2019 S3 RETAILER ASSEMBLY MANUAL TABLE OF CONTENTS LIST OF TOOLS & SUPPLIES Table of Contents ....................1 ST029 Stem Cut Calculator ................17 This manual outlines a number of procedures Tools Tools Important Information .................. 1 Fork & Stem Installation - Electric ...........18 for making optional adjustments to the S3 which List of Tools & Supplies. 2 Fork & Stem Installation - Mechanical ..........19 differ from the way the bicycle is originally sold Bicycle workstand (types which 2019 S3 Parts List. 3 Headset Adjustment. 20 by Cervélo. The following tools and parts listed are required for these adjustments. These parts secure bike by the seatpost, or Philips-head screwdriver Frame Features. 4 Stem Tightening .....................21 are only available for purchase through Cervélo pro-type stand with fork mount) Handlebar & Stem Components ............... 5 Handlebar Cable Routing - Electric. 22 retailers. Cervélo strongly recommends that Fork & Headset Components ................ 6 Handlebar Cable Routing - Mechanical. 23 all assembly and adjustment procedures be Torque wrench(es) with 2.5Nm to Slot-head screwdriver Small Parts ....................... 7 Di2 Battery Installation. 24 performed by an authorized Cervélo retailer. 15Nm range and adaptors: Frame Preparation .................... 8 Handlebar Cable Routing - Electric. 24 S3 Assembly Overview ................... 9 Electric Cable Installation ...............25 All parts available for separate purchase are noted in this manual with Cervélo part numbers listed Rear Brake Installation .................11 Mechanical Cable Installation ..............26 Pedal wrench Electric & Mechanical Cable Overview. 12 Seatpost Assembly . 27 in ALL - CAPS FORMAT, with a full listing provided Allen (Hex) head inserts: Electric Cable Routing. 13 Seatpost Cutting Instructions ..............28 on page 3. 2mm, 2.5mm, 3mm, 4mm, Mechanical Cable Routing. 14 Frame Protection Installation ..............29 5mm, 6mm, 8mm, 10mm ST029 Stem Stack .....................15 Tire Clearance. 30 NOTE: All non-proprietary components 4th hand brake cable tool ST029 Stem Cutting Instructions .............16 such as those from Shimano or SRAM are available from your local distributor. Cable cutters Di2 wire tool – Shimano NOTE: This manual was developed to compliment the Cervélo General User IMPORTANT INFORMATION Manual, and is intended as a supplement to the assembly and installation Pliers Good quality bicycle grease This manual is intended to assist Cervélo retailers in setting up and customizing the 2019 S3 bicycle. NOTE: Cervélo strongly recommends that instructions supplied by the component This manual is not intended for consumer use, and requires the use of the specified tools to ensure all assembly and adjustment procedures manufacturers (provided with this proper assembly. be performed by an authorized Cervélo bicycle). retailer. If you are a Cervélo S3 Failure to use the specified parts and to follow the supplied assembly instructions may result in a loss consumer/purchaser reading this manual of control while riding and serious injury. This manual is an overview of the steps required to assemble we suggest that before attempting to undertake any of the procedures in this this bicycle and to make any desired modifications as set forth in this manual. This manual assumes manual that you consult your authorized that the retailer has the minimum required background and skill level required of all professional Cervélo retailer, or visit us at bicycle mechanics. See https://www.probma.org/ www.cervelo.com/support 1 CER-S3R-V2 2018-10-23 2 2019 S3 PARTS LIST FRAME FEATURES A guide to the Cervélo S3 frame. Item Description Cervélo Part No. Item Description Cervélo Part No. Item Description Cervélo Part No. ST029 Stem 130mm ST029 Headset 1-1/4 Fork Clamp Wedge Kit FKI-0E0S3 ST-A029-130 HS-A029 w/ Top Cap - 1-3/8 Front Derailleur ST029 Stem Top FDM-0E0 STC-A029 SP20 Carbon Mount w/Bolts Cap Seatpost 0mm SP-SP20-ZERO AB09 Carbon Offset w/Head Rear Brake Booster BRP-BOOSTER HB-AB09-38 Handlebar 380mm SP20 Carbon ST029 Stem 80mm w/ AB09 Carbon Seatpost 25mm SP-SP20-25MM ST-A029-80 HB-AB09-40 Top Cap Handlebar 400mm Offset W/Head ST029 Stem 90mm w/ AB09 Carbon Seatpost Clamp ST-A029-90 HB-AB09-42 SPC-0E0S2S3 Top Cap Handlebar 420mm Assembly S2/S3 Front derailleur wire ST029 Stem 100mm AB09 Carbon ST-A029-100 HB-AB09-44 BB Cable Guide/Cover BBG-0E0 exit hole, electric w/ Top Cap Handlebar 440mm and mechanical ST029 Stem 110mm ST029 Stem Spacer Internal Battery Mount ST-A029-110 SS-A029-KIT MT-BINT w/ Top Cap Kit 40mm Assembly ST029 Stem 120mm ST029 Headset ST-A029-120 BC-A029 w/ Top Cap Bearing Cap Internal Di2 battery mount holes Rear dropout cable exit Bottom bracket cable port 3 4 HANDLEBAR & STEM COMPONENTS FORK & HEADSET COMPONENTS Two-piece Stem Only use the components specified in this manual Cervélo AB09 Spacers allow for for handlebar and stem assembly. Failure to use the Handlebar Fork Clamp installation or specified parts and to follow the supplied assembly 38cm HB-AB09-38 Wedge Fixing removal without instructions may result in a loss of control 40cm HB-AB09-40 Screw re-cabling. while riding and serious injury. 42cm HB-AB09-42 M6 x 45mm 44cm HB-AB09-44 5mm Stem Fork Clamp Spacers Wedge 2.5mm Stem Spacers Do not use a 2.5mm spacer directly under the Headset Bearing stem as it will not Fork Clamp Top Cap fit properly. Wedge Kit FKI-0E0S3 Headset Stem Spacer Bearing Seal Kit (40mm) ST029 Stem Top Cap Ring 1-1/4" HS-A029 STC-A029 5mm Spacer x7 Compression 2.5mm Spacer x2 Ring Top Bearing Cervélo ST029 Stem 1 1/4", 36° x 45° 80mm ST-A029-80 Headset 90mm ST-A029-90 HS-A029 100mm ST-A029-100 1 1/4" Bearing 110mm ST-A029-110 1 3/8" Bearing 120mm ST-A029-120 Top Cap 130mm ST-A029-130 ST029 is compatible with the Your Cervélo frame & fork have been designed to work Bottom Bearing Seal Ring Bar Fly 4 Direct Max and Bar Fly together. Do not attempt to install an alternative fork. 1 3/8", 36° x 45° Compression Ring Direct Mini Garmin stem mounts. 5 6 SMALL PARTS FRAME PREPARATION Designed to accommodate electronic, mechanical and hydraulic controls, the S3 frame is 1. Apply carbon paste to both frame and engineered to provide seamless integration of all shifting systems, regardless of method or brand. seatpost. In order to do so, you will require the parts shown below: 2. Insert Seatpost Clamp (SPC-0E0S2S3) fully into frame so it is fully flush with the top tube. 3. Adjust height and torque to 8Nm maximum. BB Cable Guide/Cover BBG-0E0 Apply Loctite 242 to the fixing screws, and tighten the screws equally to a maximum of 1 Nm. S3 Rear Derailleur Hanger Assembly Front Derailleur DRH-R-2012 Internal Battery Mount Kit Wire Hole Blanking MT-BINT Plug GR-ST-CLOSED With the rear wheel installed in the frame, use a Derailleur Alignment Gauge to ensure the hanger is aligned parallel to the wheel. Hydraulic Hose Guide Rear Derailleur Rear Derailleur Rear Derailleur Brake Cable Stop CBS-TTC-TT-HYDR Press-In Cable Wire Guide Blanking Plug CBS-TTC-TT-MECH Stop (Mechanical) (Electric) (Wireless) Seatpost Clamp Hold the frame using a Clamping the top tube can damage CBS-DRPOUT GR-DRPOUT-GUIDE GR-DRPOUT-CLOSED SPC-0E0S2S3 secured seatpost only. the frame and void your warranty. 7 8 * S3 ASSEMBLY OVERVIEW NOTE: See the following pages for more detailed assembly instructions. 01 03 05 07 09 11 Install lightly greased upper headset bearing With lightly greased bottom bearing in place, Starting at the stem mouth, slide enough Locate shifter and brake housing ends at Install housing with ferrules into the BB Cable into frame. install the fork into the frame and stem shifter housing through the stem steerer system, shifters. Pull and/or push gently, so the hose Guide and route shifter cables accordingly steerer so that it reaches from the shifter to the BB and housing travel through the system. through the frame. Cable Port. Repeat this for 2nd shifter housing, identifying which housing is front and rear. 02 04 06 08 10 Place desired stem spacers, headset top cap, Install the lightly greased M5 x 100mm With shifters installed on bar, attach the bar Connect the remaining controls and complete seal ring and compression ring on stem steerer preload screw. Tighten to remove any play in to the stem ensuring that shifter housings Trim the shifter housing at the leading edge Straighten stem and fix into place by assembly. for later installation. the bearings. are on the appropriate side of the faceplate. of the BB Cable Port and install cables as per tightening the Fork Clamp Wedge. manufacturers instructions. *Mechanical cabling shown 9 10 REAR BRAKE INSTALLATION ELECTRIC & MECHANICAL CABLE OVERVIEW The 2019 S3 uses direct-mount rim brake calipers. With the rear caliper Cervélo has E-Wire Rear Shifter Front Shifter added a brake booster to improve braking performance. This brake booster (BRP- BOOSTER) must be installed to ensure optimum brake performance. The front brake does not require this part. For detailed installation information, please refer to the component manufacturer’s service center or website. Rear Brake Booster BRP-BOOSTER Mechanical Route uncut shifter cable through stem faceplate Electric opening first, down the Route 1400mm Di2 stem-steerer system into E-Wire cable from the frame, and out bottom bottom bracket bracket cable opening. cable opening. through headtube. 11 12 ELECTRIC CABLE ROUTING MECHANICAL CABLE ROUTING These routing illustrations are intended as a supplement to the manufacturer’s These routing illustrations are intended as a supplement to the manufacturer’s installation instructions only. Please refer to the component manufacturer’s service installation instructions only. Please refer to the component manufacturer’s service center or website for further information.