BURLEY 851777 Pre 2004 D’Lite Bike Trailer Instruction Manual

BURLEY 851777 Pre 2004 D’Lite Bike Trailer

Introduction

• Congratulations! With the Walk’n Roller option you are able to stroll or jog with your kids – using your Burley d’Lite, Burley Lite, or Burley Encore trailer!. You can enjoy years of maintenance-free cycling and strolling together, all in one neat package. Every effort has been made to ensure that your purchase is of top quality and proven design, ready to provide you with many years and thousands of miles of happy, safe trailering.

• The Walk n’ Roller has been designed to empower you to bicycle and stroll, all in the same trip. You can bike with your Burley as a trailer to a store or a scenic park, lock your bike and quickly convert the trailer to a stroller, without tools. The conversion from trailer to stroller, and stroller to trailer, is done without removing any Walk n’ Roller components.

• Before using your converted Burley trailer, carefully read sections III to VIII of this supplement for essential information regarding daily use, safety guidelines, and maintenance. If you have any questions , we encourage you to contact your Burley dealer.
  When loaning or selling your trailer, supply the new user with both this Supplement and the original Owner’s Instruction & Safety Manual for your trailer. They must familiarize themselves with all sections, especially with Safety Guidelines and Safety Checklists prior to use.

• If you do not have a copy of the appropriate manual, contact Burley at www.burley.com or call 800-311-5294

Preparation for Installation

The Walk’n Roller requires the assembly and attachment of 3 components: handlebar, parking brake, and stroller wheel. These are covered in sections III, V, and VII. Each section has its associated part list so that you may confi rm that you have received all the parts needed. If any parts are missing contact Burley, do not proceed with installation.

Tools Required:

• 7/16 inch wrench Torque wrench Extension
• 7/16 inch socket
  • No. 2 Phillips screwdriver
  • No. 3 Phillips screwdriver Some adhesive tape

Note: The No 2 Phillips screwdriver has a shaft diameter of ¼ inch or less and is most useful here for making bolts holes through fabric. The No. 3 driver has a larger shaft (almost 1/3 inch) and is the better fi t for tightening the bolts of this assembly.

The locations of the Walk n’ Roller components are seen on the left. #1 is the handle assembly, #2 is the wheel assembly, and #3 is the brake. The directions around the trailer are in reference to the normal direction of motion, front being forward.

Handlebar Installation

Parts included for the Handlebar Assembly:

• (1) Padded handle with safety tether
• (1) Roll Bar plastic replacement hinge
• (1) Roll Bar plastic replacement catch (4) ¼” locking nuts
• (1) ¼ “ jam locking nut (hinge)
• (1) Handle Receiver –Right side
• (1) Handle Receiver – Left side
• (4) ¼” by 1-1/8” Phillips head bolts
• (2) ¼ inch standard nuts
  Note: Standard nuts are larger width, across the hex and do not possess a nylon locking ring. The locking nuts have a nylon ring built in. A jam nut is thinner, requiring less height on the bolt. In assembly, when replacing similar parts, use the new nuts provided.

NOTE: if you have a 2004 Encore, this step is not necessary.

Locate the replacement parts for the roll bar catch and hinge, and their counterparts on the trailer (see the fi gure, top of next page). The “catch” is located on the trailer’s right, the “hinge” is on the left. First remove the old hinge from the left side of the trailer by removing the hex head bolt that attaches the roll bar. Then remove the Phillips head screw that holds the hinge to the frame. Save both the hex head and Phillips bolts for installing the new hinge.

• Fasten the new hinge onto the trailer’s left side using the #3 driver, the existing Phillips head bolt and the new standard nut provided. The nut will fi t snugly into the hex shape recess in the center of the part. Tighten securely.

• Replace the roll bar into the new hinge. Use the pre-existing 1.5 inch hex bolt from the old hinge and the new jam locking nut provided. Tighten until the end of the bolt is fl ush or slightly protrudes beyond the nut.

• On the right side, remove the old catch from the frame saving the Phillips head bolt. Install the new catch using the existing Phillips head bolt and new standard nut provided. Tighten securely.

• Locate the pair of handle receiver mounting holes on the bottom of both the hinge and catch (See 1 and 2 on diagram to the left).
  Carefully punch or cut a hole through the trailer fabric, small enough to allow a bolt to pass through to the mounting holes.

(This can be done with the No. 2 Phillips driver.) The fabric is rip resistant to prevent the hole from growing
WARNING
Check that the new roll bar catch and hinge parts and the roll bar is properly installed. Check the attachment points for loose elements. Failure to do so could result in serious injury.

• Insert the Handle receivers, on right and left side using 1-1/8” bolts and locking nuts provided. The right and left receivers are side specifi c. Be sure to mount the receiver that directs the handle upward toward the back.

Using the Handle

Install the handle from the rear of the trailer. The trailer must be in the running, unfolded position. The handle needs to be removed to fold the trailer. It may remain on while towing the trailer behind a bicycle.

• The handle height is adjusted by inserting the handle with the bend upward for high, or fl ipped over with the bend downward, for low (see image below).To insert the handle, depress the button on both sides, simultaneously, while inserting into the receivers.

• The receivers have an oval hole, as shown, for the button to protrude through when inserted. The button locks the handle into the receiver. Be sure that both buttons are protruding through the hole in the receivers. This will prevent the handle from coming out during use.

WARNING
Always check the handle attachment before using. Be sure that handle is properly installed with buttons protruding in the locked position. Failure to do this could lead to loosening of handle, loss of control, and serious injury.

Mount Wheel Pivot Assembly

Parts Included for the Pivot wheel Assembly Attachment:

• (1) 1/4 x 2” hex bolt
• (3) 1/4” locking nuts
• (3) 5/8” washers
• (1) Pivot Wheel Assembly
• (3) 1/4 x 1” hex bolts

Temporary Hitch Removal
Before installing the Wheel Pivot Assembly, the hitch has to be removed from the end of the tongue. Loosen and remove the securing bolt, #1 in the drawing on the next page.

• As you remove the bolt, notice how it secures the hitch though the hitch connector (#2) and the safety strap (#4).
• Save the hitch and the d-ring (#3) for reinstallation. The locking nut (#5) and the bolt (#1) can be discarded. A longer bolt is provided for the next step.

Re-Assembly with the Pivot Wheel

• Slide the wheel pivot assembly over the end of the tongue so that the hole in the tongue lines up with the hole in the top as shown below.

• Line the hitch connector hole #4 with those same two holes.

• Run the 2-inch bolt provided through the d-ring, and then through the Wheel pivot assembly, tongue hitch connector.

• Push the bolt through the hole at the bottom, visible in the cavity underneath, and then secure with the new locking nut provided (tighten to 6 ft-lbs). The end of the bolt should be fl ush or completely pass through the end of the nut.

• Place the 1-inch bolt (#2) using 2 washers as shown and a locking nut.

• Then place the other 1-inch bolt (#3) through one washer and the remaining hole.

• On the underside of #3 place the safety strap and a locking nut.

• Tighten to 6 ft-lbs using the torque wrench. The end of the bolt must be fl ush with or completely pass through the nut.

When installed the hitch is re-attached by the bolt that goes through the tongue (and hitch’s fl exible coupling); the safety strap is anchored, and the d-ring is on top.
Note: If using the Burley Alternative Hitch, the fl exible coupling is attached in the same manner, using the bolt through the tongue. The safety strap is anchored in the same way, to the wheel assembly clamp bolt.

WARNING
Bolt must go through hole in fl exible coupling. Otherwise, hitch could come loose causing an accident resulting in injury or death.

Using the Walk n’ Roller Wheel

• The wheel has two positions. One is for use as a trailer, “bike” position. The other is for use as a stroller, “stroll” position. Before changing engage the parking brake.To rotate the wheel, loosen the knob, #1.
• This will loosen the triangular pivot clamp, #2, enough to rotate. Then rotate to either the “bike” or “stroll” position as needed. Then tighten the knob.
• Do not attempt to hitch the trailer to the bike with the wheel in “stroll” position.

Installing the Brake

Note: If you have a 2004 Encore, this step is unnecessary.

Parts Needed for Brake Installation:

• (1) brake assembly
• (1) ¼” x 1.5” hex head bolt (1) ¼” nut

Locate the gap in the trailer fabric that is behind the right wheel. The gap exposes a 1 inch diameter, aluminum main frame tube that runs along the inside of the wheel. Undo the clamp in the brake assembly by removing the 1.5 inch long hex head bolt.

WARNING
Check brake before strolling, jogging, or bicycling; or after changing a tire, or any wheel removal. Failure to do so could result in serious injury.

Safety Guidelines

WARNING
Using your Walk n’ Roller, bicycling with a trailer, and bicycling in general can be hazardous. Failure to obey the following Safety Guidelines could result in serious injury or death.

• Walk n’ Roller must be operated by a responsible adult.
• Wear street shoes. Do not wear roller or in-line skates, as you may lose balance or be unable to emergency stop.
• Check handle is secure, button protruding through handle receivers.
• Always wear wrist tether and hold securely onto handle when jogging or strolling.
• Set parking brake before release of handle to prevent loss of contol.
• Do not stroll with or jog with headphones, radios, cell phones, or other distractions as you will be unable to hear oncoming vehicles or other hazards.
• Do not use Walk n’ Roller on stairs of escalators.
• Do not use Walk n’ Roller components on any other product other than the Burley trailer for which it was designed and tested.
•  Wear helmets (adult and child) when cycling. Helmets can signifi cantly reduce injury in the event of accident.
• Avoid serious injury. Always use and properly adjust seat harness.
• Never leave child unattended.
• Cargo maximum of 12 lbs behind seat; excessive weight may cause hazardous unstable condition.
• Make sure that parking brake is properly adjusted and working prior to jogging, strolling, or cycling use. Check after any change of tire or wheel removal.
• Refer to accompanying Burley Owner’s Instruction & Safety Manual for use of seat harness, additional maintenance advice, “Safety Guidelines,” and “Safety Checklists”.

Maintenance

Grease the wheel-pivot assembly twice a year (monthly under wet, dirty, salty conditions). Use a standard grease gun with multi-purpose (thick brown, or green) grease and insert into the hole on pivot casing (1). Wipe clean all the old grease that fl ushes out. This can be done by your local bike shop or gas station while you wait.Inspect handle, receivers, parking brake and wheel pivot monthly. Replace any loose or damaged parts.

Burley Walk n’ Roller Limited Warranty

Burley will repair or replace any Walk n’ Roller parts it determines to be defective for the life of the trailer. The owner of a Burley trailer with Walk n’ Roller parts installed must present the trailer for repair at an authorized Burley dealer, together with an original sales receipt or similar proof of purchase. This warranty applies to the original owner and is non-transferable. Burley cannot be responsible for failure due to improper assembly, modifi cation of parts or instructions, neglect, abuse, accident, and/or normal wear. The warranty does not cover any trailers used for rental, competition, or commercial use, nor does it cover Walk n’ Roller parts used on anything other than a Burley trailer.Burley neither assumes nor authorizes any person to assume any other liability in connection with Burley trailers, and there are no oral agreements or warranties collateral to or affecting this agreement.This warranty gives you specifi c legal rights. You may also have other rights which vary from state to state.

Burley Design Cooperative 4020 Stewart Road • Eugene, Oregon 97402 USA 541-687-1644 • Fax 541-687-0436 www.burley.com
Copyright © 2004 by Burley Design Cooperative
“Burley” is a registered trademark of Burley Design Cooperative Burley d’Lite is a trademark of Burley Design Cooperative Burley Encore is a trademark of Burley Design Cooperative Burley Lite is a trademark of Burley Design Cooperative

References

• Burley | Bike Trailers & Strollers

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