Cerv lo FDM-2017 R5 Retailer Dura-Ace Road Bike Instruction Manual

Cerv lo FDM-2017 R5 Retailer Dura-Ace Road Bike

IMPORTANT INFORMATION

This manual is intended to guide official Cervélo retailers through the assembly and adjustment of the Cervélo R5. This manual outlines the process and procedure associated with the installation of Cervélo components, as well as the routing of shifting and braking control lines only. Proprietary parts referenced in this manual are available only through Cervélo Cycles Inc.

Failure to use the specified parts and follow these assembly instructions, may result in loss of control while riding; and lead to serious injury. This manual is not intended to replace the assembly and service instruction provided by third-party component manufactures, and assumes that the assembler is a trained, professional bicycle mechanic. See https://www.probma.org/

NOTE: Cervélo strongly recommends that all assembly and adjustment procedures be performed by an authorized Cervélo retailer. If you are a Cervélo R5 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

LIST OF TOOLS & SUPPLIES

This manual outlines a number of procedures for making adjustments to the R5 bicycle. The following tools and parts listed are required for these adjustments. Cervélo strongly recommends that all assembly and adjustment procedures be performed by an authorized Cervélo retailer.
NOTE: All non-proprietary components such as those from Shimano or SRAM are available from your local distributor.
NOTE: This manual was developed to compliment the Cervélo General

User Manual, and is intended as a supplement to the assembly and installation instructions supplied by the component manufacturers (provided with this bicycle).

R5 PARTS LIST

BB Blanking Plug

|

GR-BB-140

Rear Derailleur Hanger w/Fixing Nut

|

DRH-WMN112

Shimano Direct Mount RDH w/ Mounting Nut|

DRH-SDM

Threaded Fork Insert w/Fixing Screw

|

QRI-THD

Seat Tube Blanking Plug(1x & Wireless)

|

GR-ST-CLOSED

8mm Seat Tube Di2 Wire Grommet

|

GR-ST-JGW

Brake Hose Guide

|

CBG-DBH

FDM Blanking Screws (1x)

|

SS-FDM-192

Front Derailleur Mount w/ Fixing Screws|

FDM-2017

Dropout Blanking Plug Wireless

|

GR-DRPOUT-CLOSED

Dropout Electric Wire Guide|

GR-DROPOUT-GUIDE

SP24 Seatpost w/ Head 0mm|

SP-SP24-ZERO

SP24 Seatpost w/ Head 15mm|

SP-SP24-15MM

Seatpost Battery Mount|

MT-BINT-SP2

Seatpost Clamp w/ Cover|

SPC-0H0R5

Cervélo Front Aero Thru Axle – Removable Handle|

QRA-AERO2-F

Cervélo Rear Aero Thru Axle – Removable Handle|

QRA-AERO2-R

Cervélo Front Aero Thru-Axle|

QRA-AERO-F

Cervélo Rear Aero Thru-Axle|

QRA-AERO-R

PL -338

D-Shaped Compression Plug

|

FKI-CL005-517A

Accessory Mount Kit (Front)

|

MT-LM-F-004

Accessory Mount Kit (Rear)|

MT-LM-R-003

Chainstay Protector

|

PRO-CS-508

Split Ring 312

|

SR-312

ST31/32 HS Spacer Kit

|

SK-032

Bearing Top Cap – Tall (22mm)

|

BC-506

Bearing Top Cap-Short (7mm)

|

BC-413

SP18 Seatpost w/ Head 25mm

|

SP-SP18-25MM

SMALL PARTS

The R5 frame is engineered to provide seamless integration of electronic shifting systems, regardless of brand. In order to do so, you may require the parts shown below:

HB13 HANDLEBAR
WARNING: Use only original Cervélo components & included hardware specified for handlebar, stem, and fork assembly. Failure to use the specified parts and to follow these instructions may result in a loss of control while riding and serious injury.

ST31 STEM
Cervélo ST31 Stem (Carbon)

• 80mm ST-C031-
• 80 90mm ST-C031-90
• 100mm ST-C031-100
• 110mm ST-C031-110
• 120mm ST-C031-120
• 130mm ST-C031-130

1. Coat the surfaces where the stem body and faceplate contact the handlebar clamping area (as shown right) with carbon assembly paste.
2. Center the handlebar against the stem body and secure it in place by mounting the faceplate and tightening all faceplate fixing screws finger-tight.
3. Tighten the faceplate fixing screws evenly following a star pattern until the upper and lower stem to faceplate gaps are even.
4. Perform final tightening in a star pattern using a torque wrench to 6Nm maximum.

FRAME & COMPONENT PREPARATION

WARNING Hold the frame using a secured seatpost only.
Clamping the top tube can damage the frame and void your warranty.

Press fit Cover over the Seatpost Clamp prior to installing in the frame.
NOTE : Non-use of the Cover may result in seatpost binding due to accumulated debris.

1. Apply carbon paste to the frame and seatpost shaft to be inserted into the frame.
2. Insert the seatpost and the assembled Seatpost Clamp & Cover (SPC-0H0R5) into the frame.
3. Adjust height and torque the Seatpost Clamp to 8Nm maximum.

Lightly grease Rear Derailleur Hanger Fixing Nut and install either Rear Derailleur Hanger (DRH-WMN112) or Direct Mount Rear Derailleur Hanger (DRH- SDM) finger tight. Final tightening will be performed after rear wheel installation.

WARNING Do not final tighten rear derailleur hanger assembly without rear wheel installed. Doing so may result in a misaligned derailleur and poor shifting.

1. Lightly grease supplied M4 fixing screw.
   Install the Threaded Fork Insert (QRI-THD) and fixing screw, tightening only lightly.

2. Without wheel in place, install the axleand tighten until the flange meets the fork 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.

5. Remove axle and wheel, and re-torque the fixing screw to 3Nm.

FRAME & COMPONENT PREPARATION

SEATPOST ASSEMBLY & INSTALLATION

1. Apply a light coat of carbon assembly compound to the upper face of the Seatpost, making sure to cover area around the adjustment slots.
2. Locate saddle rail between Crossbars and Saddle Clamp Base, and place on Seatpost.
3. With alignment washers installed, attach assembly to Seatpost, by tightening lightly greased fixing screws, alternating between the two sides each 1/2 turn. Once saddle is adjusted, tighten fixing screws to a maximum of 8Nm.

FORK PREPARATION & INSTALLATION

1. Apply grease to the bearing pockets and install the upper and lower headset bearings into the frame.
2. Fit the fork provided with your frame into the head tube with the complete headset, required spacers, and the stem.
3. Apply the minimum pressure needed to ensure the assembly is fully seated. Mark the steerer tube at the top of the stem.
4. Remove fork and clearly mark the fork steerer tube at a point 4mm below the first mark. Take care to verify that this measurement is correct as this defines the cut line for the steerer tube.
5. To trim fork steerer, use only a saw suitable for cutting carbon, and a cutting guide.
6. Insert D-Shaped Compression Plug and tighten to hold in place. Do not apply final torque until after the stem is installed.
7. Place Lower Bearing over the fork steerer and insert into the frame from the bottom of the head tube.
8. Install over the steerer in order: Upper Bearing, Split Ring, Bearing Top Cap, Stem Spacers, and Stem. Do not install the Stem Top Cap.
9. Tighten the Compression Plug to 8Nm using a torque wrench.
10. Install the Stem Top Cap and Preload Fixing Screw into the stem. Tighten the Preload bolt only enough to remove all play from the headset, and ensure the bearings rotate freely (typically 1 to 2 Nm)
11. Tighten the stem to fork fixing bolts to 5Nm maximum.

Avoid breathing the dust created during cutting carbon composite materials.
Improper cutting of the steerer tube could cause a failure that may result in severe injury or death.

CAUTION The component parts of the compression plug are side-specific. Re-assembling parts incorrectly may result in loss of preload in the system. Refer to the images shown for correct assembly.

WARNING
Do not torque Compression Plug past the recommended 8Nm maximum. If the Compression Plug requires tightening past 8Nm, please contact Cervélo Customer Service.

BRAKE HOSE ROUTING

These routing illustrations are intended as a supplement to the manufacturer’s installation instructions only. For both hydraulic and mechanical disc brakes, please refer to the component manufacturer’s service center or website for further information.

Route hydraulic brake hose through the frame and fork with the Disc Hose Guide (CBG-DBH). Install and adjust calipers as per manufacturer’s instructions.

ELECTRIC WIRE ROUTING & INSTALLATION

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.

DI2 BATTERY INSTALLATION
The battery for your Shimano Di2 system mounts inside the seat tube using the Seatpost Internal Battery Mount (MT-BINT-SP2). As this is an enclosed location, it is important to test the system prior to final installation.

TIRE/RIM CLEARANCETIRE/RIM CLEARANCE
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 maintain your Limited Lifetime Warranty, a minimum of 4mm of clearance must remain between the tire and any frame element. Due to 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.
2. Measure the space between the seatstays at the top of the tire.
3. Using the smaller of those two numbers (Frame Clearance), subtract 8mm (4mm per side) to determine the maximum Allowable Tire/Rim Dimension.
4. With the tire installed and fully inflated on your wheel, measure the greater of the rim or tire width and ensure it is less than the calculated Allowable Tire/Rim Dimension width to ensure that it fits.

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.

R5 FRAME DETAILS

R5 (FM140)

Bike Name| R5
Model Year| 2022
Serial Number Code| SN140
Frame Code| FM140
Fork Code| FK140
Brake Mount Type| Flat Mount Disc
Chainstay Height (Flat Mount)| 25mm
Frame Sizes| 48/51/54/56/58/61
Wheel Size| 700c
BB Type| BBRight
Headset Type| Integrated 1-1/4″ x 1-1/2″
R5 (FM140)

Upper Headset Bearing Dimensions| 1-1/4″, 34×46.8×7, 45°x45°
Lower Headset Bearing Dimensions| 1-1/2″, 40×51.8×7.5, 36°x45°

Seatpost

| SP-SP24-ZERO, SP-SP24-15MM, SP-SP18-25MM
Seatpost Clamp| SPC-0H0R5
Rear Derailleur Hanger| DRH-WMN112
Rear Derailleur Hanger (Shimano DM)| DRH-SDM
Front Derailleur Hanger| FDM-2017
Front Thru-Axle Dimensions| 12 x 100MM
Rear Thru-Axle Dimensions| 12 x 142MM
Fork Dropout Insert| QRI-THD
Maximum Tire Width (Actual)| 34mm with 4mm clearance*

Tire measurements shall be taken at the widest point of the tire when it is installed on the rim and inflated. 4mm of distance is required between the tire and any frame or fork element.

R5 FRAME GEOMETRY

R5 (FM140)| 48cm| 51cm| 54cm| 56cm| 58cm| 61cm
---|---|---|---|---|---|---
Reach| 363mm| 371mm| 380mm| 389mm| 398mm| 407mm

Stack

|

497mm

|

522mm

|

547mm

|

572mm

|

597mm

|

622mm

Bottom Bracket Drop|

74.5mm

|

74.5mm

|

72mm

|

72mm

|

69.5mm

|

69.5mm

Chainstay Length|

410mm

|

410mm

|

410mm

|

410mm

|

410mm

|

410mm

Seat Tube Angle

|

73˚

|

73˚

|

73˚

|

73˚

|

73˚

|

73˚

Head Tube Angle

|

71˚

|

72˚

|

73˚

|

73˚

|

73˚

|

73˚

Fork Length (Axle to Crown)|

373mm

|

373mm

|

373v

|

373mm

|

373mm

|

373mm

Fork Offset

|

57.5mm

|

51.5mm

|

45.5mm

|

45.5mm

|

45.5mm

|

45.5mm

Front Center

|

574mm

|

576mm

|

578mm

|

594mm

|

611mm

|

628mm

Head Tube Length|

93mm

|

114mm

|

137mm

|

163mm

|

192mm

|

218mm

Wheelbase

|

972mm

|

974mm

|

977mm

|

994mm

|

1011mm

|

1028mm

Standover Height|

695mm

|

724mm

|

755mm

|

778mm

|

800mm

|

824mm

Seat Tube Length|

403mm

|

434mm

|

463mm

|

486mm

|

503mm

|

526mm

Top Tube Length

|

515mm

|

531mm

|

548mm

|

564mm

|

581mm

|

598mm

CERVÉLO CUSTOMER SUPPORT

Contacting Customer Support
Visit www.cervelo.com/contact-us to submit a question to Cervélo.

Product Registration
Visit www.cervelo.com/support to register your Cervélo bicycle through your MyCervélo account.

Manuals
Visit www.cervelo.com/product-manuals for additional information on Cervélo products.

Warranty
Visit www.cervelo.com/warranty for information on Cervélo’s warranty policy.

www.cervelo.com

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