BURLEY 946207 Child Trailer Instruction Manual

Owner’s Instruction and
Safety Manual

child trailer Burley Cub

Congratulations!
Your Burley ® trailer is the leading choice of refined bicycle trailer owners worldwide. Every effort has been made to ensure your purchase is a top- quality, thoroughly-tested design, ready to provide many years and miles of happy, safe trailering. Please go to www.burley.com or contact us at burley@burley.com to register your warranty information. Introduction
IMPORTANT
IT IS VERY IMPORTANT FOR YOU TO FAMILIARIZE YOURSELF WITH YOUR BURLEY BY READING THIS ENTIRE MANUAL BEFORE USE. IF YOU HAVE ANY QUESTIONS, PLEASE CONTACT YOUR AUTHORIZED BURLEY DEALER OR VISIT WWW.BURLEY.COM.
Once you’ve done the initial assembly and read the safety guidelines, you’re ready to go! Before trailering, be sure you have the safety harness, seat belt, tow bar, trailer wheels and hitch securely attached.
NOTE: Any reference to left or right is made in direction of travel, as if you were standing behind the trailer,  looking forward. Safety Guidelines
Safety Guidelines
WARNING
BICYCLING WITH A TRAILER, AND BICYCLING IN GENERAL, CAN BE HAZARDOUS. FAILURE TO OBSERVE ANY OF THE SAFETY GUIDELINES IN  HIS MANUAL COULD RESULT IN AN ACCIDENT AND SERIOUS INJURY OR DEATH.

1. Inspect and maintain your bicycle and trailer regularly. See “Safety checklists” on page 10.

2. Because of the trailer’s additional weight, a bicycle pulling a trailer is heavier and less responsive. Avoid sudden swerving, rocks, and curbs. Experiment ith the loaded trailer in an uncongested area until you become familiar with it.

3. The total weight limit for the trailer, children, and/or cargo is 100 lbs (40 kg by law in Europe).  old children and/or cargo securely in the center of the trailer, forward of the axle, and as low as possible.

4. The trainer seat is intended for 1 or 2 children who are old enough to wear a helmet, sit upright without physical support, and with adequate neck strength to hold their heads upright while trailering unless using a Burleyapproved infant accessory seat. A physician should evaluate anyone who is of questionable developmental age for trailering.
   NOTE: Go to www.burley.com to see Burley’s line of infant seats and adapters for younger children.

5. The maximum age for passengers is 6 years. Never carry children whose seated height (with helmet) exceeds 4 inches (100mm) below the internal roll bar.

6. Fasten the seat belt and shoulder harnesses so that each child is held securely. Seat a single child in the center. Periodically check the placement of the shoulder straps, especially on sleeping children.

7. Make sure children cannot put a finger into the wheel spokes.

8. Instruct children not to bounce or lean, as a weight shift could cause the trailer to tip over.

9. To protect children from flying debris, always use your cover. Never leave children unattended. Check children frequently, especially during t or cold weather.

10. Observe recommended speed limits: a maximum of 15 mph (24 km/h) on smooth, straight roads and 5 mph (8 km/h) or less when turning or on uneven roads.

11. . Set your parking brake before removing your children or H. OM. cargo.

12. Never pull your trailer with a motorized vehicle.

13. The cyclist and passengers must wear helmets.

14. Only use factory-supplied wheels, with the tires inflated to the pressure recommended on the tire side wall. Check pressure before each use. Do not use higher-pressure or knobby tires.

15. Clamp the hitch securely to the bicycle frame, and check for a tight attachment before each ride.

16. Use the safety flag.

17. Do not make alterations to the trailer. Contact your Authorized Burley Dealer or go to www.burley.com for replacement of any damaged, worn-out or missing parts.

18. Do not use your trailer on icy roads or when inclement weather makes cycling hazardous.

19. The use of a mirror on your bicycle is recommended.

20. For emergencies, breakdowns, or flat tires,  pull completely off the road and move your children to a safe area before doing rep

Parts Bag Contents:

(1) Burley Owner’s Instruction and Safety Manual
(1) Hitch
(1) Red light/bracket/batteries
(1) Clear light/bracket/batteries
(1) Brake assembly
(3) spring washers, (3) 5mm screws, (3) large flat washers
(2) Handlebar receiver sets:
(2) handlebar receiver pairs, (2) knobs, (4) lock nuts
Tools Required:
(1) No. 2 Phillips screwdriver
(1) 5mm hex key wrench
(1) 13mm open-end wrench

WARNING
TRAILERS CAN TIP OVER, CAUSING DAMAGE TO TRAILER AND SERIOUS INJURY TO PASSENGERS. AVOID CAUSES OF TIP OVER, ESPECIALLY:

• CHILDREN LEANING OR BOUNCING
• HITTING POTHOLES, CURBS, OTHER ROAD OBSTRUCTIONS
• TAKING TURNS TOO FAST
•  SUDDEN SWERVING
• IMPROPER WHEEL INSTALLATION OR TIRE INFLATION

Installing and Using Parking Brake

1. Tilt the trailer onto its nose and lean it against a wall.

Place brake assembly’s center post in hole #3 in bucket bottom. Handle grip must clear bucket. Let brake arms hang down. Hold the center post and screw it into place. FIGURE 1

Place a spring washer and fender washer on each mounting screw. From inside of the bucket, loosely thread screw/spring washer/flat washer stack through the hole and into the brake assembly center post. Do not tighten at this point.
Line up brake assembly arms with outer holes #1 and #6,  and using screw/spring washer/flat washers, fasten them from the side of the bucket.

Using one tool on the inside of the bucket and one on the outside, tighten screws firmly until spring washers are fully flattened between screw heads and flat washers. To prevent the brake return spring from distorting, use care when tightening the left screw.
Engage the parking brake by pushing the handle to the right. Exercise caution when disengaging the brake, as it may spring to the left.

Opening and Closing Your Trailer

1. Rotate the front tube upward and the rear tube back until they meet on plastic saddles. FIGURE 2
2. Rotate frame locks and snap onto the rear tube. FIGURE 3
3. To close the trailer, unclip seat buckles on the back of the seat and reverse-opening process.
   To view a video clip of “Opening and Closing Your
   Trailer” go to: www.burley.com/support/tutorials.cfm.

WARNING
CHECK THAT THE FRAME LOCKS ARE PROPERLY ENGAGED BEFORE USING THE TRAILER. FAILURE TO DO SO CAN RESULT IN SERIOUS INJURY.

Attaching the Seat
1. Behind the seat, fasten buckle sections together on upper and lower straps and adjust as needed. PHOTO 1
2. Before the closing trailer, unfasten buckles behind the seat. PHOTO 1

IMPORTANT

ALWAYS KEEP SEAT ATTACHMENTS FASTENED WHILE TRAILERING.

Installing Wheels

1. Push rubber button on outside of wheel hub.

2. Fully insert the axle into axle receiver and release button. PHOTO 2
   

3. Pull firmly on the wheel to check that axle is fully seated.

4. Verify that tires are inflated to pressure marked on the tire side wall.

WARNING
MAKE SURE WHEELS ARE HELD SECURELY, WITH WHEEL AXLE ASSEMBLY FULLY INSERTED INTO TRAILER RECEIVER. YOU SHOULD NOT BE  ABLE TO ROCK OR SHIFT WHEELS. IMPROPERLY INSTALLED WHEELS CAN FALL OFF, CAUSING AN ACCIDENT OR SERIOUS INJURY.

Installing Tow Bar

1. Slide tow bar through both tow bar mounts on the LEFT
   side. FIGURE 4
   

2. Match rear tow bar hole with rear mount hole.

3. Slide tow bar lock pin through rear holes and rotate pin toward the rear.

4. Insert retaining pin through front tow bar holes, and lock hoop securely.

WARNING
NEVER OPERATE TRAILER WITHOUT RETAINING PIN LOCKED IN PLACE. AN UNLOCKED TOW BAR CAN LOOSEN OR DETACH, CAUSING AN ACCIDENT RESULTING IN SERIOUS INJURY.

Installing Handle Bar and Roll Bar

1. Install inner handlebar receivers and roll bar with the narrow end of receiver toward trailer rear and curved roll bar front extending above trailer body. PHOTO 3 and FIGURE 5
   

2. Using provided hex key wrench, secure with screws and lock nuts as shown.

3. Match outer to inner receiver sections and insert knobs.

4. From the rear, slide the handle bar into lower handlebar receivers and tighten knobs securely. To change the height position, flip handlebar over. PHOTO 4

Mounting Lights
NOTE: Clear light is mounted facing forward, on side closest to traffic. The red light is mounted facing the rear, on the side closest to traffic.

1. Remove clips and screws from back of the lights.
2. Using screws, fasten brackets and lights together.
3.  Mount clear light/bracket diagonally on front of roll bar and red light/bracket on rear of roll bar, both on side closest to traffic. PHOTO 5

Installing Cover

1. At top of the trailer frame, fit openings on cover sides around handlebar receivers. Fasten small buckle sections together. Adjust as needed. PHOTO 6
2. On trailer sides, join buckle sections on rear cover corners to buckle sections below side windows.
3.  On trailer front, slip D-rings on front cover corners over hooked corners of tow bar mounts.

Installing Safety Flag
Insert flag pole into a hole in the top of the LEFT handlebar receiver. PHOTO 7

DO NOT USE THE TRAILER WITHOUT A SAFETY FLAG.

Installing Seat Pads

Match hook and loop fastening strips on trailer seat to strips on back of seat pads.
Installing Shoulder Harness Pads and Crotch Strap Pads
Insert shoulder straps through loops on shoulder harness pads, with straps oriented so that FLAT sides of strap buckles face each other. Slide crotch strap through crotch strap ad.
Using Seat Harness One Passenger:
NOTE: In two-passenger trailers, use inner shoulder straps and middle crotch straps.

1. Place the child in the center of the seat.
2. Snap shoulder straps into Y-buckle, with buckle positioned at child’s sternum. Adjust straps so that child cannot move too far forward in the seat.
3. Fasten and adjust the lap belt snugly. FIGURE 6

SINGLE PASSENGER MUST BE SEATED IN CENTER POSITION.
Two passengers:
NOTE: For two children, use both shoulder harnesses and two  outer crotch straps.

1. Seat first child on one side of seat.
2. Snap shoulder straps into Y-buckle, with buckle positioned at child’s sternum. Adjust straps so that child cannot movetoo far forward in seat.
3. Repeat for second child.
4. Fasten and adjust lap belts snugly. To remove children, release lap belts and harness buckles. FIGURE 7

WARNING
ALWAYS SECURE CHILDREN WITH HARNESS AND LAP BELT BEFORE USE. ONLY USE THIS SEAT IF YOUR CHILD IS CAPABLE OF SITTING UPRIGHT  ALONE. FAILURE TO DO SO COULD RESULT IN ACCIDENT AND SERIOUS INJURY OR DEATH.

NOTE: For taller children, the seat harness can be adjusted by moving the buckles on the shoulder strap webbing into the helmet pocket area, above the horizontal elastic. PHOTO 8

DO NOT SLIDE SHOULDER STRAP ASSEMBLIES ABOVE WEBBING STOPS.

Using Seat Recliner
For added comfort when children are sleeping, make the following adjustments to recline seat:

1. Loosen the tension on the lower horizontal strap on the seat back.

2. Loosen the tension on the helmet pocket straps on the upper back of seat. PHOTO 9
   

3. To return the seat to an upright position, reverse steps 1 & 2, and make sure the upper seat strap is also tightened securely.

Hitching Trailer to Your Bicycle
NOTE: The Burley Forged Standard Hitch is used for bicycles with either nutted axles FIGURE 8 or quick release assemblies. FIGURES 9 & 10

1.  Remove axle nut or rear quick release lever assembly from the bike.
2. Match hole on the flat side of hitch upper arm to left (nonchain ringside) rear dropout hole, and place hitch flat against the dropout
3. Loosely reassemble axle nut or quick release assembly through hitch, dropout, and wheel. Racks, bags, or fittings should not interfere with a hitch.
4. Slide flex connector between hitch side arms, and match holes.
5. pen retaining pin and insert through hitch and flex connector holes from above. Close retaining pin.
6. Tighten axle nut or tighten and close quick release lever, with the lever pointing to the rear of the bike. A properly adjusted quick release lever should leave an imprint on your palm when the lever is rotated to the closed position. Verify that hitch is secure  and cannot be rotated by hand.
7. Wrap safety strap twice around inside of chain stay. Fasten hook to D-ring on underside of tow bar end. FIGURE 10
8. To remove the trailer  from the bicycle, unfasten the clip from D-ring and remove the retaining pin.

WARNING
QUICK RELEASE LEVER MUST BE IN CLOSED POSITION AND HITCH SAFETY STRAP PROPERLY INSTALLED. NUTTED AXLES MUST BE  IGHTENED  SECURELY. HITCH MUST NOT INTERFERE WITH RACKS, BAGS OR FITTINGS. INSPECT HITCH AND TOW BAR FREQUENTLY FOR DAMAGE OR  OOSE FASTENERS. DAMAGED OR IMPROPERLY INSTALLED HITCHES OR INTERFERING PARTS CAN CAUSE ACCIDENTS RESULTING IN SERIOUS INJURY.

Safety Checklists

Check Before Each Ride:
√Wheels tightly and securely attached
√ Tires inflated to recommended pressure on tire side wall
√ Hitch properly secured with safety strap in place
√ Tow bar locked securely in place
√Maximum load 100 lbs (40 kg by law in Europe)
√ Bicycle safety check, especially brakes and tires
√Helmet for passengers and cyclist
√ Safety flag in place
√ All seat straps properly attached
√Children properly secured with harnesses and lap belt
Monthly Checklist:
√ Inspect tow bar, hitch, frame tubing, flex connector and
hardware for damage
√ Inspect tires for wear and cracks
√ Inspect wheels for trueness and cracks
√ Inspect wheel bearings for wear
√ Inspect fabric parts for rips, abrasion, or missing or
√ damaged hardware
√ Contact your Authorized Burley Dealer for the replacement of
√ any damaged or worn-out parts

Maintenance and Storage

Hitch and Tow Bar Maintenance Store trailer indoors if possible. Do not use or store trailer at temperatures below 32˚F (0°C), as the hitch flex connector can become brittle and possibly break, causing an accident resulting in serious injury.
Fabric Care
Hand washes fabric parts with mild soap or detergent and warm water. For heavy soiling, use a nylon ristle brush. Do not use bleach. Line-dry trailer cover. Polyester fabric will eventually fade, especially when exposed to direct sunlight. Wipe dry (to help avoid mildew) and store ut of direct sunlight in a dry, well-ventilated area, or use a Burley Trailer Storage Cover to protect your trailer. Clean windows with a damp soft cloth. The cover window may crack if railer is stored below 32°F (0°C). Replace any damaged parts.

2009 Cub Replacement Parts and Diagram

year
6| 950004| Shoulder Safety Strap (Set of 2)| 1 year
| 250239| Seat (NOT SHOWN)| 1 year
| 250173| Side Panels/Rear with Windows (NOT SHOWN)| 1 year
7| 950105| Sunshade|
8| 250275| Cover| 1 year
9| 950001| Tow Bar Receiver Kit, Left (tow bar receiver, bolts, nuts)| lifetime
| 950001R| Tow Bar Receiver Kit, Right (tow bar receiver, bolts, nuts) (NOT SHOWN)| lifetime
10| 250209| Tow Bar Assembly (tow bar, safety strap, flex connector)| lifetime – tow bar
5 years – flexcon moor/ safety strap
11| 250049| Frame Assembly, Front (tube, frame locks, hinges)| lifetime
12| 250050| Frame Assembly, Rear (tube, saddles, hinges)| lifetime
13| 160033| Wheel (with push button, axle, tire, reflectors) (SOLD INDIVIDUALLY)| 3 years
14| 250266| Brake Assembly| lifetime
15| 250032| External Roll Bar (available ONLY in Europe)| lifetime
16| 4262403| Suspension Elastomer (Set of 2)| 5 years
17| 950104| Swing Arm Assembly Kit| lifetime
18| 950038| Flex Connector w/ Safety Strap for Square Tow Bar| 5 years

Recommended Accessories

• Stroller Kit
• Storage Cover
• Baby Snuggler
• Handle Bar Console
• Alternative Hitches
• Soft Suspension Kit

Please go to www.burleygear.com for updated product parts list, diagrams and available accessories

Burley Trailer Limited Warranty

Burley trailers are warranted from the date of purchase against defects in materials and workmanship under normal use and service. Burley will repair or replace parts it determines  o be defective as follows: fabric parts for one year, plastic parts for five years and durable frame parts for the lifetime of the trailer. The Burley trailer owner must present the railer for repair at the place of purchase, with an original sales receipt or similar proof of purchase. This warranty applies only to the original owner and is nontransferable. Burley cannot be responsible for failure due to improper assembly, modification of parts or instructions, neglect, abuse, accident, and/or normal wear. The warranty does not cover any railer used for rental, competition, or commercial use.
Burley neither assumes nor authorizes any person to assume any other liability in connection with this Burley product, and there are no oral agreements or warranties collateral to or affecting this agreement. This warranty gives you specific rights. You may also have other rights which vary by state or country.

B U R L E Y D E S I G N
4020 Stewart Rd. Eugene, OR 97402
PH 541.687.1644 800.311.5294 FAX 541.687.0436
burley@burley.com : burley.com
Copyright ©2008 by Burley Design LLC.
“Burley” is a registered trademark of Burley Design LLC
170135 Manual Cub Trailer r2 : RTFM : Rev 09.08

Documents / Resources

| BURLEY 946207 Child Trailer [pdf] Instruction Manual
946207 Child Trailer, 946207, Child Trailer
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References

• Burley | Bike Trailers & Strollers
• Burley | Bike Trailers & Strollers
• Burley | Bike Trailers & Strollers

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