Apollo Radius User Manual

Download

Congratulations on your purchase. Your Apollo bicycle has been fully tested

and carefully 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.

CONGRATULATIONS

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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

PART 1

PART 2

Warranty

Inside Front Cover

DIRECTORY

PART 3

Before You Ride

Pages 8 – 21

PART 5

Comprehensive

Maintenance

Page 27 – 67

Parts Classification

Pages 4 – 7

PART 4

Bicycle Care & Servicing

Pages 22 – 26

PART 6

Purchase Details

Page 68

PART 7

Contact Addresses

Back Cover

Warning / Important

(take notice of this symbol

throughout this manual)

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

2. PARTS CLASSIFICATION 4

Mountain bicycles & Cross Bicycles 4

Suspension Bicycles 5

BMX/Loop Frame/U-Frame Bicycles 6

Road Bicycles 7

3. BEFORE YOU RIDE 8

Correct Frame Size 8

Riding Position 10

- saddle height 10

- reach 10

- handlebar height 11

Safety Checklist 12

- brakes 12

- wheels & tyres 12

- saddle 12

- steering 13

- chain 13

- bearings 13

- cranks & pedal 13

- derailleur 13

- frame & fork 13

- suspension 13

- accessories & safety 14

Helmets 14

Riding Safely 15

- general rules 15

- wet weather riding 16

- night riding 16

- pedalling technique 16

- hill technique 17

- cornering technique 17

- rules for children 17

Gears . How to Operate 18

- derailleur gears 18

- operating principles 19

- hand grip shifters 20

- below the bar shifters 20

- dual control shifters 21

4. BICYCLE CARE & SERVICING 22

- basic maintenance 22

- storage 22

- security 23

- Schedule 1. Lubrication 24

- Schedule 2. Service Checklist 25

Torque Requirements & Tools Required 26

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

5. COMPREHENSIVE MAINTENANCE 27

Wheels and Tyres 27

- wheel inspection 27

- tyre inspection 28

- recommended tyre pressures 28

- front wheel removal & replacement 29

- rear wheel removal & replacement 30

- correct Quick Release axle setting 31

- hub bearing adjustment

& lubrication 32

- how to fix a flat tyre 33

- tyre valve 34

Steering System 35

- handlebar stem 35

- handlebar / forks 36

Bicycle suspension 37

- headset 38

- quill type assemblies 38

- 'Ahead Set' type assemblies 38

- rotor installation & adjustment 40

Saddle & Seat Post 41

Brakes 43

- sidepull callipers 44

- linear pull 45

- U-brake 47

- disc brake 48

Drivetrain 49

- pedals 49

- clipless pedals 50

- crank set 52

- one piece crank set 53

- cotterless cranks (three piece) 54

- chain 56

- freewheel 57

- coaster hub 58

Derailleur Systems 59

- rear derailleur 60

- front derailleur 62

Reflectors 63

Accessories 64

Troubleshooting 66

6. PURCHASE DETAILS 68

7. CONTACT ADDRESS Back cover

INDEX

Finding the bicycle to best suit your needs is made easy by the vast array of bicycle

Top Tube

Seat

Seat Post

Seat Post Binder Bolt

Seat Stay

Rear Reflector

Rear Brake

Wheel Reflector

Freewheel

Gear Control Cable

Rear Derailleur

Handlebar Stem

Head Set

Head Tube

Seat Tube

Down Tube

Front Derailleur

Rear Gear

Control Cable

Pedal

Crank Arm

Chainwheel

Chainstay

Chain

Tyre Valve

Rim

Tyre

Shift Lever

Brake Lever

Handlebar

Brake Control Cables

Front Reflector

Front Brake

Wheel Reflector

Front Fork

Front Hub

Spokes

models and sizes available. Refer to the following diagrams to familiarize yourself with

the names of the various parts on your bicycle.

Mountain Bikes & 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.

PART 2 - PARTS IDENTIFACATION

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Suspension Bikes.

Seat

Seat Post

Seat Tube

Seat Post Binder Bolt

Rear Reflector

Brake Control Cable

Gear Conrol Cable

Rear Suspension Damper

Rear Brake

Wheel Reflector

Gear Control Cable

Freewheel

Rear Derailleur

Pedal

Crank Arm

Bottom Bracket Axle

Chainwheel

Chainstay

Drive Chain

Tyre Valve

Rim

Tyre

Shift Lever

Brake Lever

Control Cables

Reflector

Upper Fork (Suspension)

Protective Boot

Fork Brace

Front Brake

Lower Fork (Suspension)

Front Hub Axle

Spokes

Handlebar

Handlebar Stem

Head Seat

Top Tube

Front Derailleur

Down Tube

Suspension Mounting

Head Tube

Rear Frame Sub Assembly

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

absorbing 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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

BMX Bicycles.

Top Tube

Seat

Seat Post

Seat Post Binder Bolt

Seat Stay

Rear Reflector

Wheel Reflector

Rear Sprocket

Training Wheel

Crash Pad

Handlebar Stem

Head Set

Head Tube

Chainwheel

Chainstay

Chain

Tyre Valve

Rim

Tyre

Handlebar Grip

Brake Lever

Handlebar

Brake Control Cable

Reflector

Front Brake

Brake Pad

Front Fork

Wheel Reflector

Front Hub

Spokes

Chain Guard

Crank Arm

Pedal

Crash Pad

Seat Tube

Down Tube

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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Road Bicycles.

Top Tube

Seat

Seat Post

Seat Post Binder Bolt

Seat Stay

Rear Reflector

Rear Brake

Wheel Reflector

Spoke Protector Disc.

Rear Derailleur

Freewheel

Rear Dropout

Handlebar Stem

Head Set

Head Tube

Seat Tube

Down Tube

Front Derailleur

Bottom Bracket Axle

Toe Strap

Toe Clip

Pedal

Crank Arm

Chainwheel

Chainstay

Chain

Ty re Valve

Rim

Tyre

Brake Control Cable

Front Reflector

Brake/Shift Lever

Handlebar

Front Brake

Brake Pad

Wheel Reflector

Front Fork

Front Hub

Spokes

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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

PART 3 - BEFORE YOU RIDE

FRAME SIZE

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 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

the bicycle. To accommodate the vast array of

height and size variables in children, even within

the same age groups, juvenile bicycles come in

different wheel sizes and frame styles to best suit

the 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:

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.

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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Please refer to the chart below to assist you in making the correct choice.

If you have any queries refer to your dealer.

Bicycling Sizing Guide

Approx. Ages

Wheel Size (kid’s models)

Suggested Frame Size for Road Bikes

Suggested Frame Size for Mountain or Hybrid Bikes

4-6 30cm(12”) - 46cm min. 5-10 40cm(16”) - 55cm min. 6-14 50cm(20”) - 61cm min. 12-16 61cm(24”) - 61-69cm 12 plus - - 37cm(14.5”) 66-76cm 12 plus - - 43cm(17”) 71-79cm 12 plus - 50cm(19.5”) 45cm(18”)

12 plus - 55cm(21.5”) 50cm(19.5”) 79-86cm 12 plus - 57cm(22.5”) 52cm(20.5”) 81-89cm 12 plus - 60cm(23.5”) 53cm(21”) - 56cm(22”)

12 plus - 63cm(25”) 58cm(23”) - 60cm(23.5”)

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

RIDING POSITION

Arms not over exteneded

Handlebar stem height about the same as seat height

Pedal at bottom position

1. Saddle Height

To ensure pedalling efficiency, safety and rider

comfort it is crucial that the seat is set at the correct

height. The rider’s leg length is used to determine

the appropriate saddle position. When the seat is

positioned correctly the rider’s leg should not strain

from over-extension and the hips should remain

level when pedalling. To establish seat height sit

on the bicycle with one pedal at its lowest point,

and place the ball of the foot on that pedal.

If the knee is slightly bent in this position then the

seat is at its correct height. The leg should be

practically straight when the heel of that foot is

placed on the pedal.

Caution:

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)

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

3. Handlebar Height

Handlebar Binder Bolt

Stem Wedge Bolt

Maximum Height/ Minimum Insertion Mark

Exceeds 2 1/2" (64mm)

It is recommended you try various handlebar heights to find the most suitable position

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:

Ensure the handlebar’s stem does not extend beyond the minimum

insertion mark. (Refer to Part 5 on how to adjust Handlebars).

WARNING:

The steering 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.

Updated 23/05/07 RAOM0507 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:

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 enormous 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

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

4. Steering

- Check that the handlebar and stem enable correct steering

and are properly adjusted and tightened

- Check that the setting of the handlebars is correct in relation 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.

5. Chain

- Check the chain is lubricated, clean and runs freely

- In wet or dusty conditions service the chain more frequently

6. 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

7. Cranks and Pedals

- Check cranks are securely fastened to the axle and are straight

- Check pedals are properly and firmly attached to the crank

8. 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

9. 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 & rear suspension

are properly tightened

- 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

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

11. Safety & Accessories

- 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.

A bicycle helmet must:

- carry the Australia & 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

in most Australian states. Non-

compliance may result in an

enforceable penalty.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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 pedestrians, 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.

- 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

loose 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

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

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 street

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).

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Hill Technique

- Prior to a climb, gear down and continue gearing down as necessary in order to sustain

pedalling speed.

- By 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:

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 child 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.

1. Always wear a correct fitting helmet

2. Follow all road rules, especially stop signs and red lights

3. Always proceed with caution before entering a street. Only enter if there

is no traffic approaching.

4. Avoid riding on driveways or the road

5. Do not ride on busy streets

6. Be conscious of other road vehicles in the vicinity

7. Avoid night riding

8. 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:

When riding downhill never take your hands off the handlebars,

or feet off the pedals.

Updated 23/05/07 RAOM0507 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.

Rear 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

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Operating Principles

High

Medium

Low

High2Medium

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.

Recommended Chainwheel/Rear Sprocket Gear Combinations

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Hand Grip Shifters

Left

Low gear front

Right

High gear rear

High gear front Low gear rear

Front Low Gear Rear Low Gear

Front High Gear Rear High Gear

L H H L

Left

Low gear front

Right

High gear rear

High gear front Low gear rear

L H H L

Hand grip shifters are built into the hand grip and attach to the handlebars. Unlike other

types 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

left 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

to occur at any one time corresponds with how many turns are made of the shifter.

Check the diagram below for operating instructions.

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.

It 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 larger, 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

the 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

thumb the chain will move from the smaller to the larger chainring. To clarify please refer

to the following diagram.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Dual Control Shifters

High Gear Rear

Low Gear Rear

Low Gear

Front

High Gear

Front

Rapid Fire Shifters

The majority of drop bar road bicycles produced today are fitted with dual control levers.

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 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.

Updated 23/05/07 RAOM0507 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.

The 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 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.

PART 4 - BICYCLE CARE & SERVICING

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.”

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Security

Solid Post

Bicycle Frame

U - Lock

Rear Wheel

High Security using a U - Lock

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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Regular and 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 lithium 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:

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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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

32, 38, 52

for looseness

Check pedals are tight 51

Check handlebars are tight 36

Check seat and seat post are tight

and comfortably adjusted

Check all nuts and bolts are tight 26 6 monthly Lubrication as per schedule 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:

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.

Updated 23/05/07 RAOM0507 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 – 11 Nm

Brake calliper centre bolt nut 1 2 – 17 Nm

Cotterless crank nut 27 Nm

Tools needed for making adjustments:

1. Adjustable wrench

2. Flathead screwdriver

3. Allen key wrenches: 2mm, 3mm, 4mm, 5mm,

6mm, 8mm

4. Tyre pump

5. Standard multi – grip pliers

6. Phillips head screwdriver

7. Open ended or ring spanners: 8mm, 9mm,

10mm, 12mm, 13mm, 14mm, 15mm

8. Torque wrench with Newton Meter increments

9. Tyre levers

10. Crank remover

11. Tube repair kit

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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 that 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.

PART 5 - COMPREHENSIVE MAINTENANCE

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 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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 inconvenient 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 k.p.a. (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 k.p.a. (60-100 p.s.i.)

Caution:

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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Front Wheel Removal

1. Open the brake quick release, if fitted, or screw

in the brake cable adjuster. You may need to undo

the brake cable anchor bolt if more clearance

is required.

2. Where standard axle nuts are present use a

spanner to loosen. If secondary retention devices

are fitted slacken the nuts enough to give clearance

to remove the wheel.

3. Turn the lever to the open position if a quick

release axle is fitted. Where the secondary

retention devices are fitted, the adjusting nut

at the opposite end to the Quick Release lever

needs to be loosened sufficiently to permit the

wheel to be removed.

4. Remove the wheel.

Front Wheel Replacement

1. Guide the wheel into the frame ensuring that the

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 lever 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: 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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Rear Wheel Removal

1. Open the brake quick release, if fitted, or screw in brake cable adjuster. Undo the

brake cable anchor bolt if greater clearance is required.

2. Move the chain onto the smallest rear cog if derailleur gears are fitted.

3. When the wheel is fitted with standard axle nuts, loosen them with a spanner.

4. Turn the quick release lever to the open position if a quick release axle is present.

5. Hold the derailleur unit and allow the wheel to slide forward out of the frame.

6. 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.

7. 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. Wheel replacement virtually follows the reverse process to rear wheel removal

2. 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.

3. For single geared bicycles, lift the chain over the axle and onto the cog, and fit the

wheel onto the frame.

4. 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.

5. 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 Release tension and close the lever when

correct. For safety reasons the lever should be parallel to the frame seat stay tube.

6. On coaster hub bicycles, the brake arm needs to be reconnected to the brake arm clip

on the chainstay.

7. Reset the brake quick release and check the brake pad clearance. If required, adjust

the brake cable/pad clearance.

Caution:

Take care to correctly refit a rear wheel.

Failure to do so may be dangerous.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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

tools. The Quick Release mechanism consists

of a lever controlling a cam-action tightener and at

the other end a long bolt with an adjusting nut.

WARNING: It is crucial that the Quick

Release mechanism is properly adjusted

when riding. Failure to do so may cause

the wheel to wobble or disengage from the

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

wheels

2. Prior to riding your bicycle, ensure that

the wheel lever is firmly clamped.

To correctly clamp your quick release wheels in

place, refer to the following.

1. To set, open the lever so that the curved part faces

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. To operate a Quick Release seat post binder mechanism follow the same process.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Hub Bearing Adjustment

Cone Locknut

Hub Body

Axle

Washer

Axle Nut

Bearing Cone

Ball Bearings

The 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:

1. 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.

4. Hold the adjusting cone in position and secure the locknut.

5. Test that the wheel spins freely without excessive lateral movement, or binding

on the bearings.

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:

1. Take the wheel out of the frame.

2. Remove the axle nut, cone lock nut, and the bearing cone from one side of the hub axle.

3. Remove the axle, complete with the cone and lock nut, from the other side of the hub.

4. 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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

How 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:

1. Take the wheel off the bicycle.

2. Using the valve, entirely deflate the tyre.

3. Push the tyre bead inwards around the whole rim to loosen.

4. Using tyre levers only (to avoid damaging the rim), prise one side of the tyre bead up over the edge of the rim.

5. Leave the tyre on the rim and remove the tube.

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. To determine the possible cause of the leak, match the position of the puncture in the tube in relation to the tyre and mark the location on the tyre.

8. Remove the tyre completely from the rim and examine, removing any foreign objects noted, eg. glass or a nail. Also inspect the inside of the rim for other potential causes, 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 the 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.

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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Tyre Valves

Schraeder Valve

(Car/American)

Presta Valve

(French)

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 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.

™ - Schraeder is a registered Trademark

of the Schraeder Corporation Inc.

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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

STEERING SYSTEM

Stem bolt

Handlebar Binder Bolt

Maximum Height/ Minimum Insertion Mark

Expander Bolt Wedge

MTB Handlebar Stem

Stem bolt

Handlebar Clamp Bolts

Maximum Height/ Minimum Insertion Mark

Expander Bolt Wedge

BMX Handlebar Stem

Stem Bolt

Head Set

Head Tube

Maximum Height/ Minimum Insertion Mark

Expander Bolt Wedge

BMX Handlebar Assembly

Handlebar Stem

Usually the standard handlebar stem is secured

into the steering column by the binder bolt and

expander wedge. These bind with the inside of

the fork, steerer tube when tightened. The stem

may also clamp onto an unthreaded fork steerer,

as is the case with the 'Ahead Set' system.

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.

Etched on the stem is a mark about 65mm up from the bottom with the words

“max. height” or “minimum insertion”. Never ride a bicycle if the stem has been

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

on this type of stem

means you will

need to re-adjust

the front brake.

Check that the

suspension is intact

and operating

properly on bicycles

equipped with a

suspension type

handlebar stem.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Ensure that the handlebars are appropriately aligned and are tightened to a minimum

MTB Handlebar Assembly

Grip

Handlebar

Expander Bolt

Handlebar Stem

Expander Wedge

Brake Lever

Handlebar Stem

Drop Bar

Expander Wedge

Racing Handlebar Assembly

Make sure handlebars and

fork are facing forward

Note, curved rake of fork faces forward

Direction of travel

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.

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 wheel 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.

Always check the handlebar clamping mechanism has been firmly tightened

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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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 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.

WARNING: Failure to inspect and correctly adjust the suspension system

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.

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 suspension 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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Headset Inspection

Lock Nut

Lock Washer

Adjusting Cup/Cone

Ball Retainer

Top Head Cup/Cone

Bottom Head Cap

Crown Cone

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.

If the headset is loose, it needs to be tightened to

avoid potential damage to both the bicycle and the

rider. However, do not over-tighten. If the fork tends

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

loosened or removed completely, as well as the

lock washer and reflector bracket, if fitted. Turn the

adjusting cup clockwise until finger tight. Replace

the lock washer or reflector bracket and using an

appropriate wrench to re-tighten the locknut.

Note: 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’ Type 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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Lubrication and Attachment of An 'Ahead Set' Stem To The Fork

Compression Bolt

Installed By Factory

Upper Headset Cup

Lower Headset Cup

Headtube

Bearing Dust Cover

Headset Crown Race

Fork

Bearing Retainer

Bearing Race

Spacer

Headset Wedge

Steerer Tube

Stem Cap

Stem Cap Bolts

Handlebar

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 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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

HEAD SET AND

ROTOR ASSEMBLY DIAGRAM

BRAKE LEVER

UPPER CABLE

ROTOR

LOWER CABLE

BRAKE CALIPER

PARALLEL

COMPLETE ASSEMBLY

ROTOR CABLE ASSEMBLY

HEAD SET AND

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 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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Cable Tension Adjustment

Adjusting Bolt

Micro Adjustable Seat Post

Seat Clamp Nut

Standard Seat Post

1. The rotor bearing unit should 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 has slack on the bearing

hook. Pick up the slack through the adjusting

barrel. When even pull on all four cables is

reached secure all four lock nuts.

2. Check for even pull on all 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

seat post is removed from the frame, a mark

about 65mm up from the bottom can be

observed, with the words “max. height” or

“minimum insertion”. At all times a minimum

of 65mm of seat tube must always remain

in the frame.

Never ride a bicycle with the

minimum insertion/max. height mark

visible on the seat post. Doing so

may damage the seat post, the

frame or potentially even the rider.

Lubrication

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 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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 when 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:

After making any changes to the seat’s position check that the saddle

adjustment mechanism is properly tightened. It is also recommended 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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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 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 mounted 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 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 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.

If your bicycle is fitted with a Quick Release wheel mechanism, ensure that this is securely closed after any brake adjustment. Never ride a bicycle unless the mechanism is firmly locked in the closed position

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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. Set the 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 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.

Note: A screwdriver can be used on some brakes

to set the clearance on both sides of the rim.

Note: The leading edge of the brake pads should

make first contact with the rim when adjustment

is complete. Special curved washers are fitted

to some brakes to allow this, but on base models

a little force needs to be applied to the pad

and its mounting.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Installation and Adjustment – Linear Pull Brakes

5mm Allen Key

Spring hole

Stopper pin

39mm or more

Washer

Link fixing bolt

3mm washer B 6mm washer B

Washer AWasher BWasher

Shoe Fixing Link

Shoe Fixing Nut

39mm or more

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.)

Updated 23/05/07 RAOM0507 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.

5. Alter the spring tension adjustment screws to correct the balance.

6. Check the 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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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 as shown in Fig 2.

3. Use a 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. If a in Fig.1 is greater than b, (the left side), turn the arm fixing nut anti-clockwise

(in the A direction).

2. If b is 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’.

Fig.1 Fig.2 Fig.3

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Brake Shoe Replacement

Tread

Usable Brake Shoe Worn out Brake Shoe (Replace)

Tread Worn Off

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 replace the brake shoes

in pairs – never one side only.

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

brake mount.

2. Adjust the callipers’ active lever as close to the rotor

as possible.

3. Adjust the neutral side with the relevant adjuster.

If your disc brakes allow adjustment of the calliper toe-in, check:

1. The clearance is even from front to back.

2. The inner cable fixing bolt is securely tightened.

Please see brake manufacturers manual (if supplied) for detailed adjustment instructions.

Disc Brake Adjustment (Hydraulic)

Disassembly of hydraulic disc brakes systems can be a complex procedure and therefore,

it is 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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

DRIVETRAIN

Pe dal Axles

L = Left

R = Right

Turn CounterClockwise to tighten

Turn

Clockwise

to tighten

Correct Pedal Attachment

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:

Pedals fitted with toe clips and straps 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. 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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Clipless Pedals

Clipless pedals or “step-in-pedals” are designed

for maximum pedalling efficiency. The rider wears

specific 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:

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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Lubrication and Adjustment

Pedal with toe clip and strap attached

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 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.

WARNING:

Never attempt to force a pedal into a different sized bicycle crank.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Crank Set

Dust Cap

Axle Nut

Crank Arm

Tapered Axle

Chainwheel

Ball Bearing

Lockring

Fixed Cup

Axle

Adjusting Cup

Standard Bottom Bracket Assembly (Cotterless)

Together the bottom bracket axle and bearings, the crank arms and the chainrings are

known as the crank 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.

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

broken teeth, and clean off any

excess dirt and grease.

Caution:

Always ensure that your

Three Piece cranks are

firmly secured before

riding. Riding with loose

cranks is potentially

hazardous to both the

rider and condition of the

crank arms.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Lubrication and Adjustment – One Piece Cranks

Fixed Cone

Crank

Chainwheel

Ball Retainer

Bearing Cup

Adjusting Cone

Lockwasher

Locknut

One Piece Crank Assembly

To adjust:

- Turn the 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.

2. Turn the spindle clockwise and remove the left pedal.

3. Turn the left side locknut clockwise and remove, as well as the keyed lock washer.

4. Use a screwdriver to turn the adjusting cone clockwise and remove.

5. 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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Lubrication and Adjustment – Three Piece Cranks (Cotterless Cranks)

Bottom Bracket Shell

Right Hand Cup

Cup Removing Tool Three Piece Crank Removing Tool

Remove dust cap. Loosen and remove flange nut.

Left Hand Cup

Lockring

Bottom Bracket Cup

Ball Retainer

Axle

Fixed Right Hand Cup

Removable Left Hand Cup

Cartridge Style Bottom Bracket

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:

1. Remove the cranks from the axle.

2. Turn the left side lockring anti-clockwise and remove.

3. Turn the adjusting cup anti-clockwise and remove.

4. Remove the left ball retainer and slide the axle out of the frame to the left.

5. 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

you will need to use a specific

removing tool. Follow the outline

below to guide you through the

process.

1. Use a coin or a screwdriver

to remove the dust cap.

2. Remove the flange nut or bolt

and washer after loosening.

3. Attach the removing tool into

the crank and tighten.

4. Turn the screw bolt until the

crank comes away from the

axle.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Three Piece Crank Replacement

Position the crank on the axle.Screw in the removal tool. Tu rn the screwbolt clockwise.

Tighten the flange nut. Replace the dust cap.Lightly tap the crank onto the axle.

1. Place the crank arm onto the axle.

2. Use a soft mallet to gently tap the crank arm.

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

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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Chain

Rear Sprocket

Pull Up

Front Chainwheel

Straightedge

12mm

Inspection and Lubrication

Regular inspection and maintenance of your chain is vital to guard against 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 screwdriver.

- 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.

- Fit the master link into the rollers at each end of the chain.

- Position the master 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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Unlike the single speed freewheel bike, coaster hub brake or 3-speed hub bicycle the

Chain Rivet Tool

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:

- Fit the rivet tool so that the punch pin

is centred over any one of the chain

rivets.

- Push the rivet almost all the way out,

then back out the punch and remove

the tool.

- Holding the chain on both sides

of the punched rivet, bend it slightly

to release the link from the rivet.

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 within 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.

Updated 23/05/07 RAOM0507 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. 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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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

for all of the different systems. With a standard “friction” derailleur system, the rider should

feel 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 locations

(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

form 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 strands, and any damage to the cable housing. Replace as necessary to

ensure accurate shifting performance.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Lubrication

SIS Cable Barrel Adjuster Adjustment Screws

Pulley Adjustment Screw

Tension Pulley

Outer side of Top Gear

Guide Pulley

Freewheel

Rear Derailleur Rear View

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

system, fine turning of the SIS mechanism

will be the most common rear derailleur

adjustment you will need to make.

To fine tune the SIS rear derailleur:

- Raise the back wheel of your bicycle off

the ground (to enable you to rotate the

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 completing 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

pulleys need to be inspected

whilst standing behind the

bicycle. Based on your findings,

adjustments to high or low gear

may be necessary.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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 bolt 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 barrel adjuster or by repeating

the above procedures.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Adjustment – Front Derailleur

Cable Clamp Bolt

Low Adjusting Screw

High Adjusting Screw

Chainguide Clearance

Outer Chainguide

Inner Chainguide

1-3mm

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:

- Shift the chain onto the smallest front

chainring and the largest rear sprocket.

- Loosen off the control cable fixing bolt.

- Turn the adjusting screw marked ‘L’ until

the inner cage clears the chain.

- With the shift lever fully in the low

position, pull the control cable taut.

- Re-tighten the cable fixing bolt.

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 tension 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.

- Test that the chain shifts cleanly, without hesitation between each chainring.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

To fine tune racing style bicycles fitted with dual control (STI) levers:

reflectors

side view

top view

- Shift the chain to the largest rear sprocket and the largest chainring.

- Push the left hand inner lever slightly to engage the noise prevention mechanism.

- Turn the cable adjuster 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.

WARNING:

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 is dangerous and may result in serious injury or death.

Updated 23/05/07 RAOM0507 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 & 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.) 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.

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

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 luggage 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.

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

TROUBLESHOOTING

Problem Possible Reason Possible Solution

Slipping chain Excessively worn or chipped

chainring or freewheel

Replace chainring/sprockets/ chain

sprocket teeth

Chain worn/stretched Replace chain

Stiff link in chain Oil or replace link

Non compatible chain/ chainring/freewheel

Consult a professional bicycle mechanic

Brake not working correctly Brake blocks worn down Replace brake blocks

Brake blocks/rim greasy, wet

Clean blocks and rim

or dirty

Brake cables are binding/

Clean/adjust/replace cables

stretched/damaged

Brake levers are binding Alter brake levers

Brakes out of adjustment Centre brakes

Frequent punctures Inner tube old or faulty Replace inner tube

Tyre tread/casing worn Replace tyre

Tyre incompatible to rim Replace with correct tyre

Tyre not checked after previous puncture

Remove any sharp objects from tyre

Tyre pressure too low Inﬂate tyre to correct

pressure

Spoke protruding into rim File down spoke

When the brakes are applied Brake blocks worn Replace brake blocks

they squeal/squeak Brake blocks/rim greasy, wet

Clean blocks and rim

or dirty

Brake block toe-in incorrect Correct block toe-in

Brake arms loose Secure mounting bolts

Wobbling wheel Axle broken Replace axle

Wheel out of true True wheel

Hub cones loose Tighten hub bearings

Headset bindings Alter headset

Hub bearings collapsed Replace bearings

Knocking or shuddering when brakes applied

Bulge in the rim or rim out of true

True wheel or consult a bike mechanic

Brake mounting bolts loose Secure bolts

Brakes out of adjustment Centre brakes and/or adjust

brake block toe-in

Forks loose in head tube Secure headset

Constant clicking noises Stiff chain link Oil chain

when pedalling Loose pedal axle/bearings Alter bearings/axle nut

Loose bottom bracket/

Alter bottom bracket

bearings

Bent bottom bracket or pedal axle

Replace bottom bracket or pedals

Loose crankset Tighten crank bolts

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Problem Possible Reason Possible Solution

Grinding noise when Pedal bearings too tight Adjust bearings

pedalling Bottom bracket bearings too

Adjust bearings

tight

Chain fouling derailleurs Adjust chain line

Derailleur jockey wheels

Clean and oil jockey wheels

dirty/binding

Chain jumping off Chainring out of true Re-true if possible, or replace

chainwheel sprocket Chainring loose Secure mounting bolts

or chainring Chainring teeth bent or

broken

Rear to front derailleur

Repair or replace chainring/ set

Alter derailleur travel side-to-side travel out of adjustment

Freewheel does not freewheel

Incorrect gear shifting Derailleur cables sticking/

Freewheel internal pawl pins are jammed

stretched/damaged

Front or rear derailleur not

Lubricate. If problem

persists, replace freewheel

Lubricate/tighten/replace

cables

Alter derailleurs adjusted properly

Indexed shifting not adjusted

Alter indexing properly

Steering not accurate Wheels not aligned in frame Align wheels correctly

Headset loose or binding Adjust/secure headset

Front forks or frame bent Consult bicycle mechanic for

frame realignment

Knocking from rear end of Broken suspension mount repair/replace frame

suspension model Worn suspension bushing Replace worn components

Suspension dampers binding Loss of internal ﬂuid Lubricate as necessary

Internal rust Disassemble damper and

replace affected parts

Damaged internal parts Consult professional bicycle

mechanic

Updated 23/05/07 RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

NOTES

PART 6 - PURCHASE DETAILS

Updated 23/05/07RAOM0507 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469

Apollo Radius User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual