Sportworks Apex 2 Manual

All dimensions and specifications nominal. Specifications are subject to change without notice.

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Apex 2™2-Position Bicycle Rack

Operation and Maintenance Instructions

CONTENTS

1. SCOPE OF THIS DOCUMENT....................................................................................2

2. INSTALLATION............................................................................................................2

a) Mounting the Rack.................................................................................................5

3. OPERATING THE BIKE RACK....................................................................................6

a) Bicycle Loading......................................................................................................6

b) Bicycle Unloading ..................................................................................................7

4. USE OF THE BUS WASH............................................................................................9

5. INSPECTION AND MAINTENANCE..........................................................................10

a) Visual Inspection Checklist ..................................................................................10

b) 30 Day General Maintenance Inspection & Service.............................................12

6. SUPPORT ARM AND LATCH MECHANISM.............................................................13

a) Servicing the Support Arm...................................................................................14

b) Servicing the Apex 2 Latch Mechanism...............................................................15

7. WEAR LIMITS............................................................................................................16

8. CONTACT INFORMATION........................................................................................17

All dimensions and specifications nominal. Specifications are subject to change without notice.

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1. SCOPE OF THIS DOCUMENT

This document applies to all Apex 2 bicycle racks. The Apex 2 product line includes 2-position bike

racks with stainless steel frames, wheel trays, and support arms. There are two primary versions of the

Apex 2 –one with standard trays and support arms, the other with fat tire compatible trays and support

arms.

Figure 1, Apex 2 with standard trays and

support arms

Figure 2, Apex 2 with fat tire compatible trays and

support arms

Part Numbers:

101082(-XXX) Apex 2 with standard trays and arms

101082-FAT(-XXX) Apex 2 with fat tire compatible trays and arms for both tray positions.

101082-FATF(-XXX) Apex 2 with a fat tire compatible tray and arm on the front position

(farthest from the vehicle front), and a standard tray and arm on the rear

position.

101082-FATR (-XXX) Apex 2 with a fat tire compatible tray and arm on the rear position

(closest to the vehicle front), and a standard tray and arm on the front

position.

2. INSTALLATION

The installation is crucial to the safety and performance of the Sportworks bike rack system. There are

several factors to consider when mounting the rack, including:

•Load height

•Approach angle

•Protrusion and Turning radius

•Bicycle/wiper clearance

•Front mask clearance

•Footprint/headlight clearance

Carefully review the following information regarding the positioning of the rack on the bus before

beginning the installation process.

All dimensions and specifications nominal. Specifications are subject to change without notice.

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Figure 3, Factors to Consider During

Installation

Figure 4, Front Mask Clearance

Load Height

The load height is the vertical distance a bicycle must be lifted for placement in a deployed bike rack. If

the rack is mounted too high, some riders may have difficulty loading the rack.

Approach Angle

The approach angle is the angle created by a line from where the front tire contacts the pavement to

the first obstruction ahead of the front tire. This obstruction would first touch the pavement when

transitioning from flat to a very steep hill. APTA standards require a minimum approach angle of 8°,

although some agencies in hilly areas may prefer a 9° approach angle. The bike rack will limit the

approach angle if it is installed on the bumper in a position that is too low. The bike rack installer should

be aware of this possibility and investigate approach angle requirements before mounting the rack.

Protrusion

Protrusion measures the distance from the front of the bumper to the front edge of the bike rack in the

deployed position. Once the bike rack is mounted to the coach, the protrusion distance is fixed.

Protrusion is a measurement that requires attention due to the overall length, approach angle and

turning radius. Protrusion is not typically an issue with 2-position racks, however if you have any

questions or concerns, please contact us.

Bicycle/Wiper Clearance

It is important to ensure that the handlebars of a loaded bicycle do not interfere with windshield

wipers. A minimum of sixteen inches of horizontal distance is recommended between the center of

the wheel tray and the wiper arms.

Front Mask Clearance

Front mask clearance is the clearance between the stowed rack and the wiper mechanism or front-

most part of the bus mask. A minimum of 2 inches clearance is recommended, although some vehicles

may have unique requirements.

All dimensions and specifications nominal. Specifications are subject to change without notice.

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Stowed Position / Headlight Clearance

Figure 5 shows an outline of the Apex 2 against a bus front when the rack is in the stowed position.

Obstruction of headlights and turn signal indicators should be avoided. The position of the rack can be

adjusted. Remove the bike rack from the pivot plate. Remove the pivot plate from the C-brackets or

other bracket pieces and position the pivot plate up or down as required. Remount the pivot plate to the

bracket pieces and the rack to the pivot plate.

Some bracket assemblies may not have multiple height adjustment holes. If this is the case, the

bracket assembly is designed for an optimum position in terms of minimal headlight interference and

proper loading height and adjustment is not required.

Figure 5, Front View of Bus

Figure 6, Height Adjustment

All dimensions and specifications nominal. Specifications are subject to change without notice.

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a) Mounting the Rack

1. Install pivot plate using supplied hardware Item #1 and 14" or 18" hole pattern.

2. Install pivot tab bushings Item #2 in rack with flanges inside.

3. Place rack on pivot plate in stowed (up) position. The pivot plate will support the rack while

you insert the fasteners.

4. Insert the supplied fasteners Items 3, 4 and 5. Insert the supplied fasteners and torsion

spring Items 6, 7, and 8. The bent end of the torsion spring hooks into the pivot plate and

the large end of the torsion spring mount Item #7 should be toward the nut.

5. Torque 1/2"-13 bolts to torque values listed in General Torque Specs section.

Note: Standoffs can shift during service because of impacts. When installing the Apex pivot

plate on pre-installed standoffs, it may be necessary to loosen the standoffs from the back

bumper structure to align them to the 14" and 18" hole pattern. Bolt the pivot plate to standoffs,

and tighten standoff bolts.

Figure 7, Apex 2 Rack and Standoffs

All dimensions and specifications nominal. Specifications are subject to change without notice.

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General Torque Specs

Most brackets attach to the bus bumper using Grade 8 ½-13 HHCS. Standard pivot plates are attached

to the brackets using Grade 8 3/8-16 HHCS.

Recommended torque values:

•½-13 Grade 8 –80-90 FT-LB

•3/8-16 Grade 8 –30-40 FT-LB

If you are using quick-release hardware to attach the bike rack to the pivot plate or are using a Ten

Second Bracket (TSB), tighten the knobs by hand as tightly as possible and do not tighten with tools.

3. OPERATING THE BIKE RACK

All loading and unloading of bikes can be accomplished by the rider. Loading of children's bikes shall

be supervised by an accompanying adult.

b) Bicycle Loading

1. Prepare the bicycle by removing water bottles, pumps, panniers, bags, and other loose

items that could fall while the vehicle is in motion.

2. Indicate to the operator that you will be loading your bike. Bikes should be loaded from

the curbside or from in front of the vehicle. Do not step beyond the vehicle into passing

traffic to load your bike

3. If the rack is in the stowed (vertical) position, squeeze the latch handle to release the

latch, then pull the bike rack down to the loading position. Only one hand is required to

unlatch and pull the bike rack down. This enables users the ability to support the bike (it

is not necessary to lean the bike against the transit vehicle.)

4. Lift the bike onto the bike rack, fitting the front wheel into a wheel slot labeled for the

front wheel. The purpose of the directional placement is to make adjacent bikes easy to

load and unload.

5. Raise the support arm hook over the front tire. The support arm will keep the bike

secure while the vehicle is in motion.

NOTE: The support arm hook must be between the highest point of the tire and the

head tube. Incorrect placement may result in the bike falling from the rack, which could

result in injury and/or damage to the bike, the vehicle in operation, and other vehicles.

If the bicycle has fenders, place the support arm hook over or under the fender as required to

achieve the correct hook position.

Some accessories such as front racks and baskets with vertical support stays may preclude

correct hook placement. Bikes with accessories that conflict with correct support arm

placement must NOT be loaded onto the rack.

All dimensions and specifications nominal. Specifications are subject to change without notice.

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Figure 8, Proper Placement of Support Arm

c) Bicycle Unloading

1. Indicate to the operator that you will be unloading your bike as you approach your stop. Bikes

should be unloaded from the curbside or from in front of the vehicle. Do not step beyond the

vehicle into passing traffic to unload your bike.

2. Raise the support arm hook off the tire and return it to its stowed position.

3. Lift the bike out of the bike rack.

4. Step away from the transit vehicle with your bike onto the curb.

NOTE: LOADING OR UNLOADING A BIKE FROM THE STREET SIDE OF THE TRANSIT

VEHICLE MAY CAUSE INJURY OR DEATH.

Sportworks label (part no. 3575) shown in Figure 9 is available for use on the transit vehicle front

fascia. The label measures 9.5 inches by 6.0 inches. It contains the same graphic in a larger

format as the label affixed to each support arm of the rack.

All dimensions and specifications nominal. Specifications are subject to change without notice.

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Figure 9, Instructional Label with Support Arm Placement Instructions

Supported Bike Dimensions and Weight Limits

To ensure safe bicycle fit in the Apex 2 rack, each bicycle must comply with the following:

Apex 2 with standard trays and

support arms:

•Wheelbase (max): 48.0in

•Tire width (max): 3.2in

•Tire size (min-max): 16-29in (incl. 700c)

•Weight (max): 75lbs per bike

Apex 2 with fat tire compatible trays and

support arms:

•Wheelbase (max): 48.0in

•Tire width (max): 5.5in

•Tire size (min-max): 24-29in (incl. 700c)

•Weight (max): 75lbs per bike

Figure 10, Reference for Supported Bicycle Specifications

All dimensions and specifications nominal. Specifications are subject to change without notice.

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4. USE OF THE BUS WASH

Sportworks racks have been designed to safely pass-through bus wash facilities. Before taking a newly

mounted bike rack through a wash facility, the operator should check to ensure that the wash facility is

properly set up for washing the bus with a rack on it.

Most wash systems use either a "top fixed" or "top and bottom fixed" spinning brush system. The

Sportworks rack has been designed with round tubing and round edges so that the wash brushes

contact surfaces that will not catch or tear them.

Some conditions may cause excessive wear or harm to the bike rack or the wash system. This is

typically due to brush entanglement with the rack. These best practices should be followed to avoid

damage:

1. Ensure brushes are spinning at an adequate RPM. If the brushes are rotating too slowly, it may

cause the brushes to hook on protruding objects. If the axle of the brush assembly pushes

against the rack or any part of the bus that has a crevice, it may allow bristles to become

entangled.

2. Ensure the vehicle enters the wash system slowly to minimize impact between the rack and the

brushes.

3. Replace and maintain brushes at recommended intervals. Low brush density can also cause

entanglement.

4. Ensure proper brush rotation. Refer to Figure 1. The illustration shows the recommended rotation

for the brush assemblies. If the brush assembly is fixed to the driver’s side, the brush should

rotate counterclockwise, as viewed from the top. If the brush assembly is mounted on the

curbside, the brush assembly should rotate clockwise.

When operating as recommended, no unusual deterioration should occur. If damage occurs, take time to

examine the rack installation as well as the vehicle and setup of the wash facility. Please contact

Sportworks at 425-483-7000 for assistance.

Figure 11, Bus Wash Brush Orientation

All dimensions and specifications nominal. Specifications are subject to change without notice.

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5. INSPECTION AND MAINTENANCE

a) Visual Inspection Checklist

The following is recommended to ensure an operable bike rack prior to use. These

instructions are intended for use as an inspection sheet for operators.

Examine the items below before operating the vehicle. If the bike rack does not function as

described, service is recommended before continuing operation. Refer to Figure 11, Location

of Rack Components for the location of each item (as numbered below)

1. ________PIVOT BOLTS ARE TIGHT

Tighten if required.

2. ________ENDPLUGS ARE PRESENT (2 PLACES)

Replace plugs if missing or damaged.

3. ________CLEVIS PINS AND SPLIT RINGS ARE PRESENT

SECURE ARMS TO FRAME (2 PLACES)

Replace missing parts.

4. ________SUPPORT ARM MAGNETS ARE PRESENT (2 PLACES)

Replace if missing. These magnets stow the support arms.

5. ________IF OPTIONAL BIKE COUNTERS ARE INSTALLED:

SENSOR MAGNETS ARE PRESENT (2 PLACES)

Replace if missing. These magnets engage with the bike counters.

6. ________SUPPORT ARMS SLIDE IN/ OUT (2 PLACES)

Hooks move smoothly in/out and self-stow on magnet.

DO NOT LUBRICATE.

7. ________SUPPORT ARM SIDE PLAY NOT EXCESSIVE

Verify that the support arm side to side play is less than 1.5” (measured

at the hook with the support arm retracted, but not resting on the

magnet). If play is excessive, there are several possible causes including:

Broken or bent support arm bracket; Missing, bent, worn or broken hinge

clevis pin - ensure clevis pin is held in place with hairpin clip; Bent or

broken support arm spar; Worn or missing bushings in the support arm

housing. Missing or damaged components should be replaced.

8. ________LATCH HANDLE OPERATES PROPERLY

Latch is easy to release and does not get stuck.

9. ________BIKE RACK SWINGS FREELY AND LOCKS IN TWO POSITIONS

Rack pivots and locks in both the deployed and stowed positions.

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