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 Cover Assembly Installation...... 15 . The following tools and parts listed are P-Series Parts List...... 3 Top Tube SmartPak Installation...... 16 required for these adjustments. Cervélo strongly workstand (types which Pedal wrench Small Parts...... 4 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 Wire MT-BINT-SP GR-DRPOUT-GUIDE GU02 Stem Cover Insert w/ Battery Mount Guide (Electric) Assembly w/ Fixing Screw BB /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 bearings into the frame. under the Stem Top Cap Cap is advised 2. Fit the fork provided with your frame into the 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). 750mm E-Wire

300mm E-Wire For wireless shifting systems install the Rear Derailleur Blanking Plug (GR-DRPOUT-CLOSED) . Route the Di2 E-Wire through With all wires inside, cap the the GU02 Base (HBP-GU02-CVR) Cable Port with the and out through the Bottom BB Cable Guide/Cover (BBG-0E0). Bracket Cable Port .

11 12 MECHANICAL CABLE ROUTING MECHANICAL CABLE INSTALLATION 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.

Brake Rear Front Shifter

Install Rear Derailleur Press-In Cable Stop (CBS-DRPOUT).

The front cable travels across the non-drive side slot, and in Ensure that the shifter the direction of the seat tube. The rear cable travels along housing does not twist the drive side slot, and along the chainstay. When complete, Route shifter housing through together . Add ferrules fix the BB Cable Guide/Cover (BBG-0E0) into place. the GU02 Base (HBP-GU02-CVR) to the bottom bracket and out through the Bottom end of the housing . As per manufacturer’s instructions, install rear derailleur. Bracket Cable Port .

13 14 GU02 STEM COVER ASSEMBLY INSTALLATION TOP TUBE SMARTPAK INSTALLATION

M4 x 20mm Torque to 1Nm GU02 Cable Guide

M4 Washer

M5 x 18mm GU02 Stem Torque to 1-2Nm Cover M5 Washer Installed position . SmartPak 400 Top Tube Storage (SB-SB03-TT)

If not using SmartPak 400 install Bottle Boss Cover Plate After cabling is complete, install the two piece Ensure tabs are (CVR-WB) . GU02 Cable Guide to secure housing or Di2 cable in place and sides and brake hose. Install the GU02 Stem Cover to held inward during finish. Torque to 1Nm. installation . 15 16 SEATPOST ASSEMBLY

Seatpost Water Bottle Mount(MT-WB-SP)

M5 x 16mm Fixing Screws

Slide the lightly greased seatpost mount slug into the seatpost.

1. Attach saddle mount to slug using lightly greased M5 fixing screws. Torque to 6-7Nm.

2. Install lightly greased M6 Rail Binder Bolt, and install saddle.

3. Torque to 12Nm.

Rail Binder Bolt 4. Determine desired angle, and attach Attach water bottle cage using lightly greased M6 x 55mm water bottle mount to seatpost slug M5 x 8mm fixing screws. Torque to 2-3Nm. If not using the bottle cage mount, with M5 fixing screw. SP23 Seatpost UCI P5 Seatpost use the alternate seatpost slug (SP-SP23) (SP-CER-UCI-ACB) (SPS-SP2123) . 5. Torque to 4Nm. 17 18 SEATPOST CUTTING INSTRUCTIONS SEATPOST DI2 BATTERY INSTALLATION Note: It is essential that all Cervélo Aero , have a 45 Press the Di2 battery into the Seatpost Battery degree chamfer cut on the trailing edge of the post . If trimming is Mount (MT-BINT-SP) and attach the E-Wire required after fitting, the following method is recommended. according to the manufacturers instructions. Insert the assembled battery and battery 1. Taking care to maintain the minimum required seatpost insertion of 6.5cm and mount into the seatpost. maximum of 8.5cm, carefully measure and use a light coloured grease pencil to accurately mark the cut-off location on the seatpost.

2. Insert the P-Series Seatpost in the Park Tool SG-7.2 Saw Guide (or equivalent) so that the cut-off line can be seen clearly through the blade guide in the tool.

3. Using a blade designed specifically for cutting carbon composite materials (or Cut Line a fine tooth blade with greater than 32 teeth per inch); proceed with cutting the Seatpost (as per Park Tool’s instructions). 1cm 4. Use fine grit sandpaper to carefully remove any fraying or burring from the cut 1cm end. Reposition clamp approximately 10cm from the cut end. P Series Seatpost Battery Mount 5. With a grease pencil, mark a point 1cm from the cut end on the trailing edge of (MT-BINT-SP) the Seatpost, and another 1cm from the back, on the bottom edge. Draw a line connecting them, forming a 45 degree guideline.

6. Placing the blade of your saw on the grease pencil mark, very carefully proceed to cut, resulting in a 45 degree chamfer being cut onto the trailing edge of the Seatpost.

7. Carefully sand the end and after applying carbon assembly compound, return to the frame.

If trimming is required, final length should allow for a minimum 6.5cm of seatpost remaining in the frame. Failure to meet this requirement, may result in serious injury to the rider or damage to the frame not covered by warranty.

19 20 AERO WATER BOTTLE INSTALLATION TIRE CLEARANCE

Attach Aero Water Bottle (WB-WB01) cage to 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 frame and torque M5 x 18mm fixing screws maintain your Limited Lifetime Warranty, a minimum of 4mm of clearance must remain between the tire and any frame element. Due to to 2Nm. 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.

Tire/Rim Frame 2. Measure the space between the seatstays at the Dimension Clearance 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 inflated on your If not using Aero wheel, measure the widest of the rim or tire Water Bottle install width to ensure that it fits. M5 x 18mm Bottle Boss Cover Torque to 2Nm Plate (CVR-WB) .

Contact between the tire or rim and the frame or fork may result in a loss of control while riding and potentially serious injury. Failure to follow these guidelines may result in damage to the frame not covered by Cervélo Limited Lifetime Warranty.

21 22 AERO THRU-AXLE INSTALLATION To secure wheels, install the greased axle, through the drop out and the wheel hub, aligning the threaded end of the axle with the threaded insert. Once aligned and engaged, thread the axle (clock-wise) into the threaded component of the insert until the axle is secured tightly.

Tighten rear axle to 12-15Nm .

Perform final tightening on Rear Derailleur Hanger Nut using a 17mm wrench . Torque to 12-15Nm . This action is Tighten front axle unique to initial assembly,and to 12-15Nm . should not require additional adjustment .

Adjust brakes as per manufacturer’s To ensure rider safety, it is critical to install the Cervélo instructions. Aero Thru-Axle correctly. Failure to do so may result in an accident with potential for serious injury to the rider.

23 24 NOTES

25 26 P-SERIES RETAILER ASSEMBLY MANUAL www .cervelo .com CER-PS-V2 2020-01-31