Cervélo 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. It outlines the process and procedures for installing Cervélo components and routing shifting and braking control lines. Proprietary parts are available only through Cervélo Cycles Inc.

WARNING: Failure to use specified parts and follow these instructions may result in loss of control while riding, leading to serious injury. This manual supplements, but does not replace, assembly and service instructions from third-party component manufacturers. It assumes the assembler is a trained, professional bicycle mechanic. Refer to probma.org for more information.

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

List of Tools & Supplies

This section lists the tools and parts required for optional adjustments to the P-Series bicycles. Cervélo recommends that all assembly and adjustment procedures be performed by an authorized Cervélo retailer.

Note: This manual complements the Cervélo General User Manual and component manufacturer instructions.

Note: All non-proprietary components are available from your local distributor.

Tools:

• Bicycle workstand (seatpost or pro-type with fork mount)
• Torque wrench(es) with 2.5Nm to 15Nm range and adaptors (Allen/Hex: 2mm, 2.5mm, 3mm, 4mm, 5mm, 6mm, 8mm, 10mm; Open ended: 7mm, 8mm, 10mm, 17mm)
• Pedal wrench
• Brake rotor lockring tools
• Hydraulic bleed kit
• Isopropyl alcohol
• Cable cutters
• Pliers
• Phillips-head screwdriver
• Slot-head screwdriver
• Di2 wire tool – Shimano
• Good quality bicycle grease & carbon assembly compound
• Saw cutting guide (Park Tool SG-7.2 or equivalent)
• Hacksaw (with carbon specific blade)

P-Series Parts List

Small Parts

The P-Series frame is engineered for seamless integration of all shifting systems (electronic, mechanical, hydraulic). The following parts are required:

• GU02 Stem Cover Assembly w/ Fixing Screws (HBP-GU02-CVR)
• Seatpost Clamp (SPC-0EOP)
• Threaded Fork Insert w/ Fixing Screw (QRI-THD)
• Derailleur Hanger Fixing Nut
• Direct Mount Derailleur Hanger (DRH-SDM)
• Brake Hose Guide x2 (CBG-DBH)
• Derailleur Hanger (DRH-WMN112)
• BB Cable Guide/Cover (BBG-0E0)
• Seat Tube Blanking Plug (1x & Wireless) (GR-ST-CLOSED)
• Seat Tube Open Grommet (Electronic) (GR-BEC-OPEN)
• Rear Derailleur Wire Guide (Electric) (GR-DRPOUT-GUIDE)
• Rear Derailleur Press-In Cable Stop (Mechanical) (CBS-DRPOUT)
• Rear Derailleur Blanking Plug (Wireless) (GR-DRPOUT-CLOSED)
• Front Derailleur Mount w/ Fixing Screws (FDM-0E0)
• Front Derailleur Mount Blanking Plate (1x) (FDM-CVR)

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 the supplied M4 fixing screw and install the GU02 Base to the frame. Torque to 1-2Nm. (Note: In some configurations, E-wires must be installed before the GU02 Base.)
2. Apply carbon assembly compound to both the frame and seatpost.
3. Insert the Seatpost Clamp (SPC-0E0P) into the frame so it is flush with the top tube. Adjust height and torque to a maximum of 8Nm.
4. Lightly grease the supplied M4 fixing screw. Install the Threaded Fork Insert (QRI-THD) and fixing screw, tightening only lightly.
5. 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.
6. Tighten the fixing screw to 3Nm.
7. Remove the axle and install the wheel. Reinstall the axle and tighten to 12-15Nm.
8. Remove the axle and wheel, and re-torque the fixing screw to 3Nm.
9. Install the Front Derailleur Mount (FDM-0E0), ensuring fixing screws are torqued to 3Nm. For 1x systems, replace with the Front Derailleur Mount Blanking Plate (FDM-CVR).
10. Clean the chainstay with isopropyl alcohol. Install the Chainstay Protector (PRO-CS-P) by removing the 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.
11. Lightly grease the Rear Derailleur Hanger Fixing Nut and install either the Rear Derailleur Hanger (DRH-WMN112) or the Direct Mount Rear Derailleur Hanger (DRH-SDM) finger tight. Final tightening will occur after rear wheel installation.

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

Fork Preparation & Installation

CAUTION: The compression plug components are side-specific. Incorrect reassembly can lead to loss of preload. Refer to images for correct assembly.

WARNING: Avoid breathing dust created during cutting of carbon composite materials.

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

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

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

1. Apply grease to the bearing pockets and install the upper and lower headset bearings into the frame.
2. Fit the fork, headset, required spacers, and stem into the head tube.
3. Apply minimum pressure to ensure the assembly is fully seated. Mark the steerer tube at the top of the stem.
4. Remove the fork and clearly mark the fork steerer tube 4mm below the first mark. Verify this measurement for the cut line.
5. Trim the fork steerer using a saw suitable for carbon and a cutting guide.
6. Insert the D-Shaped Compression Plug (FKI-CL005-517A) and tighten to hold in place. Do not apply final torque until after the stem is installed.
7. Place the Lower Bearing over the fork steerer and insert into the frame from the bottom of the head tube.
8. Install the following components over the steerer in order: Upper Bearing, Split Ring, Bearing Top Cap, Stem Spacers, and Stem. Do not install the Stem Top Cap yet.
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 just enough to remove headset play while ensuring bearings rotate freely (typically 1-2 Nm).
11. Tighten the stem to fork fixing bolts to a maximum of 5Nm.

WARNING: Your Cervélo frame & fork are designed to work together. Do not substitute a different size fork without consulting Cervélo Customer Service for compatibility.

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

Note: The gap in the Split Ring and Bearing Top Cap should align to the front center of the head tube.

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

Brake Housing Routing

These routing illustrations supplement manufacturer's instructions. For hydraulic and mechanical disc brakes, refer to the component manufacturer's service center or website.

Recommendation: Include 20mm-25mm of additional brake hose length for final customer fit, allowing for disassembly and service.

1. Measure customer fit.
2. Add 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 using Disc Hose Guides (CBG-DBH). Install and adjust calipers per manufacturer's instructions. The brake hose pass-through in the fork steerer does not require a Disc Hose Guide.

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

Electric Wire Routing

It is recommended that wiring and junction points be installed after the brake hose. These routing illustrations supplement manufacturer's instructions. Refer to component manufacturer's service center or website for details.

Wiring Specifications:

• E-Wire (SD50): 200mm (x2), 800mm (x2), 150mm (x2)
• E-Wire (SD300): 800mm, 1400mm
• E-Wire AD305 Adapter
• E-wires to Extensions, E-wires to Base Bar

Electric Wire Installation

Run base bar E-wires and front brake hose beneath the stem, then through the gap in the Bearing Top Cap and into the frame.

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

CAUTION: Ensure Di2 wires are routed on the opposite side of the fork steerer tube from the front brake hose to prevent pinching. Pinched cables can be damaged and affect shifting function.

Install the Rear Derailleur Wire Guide (GR-DRPOUT-GUIDE).

With all wires inside, cap the Bottom Bracket Cable Port with the BB Cable Guide/Cover (BBG-0E0).

Mechanical Cable Routing

It is recommended that front and rear derailleur cables be installed after the brake hose. These routing illustrations supplement manufacturer's instructions. Refer to component manufacturer's service center or website for details.

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

Mechanical Cable Installation

Install the Rear Derailleur Press-In Cable Stop (CBS-DRPOUT).

Route shifter housing through the GU02 Base (HBP-GU02-CVR) and out through the Bottom Bracket Cable Port. Ensure shifter housing does not twist. Add ferrules to the bottom bracket end of the housing.

As per manufacturer's instructions, install the rear derailleur.

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.

• M4 x 20mm Fixing Screws
• M4 Washer
• GU02 Stem Cover

Top Tube SmartPak Installation

Install the SmartPak 400 (SB-SB03-TT) using M5 x 18mm fixing screws. Torque to 1-2Nm.

Ensure tabs are in place and sides are held inward during installation.

If not using the SmartPak 400, install the Bottle Boss Cover Plate (CVR-WB).

Seatpost Assembly

Slide the lightly greased seatpost bottle cage mount slug (MT-WB-SP) into the seatpost.

If not using the bottle cage mount, use the alternate seatpost slug (SPS-SP2123).

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 the saddle.
3. Torque to 12Nm.
4. Determine desired angle and attach water bottle mount to seatpost slug with M5 fixing screws.
5. Torque to 4Nm.

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

Seatpost Types:

• SP23 Seatpost (SP-SP23)
• UCI P5 Seatpost (SP-CER-UCI-ACB)

Seatpost Cutting Instructions

Note: All Cervélo Aero Seatposts require a 45-degree chamfer on the trailing edge. Follow this method for trimming:

1. Maintain minimum seatpost insertion of 6.5cm and maximum of 8.5cm. Measure and mark the cut-off location with a light-coloured grease pencil.
2. Insert the P-Series Seatpost into the Park Tool SG-7.2 Saw Guide (or equivalent) so the cut-off line is visible through the blade guide.
3. Using a blade designed for carbon composite materials (or a fine-tooth blade with >32 teeth per inch), cut the Seatpost per Park Tool's instructions.
4. Use fine grit sandpaper to remove any fraying or burring from the cut end. Reposition the clamp approximately 10cm from the cut end.
5. 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. Connect these marks with a line to form a 45-degree guideline.
6. Place the saw blade on the guideline and carefully cut the 45-degree chamfer onto the trailing edge.
7. Sand the end and apply carbon assembly compound before returning to the frame.

WARNING: If trimming is required, ensure at least 6.5cm of seatpost remains in the frame. Failure to do so may result in serious injury or frame damage 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 per manufacturer instructions.

Insert the assembled battery and mount into the seatpost.

Aero Water Bottle Installation

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

If not using the Aero Water Bottle, install the Bottle Boss Cover Plate (CVR-WB).

Tire Clearance

Cervélo bicycles comply with ISO 4210-2:4.10.2 for tire clearance. To maintain the Limited Lifetime Warranty, a minimum of 4mm clearance must exist between the tire and any frame element. Due to tire and rim complexities, Cervélo recommends measuring available space before selecting 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. Subtract 8mm (4mm per side) from the smaller measurement to determine remaining space.
4. With the tire installed and inflated, measure the widest part of the rim or tire to ensure it fits.

WARNING: Contact between the tire/rim and frame/fork can cause loss of control and serious injury. Failure to follow these guidelines may result in frame damage not covered by Cervélo Limited Lifetime Warranty.

Aero Thru-Axle Installation

To secure wheels, install the greased axle through the dropout and wheel hub, aligning the threaded end with the threaded insert. Thread the axle clockwise until secured tightly.

WARNING: Correct installation of the Cervélo Aero Thru-Axle is critical for rider safety. Failure to do so may result in an accident and serious injury.

• Tighten front axle to 12-15Nm.
• Tighten rear axle to 12-15Nm.

Perform final tightening on the Rear Derailleur Hanger Nut using a 17mm wrench. Torque to 12-15Nm. This is for initial assembly only.

WARNING: Adjust brakes per manufacturer's instructions.

Notes

Space for user notes.