cervelo P-SERIES Retailer Disc Instruction Manual

P-SERIES RETAILER ASSEMBLY MANUAL

IMPORTANT INFORMATION

This manual is intended to guide official Cervélo retailers, through the assembly and adjustment of the Cervélo P-Series. 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 manufacturers 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 P- Series  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 optional adjustments to the P-Series bicycles. 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: 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: All non-proprietary components are available from your local distributor.

P-SERIES PARTS LIST

SMALL PARTS

Designed to accommodate electronic, mechanical, and hydraulic controls, the P-Series 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:

FRAME PREPARATION

WARNING

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

1. Lightly grease supplied M4 fixing screw. Install the Threaded Fork Insert (QRI-THD) and fix the screw, tightening only lightly.
2. Without the 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 the wheel. Reinstall axle and tighten to 12-15Nm.
5. Remove axle and wheel, and re-torque the fixing screw to 3Nm.

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).

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.

Clean the chainstay using isopropyl alcohol. Install the Chainstay Protector (PRO-CS-P) by removing adhesive backing, and fixing the guard to the frame. The bottom rearward
edge should be approximately 15mm from the edge of the Rear Derailleur Hanger Nut.

WARNING

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

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.

WARNING
Avoid breathing the dust created during cutting carbon composite materials.

WARNING
Improper cutting of the steerer tube could cause a failure that may result in severe injury or death.

WARNING
Do not exceed 51 mm maximum total spacer height, including the Bearing Top Cap.

CAUTION
Do not exceed 5mm total spacers above the stem.

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.

Install D-Shaped Compression Plugin fork steerer and lightly tighten. Apply rated torque of 8Nm following stem and spacer installation.

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

NOTE: This diagram is for assembly reference only. During complete assembly, all hoses and control cables will be present.

Ensure the gap in the Split Ring and Bearing Top Cap align to the front center of the head tube.

WARNING
Your Cervélo frame & fork have been designed to work together. Do not substitute a different size fork without first consulting Cervélo Customer Service to confirm compatibility with your frame.

BRAKE HOUSING 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.

Brake

Route rear brake hose from chainstay through the down tube and up through the GU02 Base.

It is recommended to include 20mm-25mm of additional brake hose length to the amount required for the final customer fit. Doing so will permit sufficient length for disassembly and service purposes.

1. Measure customer fit
2. Add an additional 20-25mm of spacers
3. Cut and install brake hoses
4. Remove extra spacers
5. Complete assembly

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

ELECTRIC WIRE ROUTING

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.

ELECTRIC WIRE INSTALLATION

CAUTION

Ensure the Di2 wires are routed on the opposite side of the fork steerer tube from the front brake hose so that they are free to move. If the Di2 wires become pinched between the brake hose and the top cap the cables can be damaged and affect shifting function.

MECHANICAL CABLE ROUTING

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.

ELECTRIC WIRE INSTALLATION

CAUTION

Ensure the Di2 wires are routed on the opposite side of the fork steerer tube from the front brake hose so that they are free to move. If the Di2 wires become pinched between the brake hose and the top cap the cables can be damaged and affect shifting function.

MECHANICAL CABLE ROUTING

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.

MECHANICAL CABLE INSTALLATION

GU02 STEM COVER ASSEMBLY INSTALLATION

After cabling is complete, install the two-piece GU02 Cable Guide to secure housing or Di2 cable and brake hose. Install the GU02 Stem Cover to finish. Torque to 1Nm.

TOP TUBE SMART PAK INSTALLATION

SEATPOST ASSEMBLY

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 a saddle.
3. Torque to 12Nm.
4. Determine desired angle, and attach water bottle mount to Seatpost slug with M5 fixing screw.
5. Torque to 4Nm.

SEATPOST CUTTING INSTRUCTIONS

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

1. Taking care to maintain the minimum required Seatpost insertion of 6.5cm and a maximum of 8.5cm, carefully measure and use a light-colored 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, the final length should allow for a minimum of 6.5cm of seat post 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.

SEATPOST DI2 BATTERY INSTALLATION

Press the Di2 battery into the Seatpost Battery Mount (MT-BINT-SP) and attach the E-Wire according to the manufacturer’s 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.

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 widest of the rim or tire width to ensure that it fits.

WARNING
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.

AERO THRU-AXLE INSTALLATION

To secure wheels, install the greased axle, through the dropout 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 the 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 the manufacturer’s instructions.

NOTES

P-SERIES RETAILER ASSEMBLY MANUAL
CER-PS-V3 2021-04-06
www.cervelo.com

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