2019 Cervélo P5 Retailer Assembly Manual

Important Information

This manual is intended for official Cervélo retailers to guide the assembly and adjustment of the Cervélo P5. It details the installation and routing of Cervélo components and control lines (shifting and braking). Proprietary parts are exclusively available through Cervélo Cycles Inc.

Warning: Failure to use specified parts and follow these instructions may lead to loss of control while riding, resulting in serious injury. This manual supplements, but does not replace, third-party component manufacturer instructions. It assumes the assembler is a trained professional bicycle mechanic. Refer to probma.org for mechanic standards.

Cervélo strongly recommends that all assembly and adjustment procedures be performed by an authorized Cervélo retailer. Consumers should consult an authorized retailer or visit www.cervelo.com/support before attempting any procedures.

List of Tools & Supplies

This section outlines tools and parts required for optional adjustments, not available for consumer purchase. These are for authorized retailers only.

Required Tools:

• Bicycle workstand (seatpost or pro-type fork mount)
• Torque wrenches (2.5Nm to 15Nm range) with 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 lockring tools
• Hydraulic bleed kit
• Di2 wire tool (Shimano)
• Good quality bicycle grease

Note: Non-proprietary components are available from local distributors. This manual complements the Cervélo General User Manual and component manufacturer instructions.

P5 Parts List

A comprehensive list of Cervélo P5 specific parts:

Frame Features

The Cervélo P5 frame is designed for seamless integration of shifting systems (electronic, mechanical, hydraulic). Key features include:

• Front Derailleur Wire Exit Hole (electric and mechanical)
• Rear Dropout Cable Exit (electric and mechanical)
• Top Tube Internal Cable Port
• Bottom Bracket Cable Port
• SmartPak Top Tube Mount Holes
• Disc Brake Hose Guide
• P Series Seatpost Battery Mount
• HB11 Headset

Small Parts

Various small parts are included for different configurations. Not all parts may be used depending on the groupset fitted.

• BB Cable Guide/Cover (BBG-0E0)
• Front Derailleur Wire Hole Blanking Plug (GR-ST-CLOSED)
• Rear Derailleur Hanger Assembly (DRH-WMN112)
• Disc Hose Bushing x2 (CBG-DBH)
• Front Fork Axle Insert (QRI-THD)
• Rear Derailleur Press-In Cable Stop (Mechanical) (CBS-DRPOUT)
• Rear Derailleur Wire Guide (Electric) (GR-DRPOUT-GUIDE)
• Rear Derailleur Blanking Plug (Wireless) (GR-DRPOUT-CLOSED)
• Seatpost Clamp (SPC-0E0P5)
• Riser Post Clamp (HBP-PCLP)

Frame Preparation

General: Apply carbon assembly compound to frame and seatpost. Ensure seatpost clamp is flush with the top tube and torqued to a maximum of 8Nm.

Fork Axle Insert: Lightly grease the M4 fixing screw and install the Front Fork Axle Insert (QRI-THD) to the fork, torquing to 3Nm.

Rear Derailleur Hanger: Lightly grease the fixing nut and install the Rear Derailleur Hanger (DRH-WMN112) finger tight. Final tightening occurs after rear wheel installation. Warning: Final tightening without the rear wheel can cause derailleur misalignment and poor shifting.

Frame Securing: Hold the frame using a secured seatpost only. Warning: Clamping the top tube can damage the frame and void the warranty.

Front Derailleur Mount: Ensure fixing screws are torqued to 3Nm.

Fork Rotation Stop: Clean fork surface with isopropyl alcohol. Remove backing and fix the adhesive Fork Rotation Stop to the fork. Warning: Failure to install may result in frame damage and void warranty.

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

Brake Housing Routing

It is recommended to install the rear hydraulic brake hose or mechanical brake cable housing first. These illustrations supplement manufacturer instructions. Refer to component manufacturer for details.

Route the rear brake hose from the chainstay through the Top Tube Internal Cable Port. Route the brake hose from the bottom of the fork up through the top. Note: For Di2 builds, install the 400mm E-Wire before routing the brake hose.

Route hydraulic brake hose or mechanical brake housing through the frame and fork using Disc Hose Bushings (CBG-DBH). Install and adjust calipers per manufacturer instructions.

Electric Cable Routing

Install electric cabling and junction points after brake hoses. These illustrations supplement manufacturer instructions.

Route the 1000mm Di2 E-Wire from the Top Tube Internal Cable Port out through the Bottom Bracket Cable Port.

Mechanical Cable Routing

Install front and rear derailleur cables after brake hoses. These illustrations supplement manufacturer instructions.

Route shifter housing from the Top Tube Internal Cable Port out through the Bottom Bracket Cable Port. Ensure housing is not twisted. Add ferrules to the bottom bracket end of the housing.

Fork Preparation

Familiarize yourself with the steering system via a trial assembly without hoses or cables.

• Install preload insert in fork, torque to 8Nm.
• Prepare Basebar: clean seal seat with isopropyl alcohol and install bearing seal ring.
• For mechanical shifting or SRAM eTap, prepare Stem Preload cap by removing the rubber insert.

Warning: Cervélo frames and forks are designed to work together. Do not install an alternative fork.

Fork Installation

Note: Diagrams are for reference; hoses and cables will be present during final assembly.

1. Check Basebar and headset components for sharp edges that could damage the steerer tube. Repair or replace if necessary.
2. Press 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, ensuring the split is oriented left or right, not front or back.
4. Clean the Basebar seal seat with isopropyl alcohol and adhere the Seal Ring.
5. Slide the Basebar onto the fork steerer as shown. Use Tacx Carbon Assembly Compound™ or equivalent friction paste on the steerer for stem security (do not use grease).
6. Lightly grease the Preload Fixing Screw threads.
7. Place Stem Cap on Basebar, insert greased Preload Fixing Screw, and tighten just enough to remove headset play while ensuring free fork rotation.
8. Tighten Basebar Clamping Screw and Fork Clamping Screw to a maximum of 5Nm.
9. Verify free fork rotation without play or binding. If issues arise, loosen bolts and repeat steps 7-8.

Warning: Do not exceed maximum torque specifications. Incorrect tightening can lead to component failure, loss of control, and injury.

Monoriser Post

For Di2 systems: Install Junction A (EW-RS910) and Mounting Plate. Tighten M3 x 10mm screw to 1-2Nm.

For Mechanical & SRAM eTap: Install Rear Plug and Mounting Plate. Tighten M3 x 10mm screw to 1-2Nm.

Extension Assembly

Apply a light coating of Carbon Assembly Paste to the clamping area of the Extensions. Secure the Extension Wedge by tightening the M6 x 20mm fixing screw to 4Nm.

Available Extension types: 50° J-Bend (HPB-EX11-EXT50DEG), S-Bend (HPB-EX11-EXTBEND), 30° J-Bend (HPB-EX11-EXT30DEG).

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, torquing to 4Nm.
3. Align Arm pads with Arm Cups and press to secure.

The Aerobar water bottle mount attaches with M5 x 8mm screws, torqued to 2Nm.

Warning: Failure to use specified parts and follow instructions may result in loss of control and serious injury.

Arm Cup Positions

Two fixing screws must be installed per arm cup in a fore-aft position (not diagonal). Positions can be adjusted from farthest outside/forward to farthest outside/back.

Monoriser Post Assembly

Press wired EW-JC200 connector into Riser Plug. Connect frame E-Wire to Riser Post E-Wire using EW-JC200 junction and place in Riser Plug pocket.

Push the SM-JC41 4-Port Junction Box into the Basebar after wiring is complete.

Monoriser Post Cutting Instructions

To achieve the lowest possible stack, the Monoriser Post may require trimming. Ensure a minimum of 70mm remains inside the frame after cutting.

Procedure:

1. Mark the cut-off location on the Monoriser Post using a light-colored grease pencil. Refer to the table for frame size-specific trim amounts for lowest stack.
2. Use a carbon-specific saw blade in a guide tool (e.g., Park Tool SG-7.2) for cutting.
3. Carefully file the cut end to remove rough edges.

Cutting Table (Trim Amount for Lowest Stack):

Warning: Ensure a minimum of 70mm Monoriser Post remains in the frame after trimming. Failure to do so may result in frame damage (not covered by warranty) or serious injury.

Monoriser Assembly Installation

1. Apply carbon assembly compound to the Riser Post and install into the fork.
2. Apply carbon assembly compound to the chevron and rear surfaces of the Riser Post Clamp. Install at the rear of the Riser Post, ensuring it is fully inserted with no chevrons visible.
3. Torque to 8Nm.

Extension & Basebar - Di2 Cable Routing

Diagram illustrates Di2 cable routing, including E-Wires, Y-Connectors, Junction Boxes (SM-JC41, EW-RS910), and EW-JC200 connectors.

Extension & Basebar - eTap Cable Routing

Diagram illustrates eTap cable routing, including eTap Blip Wires.

Extension & Basebar - Mechanical Cable Routing

Diagram illustrates mechanical cable routing for front and rear shifters.

Electric Cable Installation

Install the Rear Derailleur Wire Guide (GR-DRPOUT-GUIDE). Cap the Bottom Bracket Cable Port with the BB Cable Guide/Cover (BBG-0E0) once all wires are inside.

Mechanical Cable Installation

Ensure ferrules are used to cap shifter housing at the BB Cable Guide/Cover. Install Rear Derailleur Press-In Cable Stop (CBS-DRPOUT).

For wireless shifting systems, install the Rear Derailleur Blanking Plug (GR-DRPOUT-CLOSED).

Route front cable across the non-drive side slot towards the seat tube, and rear cable along the drive side slot and chainstay. Fix the BB Cable Guide/Cover (BBG-0E0) into place.

Install rear derailleur on the hanger, cut housing, and attach cable per manufacturer instructions.

Top Tube SmartPak Installation

Install the SmartPak Top Tube Storage (SB-SB03-TT) using M5 x 18mm screws, torqued to 1-2Nm, with M5 Washers. Ensure tabs are in place and sides are held inward during installation.

Stem SmartPak Installation

Install the SmartPak Stem Storage (SB-SB04-STEM) using M4 x 12mm screws, torqued to 1-2Nm.

Seatpost Assembly

Bottle Mount Installation: Slide the lightly greased seatpost bottle cage mount slug into the seatpost. If not using the bottle cage mount, use the alternate seatpost slug (SPS-SP2123).

Saddle Clamp Installation: Install saddle mount to slug using lightly greased M5 fixing screws, torquing to 6-7Nm. Install lightly greased M6 Rail Binder Bolt and saddle, torquing to 12Nm.

Water Bottle Mount Attachment: Determine desired angle and attach water bottle mount to seatpost slug with M5 fixing screw, torquing to 4Nm.

Attach water bottle cage using lightly greased M5 x 8mm fixing screws, torqued to 2-3Nm.

Compatible Seatposts: SP23 Carbon Seatpost (SP-SP23), UCI P5 Seatpost (SP-CER-UCI-ACB).

Seatpost Cutting Instructions

All Cervélo Aero Seatposts require a 45-degree chamfer on the rear trailing edge. If trimming is needed:

1. Measure and mark the cut-off location, maintaining minimum seatpost insertion of 6.5cm and maximum of 8.5cm.
2. Use a carbon-specific saw blade in a guide tool (e.g., Park Tool SG-7.2) for cutting.
3. Use fine grit sandpaper to remove fraying or burring from the cut end. Reposition clamp approximately 10cm from the cut end.
4. Mark a 45-degree guideline (1cm from cut end on trailing edge, 1cm from back on bottom edge).
5. Cut along the guideline to create the chamfer.
6. Sand the end and apply carbon assembly compound before returning to the frame.

Warning: Ensure a minimum of 6.5cm seatpost remains in the frame after trimming. Failure to meet this may result in frame damage (not covered by warranty) or serious injury.

Seatpost Di2 Battery Installation

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

Basebar Grip Installation

Cervélo Basebar grips can be installed on either side and trimmed.

• For longest reach: install with Side A facing up.
• For 20mm shorter reach: trim 20mm behind the leading edge and install with Side B facing up.

Tire Clearance

Cervélo P5 complies with ISO 4210-2:4.10.2 for tire clearance. A minimum of 4mm clearance between the tire and any frame element is required for safety and warranty. Measure available space before selecting tires.

Procedure:

1. Measure space between chainstays at the bottom bracket.
2. Measure space between seatstays at the top of the tire.
3. Subtract 8mm (4mm per side) from the smaller measurement to determine remaining space.
4. Measure installed tire width to ensure it fits.

Warning: Tire contact with frame/fork can cause loss of control and injury. Failure to follow guidelines may result in frame damage not covered by warranty.

Aero Through-Axle Wheel Installation

Front Wheel: Install greased axle through drive-side dropout, wheel hub, and thread into opposite fork dropout until tight. Tighten to 12-15Nm using a 6mm hex key.

Rear Wheel: Install greased axle through non-drive-side dropout, wheel hub, and thread into opposite fork dropout until tight. Tighten to 12-15Nm.

Final Rear Derailleur Hanger Tightening: Use a 17mm wrench to perform final tightening on the Rear Derailleur Hanger Fixing Nut. This is only required during initial assembly.

Note: Adjust brakes and shifting per manufacturer instructions.

Warning: Correct installation of the Cervélo Aero Through-Axle is critical for rider safety. Improper installation may result in a crash and serious injury.

Appendix: EX10 Riser

An alternative pad-mount and riser system (EX10) allows for extension tilt adjustment (0°, 5°, 10°, 15°). Part codes are available from Cervélo.

EX10 Riser Assembly

Attach Riser Pad Mount (HBP-EX10-PADMNT) and Riser Post (HBP-EX10-RISER) to Tilt Adjust Plate (HBP-EX10-ADJPL) using two M6 x 20mm fixing screws, torqued to 6Nm.

Route E-Wires through Stem Preload Cap and SmartPak Stem Storage. Connect E-Wires to Junction A (SM-EW90-B 5 Port) and place inside SmartPak.

The Riser Pad Mount can be attached in two positions: Forward Position or Setback Position.

EX10 Extension Assembly

Install and adjust extensions, torquing to 3Nm. Extensions should be flush with the bottom edge of the Riser Pad Mount for internal Di2 routing.

The Aerobar water bottle mount attaches with M5 x 8mm screws, torqued to 2Nm.

EX10 Extension Angle Adjustment

The Riser Pad Mount and Extensions can be set to four angles: 0°, 5°, 10°, 15°.

1. Remove both Tilt Adjust Fixing Screws and the Tilt Adjust Plate.
2. Position the Tilt Adjust Plate in one of two orientations.
3. Install lightly greased fixing screws in the appropriate holes and torque to 6Nm.

Tilt Adjust Plate Positions:

• Position 1: 0°, 10° (Forward orientation)
• Position 2: 5°, 15° (Setback orientation)