Cerv lo P5 Disc Ultegra Di2 Triathlon Bike Instruction Manual

2023 P5 RETAILER ASSEMBLY MANUAL

IMPORTANT INFORMATION

This manual is intended to guide official Cervélo retailers through the assembly and adjustment of the Cervélo P5. 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 or its authorized distributors. Failure to use the specified parts and follow these assembly instructions may result in loss of control while riding, leading 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/ 

LIST OF TOOLS & SUPPLIES

This manual outlines a number of procedures for making adjustments to the P5 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) .

NOTE: Cervélo strongly recommends that all assembly and adjustment procedures be performed by an authorized Cervélo retailer . If you are a Cervélo P5 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

| Bicycle work stand (types which secure bike by the seatpost, or pro-type stand with fork mount)
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| Torque wrench(es) with 2.5Nm to 15Nm range and adaptors:
| Allen (Hex) head inserts: 2mm, 2.5mm, 3mm, 4mm, 5mm,6mm, 8mm, 10mm
| Open ended wrenches: 7mm, 8mm, 10mm, 17mm
| Cable cutters
| Pliers
| Phillips-head screwdriver
| Slot-head screwdriver
| Pedal wrench
| Brake rotor lock ring tools
| Hydraulic bleed kit
| Isopropyl alcohol
| Di2 wire tool – Shimano
| Good quality bicycle grease & carbon assembly compound
| Saw cutting guide (Park Tool SG-7.2 or equivalent)
| Hacksaw (with carbon and aluminum specific blades)

P5 PARTS LIST

SMALL PARTS

Designed to accommodate electronic, mechanical and hydraulic controls, the P5 frame is 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. Not all parts will be used, depending on the groupset fitted to the bicycle.

FRAME PREPARATION

1. Apply carbon paste to both frame and seatpost.
2. Insert Seatpost Clamp (SPC-0E0P) fully into frame so it is fully flush with the top tube.
3. Adjust height and torque to 8Nm maximum.

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

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).

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 axle and 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.

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.

Clean the chainstay using isopropyl alcohol. Install the Chainstay Guard by removing adhesive backing, and fixing the guard to the frame. The bottom rearward edge should  be approximately 15mm from theedge of the Rear Derailleur Hanger Fixing Nut.

FORK PREPARATION

Note: It is recommended that you familiarize yourself with the steering system before complete installation, by performing a trial assembly without hoses or control cables present .

Fork Rotation Stop
FKI-P5FRS-48
FKI-P5FRS-51
FKI-P5FRS-54
FKI-P5FRS-56
FKI-P5FRS-58
Clean the fork surface with isopropyl alcohol and let dry. Remove the backing paper and firmly affix the adhesive side of the Fork Rotation Stop flush to the rearward face of the bayonet fork.
WARNING
Not installing the Fork Rotation Stop may result in damage to the frame and void your warranty.

BRAKE H0SE ROUTING

It is recommended that the rear hydraulic brake hose or brake cable housing is installed first. 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 or mechanical brake housing through the frame and fork with the Disc Hose Bushings (CBG-DBH). Install and adjust calipers as per manufacturer’s instructions.

ELECTRIC WIRE ROUTING

It is recommended that electric cabling 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.

MECHANICAL CABLE ROUTING

It is recommended that mechanical cabling 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.

FORK INSTALLATION

1. Check the Basebar, and headset components to make sure there are no sharp or rough edges on any of the surfaces which could cut or damage the steerer tube. If any rough edges are detected, have the components repaired (sharp edges removed) or replaced before proceeding.

2. Press the lightly greased upper and lower headset bearings into the frame, and insert the fork into the head tube.

3. Slide the compression ring onto the steerer, and down until it fully seats in the top of the upper headset bearing. The split in the Split Ring must be oriented toward to left or right side of the steerer – never towards the front or back.

4. Clean the seal seat of the Basebar with isopropyl alcohol, and adhere the Seal Ring to the Basebar.

5. Slide the Basebar onto the fork steerer oriented as shown. Note the Basebar must engage both the fork steerer and the external steerer. Do not use grease on the fork steerer. The use of Tacx Carbon Assembly Compound™or equivalent friction paste is recommended to help secure the stem.

6. Lightly grease the threads of the Preload Fixing Screw.
   NOTE: This diagram is for assembly reference only . During complete assembly, hoses and control cables will be present .

7. Place the Stem Cap on top of the Basebar and insert the greased Preload Fixing Screw through the cap to engage with the star nut. Tighten the bolt only enough to remove all play from the headset, and ensure that the fork still rotates freely.

8. Tighten both the greased Basebar Clamping Screw and Fork Clamping Screw using a torque wrench. Tighten the bolts to a maximum of 5Nm.

9. As a final check ensure that the fork rotates freely in the head tube without any play or binding. If any problem is detected, loosen the bolts and perform steps 7) to 8) again.
   WARNING
   Do not exceed the maximum torque specifications listed in this manual. Correct tightening force on fasteners – nuts, bolts, screws – on your bicycle is very important. Too little force, and the fastener may not hold securely. Too much force, and the fastener can strip threads, stretch, deform or break. Either way, incorrect tightening force can result in component failure, which can cause you to lose control and fall.

EX10 RISER & HB11 BASEBAR ROUTING

EX10 RISER POST CUTTING INSTRUCTIONS

Achieving the lowest possible stack may require trimming the Riser Post. If using a cut Riser Post ensure there is always a minimum of 70mm inserted inside the frame.

1. Use a light coloured grease pencil to accurately mark the cut-off location on the Riser Post. See table below for the exact number based on frame size.
2. Insert the Riser Post 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; proceed with cutting the stem steerer (as per Park Tool’s instructions).
4. Carefully file the cut end removing any rough edges.

WARNING
If trimming is required, final length should allow for a minimum 70mm of Riser Post remaining in the frame. Failure to meet this requirement, may result in damage to the frame not covered by warranty policy, or serious injury to rider.

EX10 RISER ASSEMBLY

Attach Riser Pad Mount and Riser Post to Tilt Adjust Plate using four lightly greased M6 fixing screws. Torque to 6Nm.

ARM CUP & PAD INSTALLATION

1. Clean Arm Cups with isopropyl alcohol and apply Velcro sheets.
2. Attach Arm Cups to the Riser Post using two lightly greased M5 Fixing Screws.
3. Torque Fixing Screws to 4Nm.
4. Align the Arm Pads with the Arm Cups and press to secure them to the Velcro sheets.

ARM CUP POSITIONS

EX10 EXTENSION ASSEMBLY
NOTE: This diagram is for assembly reference only . During complete assembly, hoses and control cables will be present . Install and adjust extensions. Torque to 3Nm.

EX10 EXTENSION ANGLE ADJUSTMENT

The Riser Pad Mount and Extensions can be set in one of four discrete angles: 0˚, 5˚, 10˚, 15˚.

1. Remove both Tilt Adjust Fixing Screws and Tilt Adjust Plate.
2. Position Tilt Adjust Plate in one of two orientation, and install lightly greased fixing screws in appropriate holes.
3. Torque to 6Nm.

EX10 RISER POST CLAMP

1. Apply a light coat of carbon assembly compound to Riser Post, and install into fork.
2. Apply a light coat of carbon assembly compound to chevron and rear surfaces of the Riser Post Clamp, and install at rear of Riser Post ensuring that the clamp is fully inserted, and no chevrons are visible.
3. Torque to 8Nm.
   NOTE: This diagram is for assembly reference only . During complete assembly, hoses and control cables will be present .

ELECTRIC WIRE INSTALLATION

MECHANICAL CABLE INSTALLATION

SMARTPAK 400 INSTALLATION

SMARTPAK 100 INSTALLATION

SEATPOST ASSEMBLY

SEATPOST ASSEMBLY

SEATPOST CUTTING INSTRUCTIONS

Note: It is essential that all Cervélo Aero Seatposts, have a 45 degree chamfer cut on the rear trailing edge of the post . If trimmings required after fitting, the following method is recommended.

1. Taking care to maintain the minimum required seatpost insertion of 6.5cm and 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 a fine tooth blade with greater than 32 teeth per inch); proceed with cutting the Seatpost (as per Park Tool’s instructions).
4. Use fine grit sandpaper to carefully remove any fraying or burring from the cut end. Reposition clamp approximately 10cm from the cut end.
5. With a grease pencil, mark a point 1cm from the cut end on the trailing edge of 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.

WARNING
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 damage to the frame not covered by warranty policy, or serious injury to rider.

SEATPOST DI2 BATTERY INSTALLATION

Press the Di2 battery into the Seatpost Battery Mount (MT-BINT-SP) and attach the E-Wire according to the manufacturers instructions. Insert the assembled battery and battery mount into the seatpost.

AERO WATER BOTTLE INSTALLATION

Attach Aero Water Bottle (WB-WB01) cage to frame and torque M5 x 18mm fixing screws to 2Nm.

BASEBAR GRIP INSTALLATION

TIRE 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 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 wheel, measure the tire width to ensure that it fits.
   WARNING
   Contact between the tire 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.

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.
WARNING
To ensure rider safety, it is critical to install the Cervélo Aero Thru-Axle correctly. Failure to do so may result in an accident with potential for serious injury to the rider.

Perform final tightening on Rear Derailleur Hanger Nut using a 17mm wrench . Torque to 12-15Nm . This action is unique to initial assembly, and should not require additional adjustment .
WARNING
Adjust brakes as per manufacturer’s instructions.

APPENDIX: EX11 AEROBAR ASSEMBLY
Apply a light coating of Carbon Assembly Paste to the clamping area of the Extensions, and secure Extension Wedge by tightening the lightly greased M6 x 20mm fixing screw to 4Nm.

EX11 MONORISER POST CUTTING INSTRUCTIONS

Achieving the lowest possible stack may require trimming the Monoriser Post. If using a cut Riser Post ensure there is always a minimum of 70mm remaining inside the frame.

1. Use a light coloured grease pencil to accurately mark the cut-off location on the Monoriser Post. See table below for the exact number based on frame size.
2. Insert the Monoriser Post in the Park Tool SG-6 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; proceed with cutting the stem steerer (as per Park Tool’s instructions).
4. Carefully file the cut end removing any rough edges.

WARNING
If trimming is required, final length should allow for a minimum 70mm of Monoriser Post remaining in the frame. Failure to meet this requirement, may result in damage to the frame not covered by warranty policy, or serious injury to rider.

EX11 ARM CUP AND PAD INSTALLATION

1. Clean Arm Cups with isopropyl alcohol and apply Velcro sheets.
2. Attach Arm Cups to the Riser Post using two lightly greased M5 Fixing Screws.
3. Torque Fixing Screws to 4Nm.
4. Align the Arm pads with the arm cups and press to secure them to the Velcro sheets.

EX11 ARM CUP POSITIONS

EX11 MONORISER ASSEMBLY INSTALLATION

1. Apply a light coat of carbon assembly compound to Riser Post, and install into fork.
2. Apply a light coat of carbon assembly compound to chevron and rear surfaces of the Riser Post Clamp, and install at rear of Riser Post ensuring that the clamp is fully inserted, and no chevrons are visible.
3. Torque to 8Nm.

EX11 MONORISER & HB11 BASEBAR ROUTING

EX11 MONORISER & HB11 BASEBAR ROUTING

INTENDED USE OF THE P5 BICYCLE

WARNING
Understand your bike and its intended use. Choosing the wrong bicycle for your purpose can be hazardous. Using your bike the wrong way is dangerous.
No one type of bicycle is suited for all purposes. Your retailer can help you pick the “right tool for the job” and help you understand its limitations. There are many types of bicycles and many variations within each type.
There are many types of mountain, road, racing, hybrid, touring, cyclocross and tandem bicycles. There are also bicycles that mix features. For example, there are road/racing bikes with triple cranks. These bikes have the low gearing of a touring bike, the quick handling of a racing bike, but are not well suited for carrying heavy loads on a tour. For that purpose you want a touring bike.
Within each of type of bicycle, one can optimize for certain purposes. Visit your bicycle shop and find someone with expertise in the area that interests you. Do your own homework. Seemingly small changes such as the choice of tires can improve or diminish the performance of a bicycle for a certain purpose.
NOTE: Usage conditions are generalized and evolving . Consult your retailer or Cervélo Customer Service about how you intend to use your bike .
NOTE: Cervélo bicycles are tested to a maximum combined bicycle/rider/luggage weight of 100kg . Components have different weight limits, and if replaced can alter the maximum safe bike weight limit . Consult your retailer or Cervélo Customer Service about what components are appropriate for your bicycle .
Maximum Weight Limit – Cervélo P5

*Seat bag / water bottles / bento bag / handlebar bottle / storage mounts only High-Performance Road – Condition 1
Bikes designed for riding on a paved surface where the tires do not lose ground contact.
Intended To be ridden on paved roads only.
Not Intended For off-road, cyclocross, touring with racks or panniers, or mounting child seats or trailers.
Trade-Off Material use is optimized to deliver both light weight and specific performance. You must understand that (1) these types of bikes are intended to give an aggressive racer or competitive cyclist a performance advantage over a relatively short product life, (2) a less aggressive rider will enjoy longer frame life, (3) you are choosing light weight (shorter frame life) over more frame weight and a longer frame life, (4) you are choosing light weight over more dent resistant or rugged frames that weigh more. All frames that are very light need frequent inspection. These frames are likely to be damaged or broken in a crash. They are not designed to take abuse or be a rugged workhorse.

P5 TORQUE SPECIFICATIONS

Correct tightening torque of threaded fasteners is crucial to your safety. Always tighten fasteners to the correct torque. In case of a conflict between the instructions in this manual and those provided by a component manufacturer, consult with your retailer or with Cervélo Customer Service for clarification. Fasteners that are too tight can stretch and deform. Fasteners that are too loose can move and fatigue. Either mistake can lead to a sudden failure of the fastener. Use only a correctly calibrated torque wrench to tighten critical fasteners on your bike. Carefully follow the torque wrench manufacturer’s instructions on how to set and use the tool for accurate results. Ensure you read all relevant documentation and have the correct tools prior to attempting any adjustments yourself.
It is recommended that you permit your retailer to perform the following adjustments, as they have the proper tools and experience to ensure it is done correctly.
Prior to assembling and tightening any bolts, all threads must be generously greased with a quality, non-lithium type grease unless the bolt is pre-coated with Loctite® thread locker. All bolts should have either grease or Loctite – but never both. Torque wrenches with scale appropriate for the particular torque setting are strongly recommended for tightening all threaded fasteners.
Cervélo strongly recommends the use of carbon assembly compound/friction paste for all areas of clamping to carbon fiber, such as the seatpost to frame, the stem to fork, and the handlebar to stem joints. Benefits to using this paste include reduced corrosion potential, and a decrease in required clamping force needed to support a given load. The paste should be evenly spread on the carbon surface under the clamped area, and the applicable bolt tightened as per the following recommendations.
WARNING: In case of a disagreement or a conflict between the following list and any supplier literature on recommended torque values for original equipment components, please contact Cervélo Customer Support for review and clarification of the required torque prior to installation .

Frame & Po*
Bottom bracket cable guide bolt| 1 Nm|
Rear derailleur hanger fixing nut| 12 to 15 Nm| Finger tight prior to rear wheel installation. final torque to approximate torque using open ended wrench
Computer mount (Barfly 4 Spoon)| 3 Nm|
Riser mount Di2 junction fixing screw| 42Nm|
Stern
Riser post clamp| 8 Nm|
Preload compression plug in fork stetter| 8 Nm|
Stem top cap| 1 to 2 Nm| Apply enough torque to remove play while ensuring free rotation of the headset
Stem cover to :item| 1Nm|
Basebar clamping screw & Fork clamping screw| 5Nm|
Actobar extensions – Cervelo acrobat
Extension Clamp| 4 Nm|
Arm Pad Carrier| 4 bins|
Seatpost Clamp (frame to seinpost)
.ledge clamp – rourded rfront| SNP.| Use carbon assembly compound between the :compost and the frame
Saddle Clamp iseatpost head bolts) -HeroTriaT
Saddle clamp bolt:| 12 Nm|
Seatpost head to rail connector bolt| 6 to 7 Nm|

P5 FRAME DETAILS

P5 ( F11131)

Bike Name| P5
Model Year| 2019
Serial Number Code| SNPSD
Frame Code| FM131
Fork Code| FK63
Brake Mount Type| Flat Mount Disc
Chainstay Height (Flat Mount)| 30mm
Frame Sizes| 48/51/54156$8
Wheel Size| 700C
BB Type| Bright
Headset Type| Integrated 1″X LIB”

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. *

P5 (F11131)

Upper Headset Bearing Dimensions| 1″, 272x38x6.5, 36N45°
Lower Headset Bearing Dimensions| 1-36″, 37×48.9×6.5, 36″x45°
Seatpost| SP-SP23
Seatpost Clamp| SPC-OEOP
RD Hanger| DRH-WMN112
RD Hanger (Shimano DM)| DRH-SDM
FD Hanger| FDM-0E0
Front Axle Dimensions| 12 X 100mm
Rear Axle Dimensions| 12 X 142mm
Fork Dropout Insert| QRI-THD
Maximum Tire Width (Actual)| 28mm with 4mm clearance’

P5 FRAME GEOMETRY

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 My Cervélo 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.
2023 P5 RETAILER ASSEMBLY MANUAL
CER-P5D-V2 2023-02-20 www.cervelo.com

Documents / Resources

| Cerv lo P5 Disc Ultegra Di2 Triathlon Bike [pdf] Instruction Manual
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