-SDM) nger tight.
Final tightening will be performed after rear
wheel installation.
In preparation for assembly, pre-form threads
in the Upper Bearing Gap Spacer (FKI-GPSP)
by installing the supplied M3x8mm xing
screws with the fork separate from the frame.
Then remove the screws and Gap Spacer. The
Gap Spacer will be installed on the fork after
installation on the frame, and pre-forming
simplies the process.
Lightly grease interior of the
Tension Rod Bumper (HS-
581) and install onto Tension
Rod (HS-TRxx). Note: "xx"
denotes frame size.
Do not final tighten
rear derailleur hanger
assembly without rear
wheel installed. Doing
so may result in a
misaligned derailleur
and poor shifting.
DRH-SDMDRH-WMN112
Clean the chainstay using isopropyl alcohol. Install the
Chainstay Protector (PRO-CS-508) by removing adhesive
backing, and xing the guard to the frame. The bottom
rearward edge should be approximately 50mm forward
from the back of the rear dropout.

11 12
FORK INSTALLATION
Upper
Bearing
Gap Spacer
FKI-GPSP
Assembled 4mm
clearance to
be lled by the
Upper Bearing
Gap Spacer
1. Apply grease to the bearing
pockets and install the upper
and lower headset bearings
into the frame.
2. Orient the fork perpendicular
to the frame and with the fork
tilted away from the frame at
the top, position the raised
crown area of the fork inside
the lower bearing.
3. Tilt/rotate the top of the fork
into place over the upper
bearing. When positioned
correctly little or no eort
should be required to position
the top of the fork above the
front of the head tube & upper
bearing.
Rotate/slide the fork around
the head tube counter-
clockwise until it is mostly
aligned with the frame, and
sitting slightly o-center
relative to the frame .
4. With the lower bearing mostly
seated in this position, gently slide
the fork laterally and let the crown
settle fully into the lower bearing.
Once fully seated the top of the
fork can be fully aligned above the
upper bearing.
5. Rotate fork perpendicular to frame
and install the Upper Bearing Gap
Spacer. Fasten with the M3x8mm
xing screws, torque to 1Nm
(nger tight).
Take care not to force the fork
top over the head tube by
deviating from these installation
steps or by trying to push-
through interference between
these parts. Improper assembly
can result in damage to the paint
on the frame or fork.

13 14
Brake
BRAKE HOSE ROUTING
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.
Chainstay
height: 25mm
Route hydraulic brake hose through the frame and fork
with the Disc Hose Guide (CBG-DBH). Install and adjust
calipers as per manufacturer’s instructions.
Route rear brake hose
from chainstay through
the down tube and up
through the head tube
and fork.
Run the front brake
hose from the bottom
of the fork blade up
through the forward
hole at the top of
the fork.
Rear brake hose passes
upwards through the
gure-8 shaped opening
at the top of the fork
(forward section).

15 16
Tighten fork xing
screw to 4Nm to nish
fork installation.
Tension Rod
(HS-TRxx*)
with Tension
Rod Bumper
(HS-581)
installed
*xx = specic
frame size
Preload
Cone
HS-S5F-CN
1. Apply grease to Preload Cone
and install.
2. Grease threaded end of Tension
Rod and install.Tighten the
Tension Rod to 2Nm
3. Rotate the fork to expose the
fork xing screw and tighten to
4Nm maximum.
M3 x 16mm Fixing
Screws
DI2 BATTERY INSTALLATIONHEADSET ASSEMBLY
The battery for your Shimano Di2 system mounts
inside the down tube using the Internal Battery Mount
(BTM-705) designed to t this frame. As this is a sealed
location, it is important to test the system prior to nal
installation.
Insert a long 5mm hex key into the lower end
of the holder to work as an insertion tool.
Pass the battery and holder assembly through
the opening in the bottom bracket shell and
position it, in the down tube, so that the xing
nuts are located over the mounting holes.
Attach battery to mount
using two zip ties, and
install.
Ensure Loctite 242 is applied to the
M3 xing screws. Pass through the
mounting holes to catch the xing nuts
in the battery holder, tightening only
slightly to hold in place. Remove 5mm
hex key. Using a 2mm hex key, tighten
xing screws to maximum of 2.5Nm
over the mounting holes.

17 18
ELECTRIC WIRE ROUTING & INSTALLATION
Brake
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.
350mm
E-Wire
650mm
E-Wire
E-Wire(SD300)
With all wires inside, cap the
Bottom Bracket Cable Port with
the BB Blanking Plug (GR-BB-140)
For wireless
shifting
systems install
the Blanking
Plug (GR-576).
For wired shifting
systems install
the Shimano EW-
SD300 grommet for
6mm hole (sold by
Shimano)
See page 16 for Di2
battery installation.
NOTE: The S5 frame
and fork are designed
to be compatible with
electronic / wireless
groupsets only.