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2019 S5 Retailer Assembly Manual Table of Contents List of Tools & Supplies

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2019 S5 Retailer Assembly Manual Table of Contents List of Tools & Supplies 2019 S5 RETAILER ASSEMBLY MANUAL TABLE OF CONTENTS LIST OF TOOLS & SUPPLIES Important Information .................................... 1 Fork Installation....................................... 20 This manual outlines a number of procedures Tools Tools List of Tools & Supplies ................................. 2 Fork Topper Installation ................................ 21 for making optional adjustments to the S5 which 2019 S5 Parts List ....................................... 3 Stem Installation....................................... 22 differ from the way the bicycle is originally sold Frame Features ........................................... 4 Stack Adjustment ........................................ 23 by Cervélo.The following tools and parts listed Bicycle workstand (types which Handlebar & Stem Components .............................. 5 Stem Fixing Screw Guide................................. 24 are required for these adjustments. These parts secure bike by the seatpost, or Philips-head screwdriver pro-type stand with fork mount) Handlebar Components - Stack ............................. 6 Handlebar Installation .................................. 25 are not available for consumer purchase and are Handlebar Components - Pitch Adjust...................... 7 Handlebar & Stem - Electric Cable Routing - ............ 26 only available for purchase by Cervélo retailers. Fork & Headset Components ................................ 8 Handlebar & Stem - Mechanical Cable Routing ............. 27 Cervélo strongly recommends that all assembly Torque wrench(es) with 2.5Nm to Slot-head screwdriver Small Parts .............................................. 9 Di2 Battery Installation ................................ 28 and adjustment procedures be performed by an 15Nm range and adaptors: Frame Preparation....................................... 10 Electric Cable Installation ............................. 29 authorized Cervélo retailer. S5 Assembly Overview.................................... 11 Mechanical Cable Installation........................... 30 Allen (Hex) head inserts: All parts available for separate purchase are noted Before You Build ........................................ 13 Seatpost Assembly....................................... 31 2mm, 2.5mm, 3mm, 4mm, 5mm, Pedal wrench in this manual with Cervélo part numbers listed Electric Cable Preparation.............................. 14 Seatpost Cutting Instructions........................... 30 6mm, 8mm, 10mm Mechanical Cable Preparation ............................ 15 Frame Protection Installation........................... 33 in ALL - CAPS FORMAT, with a full listing provided Brake Housing Routing ................................... 16 Tire Clearance .......................................... 34 on page 3. These parts are available by visiting the Cervelo Customer Portal https://dealers. Torx head inserts: Electric Cable Routing .................................. 18 Rapid Axle Wheel Installation........................... 35 Brake rotor lockring tools cervelo.com T25 Mechanical Cable Routing ................................ 19 NOTE: All non-proprietary components Open ended wrenches: such as those from Shimano or SRAM are Hydraulic bleed kit IMPORTANT INFORMATION available from your local distributor. 7mm, 8mm, 10mm, 17mm This manual is intended to assist Cervélo retailers in setting up and customizing the 2019 S5 bicycle. NOTE: Cervélo strongly recommends that NOTE: This manual was developed to This manual is not intended for consumer use, and requires the use of the specified tools to ensure all assembly and adjustment procedures compliment the Cervelo General User Cable cutters Di2 wire tool – Shimano proper assembly. This manual also references proprietary parts available only to retailers through direct be performed by an authorized Cervélo Manual, and is intended as a supplement ordering from Cervélo. retailer.If you are a Cervélo S5 to the assembly and installation consumer/purchaser reading this manual instructions supplied by the component Pliers Good quality bicycle grease Failure to use the specified parts and to follow the supplied assembly instructions may result in a loss we suggest that before attempting to manufacturers (provided with this undertake any of the procedures in this bicycle). of control while riding and serious injury. This manual is an overview of the steps required to assemble manual that you consult your authorized this bicycle and to make any desired modifications as set forth in this manual. This manual assumes Cervélo retailer, or visit us at that the retailer has the minimum required background and skill level required of all professional www.cervelo.com/support bicycle mechanics. See https://www.probma.org/ 1 CER-S5-V2 - 2018-08-24 2 2019 S5 PARTS LIST FRAME FEATURES A guide to the Cervélo S5 frame. Item Description Cervélo Part No. Item Description Cervélo Part No. Item Description Cervélo Part No. S5 Stack Adjustment Aftermarket FK60 Fork AB08 Carbon KP-0E0S5 FKA-FK60-LG HB-AB08-40 Dealer Kit Assembly Kit 54-58 Handlebar 400mm Conventional 1 1/8" CS028 Stem 80mm w/ AB08 Carbon FKA-FK60-1125 ST-CS028-80 HB-AB08-42 Stem Adapter Plugs Handlebar 420mm Computer Mount CS028 Stem 90mm w/ AB08 Carbon MT-AB08-CAP ST-CS028-90 HB-AB08-44 Adapter Plate Plugs Handlebar 440mm M6X1.0X14 CS028 CS028 Stem 100mm SP20 Carbon Post BT-C028-14 ST-CS028-100 SP-SP20-ZERO BOLT KIT w/ Plugs 0mm Offset w/Head M6X1.0X20 CS028 CS028 Stem 110mm SP20 Carbon Post BT-C028-20 ST-CS028-110 SP-SP20-25MM BOLT KIT w/ Plugs 25mm Offset w/Head Front Derailleur Wire M6X1.0X25 CS028 CS028 Stem 120mm Seat Post Clamp BT-C028-25 ST-CS028-120 SPC-0E0S5 Exit Hole, electric BOLT KIT w/ Plugs Assembly 0E0 S5 and mechanical M6X1.0X30 CS028 CS028 Stem 130mm Internal Battery Mount BT-C028-30 ST-CS028-130 MT-BINT BOLT KIT w/ Plugs Assembly 0E0 M6X1.0X35 CS028 AB08 Mounting Kit BB Cable Guide/Cover BT-C028-35 HBP-AB08-ZERO BBG-0E0 BOLT KIT 0mm 0E0 M6X1.0X40 CS028 AB08 Mounting Kit Chainstay Protector BT-C028-40 HBP-AB08-2.5MM PRO-CS-S BOLT KIT 2.5mm 0E0 S Series Internal Di2 Battery Mount Holes M6X1.0X45 CS028 AB08 Mounting Kit 2.5 Disc Brake Hose BT-C028-45 HBP-AB08-2.5DEG CBG-DBH BOLT KIT Degrees Guide Aftermarket FK60 Fork AB08 Mounting Kit 5 ST28 Spacer Kit FKA-FK60-SM HBP-AB08-5DEG SS-C028-KIT Rear Dropout Cable Exit Assembly Kit 48 Degrees 30mm Aftermarket FK60 Fork AB08 Carbon Front Der Mount for FKA-FK60-MD HB-AB08-38 FDM-0E0S5 Bottom Bracket Cable Port Assembly Kit 51 Handlebar 380mm 0E0 S5 w/Rivets 3 4 HANDLEBAR & STEM COMPONENTS HANDLEBAR COMPONENTS - STACK The AB08 handlebar stack can be increased by 2.5mm or 0mm Stack Kit Only use the components specified in this manual rotated in increments of 2.5˚ or 5˚ by the use of specific for handlebar and stem assembly. Failure to use the Cervélo AB08 Stack Spacer or Pitch Adjust Wedge kits. specified parts and to follow the supplied assembly Handlebar instructions may result in a loss of control 38cm HB-AB08-38 while riding and serious injury. 40cm HB-AB08-40 42cm HB-AB08-42 44cm HB-AB08-44 14mm 0˚ Bar Fixing Screw - Handlebar Fixing Nuts (L + R) HBP-AB08-ZERO M5 x 14mm for 0mm stack Stem Cap* (Rear) Actual Size - M5 x 14mm Bolts (x4) Stem Cap* (Front) 2.5mm Stack Kit All handlebar mounting parts are clearly labeled for proper +2.5mm installation. Mixing parts will void *Stem Caps are included warranty and may result in injury. with stem. M6 Stem Fixing 16mm Screws (Sets of 3) 0˚ 0mm Stack BT-C028-14 Cervélo CS028 Stem NOTE: Refer to page 25 for 5mm Stack BT-C028-20 80mm ST-CS028-80 installation instructions of 10mm Stack BT-C028-25 90mm ST-CS028-90 the stack or pitch adjust Bar Fixing Screw - Handlebar Fixing Nuts (L + R) 15mm Stack BT-C028-30 100mm ST-CS028-100 wedge kits. M5 x 16mm for 2.5mm stack 5mm Stem Spacers x6 20mm Stack BT-C028-35 110mm ST-CS028-110 Actual Size - 2.5mm Bar Spacers (L + R) HBP-AB08-2.5MM SS-C028-KIT 25mm Stack BT-C028-40 120mm ST-CS028-120 30mm Stack BT-C028-45 130mm ST-CS028-130 - M5 x 16mm Bolts (x4) 5 6 HANDLEBAR COMPONENTS - PITCH ADJUST FORK & HEADSET COMPONENTS 2.5˚ Pitch Adjust Kit NOTE: The S5 headset Fit Top Bearing Dust assembly does not require a Seal to Fork Topper Your Cervélo frame & fork have been compression ring. before installation. designed to work together. Do not attempt to install an alternative fork. 2.5˚ - Handlebar Fixing Nut (L + R) for 2.5˚ rotation Preload Cone - 2.5˚ Pitch Adjust Wedge (L + R) Fixing Screw HBP-AB08-2.5DEG M6 x 18mm 16mm - M5 x 16mm Bolts (x4) Preload Cone Fork Topper Fixing Screws x4 M5 x 16 Bar Fixing Screw 5˚ Pitch Adjust Kit Top Bearing M5 x 16mm 1", 36° x 45° Actual Size Complete Handlebar Stack Spacer or Pitch Adjust Wedge kits must be utilized Fork Topper without substitution or combination of parts. Failure to use the specified parts Top Bearing Bottom Bearing and to follow the supplied assembly Dust Seal 1-3/8", 36° x 45° instructions may result in a loss of control while riding and potentially 5˚ serious injury. - Handlebar Fixing Nuts (L + R) FK60 Fork for 5˚ rotation Assembly Kit - 5˚ Pitch Adjust Wedge (L + R) FKA-FK60-SM HBP-AB08-5DEG FKA-FK60-MD - M5 x 16mm Bolts (x4) FKA-FK60-LG 7 8 SMALL PARTS FRAME PREPARATION Designed to accommodate electronic, mechanical and hydraulic controls, the S5 frame is 1. Apply carbon paste to both frame and Lightly grease Rear Derailleur Hanger Fixing engineered to provide seamless integration of all shifting systems, regardless of method or brand. seatpost. Nut and install Rear Derailleur Hanger (DRH- In order to
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