S3 DISC MANUAL
TABLE OF CONTENTS Introduction...1 Frame Features...2 Fork Preparation...3 Small Parts...5 Frame Preparation...6 Brake Housing Installation...7 Mechanical Cable Routing...9 Electric Cable Routing...11 Seatpost Assembly & Installation...15 Seatpost Cutting Instructions...16 Through-Axle Wheel Installation...17 INTRODUCTION Welcome to the Cervélo family, and congratulations on your decision to purchase an S3 Disc. You clearly recognize the difference that details and innovative engineering make to your riding experience. Because your new complete bicycle or frame set integrates the latest component technologies, we ask that you familiarize yourself with some of the new assembly and disassembly requirements before your first ride. This document has been prepared to guide you through these requirements, and is intended only as a supplement to the assembly instructions provided by your component manufacturer. If you choose to sell your Cervélo in the future, please pass this manual along. FRAME FEATURES A guide to your Cervélo S3 Disc frame. Front derailleur wire exit hole - electric Front derailleur wire exit hole - mechanical Down tube internal cable ports Rear dropout cable exit Bottom bracket cable port Internal Di2 battery mount holes 1 Version 2-2017-01-30 2
FORK PREPARATION A. Stem Cap + 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) F A B C D E G 1. Apply grease to the bearing seats, and Install the upper & lower headset bearings into the head tube. 2. Fit the fork 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. Do not exceed 50 mm maximum total spacer height, including the bearing cap. Avoid breathing the dust created during cutting carbon composite materials. A 2.5mm spacer under the Stem Cap is advised Max. 4mm 5. To trim fork steerer, use only a saw suitable for cutting carbon, and a cutting guide. 6. Carefully sand a bevel to the inside of the cut end of the steerer tube to fit the insert. 7. Dry fit insert to check that it is flush with the cut end of the steerer tube. 8. Use isopropyl alcohol to clean the inside of the steerer tube and the outside of the insert. 9. Fully mix the two-part epoxy and apply to the outer surface of the insert with the wooden mixing stick. 10. Slide the insert into the steerer while rotating it slowly until the flared end sits flush with the top of the steerer. 11. Wipe away any excess glue from the outside surface of the steerer tube with the isopropyl alcohol wipe. 12. Set the fork aside and allow it to sit undisturbed for the full curing period. Insert should be flush with cut end of the fork steerer tube I 1st Mark 2nd Mark / Final Cut Do not attempt to fit the fork into a bike prior to the completion of the full curing period. H J Improper cutting of the steerer tube could cause a failure that results in severe injury or death. 3 4
SMALL PARTS Designed to accommodate electronic, mechanical and hydraulic controls, the S3 Disc 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 Mechanical Shifting Cable Stop and Brake Hose Guide CBS-3DT115EM Electric Wire and Brake Hose Guide CBS-3DT115EM Single Brake Hose Guide (Wireless) CBS-3DT115WL Rear Derailleur Hanger Assembly DRH-WMN112 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 *Complete parts kits are provided with framesets only Bottom Bracket Cable Guide (Mechanical) BBG-R-2013 Mechanical Shifting Cable Stop CBS-TTC-TT-MECH Bottom Bracket Access Port Rubber Blanking Plug (Electric) GR-BB-GUIDE Down Tube Wire Hole Blanking Plug GR-DT-PLUG Disc Hose Fork Grommet GR-FORK x2 Rear Derailleur Hanger Fixing Nut Disc Hose Bushing BU-DH1290 Front Derailleur Wire Hole Blanking Plug GR-BVT-TT-S5 Rear Derailleur Hanger Seatpost Clamp SPC-S5 Lightly grease Rear Derailleur Hanger Fixing Nut and install Rear Derailleur Hanger, finger tight. Final tightening will be done after rear wheel installation. Do not final tighten rear derailleur hanger assembly without rear wheel installed. Doing so will result in a misaligned derailleur and poor shifting. Clean chain stay with isopropyl alcohol and apply chain stay protector. 5 6
BRAKE HOUSING INSTALLATION It is recommended that the hydraulic brake hose or brake cable housing is 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. Use the Single Brake Hose Guide if your frame is being built with a wireless shifting system such as SRAM etap. 1. Route hydraulic brake hose or mechanical brake housing through the frame and fork. 2. Install calipers as per manufacturer's instructions. 3. Install Disc Hose Bushing and Disc Hose Fork Grommets to secure hoses and housings in place. 7 8
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. Route gear cables out of the bottom bracket cable port. Ensure 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 Bottom Bracket Cable Guide into place. With the brake hose already in place, install two piece Mechanical Shifting Cable Stop and Brake Hose Guide on the non-drive side. Route the front cable housing (with ferrule) into stop, until the housing rests securely in the pocket. On the drive side, route the rear cable housing (with ferrule) into the single Mechanical Shifting Cable Stop until it rests securely in place. Install Rear Derailleur Press-In Cable Stop. As per manufacturer s instructions, install rear derailleur on rear derailleur hanger, cut appropriate housing length, and attach cable. 9 10
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. The battery for your Shimano Di2 system mounts inside the down tube using a battery holder (DI-BM-INT-S5D) designed to fit this frame. As this is a sealed location, it is important to test the system prior to final installation. Press the two M3 fixing nuts into the holder through the upper holes. Attach battery to mount using two zip ties, and install. With the brake hose already in place, install two piece Electric Wire and Brake Hose Guide on the non-drive side. Route the down tube electric wire through the guide down to the bottom bracket. Cover the drive side internal cable port with the Down Tube Wire Hole Blanking Plug. 11 12
Insert a long 5mm hex key into the lower end of the holder to work as insertion tool. Pass the battery and holder assembly through the opening in the bottom bracket shell and position it, in the down tube, so that the fixing nuts are located over the mounting holes. 1. Apply Loctite 242 to the M3 fixing screws 2. Pass M3 fixing screws through the frame s downtube mounting holes, so that they catch the fixing nuts in battery holder. 3. Tighten only enough to secure nut in holder. 4. Remove 5mm hex key. 5. Using 2mm hex key, tighten fixing screws to maximum of 2.5 Nm. 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. 13 14
SEATPOST ASSEMBLY & INSTALLATION SEATPOST CUTTING INSTRUCTIONS 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 maximum of 8.5cm, carefully measure and use a light coloured grease pencil to accurately mark the cut-off location on the seatpost. 2. Insert the S 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. 1. Apply a light coat of carbon assembly compound to the upper face of the Seatpost, making sure to cover area around the adjustment slots. 2. Locate saddle rail between upper and lower clamps, and place on Seatpost. 3. With alignment washers installed, attach assembly to Seatpost, by tightening lightly greased fixing bolts, alternating between the two sides each 1/2 turn. Once saddle is adjusted, tighten fixing bolts to 8-9 Nm. 1. Apply carbon paste to frame and insert Seatpost Clamp. 2. Adjust height and torque to 8 Nm maximum. 1cm 1cm Cut Line If trimming is required, final length should allow for a minimum 6.5cm of seatpost remaining in the frame. Failure to meet this requirement, may result in damage to the frame not covered by warranty policy, or serious injury to rider. 15 16
THROUGH-AXLE WHEEL INSTALLATION To secure the front wheel, install the greased axle, through the drive side drop out, through the wheel hub, and rotate to thread axle into opposite fork drop out until tight. If using an aftermarket wheelset, please refer to the component manufacturer s service center or website for further information. Adjust brakes as per manufacturer s instructions. Adjust shifting as per manufacturer s instructions. To secure the rear wheel, install the greased axle, through the non-drive side dropout, through the wheel hub, and rotate to thread axle into the Rear Derailleur Hanger until tight. Put axle lever in open position. Perform final tightening on Rear Derailleur Hanger Fixing Nut using a 17mm wrench. This action is unique to initial assembly, and should not require adjustment afterwards. Once tightened, close lever to lock. Once tightened, close lever to lock. 17 18
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