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Apollo Radius User's Manual

1. Caution D Service station pumps and pencil type automotive tyre gauges should not be relied upon for consistent accurate readings A good quality dial gauge should be used as it is far more accurate and reliable RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Front Wheel Removal 1 Open the brake quick release if fitted or screw in the brake cable adjuster You may need to undo Quick Release the brake cable anchor bolt if more clearance a d is required Open Cj 2 Where standard axle nuts are present use a spanner to loosen If secondary retention devices CJ are fitted slacken the nuts enough to give clearance Closed to remove the wheel 3 the lever to the open position if a quick Fork Front Hub release axle is fitted Where the secondary 4 Hh retention devices are fitted the adjusting nut A4 n at the opposite end to the Quick Release lever Wash r needs to be loosened sufficiently to permit the Retention Device wheel to be removed 4 Remove the wheel Front Wheel Replacement 1 Guide the wheel into the frame ensuring that the Axle correctly seated axle fits well up against the fork slots The fork legs may need to be slightly prised apart 2 If the wheel has a Quick Release axle ensure the quick release lever is open on the left side of the bicycle Check Quick Release tension and close the lever when adequate tension is achieved When closed the l
2. 1 set open the lever so that the curved part faces Clip on Device away from the bicycle 2 While holding the lever in one hand spin the adjusting nut manually until it is tight 3 Spin the lever halfway towards the closed position Tighten the adjusting nut in a clockwise direction until there is firm resistance to turning the lever beyond that point 4 Pivot the lever all the way to the closed position so that the curved part of the lever faces the bicycle 5 When the jagged edges on the Quick Release clamping parts actually begin to cut into the bicycle frame fork surfaces the wheel is firmly secured 6 Tooperate a Quick Release seat post binder mechanism follow the same process 31 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 32 Hub Bearing Adjustment he hub bearings of both wheels should be inspected for side movement Adjustment is required if there is any more than slight lateral movement To adjust Remove the wheel from the bicycle 2 Use a flat open ended cone spanner to hold the adjusting cone of the hub and simultaneously loosen the hub s locknut on the same side 3 Turn the adjusting cone as required until there is minimal side play and before binding of the bearings occurs Hold the adjusting cone in position and secure the locknut Test that the wheel spins freely without excessive lateral movement or binding on the bearings Bearing
3. J Serial Number Locations The postion may vary from model to model gt f x A near Left Fork Tip Underneath Bottom Bracket Bottom of Seat Tube Tyre Pressure Chart 12 1 2x2 1 4 16x175 16x2 125 20x1 75 20x2 125 24x 1 75 26x 1 75 26x19 27x 1 1 4 700 x 25c www apollobikes com Radius is Distributed by Apollo Bicycle Co PTY LTD ABN 60001 914 469 PO Box 5125 Studfield Victoria 3152 03 9881 6600 03 9881 6666 Apollo Bicycles New Zealand LTD PO Box 76 512 Manukau City Auckland NZ 09 263 5992 09 263 5990
4. Mountain Bikes amp Crossbikes Mountain bikes are one of the most versatile bicycles Wider wheel rims and tyres ensure maximum comfort and traction over a wider variety of surfaces and the frame and forks are strong making them particularly suitable for rough terrain Manoeuvring is made easier by the wider handlebars and convenient shift lever position The Crossbike or hybrid blends features of the mountain and racing bicycles Its frame is lighter than a mountain bike but heavier than a racing bicycle providing stability and comfort with increased speed Top Tube Shift Lever Seat Brake Lever Seat Post o Handlebar Handlebar Stem Cd Seat Post Binder Bolt Cee Head Set RS Brake Control Cables Seat Stay Head Tube Front Reflector Rear Reflector Rear Brake Wheel Reflector Seat Tube Down Tube p Front Derailleur Rear Gear Control Cable Front Brake Wheel Reflector Front Fork Crank Arm Freewheel Chainwheel Tyre Valve Gear Control Cable Chainstay Rim Front Hub Rear Derailleur Chain Tyre Spokes RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Suspension Bikes Suspension bicycles aim to maximize comfort and traction over rough terrain The basis of the mountain bike frame is blended with suspension either suspension front forks only or in combination with a rear suspension mechanism built into the frame A special shock absorbi
5. Solid Post Bicycle Frame U Lock Rear Wheel High Security using a U Lock 29 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Regular proper upkeep of your new bike means Smooth Running Longer lasting components Safer Riding Cost savings Routine bicycle maintenance is an essential component of riding The condition of your bicycle changes every time it is used meaning more frequent maintenance is necessary the more you ride your bicycle The tables listed below outline the recommendations for servicing your bicycle By referring to these and the information in Part 5 of this manual you should be able to complete most of your bicycle maintenance yourself Contact your specialist bicycle dealer if you require further assistance Schedule 1 Lubrication Frequency Component Lubricate How to Lubricate Weekly Chain chain lube or light oil brush on or squirt Derailleur wheels lube or light oil brush on or squirt Derailleurs oil oil can Brake callipers oil 3 drops form oil can Brake levers oil 2 drops from oil can Monthly Shift levers lithium based grease disassemble Brake cable ends oil 1 drop from oil can 6 monthly Hubs lithium based grease disassemble Bottom bracket lithium based grease disassemble Pedals lithium based grease disassemble Freewheel oil 2 squirts form oil can Brake cables lithium based grease disassemble Derailleur cables l
6. Bicycle Owner s Manual 2008 IMPORTANT Please Read This Manual Before Using Your New Bicycle Apollo Bicycle Limited Lifetime Warranty Subject to the terms conditions and limitations set forth below Apollo Bicycle Co Pty Ltd 914 warrants to the original purchaser of each new Apollo bicycle that has a wheelbase exceeding 640mm or a wheel size of 16 40cm or greater that Apollo Bicycle Company will repair or replace the frame or fork free of charge should it fail at any weld point provided it was purchased from and assembled by an authorised Apollo bicycle dealer Item 1T Warranty coverage for frames of Hi Tensile steel or Chromoly steel construction without rear suspension systems shall be for 10 years This covers the frame only or fork other than suspension forks Item 2 Warranty coverage for Aluminium frames without rear suspension systems shall be for a period of 3 years Frame fatigue shall not be covered under the terms of this warranty on these frames Warranty coverage for Carbon Fibre frames without rear suspension systems shall be for a period of 1 year Frame fatigue shall not be covered under the terms of this warranty on these frames Item 3 Warranty coverage for Downhill main frames Chromoly or Aluminium rear suspension systems and system components shall be for a period of one year covering faulty workmanship or materials making up the suspension system These frames except Downh
7. Lubrication Schedule 2 Service Checklist Updated 23 05 07 5 COMPREHENSIVE MAINTENANCE 27 Wheels and Tyres wheel inspection tyre inspection recommended tyre pressures front wheel removal amp replacement rear wheel removal amp replacement correct Quick Release axle setting hub bearing adjustment amp lubrication how to fix a flat tyre tyre valve Steering System handlebar stem handlebar forks Bicycle suspension headset quill type assemblies Ahead Set type assemblies rotor installation amp adjustment Saddle amp Seat Post Brakes sidepull callipers linear pull U brake disc brake Drivetrain pedals clipless pedals crank set one piece crank set cotterless cranks three piece chain freewheel coaster hub Derailleur Systems rear derailleur front derailleur Reflectors Accessories Troubleshooting 6 PURCHASE DETAILS 7 CONTACT ADDRESS Back cover RAOMO0507 27 27 28 28 32 33 34 85 35 36 37 38 38 38 40 41 43 44 45 47 48 49 49 50 52 53 54 56 57 58 59 60 62 63 64 66 68 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 X3QNI lt lt d o lt N lt Finding the bicycle to best suit your needs is made easy by the vast array of bicycle models and sizes available Refer to the following diagrams to familiarize yourself with the names of the various parts on your bicycle
8. Wheels not aligned in frame Headset loose or binding Front forks or frame bent Broken suspension mount Worn suspension bushing Loss of internal fluid Internal rust Damaged internal parts RAOM0507 Adjust bearings Adjust bearings Adjust chain line Clean and oil jockey wheels Re true if possible or replace Secure mounting bolts Repair or replace chainring set Alter derailleur travel Lubricate If problem persists replace freewheel Lubricate tighten replace cables Alter derailleurs Alter indexing Align wheels correctly Adjust secure headset Consult bicycle mechanic for frame realignment repair replace frame Replace worn components Lubricate as necessary Disassemble damper and replace affected parts Consult professional bicycle mechanic 67 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 PART 6 PURCHASE DETAILS 68 NOTES RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Purchase Record Fill in immediately and retain as a record of your purchase Dn EE ENT REB UAE Address ostcode Date Purchased Place of Purchase e Purchase Amount inc GST Brand MMA lo ae ee 7 l0 ME SerialNumber
9. if supplied for detailed adjustment instructions Disc Brake Adjustment Hydraulic Disassembly of hydraulic disc brakes systems can be a complex procedure and therefore itis best undertaken by a professional bicycle mechanic However as hydraulic systems are usually self adjusting you should be able to manage any centring of the unit to the rotor that is required Refer to the specific brand manual if supplied for more detailed instructions relating to further adjustments or fluid bleeding Note Check all rotor bolts at the time of assembly 48 RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 DRIVETRAIN The drivetrain consists of the pedals chain chainwheel crank set and freewheel These are all the components of the bicycle that transmit power to the rear wheel Pedals There is a vast range of pedals available designed for many different uses Pedals fitted with toe clips and straps aim to make the pedalling process easier for the rider The toe clips and straps ensure the cyclist s feet stay correctly positioned and cause a pulling force as well as a downward pressure to be generated on the pedals To get the full benefit of these pedals it is recommended that the rider wear cycling shoes especially designed for use with toe clips Consult your bicycle dealer for instruction on how toe clips and straps operate WARNING D Pedals fitted with toe clips and straps require a certain l
10. 2mm or less using the above process the cable length may need to be altered To do this 1 Screw the barrel adjuster in completely 2 Press the pads against the rim 3 Un fasten the cable anchor bolt and use pliers to pull the cable through 4 Re fasten the cable anchor bolt 5 Test the brake lever by applying full force and use the barrel adjuster to make any necessary minor alterations ote A screwdriver can be used on some brakes set the clearance on both sides of the rim ote The leading edge of the brake pads should make first contact with the rim when adjustment is complete Special curved washers are fitted some brakes to allow this but on base models a little force needs to be applied to the pad and its mounting RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Installation and Adjustment Linear Pull Brakes 1 When assembling linear pull brakes insert the brake body into the centre spring hole in the frame mounting boss and use the link fixing bolt to fasten the brake body to the frame 2 Hold the shoe against the rim and swap the position of the 6mm and 3mm B washer so that A is maintained at 39mm or more Refer to the following diagram for clarification 39mm or more 3mm washer B 6mm
11. Although the range of lights available is extensive all front lights must have a white beam and all rear lights a red beam Rear lights may also have a flashing mode to increase their visibility to other road users Lights may be powered by a dynamo generator or be battery operated Battery powered lights can work even when the bicycle is not moving and are generally easily removable Prior to riding always ensure that the batteries are properly charged or dynamo power cables are properly connected 5 Safety Flag To increase the rider s visibility in traffic the bright fluoro coloured flag is mounted to the rear axle 6 Rear View Mirror Just as when driving a car the rear view mirror assists the rider in keeping abreast of traffic approaching from behind 64 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 7 Child Safety Carrier Children up to approximately 18kg in weight can legally be transported in a properly designed carry seat attached to the rear of the bicycle To comply with safety standards the child safety carrier needs to be securely attached fitted with a restraining harness support the child and prevent access to the spokes of the turning rear wheel 8 Rear Carrier Transporting your goods is made easy and safe with the use of luggage carriers They are available in many different styles and sizes to suit a variety of requirements Note Only properly designed and fitted lu
12. Pty Ltd ABN 60 001 914 469 HEAD SET AND ROTOR ASSEMBLY DIAGRAM COMPLETE ASSEMBLY 000 Mi PARALLEL ROTOR CABLE ASSEMBLY ote 40 Rotor Headset A rotor is a special headset mechanism used on some BMX Freestyle bikes It enables the handlebars to be turned 360 degrees without tangling the brake cables In this system the front brake cable is connected to the right control lever via the hollow headstem and the fork The rear brake cable is split at the rotor bearing mechanism activating the rear brake by transferring the left control lever pressure Rotor Installation and Adjustment Installing and adjusting a rotor headset can be quite a complex task and one you may refer to your professional bicycle mechanic However if you feel capable the process for rotor installation and adjustment is listed below Remove fork H and upper headset cup F from your bicycle Place lower cable stop C on the top of the head tube G Replace and fasten the upper headset cup to the head tube via the lower cable stop Install headset unit onto the fork neck except the lock washer and lock nut Place rotor bearing unit B over the head set ensuring the larger side is facing up Install upper cable lock A onto the fork neck The original lock washer is now redundant Place lock nut D onto fork neck and alter the head set
13. Rear Sprocket Training Wheel 1 Crash Pad Handlebar Stem Head Set Head Tube Crash Pad Seat Tube Down Tube Chain Guard Crank Arm E E Pedal Chainwheel Tyre Valve Chainstay Rim Chain Tyre Brake Control Cable Reflector Front Brake Brake Pad Front Fork Wheel Reflector Front Hub RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Spokes Updated 23 05 07 Road Bicycles Road or racing bikes aim to cater for fast travel over long distances on smooth surfaces Frames are light weight and rims have a narrower profile for maximum efficiency and speed Top Tube Seat Front Reflector Seat Post Handlebar Stem Brake Shift Lever Seat Post Binder Bolt Head Set Handlebar Seat Stay Head Tube Rear Reflector Rear Brake Front Brake Wheel Reflector Seat Tube Brake Pad Wheel Reflector 9 Down Tube Front Fork Front Derailleur Bottom Bracket Axle Toe Strap Toe Clip Pedal Crank Arm Chainwheel Chainstay Tyre Val Chain Valve Spoke Protector Disc Freewheel Rim Front Hub Rear Derailleur Rear Dropout Tyre Spokes Updated 23 05 07 RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 FRAME SIZE C0 Choosing the appropriate frame and wheel size is imperative when purchasing a new bicycle For safe riding the size of your bicycle should properly match your build In the case of children a bike should
14. a specific right and left pedal It is important that a pedal is never forced into the incorrect crank arm as the thread is different for the two pedal sides The right pedal as indicated by the R stamped on the end of the axle screws into the crank on the chainwheel side of the bicycle in a clockwise direction The left pedal is marked with an L on the axle and it is attached to the other side in an anti clockwise direction To attach place the pedals into the correct crank arm and wind on by hand as tightly as possible in the appropriate direction Use a 15mm wrench to fasten more securely Removing a pedal is the reverse process of attaching The right pedals needs to be turned anti clockwise and the left clockwise Before fitting any new pedals ensure that the axle thread size is compatible with the cranks on your bicycle The two types of cranks available each have different axle threads Cranks that are a one piece design have no separate axle and are compatible with pedals that have a 1 2 thread Three piece crank sets with a separate left and right crank use a slightly larger 9 16 thread Pedal with toe clip and strap attached WARNING D Never attempt to force a pedal into a different sized bicycle crank 51 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 52 Crank Set Together the bottom bracket axle and bearings the crank arms and the chainrings are known as the c
15. all four lock nuts Check for even pull on four cables by rotating the handlebar while the front wheel is off the ground If a fluttering noise is heard in the rotor bearing unit as the upper and lower cables pass each other repeat the adjusting step 1 SADDLE AND SEAT POST Inspection Part of your monthly maintenance tasks needs to include inspection and adjustment of the seat post binder bolt and the seat fixing bolt ensuring both are firmly secured When the Adjusting Bolt seat post is removed from the frame a mark about 65mm up from the bottom can be observed with the words max height or ER Oar eno minimum insertion At all times a minimum of 65mm of seat tube must always remain in the frame Never ride a bicycle with the D minimum insertion max height mark visible on the seat post Doing so may damage the seat post the Seat Clamp Nut frame or potentially even the rider Lubrication Standard Seat Post Remove the seat post from the frame and clean thoroughly Lightly grease the part that will be inserted into the frame Replace the seat post into the frame and adjust and fasten Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 41 qo Adjustment As covered previously in Part 3 to accommodate the individual rider the seat can be adjusted in angle height and distance from the handlebars Generally the saddle is most comfortable wh
16. as shown in Fig 2 3 Usea 5mm Allen key wrench to hold the brake in position and secure the nut with a 10mm wrench to a torque of 7 Nm to 9 Nm See Fig 3 To connect the braking cables refer to the following steps and Fig 1 1 Attach the braking cable to the straddle cable bridge 2 Set the straddle cable as in Fig 1 and alter the shoe rim until a clearance of 1 5mm on both sides is achieved 3 Fasten the straddle cable with the cable fixing nut to a tightening torque of 5 Nm to 7 Nm 4 Trim the excess straddle cable and connect the cable cap Refer to Fig 1 to help you fine tune the shoe clearance You will need a 13mm wrench to make the adjustments 1 IfainFig 1 is greater than b the left side turn the arm fixing nut anti clockwise in the A direction 2 If bis greater than a the right side turn the arm fixing nut clockwise in the B direction To make fine adjustments of the spring tension refer to Fig 1 and use a 13mm wrench to 1 Tighten the spring tension turn the arm fixing nut to A and A as in Fig 1 2 Loosen the spring tension turn to B and B Ae ES Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Brake Shoe Replacement Brake shoes must have adequate usable tread Check your brakes shoes monthly for any indication of wear If the pads are worn past the wear line indication See diagram the brake shoes need to be replaced Always
17. fitted When the wheel is fitted with standard axle nuts loosen them with a spanner Turn the quick release lever to the open position if a quick release axle is present Hold the derailleur unit and allow the wheel to slide forward out of the frame Rest the bike upside down on the handlebars and saddle After wheel is removed do not rest bike on rear derailleur as it may be damaged or misaligned as a result For single gear bicycles with a coaster hub disengage the brake arm clip from the brake arm lift the chain off the rear cog and over the rear axle by hand then allow the wheel to slide out of the frame Rear Wheel Replacement 1 2 Caution in Closed D Take care to correctly refit a rear wheel position Wheel replacement virtually follows the reverse process to rear wheel removal For derailleur geared bicycles hold the rear derailleur spring fully back and feed the top part of the smallest hub cog into the top part of the chain Fit the wheel into the frame For single geared bicycles lift the chain over the axle and onto the cog and fit the wheel onto the frame Ensure the wheel is centred correctly in the frame and then firmly secure both axle nuts To test if the wheel is centred inspect the distance between the front of the wheel and the frame chainstay tubes on either side If the wheel has a Quick Release axle the quick release lever needs to be open and on the left side of the bicycle Check the Quick Relea
18. mounted on the downtube until the inner chainguide just clears the chain If difficulties occur when shifting the chain to the small chainring loosen the cable fixing bolt and re tension the cable REFLECTORS The reflectors fitted to your bicycle are not only an important safety feature but a legal necessity as well Your bicycle should come equipped with one white front one red rear and two orange wheel reflectors Each pedal should also have two orange reflectors fitted As a part of your bicycle maintenance ensure that all reflectors are clean intact and securely fastened The front and rear reflectors should be vertically aligned and the wheel reflectors should be secured opposite the valve within 75mm of the rim When riding at night in addition to the reflectors the bicycle should also be equipped with powered lights Reflective tape on the rider s clothing is also recommended to increase visibility side view reflectors top view WARNING D The reflectors and the reflector mounting brackets must not be removed from your bicycle Doing so may reduce your visibility to other road users potentially jeopardising your safety Serious injury or death may result if you are hit by another vehicle unable to see you WARNING Reflectors should always be used in conjunction with powered lighting when riding at night at dawn dusk or at any other time in poor visibility Failure to do so
19. never be bought with aim of growing into it Riding the appropriate sized bicycle enables the child to develop confidence as they have the necessary co ordination to control he bicycle To accommodate the vast array of height and size variables in children even within he same age groups juvenile bicycles come in different wheel sizes and frame styles to best suit he rider s size Ladies and gents bicycles are also available in a variety of frame sizes Sizing is based on the distance between the centre of the bottom bracket and the top of the frame seat tube Female riders should take into account the slope of the top tube to determine frame size suitability WARNING D For safe riding your bicycle should match your size correctly otherwise you may loose control and fall Ideally there should be a minimum clearance of 25mm between the crotch of the intended rider and the top frame tube of the bike while the rider straddles the bicycle with both feet flat on the ground PART 3 BEFORE YOU RIDE Clearance over the top of the frame ensures that the rider can safely stand astride the bike when forced out of the saddle such as stopping at traffic lights Clearance heights vary according to rider preference and between the different bicycle models RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Please refer to the chart below to assist you in making the correct choice If yo
20. the ground 2 Take the handlebar assembly from the steering tube 3 Loosen and remove the compression bolt the top cap assembly and then the stem clamp bolts 4 Remove the headset wedge whilst supporting the forks with one hand then remove the dust cover upper ball retainer 5 Pull the forks out of the frame and remove the lower ball retainer 6 Thoroughly clean and check each part of the headset for damage Replace if necessary See your dealer to replace the headset 7 Grease both the head set cups To work grease into the lower head cup re fit a ball retainer into it Re attach the forks 8 Install a bearing retainer into the bearing race and pack it with grease Push the screw cup down onto the fork steerer and into position then re fit the bearing dust cover bearing race headset wedge and spacer 9 Alter the upper cup by hand until no movement can be detected in the forks 10 Firmly tighten the stem clamp bolts then replace and secure the handlebar assembly Compression Bolt Handlebar Stem Cap ots T D Stem Cap Bolts i Spacer Headset Wedge Stem Cap Bearing Race lt Bearing Dust Cover Bearing Retainer emm Installed By Factory Upper Headset Cup Steerer Tube Headtube d Lower Headset Cup Bearing Retainer lt Bearing Dust Cover Headset Crown Race Fork 39 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company
21. 01 914 469 Updated 23 05 07 Three Piece Crank Replacement 1 Place the crank arm onto the axle Use a soft mallet to gently tap the crank arm 2 3 Reattach the washer and secure the flange nut or bolt securely to a torque of 27Nm 4 Replace the dust cover After fitting new three piece cranks some additional maintenance is required D as components can become loose with use The following adjustments should be made after several hours of riding and repeated two or three times after further use There after the cranks should remain secure 1 Remove the dust cap 2 Gently tap the crank arm with a mallet 3 Re tighten the flange nuts and refit the dust caps Lubrication and Replacement Cartridge Bottom Bracket Freeplay cannot be removed from a cartridge bottom bracket It is a sealed unit and is designed to be replaced as an entire unit when it is worn out Once the cranks have been removed a specific extraction tool is required to remove the cartridge bottom bracket Consult your specialist bicycle dealer for further advice regarding this process Turn the screwbolt clockwise Position the crank on the axle CE edil Lightly tap the crank onto the axle Tighten the flange nut Replace the dust cap 95 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 56 Chain Inspection and Lubrication Regular inspection and maintenance of your chain is vital to guard ag
22. 1 914 469 66 TROUBLESHOOTING Problem Possible Reason Possible Solution Slipping chain Brake not working correctly Frequent punctures When the brakes are applied they squeal squeak Wobbling wheel Knocking or shuddering when brakes applied Constant clicking noises when pedalling RAOMO0507 Excessively worn or chipped chainring or freewheel Sprocket teeth Chain worn stretched Stiff link in chain Non compatible chain chainring freewheel Brake blocks worn down Brake blocks rim greasy wet or dirty Brake cables are binding stretched damaged Brake levers are binding Brakes out of adjustment Inner tube old or faulty Tyre tread casing worn Tyre incompatible to rim Tyre not checked after previous puncture Tyre pressure too low Spoke protruding into rim Brake blocks worn Brake blocks rim greasy wet or dirty Brake block toe in incorrect Brake arms loose Axle broken Wheel out of true Hub cones loose Headset bindings Hub bearings collapsed Bulge in the rim or rim out of true Brake mounting bolts loose Brakes out of adjustment Forks loose in head tube Stiff chain link Loose pedal axle bearings Loose bottom bracket bearings Bent bottom bracket or pedal axle Loose crankset Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Replace chainring sprockets chain Replace chain Oil or replace link Consult a professional bicycle mechanic Repl
23. Cone Axle Nut Cone Locknut Hub Lubrication At least once a year your wheel bearings need to be disassembled and re greased Riding in very muddy or wet conditions will mean more frequent servicing Due to the complexity of the task you may prefer to have a professional bicycle mechanic perform the disassembly However if you feel capable the process is listed below Take the wheel out of the frame Remove the axle nut cone lock nut and the bearing cone from one side of the hub axle Remove the axle complete with the cone and lock nut from the other side of the hub oom If your bicycle is fitted with dust caps carefully remove them from both sides of the hub to expose the ball bearings 5 If ball bearings and ball retainers are present carefully remove these from both sides of the hub 6 Remove the freewheel on rear hubs with screw on type freewheels before disassembling the axle You will need to use a special tool to do this 7 Clean all the hub components thoroughly and check for damage especially looking for pits or grazes in the bearing surfaces and cones and damaged ball bearings Replace if required 8 Insert grease into each clean or new ball bearing and into the inner cups of the hub and refit 9 Re assemble the hub axle in reverse sequence to disassembling taking care to properly re adjust the bearing cones RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Ho
24. They are very reliable and easy to operate the rider simply applies backward pedal pressure to activate The rider can then coast without pedalling if desired Coaster hub brakes come in several different models Regardless of which style is fitted to your bicycle only minimal maintenance is required by the rider The coaster hub sprocket should be kept clean and lubricated whenever the chain is oiled Any adjustments or replacements are best handled by a professional bicycle mechanic since the coaster hub s internal mechanisms are very complex 58 RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Derailleur Systems The front and rear derailleurs the shift controls and the derailleur control cables collectively are known as the derailleur system For smooth gear changes all the components of the derailleur system must operate properly Several different types of derailleur systems are available the friction type system the index system e g SIS and the fully integrated system e g STI The basic operating principles are the same or all of the different systems With a standard friction derailleur system the rider should eel each gear shift into position With an index system changing gears is very easy and precise each different gear position is linked to a positive click mechanism in the shifter The shifting levers may be positioned above or below the handlebar or in both l
25. ace brake blocks Clean blocks and rim Clean adjust replace cables Alter brake levers Centre brakes Replace inner tube Replace tyre Replace with correct tyre Remove any sharp objects from tyre Inflate tyre to correct pressure File down spoke Replace brake blocks Clean blocks and rim Correct block toe in Secure mounting bolts Replace axle True wheel Tighten hub bearings Alter headset Replace bearings True wheel or consult a bike mechanic Secure bolts Centre brakes and or adjust brake block toe in Secure headset Oil chain Alter bearings axle nut Alter bottom bracket Replace bottom bracket or pedals Tighten crank bolts Updated 23 05 07 Problem Possible Reason Possible Solution Grinding noise when pedalling Chain jumping off chainwheel sprocket or chainring Freewheel does not freewheel Incorrect gear shifting Steering not accurate Knocking from rear end of suspension model Suspension dampers binding Updated 23 05 07 Pedal bearings too tight Bottom bracket bearings too tight Chain fouling derailleurs Derailleur jockey wheels dirty binding Chainring out of true Chainring loose Chainring teeth bent or broken Rear to front derailleur side to side travel out of adjustment Freewheel internal pawl pins are jammed Derailleur cables sticking stretched damaged Front or rear derailleur not adjusted properly Indexed shifting not adjusted properly
26. ainst premature wear At least monthly or after riding in wet muddy or dusty conditions the chain should be cleaned and lightly oiled Any excess oil should be removed and care taken to ensure the lubricant does not come into contact with the tyres or rim braking surfaces Check that all links of the chain move freely Replace the chain if it appears stretched broken or causes problems when changing gears Adjustment and Replacement Note Fitting or adjusting a chain can be a complex task and one which you may wish to refer to your specialist bicycle mechanic To adjust the chain on single speed freewheel coaster hub brake or 3 speed hub geared bicycles 1 Loosen the rear axle nuts and coaster brake arm clip if fitted 2 Move the wheel in the frame until the chain has approximately 10mm of vertical movement when checked in the centre between the chainwheel and the rear sprocket Moving the wheel forward loosens the chain and backward movement will make it tighter 3 Centre the wheel in the frame and re tighten the axle nuts To remove a chain from one of these bicycles Prise off a U shape plate on the master link with a screwariver Disconnect the chain using a special joining link To replace a chain on a single speed freewheel bike coaster hub brake or 3 speed hub bicycle Thread the chain around the chainwheel and rear sprocket Fitthe master link into the rollers at each end of the chain Position the m
27. arger rear cog is engaged One cog can be selected through one firm push or by continuing to push on the lever multiple cogs can be engaged By pushing he upper smaller lever on the left inwards with your index finger the chain moves to a smaller chainring A higher gear can be selected by pushing the upper right lever with your index finger to activate a smaller rear cog By pushing the lower left lever with your humb the chain will move from the smaller to the larger chainring To clarify please refer o the following diagram Left Right Low gear front High gear rear High gear front Low gear rear RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Dual Control Shifters The majority of drop bar road bicycles produced today are fitted with dual control levers EWS Since both the brakes and the gears are built into the one mechanism dual control shifters make it possible to change gears without having to remove your hands from the handlebars Shifting can be performed whilst your hands are resting on the lower bend of the handlebars or on the brake lever hoods in the drops Pulling the shifter towards the bar activates the brakes while shifting the dual control lever in towards the front wheel engages the gears To select a higher gear the small right lever is pushed to engage a smaller rear cog Pushing the large lever inwards activates the large front chainwheel To select a lower
28. as usual Connect the upper cable to the left brake lever Discard cable ferrule provided on the upper cable if your lever is already equipped with a cable adjuster Hook the two cable ends 1 to the top hooks B1 of the rotor bearing unit Screw the adjusting barrels into the upper cable stop Pull rotor bearing unit downward to pick up the slack of cables Adjust the height of bearing unit though the cable adjuster on the brake lever or cable splitter until the bottom hooks B2 of the rotor bearing unit are approximately 1 8 1 4 away from the lower cable stop Run the lower cable under the frame tube with the split cables on each side of the frame Hook the two cable ends 1 to the bottom hooks B2 of the bearing unit Screw the adjusting barrels into the lower cable stop Measure and cut the single measure housing 3A to the correct length Caution This is the only cable that can be cut to adjust for different frame lengths Connect the cable to the rear brake calliper in the usual manner RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 1 The rotor bearing unit sh Cable Tension Adjustment ould appear parallel to the upper and lower cable stops once installed If the unit is tilted pull each cable end one at a time to see which one h hook Pick up the slack as slack on the bearing hrough the adjusting barrel When even pull on all four cables is reached secure
29. aster link side plate and slip on the U shaped snap on plate Ensure the open end of the U shaped plate is trailing as the link approaches the chainwheel when pedalling forward Front Chainwheel Straightedge 12mm RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Unlike the single speed freewheel bike coaster hub brake or 3 speed hub bicycle the chains on derailleur geared bicycles are automatically tensioned by the rear derailleur Consequently manual adjustment of the chain is not necessary on derailleur geared bicycles The process for removing and replacing chains or altering the length of the chain on a derailleur geared bicycle also differs from that used on the other bike types The chains on derailleur geared bicycles are narrower meaning a special tool is needed to complete any of the procedures To remove a chain on a derailleur geared bicycle Fitthe rivet tool so that the punch pin is centred over any one of the chain rivets Pushthe rivet almost all the way out then back out the punch and remove Holding the chain on both sides of the punched rivet bend it slightly to release the link from the rivet Chain Rivet Tool To install a chain on a derailleur geared bicycle Thread the chain around the chainwheel rear sprocket and derailleur cage with the rivet facing away from the bicycle Bring the two ends together wi
30. ded this be done prior to every ride A loose saddle clamp or seat post binder can allow the saddle to move which may damage the seat post or cause you to lose control when riding and fall Seek assistance from your dealer to ensure you know how to clamp your seat post correctly whatever type of mechanism is fitted to your bicycle CAUTION If your bicycle is fitted with a suspension type seat post check that this is intact and functioning properly RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 BRAKES For safe riding it is crucial that your bicycle s brakes function correctly With use the bicycle s brake pads wear and the control cables stretch Consequently prior to every ride the brakes should be inspected and adjusted as necessary to ensure proper operation WARNING A bicycle should never be ridden unless the Linear D brakes are working correctly Take care when using the front brake Applying it abruptly or excessively may throw the rider over the handlebars potentially causing serious injury or death Hand Controlled Brakes There are five main types of hand controlled brakes used on bicycles the sidepull the V brake the Linear Pull brake U type calliper brakes and disc brakes All are operated by the rider squeezing the control lever attached to the handlebar which activates the brake Differences occur between the four hand operated brakes by how they are mou
31. ds and any damage to the cable housing Replace as necessary to ensure accurate shifting performance 59 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 60 Lubrication Lightly oil all the pivoting points of the front and rear derailleurs at least every month Any excess oil should be wiped off to prevent dirt entering into the mechanisms Clean and apply a thin layer of grease to the shifting cables every six months or whenever new cables are fitted Adjustment Rear Derailleur If your bicycle is fitted with a SIS derailleur YO system fine turning of the SIS mechanism ants See gt S will be the most common rear derailleur adjustment you will need to make A og x To fine tune the SIS rear derailleur Adjusting 7 Raise the back wheel of your bicycle off barrel 2 f the ground to enable you to rotate the JN pedals forward and set the shift lever on SIS mode Change the gears from top to second top gear and observe the chain s response If the chain will not move to second gear turn the cable adjusting barrel anti clockwise to increase the cable tension Turn the adjuster clockwise to decrease the tension if the chain moves past the second gear Spin the pedals and with the chain still in second gear turn the adjuster anti clockwise until just before the chain makes noise against the third gear This adjustment increases the tension of the inner cable If after com
32. e lockring anti clockwise and remove Turn the adjusting cup anti clockwise and remove Remove the left ball retainer and slide the axle out of the frame to the left a R0 DN Turn the right side fixed cup anti clockwise and remove as well as the right ball retainer Once the crank is dismantled clean all bearing surfaces and the ball retainers and check for wear Replace any damaged parts and pack grease into the ball bearing retainers Re assemble the crank in the reverse order of the procedure listed above Three Piece Crank Removal To remove Cotterless cranks ou will need to use a specific c LL AO removing tool Follow the outline 7 below to guide you through the N M N A w process f es NO Bottom Bracket Shell UA 1 Use a coin or a screwdriver md Three Piece Crank Removing Tool to remove the dust cap Removable Left Fixed Right Hand Cup 2 Remove the flange nut or bolt and washer after loosening NB Bottom Bracket Cup ai aK 3 Attach the removing tool into L t le the crank and tighten Bal di a Bottom Bracket Left Hand Cup 3 en UF 4 Turn the screw bolt until the Locking P crank comes away from the T Ple axle T OWN e o v NOM ron C 17 BITE NP Remove dust cap Loosen and remove flange nut 54 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 0
33. e tube into the tyre 12 Starting either side of the valve use your hands to remount the other side of the tyre by pushing the edge toward the centre of the rim Work around the rim until the tyre is almost completely remounted 13 Push the valve up into the rim and ensure that the tyre sits properly in position 14 Remount the remainder of the tyre by using your thumbs to roll the last most difficult part on Note Do not use tyre levers as these can easily puncture the tube or damage the tyre 15 Ensure that the tube is completely free of the rim and the tyre bead at all points N 16 Inflate the tube with a hand pump until the tyre begins to take shape ensuring the tyre bead sits evenly around the entire rim Fully inflate the tyre to the pressure marked on the sidewall when properly positioned Check pressure with a tyre air pressure gauge 17 Replace the wheel into the frame and adjust gears brakes and quick release levers as necessary 33 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Tyre Valves Bicycles primarily use either Schraeder or Presta tyre valves To inflate tyres the pump needs to be fitted with the appropriate attachment specific to the valve stem The Schraeder valve is the most commonly used tyre valve It is also known as the car or the American valve Tyres fitted with Schraeder valves can be inflated using either a hand pump or a service
34. ecific cycling shoes with a plate on the sole which clicks into a spring loaded fixture on the pedal This maintains the cyclist s foot in the most effective pedalling position The amount of force required to clip the foot in an out of the pedal can be adjusted on many clipless pedals For further instruction on how to do this consult your dealer WARNING D Clipless pedals should only be used with shoes specifically made to fit the make and model of the pedal being used WARNING Clipless pedals require a certain level of skill to operate safely Riders should repeatedly practice using such pedals in areas free from traffic hazards or obstacles until operation becomes a reflex action Failure to do so could result in the cyclist losing control of the bicycle and falling 50 RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Lubrication and Adjustment The maintenance your pedals need will depend upon whether or not they can be disassembled to enable access to the internal bearings and axle If they cannot be disassembled every six months a small amount of oil should be injected onto the inside bearings of pedals Pedals that can be fully disassembled should have the bearings removed cleaned and greased every six to twelve months However due to the complexity of this task it is recommended that it be completed by a professional bicycle mechanic Attachment Each pair of pedals has
35. eel hub A single Allen key or hexagonal bolt is used to secure the handlebar into the stem on MTB and Racing style bicycles BMX bicycles may have four clamping bolts These should be tightened to 18Nm Ensure that the curved rake of the fork is angled to the front of the bicycle when setting the handlebars in the fork Make sure handlebars and fork are facing forward _ Note curved rake of fork faces forward Direction of travel Always check the handlebar clamping mechanism has been firmly tightened D prior to riding Regularly inspect the handlebar grips and tube end plugs If damaged replace especially on children s bicycles as exposed ends on handlebars can cause injuries Replacement forks must have the same rake length and inner tube diameter as those originally supplied on the bicycle RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Bicycle Suspension To help combat some of the jarring associated with riding on rough terrain some Mountain Bikes are fitted with suspension systems Primarily suspension systems are built into the forks or the rear of the frame but can also be included in seat posts as well By equipping the bicycle with suspension can improve its comfort and handling properties and potentially enable the cyclist to rider faster However for safety reasons it is imperative you still ride within your own limits Over time as your riding capabilities improve
36. eight Minimum Insertion Mark Minimum Insertion Mark MTB Handlebar Stem BMX Handlebar Stem 35 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 36 Ensure that the handlebars are appropriately aligned and are tightened to a minimum 17Nm of torque when re fitting the stem Use only the appropriate Allen key or hex wrench for fastening and take care not to over tighten Test the attachment by bracing the front wheel between your knees and try to move the handlebars up and down and from side to side The handlebars are secure within the stem and the stem within the fork steerer tube if no movement is detected when applying turning pressure Brake Lever Grp Handlebar Assembly Drop Bar Expander Bolt Handlebar Stem Expander Wedge Handlebar Handlebar Stem Expander Wedge Racing Handlebar Assembly Handlebar Forks Handlebar positioning is largely directed by rider preference However there are general principles governing how the handlebars should be set up for the different bicycle types On BMX bicycles the handlebar should remain roughly in an upright position with slight forward or backward adjustments for rider comfort For MTB bikes it is recommended that the bar should be almost horizontal with the ends pointing back and slightly down The drop style handlebars of racing bicycles should have the ends angled toward the rear wh
37. en the top of the seat is angled almost parallel to the ground or the front is slightly raised The most comfortable reach to the handlebars can be identified by sliding the saddle forward or back along the mounting rails until the rider s preferred distance is located Once identified the saddle clamping mechanism needs to be tightened as firmly as possible When attaching the seat post to the seat position the seat post into the clamp under the saddle Place it in the frame without tightening and adjust until the desired angle and position on the post are found Fasten the clamping mechanism Adjust the height to the required level and tighten the binder bolt Note The seat post must not extend beyond the minimum insertion max height mark Bicycles are most commonly fitted with two types of seat clamps The majority use a steel clamp with hexagonal nuts on either side to tightened The second type a micro adjustable clamp uses a single vertically mounted Allen head fixing bolt which is tighten A quick release mechanism may also be used The operation of a Quick Release seat post mechanism is the same as for Quick Release hubs Refer to Page 31 To test the tension of the binder bolt hold the seat and try to force it sideways If the saddle moves you need to further tighten the binder bolt WARNING D After making any changes to the seat s position check that the saddle adjustment mechanism is properly tightened It is also recommen
38. ened Check the rear suspension components for excessive wear or side play If the suspension components come with a separate specific manual refer to this for more in depth information 13 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 11 Safety amp Accessories S Check that all reflectors are attached correctly and visible For riding at night fit fully functioning dynamo or battery powered lights Check that the bell is fully operational Check all additional components on the bike are appropriately secured and functioning Ensure the bicycle rider and any passenger in a child seat are wearing helmets HELMETS When riding your bicycle it is recommended that you always wear an appropriately fitting Australian Standards Approved bicycle helmet This also applies to any passengers you may carry in a child safety seat LEN x A bicycle helmet must carry the Australia amp New Zealand Standards approved mark AS NZS 2063 label fit properly The helmet should be well ventilated comfortable lightweight The wearing of helmets is mandatory D in most Australian states Non compliance may result in an enforceable penalty RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 RIDING SAFELY General Rules The same road rules used for vehicles apply to cyclists Obey the road rules at all times such as giving way to pedestria
39. enient but potentially dangerous To minimise the likelihood of a flat tyre from air leaking from a valve ensure valve caps are fitted and that valves are clean Bead setting Ensure the bead is correctly fitted in the rim when inflating or changing tyres Recommended Tyre Pressures Tyre pressure directly influences the performance of a tyre on different surfaces and in varying weather conditions Recommended tyre pressure is given either as maximum pressure or as a pressure range For riding on smooth slick terrain such as hard packed clay and on deep loose surfaces such as deep dry sand tyres should be inflated to lower pressures at the bottom of the recommended pressure range This helps to cushion the rider against the impact Using high pressures at the top of the recommended pressure range enables a faster but rougher ride These pressures are ideal for riding on a smooth dry pavement Failure to sufficiently inflate the tyres according to the rider s weight and intended use can cause the tube to puncture Tyres should be inflated to the recommended pressure moulded on the sidewall of the bicycle s tyres Use this chart as a reference if you are unable to find the relevant information on your tyre BMX 241 344 35 50 p s i MTB 276 448 k p a 40 65 p s i Road Touring 483 620 k p a 35 50 p s i Road Racing 755 862 k p a 110 125 p s i Hybrid Crossbike 414 690 60 100 p s i
40. evel of skill to operate safely Riders should repeatedly practice using such pedals in areas free from traffic hazards or obstacles until operation becomes a reflex action Failure to do so could result in the cyclist losing control of the bicycle and falling It is also recommended that the straps be kept loose initially and gradually tightened as the rider s skill in using the pedals increases However toe straps should never be tight when riding in traffic Inspection Every month the pedals should be inspected Check that Pedals are securely fastened into the cranks Loose pedals are a potential hazard for both the rider and the integrity of the cranks Pedal bearings are adjusted correctly Alter grease or replace if any roughness or looseness is detected in the pedal bearings when the pedals are moved up and down laterally or rotated by hand The front and rear pedal reflectors are clean and firmly attached If toe clips are fitted ensure that they are fastened tightly to the pedals Correct Pedal Attachment R NN E E Fe Pedal Axles N L Left Turn Counter Turn Clockwise Clockwise to tighten to tighten Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 49 Clipless Pedals Clipless pedals or step in pedals are designed for maximum pedalling efficiency The rider wears sp
41. ever should be parallel to the fork to prevent accidental opening when riding 3 When secondary retention devices are present ensure they are properly lodged in the fork ends 4 If fitted firmly fasten both axle nuts 5 Re set the brake quick release and inspect the brake pad clearance If able adjust the brake cable pad clearance WARNING D The secondary retention device is crucial to safe riding Tampering with or removal of this device may cause serious injury or death It may also void your warranty CAUTION You need to ensure the tension of the quick release lever is sufficient To tighten open the lever and turn the tension adjusting nut clockwise a quarter turn until you can only fully close the quick release by wrapping your fingers around the fork for leverage and the lever leaves a clear imprint in the palm of your hand WARNING Quick release adjustments are still necessary even if secondary retention devices are fitted Failure to properly adjust the quick release mechanism may lead to wheel instability which ultimately could cause the rider to lose control and fall E29 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 30 Rear Wheel Removal js oa fF Oo m Open the brake quick release if fitted or screw in brake cable adjuster Undo the brake cable anchor bolt if greater clearance is required Move the chain onto the smallest rear cog if derailleur gears are
42. g action may be compromised if the stem binder bolt the handlebar binder bolt or the bar end extension clamping bolts are not sufficiently tightened This could result in the rider losing control and falling To check try to twist the handlebar stem assembly whilst the front wheel of the bike is positioned between your legs If the stem twists in relation to the front wheel the handlebars turn relative to the stem or the bar end extension rotates in relation to the handlebar the bolts need to be tightened A Stem Wedge Bolt Maximum Height Minimum Insertion Mark Exceeds 2 1 2 64mm Y 11 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 SAFETY CHECKLIST Safety checks are an important part of any ride In conjunction with the recommended maintenance in Parts 4 and 5 of this manual it is also suggested that a thorough inspection should be undertaken fortnightly tightening all nuts and bolts replacing worn and damaged parts and ensuring all components are in their correct positions For further details please refer to Parts 5 and 6 WARNING D Body parts and other objects should be kept clear from the moving components of the bicycle when in use such as the spinning wheels and the moving chain When riding always wear appropriate footwear i e shoes that will grip the pedals and no sandals Refrain from jumping with your bike Jumping puts enor
43. gear shift the large right lever inward to engage a larger rear cog One firm push shifts the chain one cog while continuing to press will move the chain over multiple cogs Rapid Fire Shifters ON Q K 27 High HT Rear Low Gear High Gear Rear Front Low Gear Front 21 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 BICYCLE CARE Basic maintenance To keep your bicycle in prime condition follow the recommendations listed below Painted frames should be dusted and any loose dirt dislodged with a dry cloth Clean by wiping with a damp cloth soaked in a mild detergent mixture Use a cloth to dry and polish with car or furniture wax Plastic parts and rubber tyres should be cleaned with soap and water Wipe a rust preventative fluid over chrome plated bikes All moving parts should be habitually cleaned and lubricated and components secured and adjusted as needed Refer to Parts 4 and 5 of this manual for further details Apply touch up paint or clear nail varnish to any areas where the paint has become scratched or clipped to the metal This will help prevent rusting he potential for rusting is limited by the use of alloy components and B E D black electronic deposit treated steel rims To avoid rapid bearing deterioration the hub and bottom bracket bearings need to be removed and re greased if the bicycle has been submerged in water Avoid cycling
44. ggage carriers should be used on your bicycle 9 Pannier Bags Carry bags equipped with several weather resistant compartments that usually fit either side of a rear mounted carrier Ideal for bicycle touring i e enable you to carry extra gear and keep it dry 10 Saddle Bags As the name implies they attach under the seat for discreet storage for all your essentials Such as tools a spare tube or a puncture kit Other small bags are also available to fit on the handlebars or in the corner of the main frame 11 Bar Ends Fitted to the ends of Mountain Bicycle handlebars bar ends increase the rider s hand positioning options especially when climbing a hill 12 Computer A multi function device enabling the rider to monitor their speed distance travelled and time Recommended for use when fitness training 13 Mudguards Help to minimise road dirt and water soiling your clothes and getting in eyes 14 Water Bottles Keeping well hydrated when riding is very important especially in hot weather Bicycle water bottles are available in various sizes and colours They can be conveniently stored in frame mounted carry cages so that fluids are easily accessible 15 Gloves Wear gloves on long rides to prevent soreness and blisters on your hands or as means of protection in the event of a fall They are available in a variety of colours and designs 65 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 00
45. h the inside of the fork steerer tube when tightened The stem TR may also clamp onto an unthreaded fork steerer as is the case with the Ahead Set system Maximum Height Minimum Insertion Mark Expander Bolt Wedge Head Tube BMX Handlebar Assembly Note The handlebar height can be altered to suit the rider s preference To remove a standard stem the expander bolt needs to be loosened two or three turns and then tapped to free the wedge inside Servicing involves applying a thin film of grease to the part after it has been wiped clean Also lubricate the wedge that will be inserted into the frame NOTE These same adjusting principles cannot be applied to the Ahead Set headstem system max height or minimum insertion Never ride a bicycle if the stem has been Etched the stem is a mark about 65mm up from the bottom with the words raised so that the minimum insertion max height line can be seen The front brake cable is routed through a hole in the front of the stem on some MTB bikes Adjusting the height Handlebar Clamp Bolts D on this type of stem Handlebar Binder EM m MN means you will need to re adjust Pd B the front brake S i Check that the Qe suspension is intact and operating properly on bicycles equipped with a suspension type T Expander Bolt Wedge V Expander Bolt Wedge handlebar stem MK M Maximum Height lt Maximum H
46. hat all spokes are present intact and are taut Spoke repairs can be difficult and are best undertaken by a professional bicycle mechanic Loose hub bearings Caution Do not ride your bicycle if the hub bearings are loose or damaged Check the hubs by moving the wheel from side to side If movement is detected adjustments will be needed Rims Brakes can become ineffective if dirt or grease accumulate on the rims Check that your rims are clean and dry before using Take care to prevent oil contact on the rim braking surfaces when lubricating your bicycle Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 y gt J U JJ m SE m Z 2 lt m P m gt m 27 28 Tyre inspection As tyres are the rider s only contact with the road correct tyre maintenance is crucial for stability and safety Consider the following when inspecting your tyres Tread Check the tread for signs of excessive wear or flat spots and cuts or damage Caution Riding on excessively worn or damaged tyres may be hazardous so tyres should be replaced Inflation Maintain tyre pressure at the level recommended on the tyre sidewalls Preferably use a tyre gauge and a hand pump to inflate rather than a service station pump Caution Using a service station pump for inflation can lead to sudden over inflation potentially resulting in a blow out Valves A flat tyre is not only inconv
47. he locknut on the left side clockwise to loosen Turn the adjusting cone anti clockwise with a screwdriver until correctly secured Turn the locknut in an anti clockwise direction to re fasten To disassemble 1 Take the chain from the chainwheel Turn the spindle clockwise and remove the left pedal Turn the left side locknut clockwise and remove as well as the keyed lock washer Use a screwdriver to turn the adjusting cone clockwise and remove a fF oO Remove the left ball retainer slide the crank assembly out of the frame to the right and remove the right ball retainer Once the crank is dismantled clean all bearing surfaces and the ball retainers and check for wear Replace any damaged parts and pack grease into the ball bearing retainers Re assemble the crank in the reverse order of the procedure listed above Locknut Fixed Cone N AN Lockwasher 4 Adjusting Cone A 2 Ball Retainer Bearing Cup Ball Retainer One Piece Crank Assembly Chainwheel 53 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Lubrication and Adjustment Three Piece Cranks Cotterless Cranks To adjust Turn the lockring on the left side anti clockwise Turn the adjusting cup until appropriately set Carefully re fasten the lockring without disturbing the cup adjustment To disassemble Remove the cranks from the axle Turn the left sid
48. ill main frames are covered under the regular warranty for frames of the same material construction should they fail at any regular weld point Rear suspension design is not covered under this warranty Item 4 Warranty coverage for front suspension systems shall be for a period of one year covering faulty workmanship or materials only Item 5 Warranty coverage shall last 6 months from the date of purchase for all other parts and accessories Tyres and tubes are not covered by this warranty The above warranty coverage periods are subject to all the limitations described overleaf This limited warranty is not transferable and shall only apply to normal and ordinary use of this product To obtain service under this warranty the bicycle should be returned to the Apollo dealer from whom it was purchased together with a receipt or appropriate proof of purchase document which identifies the bicycle by frame number Should this bicycle or any part or accessory be determined by Apollo to be defective and covered by this limited warranty Apollo will at its option either replace or repair any defective product part or accessory Repair services or replacement parts will be provided free to you Dealer labour charges for installing replacement parts or accessories are not covered by this limited warranty The cost of transportation to and from an authorised Apollo dealer for repair or replacement of any defective part and or accessory is to be borne by
49. in the rain or exposure to corrosive materials such as the salt from riding on the beach as much as possible If unavoidable wash and dry your bicycle often and wipe or spray all unpainted parts with an anti rust treatment Dry the wheel rims so braking performance is not hindered Storage Protect your bicycle from the elements by storing it in a dry shady location Prolonged ultra violet light exposure may cause the paint to fade or the rubber and plastic parts to crack The bicycle should be cleaned lubricated and the frame waxed if it is to be stored for any length of time Deflate the tyres to half pressure and hang the bicycle off the ground 2 2 Cc Lu o o Lu lt O Lu O gt 2 m lt n Store away from electric motors as ozone emissions may damage the rubber and paint Do not cover with plastic as rusting may occur due to sweating 22 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Security In an attempt to prevent your bicycle from being stolen the following precautions should be undertaken 1 Take note of the bicycle serial number generally located underneath the bottom bracket of the frame 2 Register the bicycle with the manufacturer distributor and local police 3 If your bicycle is left unattended always secure it to an immovable object such as a lamp post Use a high quality bicycle lock that will resist hack saws and bolt cutters
50. ion to the forks and the direction of travel Check the head set locking mechanism is appropriately fixed and fastened If handlebar extensions are fitted check they are positioned and secured correctly Ensure the minimum insertion mark cannot be seen on the handlebar stem Ensure the ends of the handlebars and bar ends are covered or capped Chain Check the chain is lubricated clean and runs freely In wet or dusty conditions service the chain more frequently Bearings Check headset wheel bearings pedal bearings and bottom bracket bearings Check all bearings are oiled run smoothly and show no signs of excess movement grinding or rattling Cranks and Pedals Check cranks are securely fastened to the axle and are straight Check pedals are properly and firmly attached to the crank Derailleurs Check the front and rear mechanisms are operating appropriately Check control levers are securely anchored Check derailleurs control cables and shift levers are sufficiently lubricated If the gear components come with a separate specific manual refer to this for further information Frame and fork Check that the frame and fork are straight and intact Replace if either is bent or broken 10 Suspension if applicable Check that components operate smoothly with no binding Keep clean of grit and lubricate top of outer leg seal Check that all components of the fork amp rear suspension are properly tight
51. is dangerous and may result in serious injury or death 63 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 ACCESSORIES To make your riding safer more convenient or even more enjoyable you may wish to equip your bike with some of the many bicycle accessories available Before fitting any accessory however it is important to check that is suitable for your bicycle Also ensure that the accessory is appropriately attached and will not interfere with your handling of the bicycle prior to riding Listed below is a sample of the many kinds of bicycle accessories available 1 Pump A pump is crucial if you are to maintain the appropriate tyre pressure Check that the end connection is compatible with the valves on your bicycle s tubes 2 Repair Kit Tyre Levers amp Spare Tube It is recommended that you always carry these if you wish to avoid the inconvenience of being stranded with a puncture 3 Lock Do not risk leaving your bicycle unsecured When your bicycle is unattended always lock it to an immovable object to help minimise the risk of theft Take care when choosing a lock for the range available is considerable but not all are necessarily effective anti theft devices 4 Lights For safety it is recommended your bicycle should always be fitted with lights when riding at night or in other low light conditions These should be used in conjunction to your bicycle s fitted reflectors
52. ithium based grease disassemble Yearly Wheels bearings lithium based grease disassemble Headset lithium based grease disassemble Seat pillar lithium based grease disassemble Note Increase the regularity of maintenance the more you ride and use in wet or dusty conditions Take care not to over lubricate excess lubricant should be removed to prohibit dirt build up WARNING D Always seek expert advice for any maintenance requirements you feel unable to complete You run the risk of potentially damaging your bicycle or yourself from falling if your bike is not correctly serviced or adjusted RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Schedule 2 Service Checklist Frequency Task Page Reference Before every ride Check tyre pressure 28 Check brake operation 43 Check wheels for loose spokes 27 Make sure nothing is loose 26 After every ride Quick wipe down with damp cloth 22 Weekly Lubrication as per schedule 1 24 Monthly Lubrication as per schedule 1 24 Check derailleur adjustment 61 Check brake adjustment 44 Check brake and gear cable adjustment 44 61 Check tyre wear and pressure 28 Check wheel are true and spokes tight 27 Check hub head set and crank bearings 32138 152 for looseness Check pedals are tight 51 Check handlebars are tight 36 Check seat and seat post are tight 41 and comfortably adjusted Check all nuts and bolts are tight 26 6 monthly Lubrication as per sched
53. ld bicycle rider needs to be taught correct riding skills and behaviour particularly addressing safety before they take to the streets Hopefully by doing so accidents can be avoided Always wear a correct fitting helmet 2 Follow all road rules especially stop signs and red lights 99 Always proceed with caution before entering a street Only enter if there is no traffic approaching Avoid riding on driveways or the road Do not ride on busy streets Be conscious of other road vehicles in the vicinity Avoid night riding Oo OC A Take extra care when riding downhill Slow down using the brakes and maintain control of the steering As suggested by the Consumer Affairs Department riding bicycles with small wheel diameter at excessive speeds can lead to instability and is therefore not recommended Caution D When riding downhill never take your hands off the handlebars or feet off the pedals 17 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 GEARS HOW TO OPERATE Derailleur Gears Derailleur gears are the most common type of gear systems used on bicycles They are the changing mechanism used to move the drive chain up and down a series of cogs or sprockets the cluster or cassette stack at the rear of the bicycle and across the chainwheel at the front of the bike if fitted Multispeed bicycles today can range form 5 6 gears to as many as 30 Rea
54. lt when adjustment is complete Position the right shifter all the way to the low position fully forward for downtube shifters fully back on MTB top bar shifters Ensure that the derailleur cable is taut If too much slack is detected loosen the cable fixing bolt pull the cable taut and re tighten the bolt To adjust low gear Turn the adjustment screw marked L anti clockwise until you can shift the chain onto the largest rear sprocket and the smallest chainring Move the shifter until the derailleur guide pulley and the sprocket are aligned Rotate the L adjustment screw until it meets resistance The derailleur will move outward and throw the chain off the sprocket when pedalling if the screw is turned in too far Conversely if the adjustment stops the derailleur moving far enough the chain may not engage in low gear Test the adjustment by rapidly shifting the chain up and down the freewheel Note On bicycles equipped with indexed derailleur systems SIS the chain should pause when moving into each position If the chain does not move easily onto the large sprocket while on the small chainring screw out the L adjusting screw slightly If the small sprocket is difficult to engage with the chain on the large chainwheel screw out the H adjusting screw slightly If the chain does not easily shift to the large freewheel cog or the large chainwheel re adjust the cable either with the bar
55. mous stress on many components of your bicycle especially your front fork Prior to every ride please complete the following safety checks 1 Brakes Check front and rear brakes are working correctly Check brake control cables for wear and ensure they are oiled and properly adjusted Check brake control levers are lubricated and securely fastened to the handlebar Check brake shoe pads for wear and their positioning in relation to the rims 2 Wheels and Tyres Check tyre pressure is as recommended according to the specification displayed on the tyre sidewall Check tyres for tread and ensure they do not have any bulges or excessive wear Check all wheel spokes are firm and are intact Check rims run true and are without any obvious buckles or kinks Check that axle nuts are tight For bicycles equipped with quick release axles ensure locking levers are tensioned appropriately and in the closed position 3 Saddle Check the clamp underneath the saddle is firmly secured to the saddle post Check frame clamping mechanism is tightly fastened Ensure that the minimum insertion mark cannot be seen on the saddle pillar 12 RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Updated 23 05 07 Steering Check that the handlebar and stem enable correct steering EWS and are properly adjusted and tightened Check that the setting of the handlebars is correct in relat
56. ng seat pillar may also be present for improved rider comfort Despite the variety of suspension bikes available the basic components are similar in all models such as wide rims and tyres for increased traction and comfort Handlebar Handlebar Stem Head Seat Seat Seat Post Seat Tube Fi De h Seat Post Binder Bolt Derelleur Down Tube Rear Reflector 9 Brake Control Cable bo zm E Gear Conrol Cable end Rear Suspension Damper Rear Brake BZ Rear Frame Sub Assembly 22 AA 0 e s Pedal Crank Arm Wheel Reflector Bottom Bracket Axle Gear Control Cable Chainwheel Tyre Valve Freewheel Chainstay Rim Rear Derailleur Drive Chain Tyre Updated 23 05 07 RAOMO0507 Shift Lever Brake Lever Control Cables Reflector Upper Fork Suspension Protective Boot Fork Brace Front Brake Lower Fork Suspension Front Hub Axle Spokes Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 BMX Bicycles BMX style bicycles are ideal for young riders Their durable simple design makes them perfect for general purpose use with minimal maintenance required Alternative frame styles such as U shape frames and loop frames may also be used for other varieties of children s bicycles Handlebar Grip Brake Lever Handlebar Top Tube Seat Seat Post Seat Post Binder Bolt Seat Stay Rear Reflector Wheel Reflector
57. ns and stopping at red traffic signals Notify the Road Traffic Authority in your state if further information is required Ride on the left side of the road and never against the traffic Take extra care when attempting to overtake other vehicles and at intersections Indicate intended actions such as turning or stopping by using appropriate hand signals Ride predictably and in a straight line Always ride defensively You may be difficult to see to other road users Closely observe the riding terrain Avoid obstacles such as pot holes gravel wet road markings oil curbs speed humps and drain grates Be alert Watch for such things as motorists opening doors or backing out of concealed driveways 4e Sound your bell for a warning when required Train and tram tracks should be crossed at a 90 degree and preferably walk your bicycle over Know how your bicycle operates Practice braking gear shifts and if fitted using toe clips and straps Always apply the rear brake first then the front when braking The front brake is more potent and if it is not used properly you may loose control and fall Allow reasonable space between yourself and other vehicles and objects when riding and stopping Take note of weather conditions and its possible impact on safe braking distances e g Wet riding surfaces increase braking distances Use leg clips or elastic bands if you are wearing loo
58. nsion dips under braking The rider needs to familiarise themself with the suspension system before attempting riding at great speeds or down hilling Failure to do so could cause the rider to lose control and fall 3f Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Headset Inspection The headset is responsible for locking the fork into the frame Every month the headset bearing adjustment should be tested This is done by standing astride the frame top tube with both feet on the ground and firmly applying the front brake and rocking the bicycle back and forward Kk Washer If the headset is loose it needs to be tightened to i tential d t th the bicycl d th ids potential damage to pe e bicycle and the D rider However do not over tighten If the fork tends S amp S to stick or bind at any point when rotated slowly sideways the bearings are too tight Quill Type Assemblies Adjustment To adjust the headset the top locknut needs to be oosened or removed completely as well as the ock washer and reflector bracket if fitted Turn the adjusting cup clockwise until finger tight Replace he lock washer or reflector bracket and using an appropriate wrench to re tighten the locknut ote Bearing damage will occur if over tightened Prior to riding always check that the headset is properly adjusted and that the headset locknut is securely fastened Ahead Set Ty
59. nted to the bicycle V Linear Pull and U type brakes use two brake pivot arms each mounted on separate pivots on either side of the frame or Dua Synt fork Sidepull calliper brakes are attached to the frame or fork by a single pivot point Disc brake callipers are attached to the frame and fork via disc brake mounts Foot Controlled Brakes The coaster brake is a pedal activated brake fitted to most juvenile bikes and some BMX bikes with out gear mechanisms The brake is activated by pushing backwards on the pedal This activates a brake in the rear hub and allows the rider to slow or stop Inspection The brake levers and the brake pads are the two main components that need to be checked to ensure your brakes are functioning effectively Positioning of the brake levers should be checked to ensure they can be easily reached by the rider s hands and alterations made as necessary Some brake levers have a screw adjuster to change the distance between the lever and the handlebar grip This should be checked for tightness every three months Similarly at least every three months the brake levers should be tested to ensure they do not move on the handlebars and each brake lever moves freely when compressed Prior to every ride inspection of the brake pads is recommended The brake pads must be centred with approximately 1 5mm 2mm clearance between each pad and the rim when the brakes are not in use Test that when
60. ocations dual levers or the shifting mechanism may even be incorporated into the hand grip The fully integrated system is an upgrade of the index derailleur system Braking and changing gears can occur simultaneously as the shift lever and brake lever mechanisms orm an integrated unit with the derailleur system For further information relating to your derailleur system refer to the separate specific manual supplied with your bicycle otherwise consult your professional bicycle mechanic Inspection Review the overall functioning of the derailleur system at least monthly Begin by testing the rear derailleur Check that it moves the chain easily and speedily from one cog to the next with no rubbing after shifting Ensure the chain does not fall from the inner or outer freewheel cogs when the rear derailleur is activated In the case of bicycles fitted with SIS derailleur systems each notched position in the shifter must equate to a new gear position Check that the front derailleur shifts the chain smoothly and without hesitation between each chainring Ensure that the chain does not rub on the front derailleur when it moves onto a new chain ring and that it never falls off the chainring In SIS derailleur Systems each click or stop in the shifter should equate exactly to a new gear position when the front SIS is activated It is also important to check the derailleur control cables for any signs of rust fraying kinks broken stran
61. ollo Bicycle Company Pty Ltd ABN 60 001 914 469 SNOILVINLVYDSNOO DIRECTORY Y RAOMO0507 PART 1 Warranty Inside Front Cover PART 3 Before You Ride Pages 8 21 PART 5 Comprehensive Maintenance Page 27 67 PART 7 Contact Addresses Back Cover Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 PART 2 Parts Classification Pages4 7 PART 4 Bicycle Care amp Servicing Pages 22 26 PART 6 Purchase Details Page 68 0 D Warning Important take notice of this symbol throughout this manual Updated 23 05 07 2 PARTS CLASSIFICATION Mountain bicycles amp Cross Bicycles Suspension Bicycles BMX Loop Frame U Frame Bicycles Road Bicycles 3 BEFORE YOU RIDE Correct Frame Size Riding Position saddle height reach handlebar height Safety Checklist brakes wheels amp tyres saddle steering chain bearings cranks amp pedal derailleur frame amp fork suspension accessories amp safety Helmets Riding Safely general rules wet weather riding night riding pedalling technique hill technique cornering technique rules for children Gears How to Operate Torque Requirements amp Tools Required derailleur gears operating principles hand grip shifters below the bar shifters dual control shifters BICYCLE CARE amp SERVICING basic maintenance storage Security Schedule 1
62. ommended Chainwheel Rear Sprocket Gear Combinations 19 Updated 23 05 07 RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 20 Hand Grip Shifters Hand grip shifters are built into the hand grip and attach to the handlebars Unlike other ypes of shifting mechanisms the hand grip shifters mean you do not need to change your hand position to select different gears The rider just simply twists forwards or backwards dependent upon their gear selection By twisting the right shifter toward you a lower gear is chosen as a larger rear cog is selected Twisting this shifter away from you has the opposite effect a higher gear is selected as a smaller rear cog is engaged Turning the eft shifter forward or away from you activates a smaller front chainwheel and a larger front chainwheel is engaged by twisting it backwards The number of gear changes occur at any one time corresponds with how many turns are made of the shifter Check the diagram below for operating instructions Front Low Gear Rear Low Gear Front High Gear Rear High Gear Below the Bar Shifters The majority of mountain style bicycles use below bar shifters These shifters are mounted on the underside of the handlebars usually between the grips and the handlebars t is a two finger operating system which uses the thumb and index finger to make the gear selection By pushing the lower larger right shifter with your thumb a lower gear is selected as a l
63. on adjuster on the shifter levers enables the positioning to be fine tuned to a lower or higher location Increasing tension moves the derailleur to a higher position and lessening the tension moves it to a lower position After making any adjustments it is important to test the gears in all possible front and rear chain positions If the chain rubs against the cage when on the inner or outer chainring in any rear sprocket position then turn the appropriate adjusting screw anti clockwise If the chain falls off either the inner or outer chainring turn the appropriate adjusting screw clockwise If the chain will not shift onto either the inner or outer chairing turn the appropriate adjusting screw anti clockwise To fine tune the front derailleur on MTB bicycles fitted with front SIS Shift the chain to the largest rear sprocket and the largest front chainring Shift from the largest to the middle chainring Turn the cable adjusting barrel located in the shifter so that the inner chainguide just clears the chain Testthat the chain shifts cleanly without hesitation between each chainring RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 To fine tune racing style bicycles fitted with dual control STI levers Shiftthe chain to the largest rear sprocket and the largest chainring Pushthe left hand inner lever slightly to engage the noise prevention mechanism Turn the cable adjuster
64. p 5 Standard multi grip pliers 6 Phillips head screwariver 2 7 Open ended or ring spanners 8mm 9mm 10mm 12mm 13mm 14mm 15mm 6 8 Torque wrench with Newton Meter increments 9 Tyre levers 3 10 Crank remover 9 11 Tube repair kit 7 4 8 E REPAIR 11 26 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 WHEELS AND TYRES Wheels Inspection Maintaining your wheels in prime condition is imperative for not only for riding efficiency and performance but safety as well When inspecting your wheels look for the potential hazards listed below Quick release Caution Quick release skewer levers should always read closed Prior to each ride check that these are set to the closed position and are at the correct tension Serious injury may result if these guidelines are not observed Axle nuts Caution Do not ride the bicycle without first ensuring that the axle nuts are tight Buckled Wheels Prior to each ride test each wheel to ensure that it is spinning straight If the wheels are misaligned adjustment will be necessary We recommend any adjustments should be completed by a professional bicycle mechanic as it is quite a complex task In the case of buckled wheels that use rim brakes braking is adversely effected Broken or loose spokes Caution Damaged spokes can create severe instability and have the potential to cause an accident for the rider Before riding ensure t
65. pe Assemblies When assembling a new bike with this type of fitting the dust cap covering the Allen head bolt needs to be removed and the bolt holding the top plug undone Remove the cardboard cover Slip the handlebar stem over the exposed fork steerer and replace the top plug The handlebars and the forks need to be facing the front Using the Allen head centre bolt secure the steering assembly until there is no freeplay Take care not to over tighten Tighten up the binder bolts which clamp the handlebar stem to the fork steerer Ensure the handlebar stem cannot turn in the steerer tube To adjust the headset after the bicycle is assembled Loosen the stem binder bolts Use the Allen bolt to re adjust the compression mechanism Re fasten the stem binder bolt firmly Unlike standard headsets the Ahead Set has an unthreaded full thickness bicycle fork steering tube Adjustments are made using an Allen headed compression bolt and then are fastened by clamping the handlebar stem directly onto the fork steerer 38 RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Lubrication and Attachment of An Ahead Set Stem To The Fork Every year your bicycle should have a complete lubrication This can be quite a complex task and may be best handled by a professional bicycle mechanic However if you feel capable the following procedure will guide you 1 Suspend the bicycle so that the front wheel is off
66. pleting the above process further adjustment is still required stand behind the bike Shift the chain to the smallest rear cog and the largest front chainwheel and loosen the cable fixing bolt Also check whether your SIS derailleur system is fitted with an additional adjustment screw to set the guide pulley as close as possible to the sprocket If so shift the chain onto the small cog and adjust until there is no sound of rubbing or fouling when the pedals are turned backwards Whatever type of derailleur system is fitted to your bicycle the alignment of the chain the rear sprockets and the derailleur lan pulleys need to be inspected whilst standing behind the bicycle Based on your findings adjustments to high or low gear Guide may be necessary Rear Derailleur Rear View Outer side of Top Gear Pulley Adjustment Screw Freewheel B CO SIS Cable Barrel Adjuster Adjustment Screws Tension Pulley RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 To adjust high gear Turn the adjustment screw marked H until the top guide pulley lines up with the outside edge of the outermost sprocket Setting the guide pulley beyond the outside edge of the sprocket will cause the chain to come off when pedalling Setting the guide pulley too far toward the larger cogs may prevent the chain wheel shifting onto the small sprocket Re tighten the cable fixing bo
67. r derailleurs are fitted to all multispeed bicycles while front derailleurs are only present on those bicycles with the higher number of gears Gears enable the cyclist to select the most appropriate pedalling resistance best suited for the riding conditions The more gears fitted to the bicycle the greater choice available to the rider TYPES OF GEAR SHIFTERS Hand Grip Shifters Below Bar Shifters Dual Control Shifters 18 RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Operating Principles Although the number of gears present on multispeed bicycles varies greatly how the gears function remains the same The right shifter works the rear derailleur and the left shifter works the front derailleur If the pedals are stationary or rotating backwards gears cannot be changed They can only be altered when pedalling forward To achieve a successful gear change either moving up or down in gears the pedalling pressure must be relaxed Failure to ease the pressure when changing gears may result in bicycle damage or could even cause the rider to lose control If a rubbing sound is detected after attempting to alter gears adjust the shifter until the sound ceases Generally the lower gears are for ascending hills and the higher gears are for descending To extend the life of your chain avoid using extreme gear combinations as shown in the diagrams below b 1 2 High Medium Rec
68. raight when the heel of that foot is for A Height Mark placed on the pedal 2 Mark should L never be visible Allen Bott Caution D Ensure the seat pillar post does not extend beyond the minimum insertion mark Refer to Page 42 on how to adjust the seat height Take special note if your bicycle is fitted with a suspension type seat post 2 Reach When riding it is important not to overextend one s reach To determine the ideal positioning place your elbow against the seat and stretch out your arm toward the handlebars The distance between the handlebar and the outstretched fingertips of the arm should be 20mm 50mm This distance can be adjusted by altering the location of the seat in relation to the seat pillar Refer to Part 5 on how to adjust the seat clamp Arms not over exteneded Handlebar stem height y about the same as seat height Pedal at bottom position 10 RAOMO507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 3 Handlebar Height It is recommended you try various handlebar heights to find the most suitable position EWS for you Usually it is most comfortable when the handlebar height is the same as the height of the seat The handlebar stems of some bikes can be altered to customize fit even further Caution D Ensure the handlebar s stem does not extend beyond the minimum insertion mark Refer to Part 5 on how to adjust Handlebars WARNING D The steerin
69. rank set There are two types of crank sets One Piece Cranks or Three Piece Cotterless Cranks One Piece Cranks are relatively easy to maintain as the crank arms and the bottom bracket are a single component In Three Piece Cranks the crank arms bolt onto the bottom bracket axle without using old fashioned type cotterpins This system requires more detailed servicing Crank Arm Dust Cap Inspection and Maintenance Every month the crank set should be checked to ensure that it is properly adjusted For Three Piece Cranks Check that the crank axle nuts are tight Adjust the bottom bracket bearings as necessary Remove the chain and test for crank movement on the axle by attempting to move the cranks from side to side with your hands Only very slight movement in the bottom bracket should be noted Rotate the cranks Adjust and oil if they do not spin freely or a grinding noise is detected Check the chainrings for any Standard Bottom Bracket Assembly Cotterless broken teeth and clean off any excess dirt and grease Caution D Always ensure that your Ball Bearing A Three Piece cranks are Lockring _ _ A 2 firmly secured before riding Riding with loose Cup cranks is potentially hazardous to both the rider and condition of the crank arms RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Lubrication and Adjustment One Piece Cranks To adjust Turn t
70. reet lighting when able Pedalling Technique Place the ball of your foot on the centre of the pedal Ensure your knees are parallel to the bicycle frame when pedalling Keep your elbows slightly bent This will help to absorb shock Learn how to use the gears correctly Refer to Pages 18 21 in this part of the manual Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Hill Technique Priorto a climb gear down and continue gearing down as necessary in order to sustain EWS pedalling speed standing up on your pedals you will be able to generate greater power from each turn of the pedal This is useful if you are straining and are using the lowest gear Use the high gears on a descent to prevent rapid pedalling Take extra care when descending Do not exceed a comfortable speed and maintain control WARNING D Downhill mountain biking can be a dangerous activity To reduce the likelihood of injury appropriate safety equipment should be worn and ensure that your bike is working perfectly Follow all of the above instructions Cornering Technique Before entering a corner brake slightly and begin to lean your body into the corner The inside pedal should be held at the 12 o clock position and the inside knee angled slightly in the direction you are turning The other leg should be kept straight Avoid pedalling through fast or tight corners Rules for Children Any chi
71. rel adjuster or by repeating the above procedures Updated 23 05 07 RAOMO0507 61 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 62 Adjustment Front Derailleur The front derailleur is positioned correctly when its chain guides are parallel to the chainrings and there is approximately 2mm 4mm of clearance between the outer chain guide and the large chainring To achieve this ideal derailleur positioning loosen the clamp bolt and make the necessary adjustments To adjust the clamp position lower for top mounted cable systems disconnect the derailleur cable To adjust low gear on front derailleurs Cable Cl Bolt Shift the chain onto the smallest front Low Adjusting Screw chainring and the largest rear sprocket High Adjusting Screw Loosen off the control cable fixing bolt Chainguide Clearance Turn the adjusting screw marked L until 1 3mm the inner cage clears the chain With the shift lever fully in the low position pull the control cable taut Outer Chainguide Re tighten the cable fixing bolt Inner Chainguide To adjust high gear on front derailleurs Shift the gears until the chain moves to the smallest rear sprocket Turn the adjusting screw marked H until the chain moves to the largest chainring Turn the H adjusting screw further until the inside of the out cage of the derailleur just clears the chain For triple systems altering the cable tensi
72. replace the brake shoes in pairs never one side only Troad Tread Worn Off Usable Brake Shoe Worn out Brake Shoe Replace For replacement disconnect the holding mechanism specific to your brake type i e a hexagonal nut or an Allen screw arrangement or a combination of both Remove the worn brake shoes paying careful attention to the order and position in which the various Curved washers and spacers are attached Fit the new brake shoes and tune the angle and the clearance to the rim as required Typically before the rim clearance can be adjusted the control cable anchor bolt needs to be loosened and then the cable adjusters fasten and the cable tensioned Refer to the Installation Adjustment section relevant to your brake type for detailed instructions Once the adjustments are complete securely fasten the brake shoes in place and test that the brakes are functioning correctly Do not ride the bicycle until the brakes are working effectively Disc Brake Adjustment Mechanical 1 Ensure the fixing bolts are securely fastened to the disc j o ra brake mount A 2 Adjust the callipers active lever as close to the rotor as possible 3 Adjust the neutral side with the relevant adjuster M If your disc brakes allow adjustment of the calliper toe in check 1 The clearance is even from front to back 2 cable fixing bolt is securely tightened Please see brake manufacturers manual
73. se tension and close the lever when correct For safety reasons the lever should be parallel to the frame seat stay tube On coaster hub bicycles the brake arm needs to be reconnected to the brake arm clip on the chainstay Reset the brake quick release and check the brake pad clearance If required adjust the brake cable pad clearance QR lever Failure to do so may be dangerous RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Correct Quick Release Axle Setting The process of removing wheels is made considerably easier if a Quick Release mechanism is fitted to the wheel axle Wheels can be removed without using Spring Sp ing Lever tools The Quick Release mechanism consists Lo N of a lever controlling a cam action tightener and at iudi 2 Cam the other end a long bolt with an adjusting nut Agusting Skewer WARNING It is crucial that the Quick D Release mechanism is properly adjusted when riding Failure to do so may cause the wheel to wobble or disengage from the Nut bicycle possibly resulting in harm to the bicycle and or the rider Consequently 1 Seek instruction from your bicycle specialist on the correct process for removing and installing Quick Release 4f E wheels AST 2 Prior to riding your bicycle ensure that Locked Position the wheel lever is firmly clamped To correctly clamp your quick release wheels in M place refer to the following
74. se trousers to stop them catching in the chain Ensure your vision or control of the bicycle is not obstructed by any items you may be transporting Do not use items that may impede your hearing e g Headphones 15 Updated 23 05 07 RAOM0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Wet Weather Ride more cautiously in wet weather Avoid sudden braking slow overall riding pace and approach corners more carefully Brake sooner stopping distance increases in wet conditions Remember pot holes and slippery surfaces such as line markings and tram tracks all become more hazardous in the wet Try to avoid where possible Cornering traction will also be reduced in wet weather Night Riding Wear reflective and light coloured clothing Reflectors should be fitted correctly to the bicycle and clearly visible Refer to Part 5 of this manual Riding in the dark should never be D undertaken without fully operational front and rear bicycle lights The use of bicycle lights is mandatory for night riding in most Australian States Attach a fully operational lighting set Lights should have a white front lamp and a red rear lamp Use a flashing rear light to improve visibility Charge batteries if battery powered lights are to be used Check wiring connections for dynamo powered lights Avoid riding at night if possible If not slow down and opt for familiar roads with st
75. station pump as it is the same valve used on cars Inflation involves removing the valve dust cap then screwing or pushing on the pump connector to the end of the valve stem and inflating By depressing the pin in the end of the valve stem the tyre can be deflated The Presta valve is also referred to as the French or high pressure valve In order to inflate tyres equipped with this valve the pump needs to have a special fitting attached to accommodate the valve s narrower profile The service station pump can be used if an adapter is screwed onto the valve stem Inflation involves removing the dust cap unscrewing the valve stem locknut freeing the valve stem by pushing down on it then fitting the pump head and inflating Deflation is achieved by opening the valve stem locknut and depressing the valve stem Note The valve dust cap should always be replaced in order to prevent dirt entering and damaging the valve Using a service station pump to inflate tyres is not encouraged as tyres may blow out if sudden over inflation occurs Schraeder is a registered Trademark S hraedar Valve Presta Valve 34 of the Schraeder Corporation Inc Car American French RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 STEERING SYSTEM Handlebar Stem Usually the standard handlebar stem is secured into the steering column by the binder bolt and Sus Boh expander wedge These bind wit
76. the brakes are applied that the brake pads squeeze the rims sufficiently to stop the bike Replace the brake pads if the grooves or pattern has worn away from the surface Ensure that the brake pads are firmly secured before every ride and at least every three months check the tightness of the numerous bolts and nuts supporting the brake pads closed after any brake adjustment Never ride a bicycle unless the mechanism is firmly If your bicycle is fitted with a Quick Release wheel mechanism ensure that this is securely D locked in the closed position 43 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 44 Lubrication calliper brakes Lubricate the brake lever and the brake calliper pivot at least every three months with 2 3 drops of light oil This will help to limit wear and tear and ensure smooth operation At least every six months remove cables from their casings and grease along their entire length Prior to fitting any new cable always apply grease Adjustment Sidepull Callipers To make minor brake adjustments use the barrel cable adjuster usually found at the upper cable arm Use the following outline as a guide 1 Squeeze the brake pads against the rim and loosen the lock nut 2 Setthe adjuster so there is approximately 1 5mm 2mm clearance between the brake pad and the rim 3 Re fasten the lock nut If the clearance between the brake pad and the rim cannot be set to
77. the owner This bicycle Item 1 has not been designed manufactured or sold for use at any time or place or in any manner whatsoever as power driven vehicle or for the purposes or racing motorcross stunt riding ramp jumping acrobatics dirt riding or any other similar competitive event or activity or rental hiring or other such commercial activity and this limited warranty does not cover these acts This limited warranty does not cover any personal injuries mechanical damage or any other damage or injury due to misuse neglect accident normal wear and tear abuse improper use or improper maintenance corrosion to the frame or any part or accessory due to exposure to the weather or exposure to a chemical environment or modifications to the original specifications or factory fitted components treatment or assembly of this bicycle Any use of this bicycle which is in compatible with those parts and accessories installed as original equipment by the factory is not covered Subject to the Trade Practices Act and any equivilent state legistration this statement constitutes the exclusive expression of warranties by the manufacturer and the supplying dealer and to the extent permitted by law is in lieu of any and all other warranties or merchantability or fitness purposes Apollo Bicycle Compary Pty Ltd AB8N 60 001 914 469 Updated 23 05 07 Congratulations on your purchase Your Apollo bicycle has been fully tested and carefull
78. thin the special tool and punch the rivet into place Take care not to push rivet too far through the side plate Derailleur geared bicycles can now be fitted with some new types of chains that do not require special tools to remove or replace Instead a new special disposable connecting link is used every time you disassemble the chain For further details on these particular chains including installation guidelines refer to the manufacturer s specific instructions Freewheel Inspection and Lubrication To prevent premature wear the freewheel must be kept clean and well lubricated Any accumulated dirt should be brushed from the freewheel and the component cleaned with kerosene or degreaser Lubricate the freewheel whenever the chain is oiled Any excess oil should be removed To ensure the freewheel is operating appropriately remove the chain from the freewheel and spin it with your hand If a grinding noise is audible or if the freewheel suddenly stops after spinning it adjustment or replacement may be required Such tasks are best referred to your professional bicycle mechanic as they are quite complex and require special tools Note Generally whenever the chain needs to be replaced the freewheel should also be changed 57 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Coaster Hub Coaster Hub Brakes are commonly fitted in the rear wheel of many BMX style and other children s bicycles
79. u have any queries refer to your dealer Bicycling Sizing Guide Approx Wheel Suggested Suggested Frame Size Ages Size kid s Frame Size for for Mountain or Hybrid models Road Bikes Bikes 4 6 30cm 12 46cm min 5 10 40cm 16 55cm min 6 14 50 20 61cm min 12 16 61 24 61 69cm 12 plus 37em 14 5 66 76cm 12 plus 43 17 71 79 12 plus 50cm 19 5 45cm 18 12 plus 55em 21 5 50cm 19 5 79 86cm 12 plus 57 22 5 52cm 20 5 81 89cm 12 plus 60cm 23 5 53 21 56 22 12 plus 63cm 25 58cm 23 60cm 23 5 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 RIDING POSITION 1 Saddle Height To ensure pedalling efficiency safety and rider Close Am i Close comfort it is crucial that the seat is set at the correct fe eV ii height The rider s leg length is used to determine f SL Di Open Open Y 74 Y L4 he appropriate saddle position When the seat is positioned correctly the rider s leg should not strain Standard Binder QR Type Binder from over extension and the hips should remain evel when pedalling To establish seat height sit on the bicycle with one pedal at its lowest point N and place the ball of the foot on that pedal f the knee is slightly bent in this position then the A PB I Maximum seat is at its correct height The leg should be practically st
80. ule 1 24 Check all points as per monthly service 25 Check and replace brake pads if required 48 Check chain for excess play or wear 56 Yearly Lubrication as per schedule 1 24 WARNING D All components of the bicycle are subjected to wear and stress through use Watch closely for any scratches cracks or discolouration on your bicycle components These are signs of a stress caused fatigue and indicate that a part needs to be replaced Failure to replace can cause the component to suddenly fail when riding which may result in serious injury or even death 25 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Torque requirements Nuts and bolts should only be adjusted using a torque wrench This helps to prevent over tightening and damage to the threads Different torque measurements are recommended when tightening different components Use the following table to guide you in your torque application Component Torque Front axle nuts 22 27 Nm Rear axle nuts 24 29 Nm Handlebar clamp nut 17 19 Nm Head stem expander bolt 17 19 Nm Seat clamp nuts 12 17 Nm Seat post binder nut 15 19 Nm Brake cable fixing nut 7 11Nm Brake calliper centre bolt nut 1 2 17 Nm Cotterless crank nut 27 Nm Tools needed for making adjustments fS 1 Adjustable wrench 2 Flathead screwdriver 1 Allen key wrenches 2mm 3mm 4mm 5mm 6mm 8mm s 4 Tyre pum
81. w To Repair A Flat Tyre There comes a time when most cyclists will need to repair a flat tyre Use the following steps to guide you through the process a ils ake the wheel off the bicycle V sing the valve entirely deflate the tyre Pd 2 3 Push the tyre bead inwards around the whole rim to loosen 4 C W c sing tyre levers only to avoid damaging the rim prise one ide of the tyre bead up over the edge of the rim v e Leave the tyre on the rim and remove the tube I DH 6 Replace or repair the tube Note The replacement tube Size needs to correspond with the size detailed on the sidewall of the tyre and the valve type needs to be suitable for your bicycle Refer to the instructions in your tyre repair kit to successfully patch a tube 7 determine the possible cause of the leak match the 5 position of the puncture the tube in relation to the tyre and mark the location on the tyre 8 Remove the tyre completely from the rim and examine REPAIR removing any foreign objects noted eg glass or a nail 1 1 Also inspect the inside of the rim for other potential causes i Such as protruding spokes Replace the rim tape covering the spoke ends if damaged 9 Remount the side of the tyre onto the rim 10 Partially inflate the tube with a hand pump until it starts to take shape 11 Taking care not to twist the valve stem place it through the hole in the rim and work th
82. washer B Shoe Fixing Nut Washer A Washer B Washer Shoe Fixing Link 45 Updated 23 05 07 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 3 Fasten the shoe fixing nut while holding the shoe against the rim 5mm Allen Key 4 Thread the inner cable through the inner cable lead When a clearance of 1mm between each brake pad and the rim is achieved secure the cable fixing bolt 6 Checkthe brake operation and shoe clearance by fully squeezing the brake lever repeatedly about 10 times Loosen and then re fasten the cable fixing bolt as per Step 4 until adjustment is correct Make any fine alterations via the adjusting screw at the brake lever 46 RAOMO0507 Apollo Bicycle Company Pty Ltd ABN 60 001 914 469 Updated 23 05 07 Installation and Adjustment U Brakes To install U Brakes 1 Lubricate the contacting surfaces of the frame bosses and the brake arm attaching area 2 Secure the spring to the hole on the brake arm spring cover and fixing arm nut 3 Fasten the attaching bolt with a 5mm Allen key wrench to a torque of 6 Nm to 8 Nm Note The spring winds in different directions for the right and left arms See Fig 1 When adjusting brake shoes the brake arm needs to be able to move freely To adjust and secure brake shoes 1 Attach the brake shoe so the direction of the arrow sign is the same as the rim rotation direction 2 Face the shoe surface to the rim and set it
83. y produced with performance comfort and safety in mind With proper care and maintenance your bicycle will give you years of riding pleasure Use this owner s manual as a guide for the recommended maintenance and safe usage of your new bicycle Take the time to read and understand this manual and for parents of young riders please explain the content to your child Please note that it is not intended as a full workshop manual Every effort has been made to ensure that the content in this manual is accurate and current as at May 2007 Please consult a specialist bicycle dealer if a specific subject is not covered in this manual the subject matter seems beyond your level of experience or ability you have any further questions General Warning It is your responsibility to correctly maintain your bicycle Failure to maintain or inspect your bicycle may have severe consequences such as losing control when riding and falling which may ultimately result in injury or death The risk of injury or death due to falling is implicit in the many warnings and cautions stated in this manual As such whenever the risk of falling is stated we do not repeat the warning of possible death or injury Please Note This is a partially assembled bicycle requiring final assembly and adjustments before riding Final assembly and adjustment should only be carried out by a qualified bicycle mechanic at your specialist bicycle store RAOMO0507 Ap
84. you may be able to fully appreciate and handle the bike s features Please note using your bicycle for competitive events dirt biking bicycle racing ramp riding jumping stunt riding downhill racing or similar activities or training for such competitive activities is not recommended The range of suspension systems available is vast and will not be detailed comprehensively in this manual Instead if your bicycle is equipped with a suspension System and you require further information refer to the separate leaflet included with your bike where supplied or seek assistance from your specialist dealer may result in suspension malfunction potentially causing you to lose control and fall Keep all exposed moving portions of the suspension system clean and lubricated 0 WARNING Failure to inspect and correctly adjust the suspension system CAUTION Suspension adjustment should only be made according to the suspension system s manufacturer instructions and recommendations Always test ride your bicycle following alterations to the suspension adjustment looking for any changes to the bike s handling and braking characteristics CAUTION Always refer to the bicycle s manufacturer before attempting to retrofit suspension as not all bikes can be retrofitted with some types of suspension Please note changes from the original specifications may void your bicycle warranty WARNING Please note the front of a bicycle fitted with suspe

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