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.
DIRECTORY PART 1 PART 2 Warranty Parts Classification Inside Front Cover Pages 4 – 7 PART 3 PART 4 Before You Ride Bicycle Care & Servicing Pages 8 – 21 Pages 22 – 26 PART 5 PART 6 Comprehensive Maintenance Purchase Details Page 68 Page 27 – 67 PART 7 Contact Addresses Warning / Important (take notice of this symbol throughout this manual) Back Cover 2 RAOM0507 Apollo Bicycle Company Pty. Ltd.
4 5. COMPREHENSIVE MAINTENANCE 27 Mountain bicycles & Cross Bicycles 4 Wheels and Tyres 27 Suspension Bicycles 5 - wheel inspection 27 BMX/Loop Frame/U-Frame Bicycles 6 - tyre inspection 28 Road Bicycles 7 - recommended tyre pressures 28 3.
PART 2 - PARTS IDENTIFACATION Finding the bicycle to best suit your needs is made easy by the vast array of bicycle models and sizes available. Refer to the following diagrams to familiarize yourself with the names of the various parts on your bicycle. Mountain Bikes & Crossbikes. Mountain bikes are one of the most versatile bicycles.
Suspension Bikes. Suspension bicycles aim to maximize comfort and traction over rough terrain. The basis of the mountain bike frame is blended with suspension – either suspension front forks only or in combination with a rear suspension mechanism built into the frame. A special shock absorbing seat pillar may also be present for improved rider comfort.
BMX Bicycles. BMX style bicycles are ideal for young riders. Their durable, simple design makes them perfect for general purpose use with minimal maintenance required. Alternative frame styles, such as U-shape frames and loop frames, may also be used for other varieties of children’s bicycles.
Road Bicycles. Road or racing bikes aim to cater for fast travel over long distances on smooth surfaces. Frames are light weight and rims have a narrower profile, for maximum efficiency and speed.
FRAME SIZE PART 3 - BEFORE YOU RIDE 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.
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 46cm min. 55cm min. 61cm min. 61-69cm 66-76cm 71-79cm 79-86cm 81-89cm Approx. Ages Wheel Size (kid’s models) Suggested Frame Size for Road Bikes Suggested Frame Size for Mountain or Hybrid Bikes 4-6 5-10 6-14 12-16 12 plus 12 plus 12 plus 12 plus 12 plus 12 plus 12 plus 30cm(12”) 40cm(16”) 50cm(20”) 61cm(24”) - 50cm(19.5”) 55cm(21.5”) 57cm(22.5”) 60cm(23.
RIDING 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.
3. Handlebar Height 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).
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.
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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.
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.
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.
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.
Operating Principles Although the number of gears present on multispeed bicycles varies greatly, how the gears function remains the same. The right shifter works the rear derailleur and the left shifter works the front derailleur. If the pedals are stationary or rotating backwards, gears cannot be changed. They can only be altered when pedalling forward. To achieve a successful gear change, either moving up or down in gears, the pedalling pressure must be relaxed.
Hand Grip Shifters Left Right Hand grip shifters are built into the hand grip and attach to the handlebars. Unlike other Low gear front High gear rear 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 L H H L dependent upon their gear selection. By twisting the right shifter toward you, a lower gear is chosen as a larger rear cog is selected.
Dual Control 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”).
BICYCLE CARE Basic maintenance PART 4 - BICYCLE CARE & SERVICING 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.
Security In an attempt to prevent your bicycle from being stolen the following precautions should be undertaken. 1. Take note of the bicycle serial number, generally located underneath the bottom bracket of the frame. 2. Register the bicycle with the manufacturer/distributor and local police 3. If your bicycle is left unattended, always secure it to an immovable object, such as a lamp post. Use a high quality bicycle lock that will resist hack saws and bolt cutters.
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.
Schedule 2 – Service Checklist Frequency Before every ride After every ride Weekly Monthly 6 monthly Yearly Task Check tyre pressure Check brake operation Check wheels for loose spokes Make sure nothing is loose Quick wipe down with damp cloth Lubrication as per schedule 1 Lubrication as per schedule 1 Check derailleur adjustment Check brake adjustment Check brake and gear cable adjustment Check tyre wear and pressure Check wheel are true and spokes tight Check hub, head set and crank bearings for loose
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.
WHEELS AND TYRES Wheels Inspection 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.
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.
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.
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.
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.
Hub Bearing Adjustment 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.
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.
Tyre Valves Bicycles primarily use either Schraeder™ or Presta tyre valves. To inflate tyres the pump needs to be fitted with the appropriate attachment specific to the valve stem. The Schraeder™ valve is the most commonly used tyre valve. It is also known as the car or the American valve. Tyres fitted with Schraeder™ valves can be inflated using either a hand pump or a service station pump, as it is the same valve used on cars.
STEERING SYSTEM 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. Stem Bolt Head Set Maximum Height/ Minimum Insertion Mark Expander Bolt Wedge Head Tube Note: The handlebar height can be altered to suit the rider’s preference.
Ensure that the handlebars are appropriately aligned and are tightened to a minimum 17Nm of torque when re-fitting the stem. Use only the appropriate Allen key or hex wrench for fastening and take care not to over tighten. Test the attachment by bracing the front wheel between your knees and try to move the handlebars up and down and from side to side. The handlebars are secure within the stem and the stem within the fork steerer tube if no movement is detected when applying turning pressure.
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.
Headset Inspection The headset is responsible for locking the fork into the frame. Every month the headset bearing adjustment should be tested. This is done by standing astride the frame top tube with both feet on the ground and firmly applying the front brake and rocking the bicycle back and forward. 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.
Lubrication and Attachment of An 'Ahead Set' Stem To The Fork Every year your bicycle should have a complete lubrication. This can be quite a complex task and may be best handled by a professional bicycle mechanic. However, if you feel capable the following procedure will guide you. 1. Suspend the bicycle so that the front wheel is off 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.
HEADSET SET AND HEAD AND Rotor ROTOR ASSEMBLY DIAGRAM ROTOR ASSEMBLY DIAGRAM D B1 B2 B2 E F 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.
Cable Tension Adjustment 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.
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.
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.
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.
Installation and Adjustment – Linear Pull Brakes 1. When assembling linear pull brakes, insert the brake body into the centre spring hole in the frame mounting boss, and use the link fixing bolt to fasten the brake body to the frame. 39mm or more A 5mm Allen Key Washer Spring hole Link fixing bolt Stopper pin 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.
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. 5mm Allen Key 5mm Allen Key 5mm Allen Key 5. Alter the spring tension adjustment screws to correct the balance. 5mm Allen Key 5mm Allen Key 5mm Allen Key 6.
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.
Brake Shoe Replacement Brake shoes must have adequate usable tread Tread Usable Brake Shoe Tread Worn Off Worn out Brake Shoe (Replace) 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.
DRIVETRAIN The drivetrain consists of the pedals, chain, chainwheel, crank set, and freewheel. These are all the components of the bicycle that transmit power to the rear wheel. Pedals There is a vast range of pedals available, designed for many different uses. Pedals fitted with toe clips and straps aim to make the pedalling process easier for the rider.
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.
Lubrication and Adjustment The maintenance your pedals need will depend upon whether or not they can be disassembled to enable access to the internal bearings and axle. If they cannot be disassembled, every six months a small amount of oil should be injected onto the inside bearings of pedals. Pedals that can be fully disassembled should have the bearings removed, cleaned and greased every six to twelve months.
Crank Set 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.
Lubrication and Adjustment – One Piece Cranks 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.
Lubrication and Adjustment – Three Piece Cranks (Cotterless Cranks) To adjust: - Turn the lockring on the left side anti-clockwise. - Turn the adjusting cup until appropriately set. - Carefully re-fasten the lockring without disturbing the cup adjustment. To disassemble: 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.
Three Piece Crank Replacement 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.
Chain 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.
Unlike the single speed freewheel bike, coaster hub brake or 3-speed hub bicycle the chains on derailleur geared bicycles are automatically tensioned by the rear derailleur. Consequently, manual adjustment of the chain is not necessary on derailleur geared bicycles. The process for removing and replacing chains or altering the length of the chain on a derailleur geared bicycle, also differs from that used on the other bike types.
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.
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.
Lubrication Lightly oil all the pivoting points of the front and rear derailleurs at least every month. Any excess oil should be wiped off to prevent dirt entering into the mechanisms. Clean and apply a thin layer of grease to the shifting cables every six months, or whenever new cables are fitted. Adjustment – Rear Derailleur If your bicycle is fitted with a SIS derailleur system, fine turning of the SIS mechanism will be the most common rear derailleur adjustment you will need to make.
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.
Adjustment – Front Derailleur The front derailleur is positioned correctly when its chain guides are parallel to the chainrings and there is approximately 2mm-4mm of clearance between the outer chain guide and the large chainring. To achieve this ideal derailleur positioning, loosen the clamp bolt and make the necessary adjustments. To adjust the clamp position lower for top mounted cable systems, disconnect the derailleur cable.
To fine tune racing style bicycles fitted with dual control (STI) levers: - 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.
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.
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.
TROUBLESHOOTING Problem Possible Reason Slipping chain Excessively worn or chipped Replace chainring/sprockets/ chainring or freewheel chain sprocket teeth Brake not working correctly Possible Solution Chain worn/stretched Replace chain Stiff link in chain Oil or replace link Non compatible chain/ chainring/freewheel Consult a professional bicycle mechanic Brake blocks worn down Replace brake blocks Brake blocks/rim greasy, wet Clean blocks and rim or dirty Frequent punctures Brake cables ar
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 dirty/binding Clean and oil jockey wheels 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 Repair or replace chainring/ set Rear to fro
PART 6 - PURCHASE DETAILS NOTES 68 RAOM0507 Apollo Bicycle Company Pty. Ltd.
