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Cervélo S5 2023 User Manual

Cervélo S5 2023
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2023 S5 RETAILER ASSEMBLY MANUAL
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Cervélo S5 2023 Specifications

General IconGeneral
Frame MaterialCarbon
ForkCervélo All-Carbon, Tapered S5 Fork
BrakesShimano Dura-Ace R9270 Hydraulic Disc
HandlebarCervélo HB14 Carbon
ShiftersShimano Dura-Ace Di2 R9270
Front DerailleurShimano Dura-Ace Di2 R9250
Rear DerailleurShimano Dura-Ace Di2 R9250
ChainShimano CN-M9100
GroupsetShimano Dura-Ace Di2
WheelsetReserve 52/63
TiresVittoria Corsa TLR
SeatpostCervélo SP20 Carbon
SaddleFizik Argo R5
CranksetShimano Dura-Ace
CassetteShimano Dura-Ace, 11-30

Summary

Important Information

List of Tools & Supplies

2023 S5 Parts List

Small Parts

Fork & Headset Components

S5 Fork

Details the specific Cervélo S5 fork models for different frame sizes.

Upper Bearing Gap Spacer

Component for headset assembly, ensuring proper fit and alignment.

Preload Cone

Part of the headset assembly, used with the tension rod.

Tension Rod

Component for headset tension adjustment.

Tension Rod Bumper

Part of the headset tension rod assembly.

Lower Bearing

Component for headset assembly, typically 1-3/8".

Handlebar & Stem Components

Cervélo HB14 Handlebar

Details the available sizes for the Cervélo HB14 handlebar.

Cervélo C035 Stem

Lists the available lengths for the Cervélo C035 stem.

Stem Fixing Screws

Specific screws used for stem installation and adjustment.

Handlebar Mounting Inserts

Components that attach the handlebar to the stem.

C035 Stem Spacers

Spacers used for adjusting handlebar height and stem angle.

T25 Torx Fixing Screws

Screws used for securing stem components.

Frame & Fork Preparation

Install Front Derailleur Mount

Procedure for installing the front derailleur mount or blanking plate.

Threaded Fork Insert

Installation of the threaded insert into the fork dropout.

Rear Derailleur Hanger

Installation of the rear derailleur hanger (direct mount or standard).

Chainstay Protector

Installation of the chainstay protector for frame protection.

Upper Bearing Gap Spacer Pre-forming

Pre-forming the upper bearing gap spacer before fork installation.

Tension Rod Bumper Installation

Installing the tension rod bumper onto the tension rod.

Fork Installation

Install Headset Bearings

Applying grease and installing upper and lower headset bearings into the frame.

Orient Fork

Positioning the fork correctly relative to the frame and headset.

Tilt and Rotate Fork Top

Maneuvering the fork top over the upper bearing and head tube.

Align Fork Crown

Settling the fork crown into the lower bearing for alignment.

Install Upper Bearing Gap Spacer

Securing the upper bearing gap spacer with fixing screws.

Brake Hose Routing

Route Rear Brake Hose

Routing the rear brake hose through the frame and head tube.

Run Front Brake Hose

Routing the front brake hose from the fork blade to the head tube.

Route Hydraulic Brake Hose

Using the Disc Hose Guide for routing hydraulic brake hoses.

Headset Assembly

Apply Grease to Preload Cone

Greasing and installing the preload cone.

Grease Tension Rod

Greasing the threaded end of the tension rod and installing it.

Tighten Fork Fixing Screw

Tightening the fork fixing screw to complete headset installation.

Di2 Battery Installation

Attach Battery to Mount

Securing the Di2 battery to the internal battery mount.

Insert Battery Holder

Inserting the battery and holder assembly into the down tube.

Tighten Fixing Screws

Applying Loctite and tightening screws for the battery holder.

Electric Wire Routing & Installation

Route E-Wire

Routing the electronic wires (E-Wire) through the frame.

Cap Bottom Bracket Cable Port

Using the BB Blanking Plug to seal the bottom bracket cable port.

Install SD300 Grommet

Installing the Shimano EW-SD300 grommet for wired systems.

Install Blanking Plug

Installing the blanking plug for wireless shifting systems.

Stack Adjustment

Spacer Stack Adjustment

Adjusting the spacer stack height for desired fit.

Base Position

Description of the base position for stem and handlebar setup.

Stem Installation

Grease Stem Components

Applying grease to fixing screws, stem, and spacers.

Assemble Washers and Tighten Screws

Installing washers and torquing stem fixing screws.

Check Gap Between Bar and Spacers

Ensuring proper fit and gap elimination during tightening.

Re-tighten Fork Fixing Screw

Final tightening of the fork fixing screw after stem installation.

Handlebar Installation

Grease Fixing Screws

Applying grease to handlebar fixing screws before attachment.

Attach Handlebar to Stem

Securing the handlebar to the stem using mounting inserts.

Handlebar and Stem Rotation

Note on the allowed rotation range for handlebar and stem.

Before Final Fitting

Stem Spacer and Cable Length

Consideration of stem spacers and cable length for fit adjustments.

Hydraulic Hose Length

Recommendations for additional hydraulic brake hose length.

Reinstalling Stem with No Spacers

Steps for reinstalling the stem when using no spacers.

Seatpost Assembly

Install Crossbar and Adjustment Dial

Installing the crossbar and adjustment dial in the seatpost cutout.

Install Spherical Washer

Correct orientation of the spherical washer on the cap screw.

Install Saddle Clamp Base

Procedure for installing the lower saddle clamp base.

Position Saddle Rails

Placing saddle rails between the upper and lower clamping surfaces.

Establish Saddle Angle

Adjusting saddle angle using the adjustment wheel.

Tighten Angle Adjusting Screw

Securing the saddle angle by tightening the adjusting screw.

Seatpost Cutting Instructions

Mark Cut-off Location

Measuring and marking the seatpost for cutting.

Cut Seatpost

Procedure for cutting the seatpost using a saw guide.

Remove Fraying/Burring

Sanding the cut end to remove any imperfections.

Mark 45 Degree Chamfer

Marking the seatpost for a 45-degree chamfer cut.

Cut 45 Degree Chamfer

Cutting the 45-degree chamfer on the trailing edge of the seatpost.

Aero Thru-Axle Installation

Install Greased Axle

Inserting and aligning the axle through the dropouts and hub.

Tighten Front Axle

Torquing the front axle to the specified Nm range.

Tighten Rear Axle

Torquing the rear axle to the specified Nm range.

Final Tightening on Rear Derailleur Hanger Nut

Performing final tightening on the rear derailleur hanger nut.

Tire/Rim Clearance

Measure Chainstay Space

Measuring clearance between chainstays at the bottom bracket.

Measure Seatstay Space

Measuring clearance between seatstays at the top of the tire.

Determine Allowable Tire/Rim Dimension

Calculating the maximum allowable tire/rim dimension.

Ensure Tire Width Fits

Verifying the tire width is less than the calculated dimension.

Intended Use of the S5 Bicycle

S5 Torque Specifications

Frame Torque Specifications

Torque values for frame components like bottom bracket and derailleur hanger.

Fork Torque Specifications

Torque values for fork components like headset and dropout inserts.

Stem Torque Specifications

Torque values for stem installation to fork and handlebar.

Handlebar Torque Specifications

Torque values for handlebar components like levers and mounts.

Seatpost Torque Specifications

Torque values for seatpost clamp and saddle clamp.

Wheel Torque Specifications

Torque value for Cervélo aero thru-axles.

Pedal Torque Specifications

Torque value for pedal installation.

Cervélo Customer Support

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