Cervélo S5 User manual

2019 S5 DISC RETAILER ASSEMBLY MANUAL
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1
This manual is intended to assist Cervélo retailers in setting up and customizing the 2019 S5 Disc
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
2019 S5 Disc Parts List.................................. 3
Frame Features........................................... 4
Handlebar & Stem Components.............................. 5
Handlebar Components - Stack............................. 6
Handlebar Components - Pitch Adjust...................... 7
Fork & Headset Components................................ 8
Small Parts.............................................. 9
Frame Preparation....................................... 10
S5 Disc Assembly Overview............................... 11
Before You Build........................................ 13
Electric Cable Preparation.............................. 14
Mechanical Cable Preparation............................ 15
Brake Housing Routing................................... 16
Electric Cable Routing.................................. 18
Mechanical Cable Routing................................ 19
Fork Installation....................................... 20
Fork Topper Installation................................ 21
Stem Installation....................................... 22
Stack Adjustment........................................ 23
Stem Fixing Screw Guide................................. 24
Handlebar Installation.................................. 25
Handlebar & Stem - Electric Cable Routing - ............ 26
Handlebar & Stem - Mechanical Cable Routing............. 27
Di2 Battery Installation................................ 28
Electric Cable Installation............................. 29
Mechanical Cable Installation........................... 30
Seatpost Assembly....................................... 31
Seatpost Cutting Instructions........................... 30
Frame Protection Installation........................... 33
Tire Clearance.......................................... 34
Rapid Axle Wheel Installation........................... 35
CER-S5-V2 - 2018-08-24
TABLE OF CONTENTS
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 Disc
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
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2
NOTE: This manual was developed to
compliment the Cervelo 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 Disc 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 Cervelo 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
Tools
Philips-head screwdriver
Slot-head screwdriver
Pedal wrench
Brake rotor lockring tools
Hydraulic bleed kit
Di2 wire tool – Shimano
Good quality bicycle grease
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2019 S5 DISC PARTS LIST
Item Description Cervélo Part No.
S5 Stack Adjustment
Dealer Kit KP-0E0S5
Conventional 1 1/8"
Stem Adapter FKA-FK60-1125
Computer Mount
Adapter Plate MT-AB08-CAP
M6X1.0X14 CS028
BOLT KIT BT-C028-14
M6X1.0X20 CS028
BOLT KIT BT-C028-20
M6X1.0X25 CS028
BOLT KIT BT-C028-25
M6X1.0X30 CS028
BOLT KIT BT-C028-30
M6X1.0X35 CS028
BOLT KIT BT-C028-35
M6X1.0X40 CS028
BOLT KIT BT-C028-40
M6X1.0X45 CS028
BOLT KIT BT-C028-45
Aftermarket FK60 Fork
Assembly Kit 48 FKA-FK60-SM
Aftermarket FK60 Fork
Assembly Kit 51 FKA-FK60-MD
Item Description Cervélo Part No.
Aftermarket FK60 Fork
Assembly Kit 54-58 FKA-FK60-LG
CS028 Stem 80mm w/
Plugs ST-CS028-80
CS028 Stem 90mm w/
Plugs ST-CS028-90
CS028 Stem 100mm
w/ Plugs ST-CS028-100
CS028 Stem 110mm
w/ Plugs ST-CS028-110
CS028 Stem 120mm
w/ Plugs ST-CS028-120
CS028 Stem 130mm
w/ Plugs ST-CS028-130
AB08 Mounting Kit
0mm HBP-AB08-ZERO
AB08 Mounting Kit
2.5mm HBP-AB08-2.5MM
AB08 Mounting Kit 2.5
Degrees HBP-AB08-2.5DEG
AB08 Mounting Kit 5
Degrees HBP-AB08-5DEG
AB08 Carbon
Handlebar 380mm HB-AB08-38
Item Description Cervélo Part No.
AB08 Carbon
Handlebar 400mm HB-AB08-40
AB08 Carbon
Handlebar 420mm HB-AB08-42
AB08 Carbon
Handlebar 440mm HB-AB08-44
SP20 Carbon Post
0mm Oset w/Head SP-SP20-ZERO
SP20 Carbon Post
25mm Oset w/Head SP-SP20-25MM
Seat Post Clamp
Assembly 0E0 S5 SPC-0E0S5
Internal Battery Mount
Assembly 0E0 MT-BINT
BB Cable Guide/Cover
0E0 BBG-0E0
Chainstay Protector
0E0 S Series PRO-CS-S
Disc Brake Hose
Guide CBG-DBH
ST28 Spacer Kit
30mm SS-C028-KIT
Front Der Mount for
0E0 S5 w/Rivets FDM-0E0S5
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A guide to the Cervélo S5 Disc frame.
Rear Dropout Cable Exit
Front Derailleur Wire
Exit Hole, electric
and mechanical
Bottom Bracket Cable Port
Internal Di2 Battery
Mount Holes
FRAME FEATURES
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HANDLEBAR & STEM COMPONENTS
Cervélo AB08
Handlebar
Cervélo CS028 Stem
38cm HB-AB08-38
40cm HB-AB08-40
42cm HB-AB08-42
44cm HB-AB08-44
5mm Stem Spacers x6
SS-C028-KIT
M6 Stem Fixing
Screws (Sets of 3)
0mm Stack BT-C028-14
5mm Stack BT-C028-20
10mm Stack BT-C028-25
15mm Stack BT-C028-30
20mm Stack BT-C028-35
25mm Stack BT-C028-40
30mm Stack BT-C028-45
Stem Cap* (Rear)
Stem Cap* (Front)
*Stem Caps are included
with stem.
80mm ST-CS028-80
90mm ST-CS028-90
100mm ST-CS028-100
110mm ST-CS028-110
120mm ST-CS028-120
130mm ST-CS028-130
Only use the components specied in this manual
for handlebar and stem assembly. 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.
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0˚
0˚
+
2.5mm
6
HANDLEBAR COMPONENTS - STACK
- Handlebar Fixing Nuts (L + R)
for 0mm stack
- M5 x 14mm Bolts (x4)
- Handlebar Fixing Nuts (L + R)
for 2.5mm stack
- 2.5mm Bar Spacers (L + R)
- M5 x 16mm Bolts (x4)
0mm Stack Kit
HBP-AB08-ZERO
2.5mm Stack Kit
HBP-AB08-2.5MM
Bar Fixing Screw
M5 x 14mm
Actual Size
Bar Fixing Screw
M5 x 16mm
Actual Size
14mm
16mm
The AB08 handlebar stack can be increased by 2.5mm or
rotated in increments of 2.5˚ or 5˚ by the use of specic
Stack Spacer or Pitch Adjust Wedge kits.
All handlebar mounting parts
are clearly labeled for proper
installation. Mixing parts will void
warranty and may result in injury.
NOTE: Refer to page 25 for
installation instructions of
the stack or pitch adjust
wedge kits.
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2.5˚
5˚
7
HANDLEBAR COMPONENTS - PITCH ADJUST
- Handlebar Fixing Nut (L + R)
for 2.5˚ rotation
- 2.5˚ Pitch Adjust Wedge (L + R)
- M5 x 16mm Bolts (x4)
- Handlebar Fixing Nuts (L + R)
for 5˚ rotation
- 5˚ Pitch Adjust Wedge (L + R)
- M5 x 16mm Bolts (x4)
2.5˚ Pitch Adjust Kit
HBP-AB08-2.5DEG
5˚ Pitch Adjust Kit
HBP-AB08-5DEG
Bar Fixing Screw
M5 x 16mm
Actual Size
16mm
Complete Handlebar Stack Spacer or
Pitch Adjust Wedge kits must be utilized
without substitution or combination of
parts. 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.
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FORK & HEADSET COMPONENTS
Preload Cone
Fork Topper
Top Bearing
Dust Seal
Fork Topper
Fixing Screws x4
M5 x 16
Top Bearing
1", 36° x 45°
Bottom Bearing
1-3/8", 36° x 45°
Preload Cone
Fixing Screw
M6 x 18mm
NOTE: The S5 Disc headset
assembly does not require a
compression ring.
Fit Top Bearing Dust
Seal to Fork Topper
before installation.
FK60 Fork
Assembly Kit
FKA-FK60-SM
FKA-FK60-MD
FKA-FK60-LG
Your Cervélo frame & fork have been
designed to work together. Do not
attempt to install an alternative fork.
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Front Fork Axle Insert
QRI-RAT
Internal Battery Mount Kit
MT-BINT
BB Cable
Guide/Cover
BBG-0E0
Front Derailleur
Wire Hole Blanking
Plug
GR-ST-CLOSED
Disc Hose Bushing x2
CBG-DBH
Seatpost Clamp
SPC-0E0S5
Computer Mount
Adaptor Plate
MT-AB08-CAP
Rear Derailleur
Hanger Assembly
DRH-RAT
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
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 tted to the bicycle.
SMALL PARTS
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