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Apollo 2013 Owner's Manual & Technical Handbook

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BICyCLE OwnEr'S MAnuAL
& TEChnICAL hAndBOOK 2013
IMPORTANT! Please read this manual before using your new bicycle

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Summary of Contents for Apollo 2013

  • Page 1 BICyCLE OwnEr'S MAnuAL & TEChnICAL hAndBOOK 2013 IMPORTANT! Please read this manual before using your new bicycle...
  • Page 2 Subject to the terms, conditions and limitations set forth below, Apollo warrants to the original purchaser of each new Apollo bicycle (that has a wheelbase exceeding 640mm or a wheel size of 16” (40cm) or greater.) that Apollo Bicycle Company will repair or replace the frame or fork should it fail at any weld point, provided it was purchased new from, and assembled by, an authorised Apollo bicycle dealer.
  • Page 3 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.

  • Page 4: Parts Classification

    Page 27 – 67 PART 8 PART 7 Contact Addresses Electric Bicycle Manual Back Cover Pages 69 – 76 Warning / Important (take notice of this symbol throughout this manual) APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 5: Table Of Contents

    - Schedule 2. Service Checklist Torque Requirements & Tools Required 5. COMPREHENSIVE MAINTENANCE Wheels and Tyres - Wheel inspection - Tyre inspection - Recommended tyre pressures - Front wheel removal & replacement APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 6 Front Fork Seat Tube Down Tube Front Derailleur Rear Gear Control Cable Pedal Crank Arm Freewheel Chainwheel Tyre Valve Gear Control Cable Chainstay Front Hub Rear Derailleur Chain Tyre Spokes APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 7: Suspension Bicycles

    Rear Frame Sub Assembly Pedal Crank Arm Wheel Reflector Bottom Bracket Axle Gear Control Cable Chainwheel Tyre Valve Freewheel Chainstay Front Hub Axle Rear Derailleur Drive Chain Tyre Spokes APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 8: Bmx Bicycles

    Crash Pad Rear Reflector Wheel Reflector Wheel Reflector Seat Tube Down Tube Chain Guard Crank Arm Pedal Chainwheel Tyre Valve Rear Sprocket Front Hub Chainstay Training Wheel Chain Tyre Spokes APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 9: Road Bicycles

    Front Derailleur Bottom Bracket Axle Toe Strap Toe Clip Pedal Crank Arm Chainwheel Chainstay Tyre Valve Chain Spoke Protector Disc. Freewheel Front Hub Rear Derailleur Rear Dropout Tyre Spokes APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 10 Clearance heights vary according to rider preference and between the different bicycle models. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 11 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”) APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 12: Riding Position

    (Refer to Part 5 on how to adjust the seat clamp) Arms not over exteneded Handlebar stem height about the same as seat height Pedal at bottom position APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 13: Handlebar Height

    Stem Wedge Bolt Handlebar Binder Bolt Maximum Height/ Minimum Insertion Mark Exceeds 2 1/2" (64mm) APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 14: Safety Checklist

    - 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 APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 15: Steering

    - 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 APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 16: Helmets

    - 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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 17: Riding Safely

    - 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 APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 18: Night Riding

    - 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). APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 19: Hill Technique

    Caution: When riding downhill never take your hands off the handlebars, or feet off the pedals. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 20: Gears - How To Operate

    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 APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 21: Operating Principles

    To extend the life of your chain avoid using extreme gear combinations as shown in the diagrams below. High Medium High Medium Recommended Chainwheel/Rear Sprocket Gear Combinations APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 22: Hand Grip Shifters

    To clarify please refer to the following diagram. Left Right Low gear front High gear rear High gear front Low gear rear APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 23: Dual Control Shifters

    One firm push shifts the chain one cog, while continuing to press will move the chain over multiple cogs. Rapid Fire Shifters High Gear Low Gear Rear Front High Gear Low Gear Front Rear APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 24: Basic Maintenance

    Deflate the tyres to half pressure and hang the bicycle off the ground. 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.” APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 25: Security

    Use a high quality bicycle lock that will resist hack saws and bolt cutters. Solid Post Bicycle Frame U - Lock Rear Wheel High Security using a U - Lock APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 26: Schedule 1. Lubrication

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 27: Schedule 2. Service Checklist

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 28 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 APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 29: Wheels And Tyres

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 30: Tyre Inspection

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 31 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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 32 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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 33: Correct Quick Release Axle Setting

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 34 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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 35 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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 36: Tyre Valve

    ™ - Schraeder is a registered Trademark Schraeder Valve Presta Valve of the Schraeder Corporation Inc. (Car/American) (French) APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 37: Steering System

    Maximum Height/ Minimum Insertion Mark Minimum Insertion Mark properly on bicycles equipped with a suspension type Expander Bolt Wedge Expander Bolt Wedge handlebar stem. MTB Handlebar Stem BMX Handlebar Stem APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 38: Handlebar / Forks

    Replacement forks must have the same rake, length and inner tube diameter as those originally supplied on the bicycle. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 39: Bicycle Suspension

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 40: Headset

    Unlike standard headsets, the 'A-head 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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 41 Stem Cap Headset Wedge Bearing Race Bearing Dust Cover Bearing Retainer Installed By Factory Upper Headset Cup Headtube Lower Headset Cup Bearing Retainer Bearing Dust Cover Headset Crown Race Fork APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 42: Rotor Installation & Adjustment

    (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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 43: Saddle & Seat Post

    Remove the seat post from the frame and clean thoroughly. Lightly grease the part that will be inserted into the frame. Replace the seat post into the frame and adjust and fasten. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 44 CAUTION: If your bicycle is fitted with a suspension type seat post check that this is intact and functioning properly. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 45: Brakes

    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 APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 46: Sidepull Callipers

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 47: Linear Pull

    39mm or more 5mm Allen Key Washer 3mm washer B 6mm washer B Link fixing Shoe Fixing Nut bolt Washer A Washer B Washer Shoe Fixing Link APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 48 (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. 5mm Allen Key APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 49: U-Brake

    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 APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 50: Disc Brake

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 51: Drivetrain

    - If toe clips are fitted, ensure that they are fastened tightly to the pedals. Correct Pedal Attachment L = Left R = Right Pedal Axles Turn Counter- Turn Clockwise Clockwise to tighten to tighten APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 52: Clipless Pedals

    Failure to do so could result in the cyclist losing control of the bicycle and falling. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 53 9/16” thread. Pedal with toe clip and strap attached WARNING: Never attempt to force a pedal into a different sized bicycle crank. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 54: Crank Set

    Always ensure that your Axle Three Piece cranks are Lockring firmly secured before Adjusting riding. Riding with loose cranks is potentially hazardous to both the rider and condition of the crank arms. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 55 Re-assemble the crank in the reverse order of the procedure listed above. Locknut Bearing Cup Fixed Cone Lockwasher Adjusting Cone Ball Retainer Bearing Cup Ball Retainer Crank One Piece Crank Assembly Chainwheel APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 56 Ball Retainer Bottom Bracket Left Hand Cup 4. Turn the screw bolt until the Lockring crank comes away from the axle. Remove dust cap. Loosen and remove flange nut. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 57 Screw in the removal tool. Turn the screwbolt clockwise. Position the crank on the axle. Lightly tap the crank onto the axle. Tighten the flange nut. Replace the dust cap. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 58: 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. Front Chainwheel Rear Sprocket Pull Up Straightedge 12mm APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 59: Freewheel

    Note: Generally, whenever the chain needs to be replaced the freewheel should also be changed. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 60: Coaster Hub

    Any adjustments or replacements are best handled by a professional bicycle mechanic since the coaster hub’s internal mechanisms are very complex. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 61: Derailleur Systems

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 62: Rear Derailleur

    Freewheel whilst standing behind the bicycle. Based on your findings, Guide Pulley adjustments to high or low gear may be necessary. SIS Cable Barrel Adjuster Adjustment Screws Tension Pulley APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 63 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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 64: Front Derailleur

    - 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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 65: Reflectors

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 66: Accessories

    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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 67 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. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 68: Troubleshooting

    Loose pedal axle/bearings Alter bearings/axle nut Loose bottom bracket/ Alter bottom bracket bearings Bent bottom bracket or pedal Replace bottom bracket or axle pedals Loose crankset Tighten crank bolts APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 69 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 APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 70 1. Unfold / fold the bikes mainframe and lock pull to lock 2. Unfold / fold the handlebar/stem and lock twist to lock 3. Adjust seat height and unfold pedals APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 71: Basic Overview

    Please be sure to read the ‘battery charging’ section before operating your bike’s electrical functions. The electric bicycle’s battery must be charged completely before the motor can be operated safely. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 72 Please note: The position of the motor may vary depending upon which Apollo model you have selected. You may either have a rear hub motor or front hub motor as pictured.
  • Page 73 • Ambient temperatures between 10° ~ 30° C. will significantly enhance the range and performance of your battery. • Get your bike serviced regularly (every 12 months) at a local approved dealer. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 74: Safety

    • Do not rotate the pedals when charging the battery while it is mounted on the bicycle. • Do not apply voltage over the rated value to the charger. • Do not use damaged components such as charge case, power cord, plug etc. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 75 If the LED lights continuously flash there is a malfunction. Reset the power. If the symptom persists even after resetting, take your bike back to an authorised dealer. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...
  • Page 76 Never, ever carry a passenger. You may carry a child as long as he/she is placed in a proper child seat that is fitted securely to the bicycle. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 77: Maintenance

    Take your bike to your authorised dealer for immediate service or replacement. Do not recharge the battery for over 12 hours. This could seriously reduce the long-term life of the battery. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 78: Battery Charging

    Step 4. Disconnect the battery from the charger after the charge is completed. Step 5. Side-mount the battery onto the bicycle. The key must be turned anti-clockwise to open and allow battery to fit into the frame. APOM0312 Apollo Bicycle Company Pty. Ltd. ABN: 60 001 914 469...

  • Page 79: Purchase Record

    FRAME SIZE SERIAL NUMBER | | | | | | | | | | | | | | | wE rECOMMEnd yOu ALSO rEGISTEr yOur BIKE OnLInE wITh APOLLO AT www.apollobikes.com/register SErIAL nuMBEr LOCATIOn SErIAL nuMBEr LOCATEd undEr BOTTOM BrACKET TyrE PrESSurE COnVErSIOn ChArT 0.70...
  • Page 80 Apollo is Distributed by Apollo Bicycle Co. Pty. Ltd. Bikes International Limited ABN: 60001 914 469 44E Dalgety Drive, Manukau City, PO Box 5125, Studfield, Victoria, 3152 Auckland, NZ Ph: (03) 9881 6600 Fax: (03) 9881 6666 Ph: (09) 261 2646 Fax: (09) 261 2648 APOLLOBIKES.COM...

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