Cervélo R5 Disc Manual: Assembly and Installation Guide

Introduction

Welcome to the Cervélo family! Congratulations on choosing the R Series bicycle. The ultra-lightweight engineering of your Cervélo R Series classic road bike is designed to help you conquer climbs and enjoy speed and control on descents. Its understated design allows performance to shine through with a settled ride that responds to the road.

As with any high-performance vehicle, it is important to familiarize yourself with its features and service requirements. Please read this manual thoroughly before assembly or use.

This document provides guidance for assembling the unique features of the R Series and serves as a supplement to the assembly instructions provided by your component manufacturer.

Version 2 - 2018-05-07 - CER-R5D-V2

Frame Features

A guide to your Cervélo R5 Disc frame.

The frame features:

Front derailleur wire exit hole (compatible with electric and mechanical systems)
Rear dropout cable exit
Top tube internal cable port
Bottom bracket cable port

Fork Preparation

Parts List:

A. Stem Caps + 5mm bolt
B. Headset Spacers
C. Bearing Cap
D. Compression Ring
E. Bearings
F. Fork Insert
G. Two-Part Epoxy
H. Mixing Stick
I. Isopropyl Alcohol Wipe
J. Sandpaper (120 Grit)

Installation Steps:

Apply grease to the bearing seats and install the upper & lower headset bearings into the head tube.
Fit the fork provided with your frame into the head tube with the complete headset, required spacers, and the stem.
Apply minimum pressure to ensure the assembly is fully seated. Mark the steerer tube at the top of the stem.
Remove the fork and clearly mark the fork steerer tube at a point 4mm below the first mark. Verify this measurement carefully, as it defines the cut line for the steerer tube.

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

Avoid breathing the dust created during cutting carbon composite materials.

Cutting the Steerer Tube:

To trim the fork steerer, use only a saw suitable for cutting carbon, and a cutting guide.
Carefully sand a bevel to the inside of the cut end of the steerer tube to fit the insert.
Dry fit the insert to check that it is flush with the cut end of the steerer tube.
Use isopropyl alcohol to clean the inside of the steerer tube and the outside of the insert.
Fully mix the two-part epoxy and apply it to the outer surface of the insert using the wooden mixing stick.
Slide the insert into the steerer while rotating it slowly until the flared end sits flush with the top of the steerer.
Wipe away any excess glue from the outside surface of the steerer tube with the isopropyl alcohol wipe.
Set the fork aside and allow it to sit undisturbed for the full curing period.

Do not attempt to fit the fork into a bike prior to the completion of the full curing period.

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

Do not exceed 50mm maximum total spacer height, including the bearing cap.

Small Parts

The R5 Disc frame is engineered to accommodate electronic, mechanical, and hydraulic controls, providing seamless integration of all shifting systems, regardless of method or brand. The following parts are required:

Top Tube Cable Stop (Mechanical): ICS4-S5D
Top Tube Cable Stop (Electric): GR-TTFILL-S5D
Top Tube Cable Plug (Wireless): GR-ICS4TT-CLOSED
Top Tube Cable Stop Noodle (Mechanical): CH-TE-TTC-ICS3 x2
R Series Disc Rear Derailleur Hanger Assembly: DRH-RAT
Rear Derailleur Press-In Cable Stop (Mechanical): CBS-DRPOUT
Rear Derailleur Wire Guide (Electric): GR-DRPOUT-GUIDE
Bottom Bracket Cable Guide (Mechanical): BBG-R-2013
Bottom Bracket Access Port Rubber Blanking Plug (Electric): GR-BB-GUIDE
Rear Derailleur Hanger Fixing Nut
Seatpost Clamp Cover Assembly: SPCC
Rear Derailleur Blanking Plug (Wireless): GR-DRPOUT-CLOSED
Front Derailleur Wire Hole Blanking Plug: GR-ST-CLOSED
Seatpost Clamp: SPC-R5-SM (48cm-51cm), SPC-R5-LG (54cm-61cm)
Seatpost Cover
Seatpost Cover Mount

*Complete parts kits are provided with framesets only.

Frame Preparation

Lightly grease the Rear Derailleur Hanger Fixing Nut and install the Rear Derailleur Hanger finger tight. Final tightening will be performed after rear wheel installation.

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

Install the front fork Cervélo Rapid Axle insert (QRI-RAT). Lightly grease the bolt and tighten to a maximum of 3 Nm.

Brake Housing Installation

It is recommended that hydraulic brake hoses or brake cable housing be 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.

Removing the fork allows for easier routing of the rear hydraulic hose or brake housing.

Route hydraulic brake hose or mechanical brake housing through the frame and fork. Install and adjust calipers as per manufacturer's instructions.

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.

Insert plastic noodles into the Top Tube Cable Stop (Mechanical).

Assemble shifter cables (with ferrules) so that the rear housing is inserted into the drive-side port of the Top Tube Cable Stop, and the front housing into the non-drive side. The housing should be long enough to pass in a smooth arc from the lower back of the bar, over the stem cap, and enter perpendicular to the top tube. The housing nests in the cable stop, with the cables continuing into the frame through the noodles.

Failure to use the cable noodles may result in damage to the frame.

Route gear cables out of the bottom bracket cable port, ensuring that the cables are not twisted together.

The front cable travels across the non-drive side slot and in the direction of the seat tube. The rear cable travels along the drive side slot and along the chain stay. When complete, snap the Bottom Bracket Cable Guide into place.

Install Rear Derailleur Press-In Cable Stop.

As per manufacturer's instructions, install the rear derailleur on the rear derailleur hanger, cut appropriate housing length, and attach the cable.

Electric Cable 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.

Route the down tube electric wire to the bottom bracket, through the Top Tube Cable Stop (Electric).

For wireless shifting systems, use the Top Tube Cable Plug.

With all wires inside, cap the bottom bracket access port with the Bottom Bracket Access Port Rubber Blanking Plug.

Install the Rear Derailleur Wire Guide. For wireless shifting systems, install the Rear Derailleur Blanking Plug.

Seatpost Assembly & Installation

The R5 uses a proprietary shaped seatpost. Do not attempt to use any seatpost other than the model provided by Cervélo.

Apply a light coat of carbon assembly compound to the upper face of the Seatpost, ensuring coverage around the adjustment slots.
Locate the saddle rail between the upper and lower clamps, and place it on the Seatpost.
With alignment washers installed, attach the assembly to the Seatpost by lightly tightening greased fixing bolts, alternating between the two sides each 1/2 turn. Once the saddle is adjusted, tighten fixing bolts to a maximum of 8 Nm.

Ensure the Seatpost Clamp Cover and Seatpost Clamp Cover Mount are placed onto the seatpost and lightly tightened before installing the Di2 battery or inserting the post into the frame.

Press the Di2 battery into the R-Series Internal Battery Holder and attach the cable according to manufacturer's instructions.

Insert the assembled battery and holder into the seatpost.

Apply carbon paste to the frame and insert the Seatpost Clamp.
Adjust height and torque the seat wedge to 8 Nm maximum.
Position the Seatpost Clamp Cover Mount at the top of the frame surface and torque to 1 Nm maximum.
Push the Seatpost Clamp Cover down and fit it over the Cover Mount.

Frame Protection Installation

Install the front derailleur using the bolt provided with the derailleur. Torque to the derailleur specifications.

Install the chain catcher when installing the front derailleur. Complete final adjustment with the chain in the small chainring and largest cassette cog. Tighten the connecting bolt to 4 Nm.

Clean the chain stay using isopropyl alcohol. Install the Chain Stay Guard by removing the adhesive backing and fixing the guard to the frame. The bottom rearward edge should be 12mm from the edge of the Rear Derailleur Hanger Fixing Nut.

CS026 Stem

The CS026 stem supports internal routing of Di2 wires when used with the Shimano EW-RS910 bar end junction and a compatible handlebar. Please refer to the component manufacturer's service center or website for further information.

The Pass-through fitting stem cap has been provided for test fitting purposes. Once your stem height has been confirmed and your fork steerer is cut to your desired length, it should be replaced with the Aero stem cap and the bond-in fork insert installed.

Should you wish your fork steerer to remain long, with the bond-in fork insert in place, you can use the Pass-through fitting stem cap as a permanent solution. Use with spacers placed on top, and a standard top-cap to adjust the headset.

A. Aero stem cap

B. Pass-through stem fitting cap

Torque to 5 Nm maximum (for stem bolts).

Compatible with Bar Fly Direct MINI and MAX stem mounts.

AB06 Handlebar

The AB06 handlebar supports the internal routing of Di2 wires when used with the Shimano EW-RS910 bar end junction and a compatible stem. 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.

Reach: 80mm
Drop: 128mm

Brake and mechanical shifter housing are routed externally in pockets on the underside of the bar.

Di2 Cable Routing:

Di2 Cable Exit
Di2 Cable to Junction B
EW-JC200 Connector
EW-RS910 Junction A
Di2 Cable to Rear Shifter
EW-JC130 Cable

Tire Clearance

Your Cervélo bicycle complies with the ISO 4210-2:4.10.2 standard for tire clearance. 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.

Measurement Procedure:

Measure the space between the chainstays at the bottom-bracket junction.
Measure the space between the seatstays at the top of the tire.
Using the smallest of those two numbers, subtract 8mm (4mm per side) to determine the remaining space.
With the tire installed and fully inflated on your wheel, measure the tire width to ensure that it fits.

Failure to follow these guidelines may result in damage to the frame not covered by Cervélo Limited Lifetime Warranty.

Rapid Axle Wheel Installation

Front Wheel Installation:

To secure the front wheel, install the greased axle through the drive-side dropout, through the wheel hub, aligning the T-End of the axle with the insert. Rotate the axle 90° clockwise until the T-End is stopped by the insert. If the lever is clamping too much or too little, adjust the preload nut until the lever clamps securely.

The force required to close the lever should leave a clear imprint in the palm of your hand, or require wrapping your fingers around the fork leg for leverage while closing.

Put the Cervélo Rapid Axle lever in the open position. (When the axle lever is in the open position, the arrows are visible. When closed, the Cervélo logo is visible.)
Insert axle.
Rotate 90° to secure.
Use the preload nut to set the desired tension before closing.
Once adjusted, close lever to lock.

Rear Wheel Installation:

To secure the rear wheel, install the greased axle through the non-drive side dropout, through the wheel hub, aligning the T-End of the axle with the derailleur hanger insert. Rotate the axle 90° clockwise until the T-End is stopped by the insert. If the lever is clamping too much or too little, adjust the preload nut until the lever clamps securely.