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P-Series Retailer Assembly Manual Table of Contents List of Tools & Supplies

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P-SERIES RETAILER ASSEMBLY MANUAL TABLE OF CONTENTS LIST OF TOOLS & SUPPLIES Important Information . 1 Mechanical Cable Installation . 14 This manual outlines a number of procedures for making optional adjustments to the P-Series Tools Tools List of Tools & Supplies . 2 GU02 Stem Cover Assembly Installation . 15 bicycles. The following tools and parts listed are P-Series Parts List . 3 Top Tube SmartPak Installation . 16 required for these adjustments. Cervélo strongly Bicycle workstand (types which Pedal wrench Small Parts . 4 Seatpost Assembly . 17 recommends that all assembly and adjustment secure bike by the seatpost, or pro-type stand with fork mount) Frame & Fork Preparation . 5 Seatpost Cutting Instructions . 19 procedures be performed by an authorized Cervélo retailer. Fork Installation . 7 Seatpost Di2 Battery Installation . 20 Torque wrench(es) with 2.5Nm to Brake rotor lockring tools Brake Housing Routing . 9 Aero Water Bottle Installation . 21 NOTE: This manual was developed to 15Nm range and adaptors: Electric Wire Routing . 11 Tire Clearance . 22 compliment the Cervélo General User Electric Wire Installation . 12 Aero Thru-Axle Installation . 23 Manual, and is intended as a supplement Allen (Hex) head inserts: Mechanical Cable Routing . 13 to the assembly and installation 2mm, 2.5mm, 3mm, 4mm, 5mm, Hydraulic bleed kit instructions supplied by the component 6mm, 8mm, 10mm manufacturers (provided with this bicycle) . Open ended wrenches: Isopropyl alcohol NOTE: All non-proprietary components are 7mm, 8mm, 10mm, 17mm available from your local distributor . Di2 wire tool – Shimano Cable cutters IMPORTANT INFORMATION Good quality bicycle grease & This manual is intended to guide official Cervélo retailers, through the assembly and adjustment of the NOTE: Cervélo strongly recommends that Pliers carbon assembly compound Cervélo P-Series. This manual outlines the process and procedure associated with the installation of all assembly and adjustment procedures Cervélo components, as well as the routing of shifting and braking control lines only. Proprietary parts be performed by an authorized Cervélo Saw cutting guide (Park Tool SG-7.2 referenced in this manual are available only through Cervélo Cycles Inc. directly. retailer . If you are a Cervélo P-Series consumer/purchaser reading this manual Phillips-head screwdriver or equivalent) Failure to use the specified parts and follow these assembly instructions may result in loss of control we suggest that before attempting to undertake any of the procedures in this while riding, leading to serious injury. This manual is not intended to replace the assembly and service manual that you consult your authorized Hacksaw (with carbon specific instruction provided by third-party component manufactures, and assumes that the assembler is a Slot-head screwdriver Cervélo retailer, or visit us at blade) trained, professional bicycle mechanic. See https://www.probma.org/ www .cervelo .com/support 1 CER-PS-V2 - 2020-01-31 2 P-SERIES PARTS LIST SMALL PARTS Designed to accommodate electronic, mechanical and hydraulic controls, the P-Series frame is Item Description Cervélo Part No. Item Description Cervélo Part No. Item Description Cervélo Part No. 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: Seatpost Water Bottle Top Tube Brake Hose MT-WB-SP Brake Hose Guide CBG-DBH Shift Housing Guide HBP-GU02-CVR Mount Threaded Fork Kit P-Series Seatpost Rear Derailleur Wire MT-BINT-SP GR-DRPOUT-GUIDE GU02 Stem Cover Insert w/ Battery Mount Guide (Electric) Assembly w/ Fixing Screw BB Cable Guide/Cover BBG-0E0 Fixing Screws QRI-THD Cervélo Front Aero Rear Derailleur QRA-AERO-F HBP-GU02-CVR Chainstay Protector Through Axle Press-In Cable Stop CBS-DRPOUT PRO-CS-P P Series (Mechanical) Cervélo Rear Aero QRA-AERO-R Threaded Fork Insert QRI-THD Through Axle Rear Derailleur Blanking Plug GR-DRPOUT-CLOSED Derailleur Hanger Front Derailleur Seatpost Clamp w/ Fixing Nut Derailleur Hanger w/ (Wireless) DRH-WMN112 Mount w/ Fixing FDM-0E0 SPC-0E0P DRH-WMN112 Mounting Nut Smartpak400 w/Fixing Screws SB-SB03-TT Seat Post Clamp Screws Brake Hose Guide x3 SPC-0E0P Front Derailleur CBG-DBH Assembly P-Series Aero Water Bottle w/ Mount Blanking Plate FDM-CVR WB-WB01 BB Cable SP23 Carbon Seatpost Cage SP-SP23 (1x) Guide/Cover Seat Tube Blanking Seat Tube Open With Head Bottle Boss Cover BBG-0E0 Plug(1x & Wireless) Grommet(Electronic) Seat Tube Blanking CVR-WB GR-ST-CLOSED Plate GR-ST-CLOSED GR-BEC-OPEN UCI P5 Seatpost SP-CER-UCI-ACB Plug(1x & Wireless) SP21, SP23 Saddle Seat Tube Open SPS-SP2123 GR-BEC-OPEN Clamp Slug Grommet(Electronic) Front Derailleur Rear Derailleur Rear Derailleur Rear Derailleur Mount Wire Guide Press-In Cable Blanking Plug Front Derailleur Blanking (Electric) Stop (Mechanical) (Wireless) Mount w/ Fixing Plate (1x) GR-DRPOUT-GUIDE CBS-DRPOUT GR-DRPOUT-CLOSED Screws FDM-OEO FDM-CVR 3 4 FRAME & FORK PREPARATION 1. Apply carbon assembly compound to both Lightly grease supplied M4 fixing screw, and frame and seatpost. install the GU02 Base to the frame. Torque to 1-2Nm. 2. Insert Seatpost Clamp (SPC-0E0P) in frame so M4 x 16mm it is flush with the top tube. Fixing Screw 3. Adjust height and torque to 8Nm maximum. Install Front Derailleur Mount (FDM-0E0), and ensure fixing screws are torqued to 3Nm. For 1x systems replace with the Front Derailleur Mount Blanking Plate (FDM-CVR). GU02 Base 1. Lightly grease supplied M4 fixing screw. Clean the chainstay using isopropyl alcohol. Install the Threaded Fork Insert (QRI-THD) Install the Chainstay Protector (PRO-CS-P) by and fixing screw, tightening only lightly. removing adhesive backing, and fixing the guard to the frame. The bottom rearward edge should be 2. Without wheel in place, install the axle approximately 15mm from the edge of the Rear and tighten until the flange meets the fork Derailleur Hanger Nut. dropout face, but does not compress the fork blades. 3. Tighten the fixing screw to 3Nm. 4. Remove the axle and install wheel. Reinstall axle and tighten to 12-15Nm. Lightly grease Rear Derailleur Hanger 15mm Fixing Nut and install Rear Derailleur Do not final tighten rear derailleur hanger NOTE: Install GU02 5. Remove axle and wheel, and re-torque the Hanger (DRH-WMN112) finger tight. Hold the frame using a secured seatpost only. Base onto frame prior assembly without rear wheel installed. fixing screw to 3Nm. Final tightening will be performed after Clamping the top tube can damage the frame to installing fork . Doing so may result in a misaligned and void your warranty. rear wheel installation. derailleur and poor shifting. 5 6 Preload Fixing FORK INSTALLATION Screw M6 x 30mm 1. Apply grease to the bearing pockets and install the upper and lower A 2 .5mm spacer Stem Preload headset bearings into the frame. under the Stem Top Cap Cap is advised 2. Fit the fork provided with your frame into the head tube with the Max . 1st Mark complete headset, required spacers, and the stem. 4mm Stem Do not exceed 50 mm 3. Apply the minimum pressure needed to ensure the assembly is fully maximum total spacer seated. Mark the steerer tube at the top of the stem. 2nd Mark / height, including the Final Cut bearing top cap. 4. Remove fork and clearly mark the fork steerer tube at a point 4mm Bearing below the first mark. Take care to verify that this measurement is Top Cap correct as this defines the cut line for the steerer tube. Compression Ring 5. To trim fork steerer, use only a saw suitable for cutting carbon, and a 1 1/8" Upper Bearing cutting guide. (36˚x 45˚) 6. Carefully sand a bevel to the inside of the cut end of the steerer tube to fit the Preload Compression Plug. Install 1 1/8" Preload 7. Dry fit Preload Compression Plug to check that it is flush with the cut Compression Plug end of the steerer tube. in fork steerer . NOTE: This diagram is for Avoid breathing the dust created during cutting Torque to 8Nm assembly reference only . 8. Install Preload Compression Plug in fork. Torque to 8Nm. carbon composite materials. During complete assembly, hoses and control cables will 9. Install headset, stem and spacers. Tighten Preload Fixing Screw to be present . remove any play in the bearings. Improper cutting of the steerer tube could cause a failure that may result in severe injury or death. Your Cervélo frame & fork have been designed to 1 3/8" Lower Bearing work together. Do not substitute a different size (36˚x 45˚) fork without first consulting Cervélo Customer Service to confirm compatibility with your frame. Fork Steerer w/Preload Compression Plug 7 8 BRAKE HOUSING ROUTING These routing illustrations are intended as a supplement to the manufacturer’s Route hydraulic brake hose or mechanical brake housing through the frame installation instructions only. For both hydraulic and mechanical disc brakes, and fork with the Disc Hose Bushings (CBG-DBH). Install and adjust calipers please refer to the component manufacturer’s service center or website for as per manufacturer’s instructions. further information. Route brake hose from bottom of fork up and out through the upper fork exit hole . Chainstay Route rear brake hose from height: 30mm chainstay through down tube and up through the GU02 Base . 9 10 ELECTRIC WIRE ROUTING ELECTRIC WIRE INSTALLATION It is recommended that 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. Brake E-Wire 1000mm E-Wire 750mm E-Wire Install the Rear Derailleur Wire Guide (GR-DRPOUT-GUIDE).
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