BURLEY 2004 Flatbed Cargo Trailer Owner’s Manual

BURLEY 2004 Flatbed Cargo Trailer

Congratulations!
You’ve just purchased a Burley® trailer, the leading choice of discrim I nat ing bicycle trailer owners worldwide. Every effort has been made to ensure your purchase is of top quality and proven design, ready to provide you with many years and miles of happy, safe trailering.

IMPORTANT: Because some of the features and guidelines for using the Burley Flatbed merit close attention, it is very important that you familiarize yourself with the trailer by reading this entire manual before use. If you have any questions, we encourage you to contact your authorized Burley dealer.

Introduction

Your Burley Flatbed is shipped almost completely assembled from the factory. This manual is written sequentially to assist initial setup. You need only to install the quick-release skewers, mount the re fl ec tors, and attach the wheels.
Before trailering, be sure you have a thorough understanding of the trailer hitch operation. Check to see that the trailer wheels and hitch are securely attached. We again request that you read this manual from start to finish before use, and then refer to it as necessary in the future.

NOTE: Any reference to left or right is made in the direction of travel as if you were standing behind the trailer looking forward.

When Loaning or Selling Your Trailer

If you loan or sell your Burley Flatbed, supply the new user with this manual. They must familiarize themselves with all sections—especially sections
“VIII. Safety Guidelines” and “IX. Safety Checklists” prior to use. It is es sen trial that they understand the differences between riding a bicycle with a trailer and without one. It is also essential that they understand the correct wheel attachment.

Hardware Bag Contents and Tool List

IMPORTANT: Please verify that you have received all of the contents listed. Do not proceed with as sem bly if any parts are missing; contact Burley in me di ate ly for replacement parts.

Hardware Bag Contents

Reflectors: Quick-Release Levers:
(2) Rear refl ector, red
(2) Self-tapping screw, refl ector
(2) Quick-release lever (2) Pair tie-down straps

Envelope: Tools Required:
Trailer Checklist 5/16″, 8mm or small ad just able wrench
Warranty Card
Burley Flatbed Owner’s Instruction & Safety Manual

Mounting the Reflectors
Fasten the refl sectors to the brackets located on the rear of the main
frame using the self-tapping screws found in the hardware bag. ( Note the designation “Top” on the back of each reflector.)

Installing the Quick-Release Levers
In the bag with the reflectors you’ll fi nd two quick-release levers. Install these through the hollow axle of the wheel. Make sure the lever is on the fl at the side of the wheel, the thumb nut is on the deep-dished side, and the springs are mounted on each side as shown in the illustration below.

Attaching the Wheels and Tongue

First, verify that the tires are inflated to 30–35 P.S.I. Next, tip the trailer frame on its back end. If you are working on a rough or dirty surface, lay down a cloth or other protective barrier to avoid damage to your trailer. Move the quick-release lever to the unlocked position and place the wheels into the dropouts, making certain that the axles go all the way into the slots.

IMPORTANT: Wheels are dished off-center and must be installed so that tires are offset away from side rails, closest to the outer frame. Dished wheels are a unique feature from Burley; they create a wider track, and thus a more stable trailer.
The quick-release lever and flat side of the wheel must be installed toward the outside of the trailer.

Once the wheels are fully seated in the dropout slots, the quick-release lever should be positioned so that it operates in the fore and aft direction. The lever is marked for open or closed positions. Tighten the right-hand wheel by moving the lever from the front (open) to the rear (closed) position. Tighten the left-hand wheel by moving the lever from the rear (open) to the front
(closed) position. Use the thumb nut to adjust for correct spacing of the quick-release lever.
When properly adjusted, you will feel resistance halfway through tightening the lever (when the lever is pointing straight out away from the trailer). If you are unfamiliar with the use of quick-release levers, contact your Burley dealer for a demonstration.

The quick-release lever
op er ates in fore-aft di rec tion (with lever below the axle). The drawing shows the left-hand wheel in the closed position.

Burley Flatbed Owner’s Instruction and Safety Manual

WARNING
Make sure wheels are held securely; you should not be able to rock or shift wheels. Improperly installed wheels can fall off, causing accidents and serious injuries.

WARNING
Only use dished, 20 x 1.75 wheels supplied with Burley Flatbed. Do not operate with tires inflated above 35 P.S.I.Failure to comply can cause a trailer to tip over, resulting in accidents and serious injury for cyclists.

Swing Tongue and Hitch into Place
Tip your trailer frame on its back end. If you are working on a rough or dirty surface, lay down a cloth or other protective barrier to avoid damage to your trailer. Swing the tongue 180˚ forward so that it snaps into the plastic tongue re cep tacle at the front frame. Slip the safety pin through the hole in the tongue receptacle to lock the tongue in place. Refer to the illustration below for correct use of the safety pin.

WARNING
The safety pin must be locked in place before using a trailer, otherwise, tongue could shift and cause accident and serious injury.

Hitching the Burley Flatbed to Your Bicycle

The trailer hitch was designed to quickly and safely attach to view ally all types of bicycles. It is inserted in front of the left rear drop-out of your bicycle.

Loos en the knob on the eye bolt until the two arms are A spread fully apart.
Slip the low er hitch arm under the chainstay (A) and the upper arm above the seat stay (B). (See illustration above.) Wedge the hitch cone all the way back into the angle formed by the stays at the wheel. Tighten the knob until the arms are fi rm ly clamped against the stays. Wrap the safety strap around the inside of the chainstay, over the hitch body, and back to the D-ring at the end of the tongue.
Make sure that the cone is wedged se cure ly into the stays. The knob should be fi n ger-tight; do not over-tighten. The hitch should not move but should allow the bicycle complete movement, in cloud ing lying it down on the ground. It should clear any racks, bags, or fit things you have on your bicycle. If there is any interference, contact your Burley dealer.

IMPORTANT: Re-move the trailer from your bi cy cle when it’s not in use to pre vent de form ing the plastic hitch.

WARNING:

• Do not operate the trailer without the hitch safety strap properly installed. A dangling safety strap can contact the spokes and damage the rear wheel or cause accident resulting in serious injury.
• Hitch must seat properly into stays and not interfere with racks, bags, or fittings. Inspect hitch and tongue frequently for damage or loss of fasteners. Interfering parts or damaged hitch can cause ac ci dent resulting in serious injury.
• Do not use or store trailer at temperatures below 32˚ Fahrenheit as hitch rubber fl ex-con NEC tor can become brittle and possibly break, causing an accident resulting in serious injury.

Loading Cargo

Burley has created the Flatbed trailer to be a flexible and useful tool, for use in a variety of cargo applications. The trailer is not designed to carry occupants of any kind (with the exception of pets that are secured within a pet carrier that is securely fastened to the trailer.) This is a flexible platform utility vehicle allowing cargo of varying sizes and shapes. The limitations depend on the operator’s ability to properly secure cargo for good performance and trailer safety. Cargo can be fastened by a rope, cargo tie- down cords, netting, or within a container that is securely fastened to the Flatbed trailer.

Be Sure Cargo is Secure
When loading cargo on your trailer, always ensure that the load is adequately fastened and centered on the trailer floor. Cargo needs to remain securely fastened within the perimeter of the trailer. Do not permit cargo to extend past the perimeter of the fabric floor on either side. Objects loaded too close to the trailer wheels when stationary risk catching spokes or interfering with wheels when the trailer is in motion. The area in front of the trailer frame must also remain clear to avoid interfering with the bicycle’s rear wheel. Objects that extend beyond the back can ob secure reflectors, cause an unstable weight balance on the bicycle’s rear wheel, or contact the ground on uneven terrain (hills, speed bumps, driveways, etc.)

Secure a Container First
When carrying smaller items, it is suggested that you fasten a sturdy container to the trailer fi rst and then carefully load the items you wish to carry. Use of a container simplifi es securing cargo, and reduces wear on your trailer due to rubbing of edges of small items.

Center the load
It is important to center the load you are carrying. A load-balanced front and back will detract the least from bicycle handling. As weight is placed further forward on the trailer, the rear bicycle wheel carries more load. If the load is placed behind the trailer wheels, weight is removed from the bicycle wheel, making the bicycle less stable. The weight center of your cargo is ideally located over the center of the trailer’s fabric floor.

WARNING: Cargo must be secured and fi t within the fabric fl oor space of the trailer, avoiding any contact with trailer wheels or the wheels of the bicycle pulling it. Shifting cargo can interfere with wheels causing an accident that can result in serious injury or death. Weight limit: 100 lbs. Speed Limit: 15 m.p.h.

Trailer Main te nance and Care

Hitch and Tongue Maintenance
Your trailer is designed for low maintenance and easy care. Clean and grease the eyebolt threads on the hitch periodically to ensure that the eyebolt knob can be properly tightened.
Because of ultraviolet degradation, we recommend that the hitch be replaced every fi ve years under normal use. In sunny or smoggy locations or for trailers that are stored outdoors, the hitch should be replaced every two to three years for safety. Replace your hitch or tongue if there are any signs of damage—i.e., cracks, dents, scratches.

IMPORTANT: For any eyebolt service other than lubrication, contact your Burley Dealer.

Fabric Care
Your Burley Flatbed is manufactured from tough, durable vinyl-coated polyester. The fabric is coated for waterproofness and is highly resistant to fading. The fabric can be easily cleaned with any mild soap or detergent and warm water. For more persistent soil, use a nylon bristle brush. When not in use, store your trailer in a dry, well-ventilated area; wipe it dry before storing to help avoid mildew.
To extend the life of your fabric, as well as the hitch and other components, do not store your trailer in direct sunlight. Do not use bleach for cleaning, as it will damage the fabric.

Safety Guidelines

Bicycling with a trailer is different from bi-cycling without one, in ways that aren’t always obvious. It is therefore essential that you read and understand all of the following safety guidelines—in addition to the warnings and instructions in the previous sections—prior to using your trailer. Before loaning your trailer to others, make sure they too un der stand its proper, safe use. Contact your dealer or Burley if any of these instructions are unclear.

WARNING: Bicycling with a trailer, and bicycling in general, can be hazardous. Failure to observe any of section “VIII. Safety Guidelines” could result in an accident and serious injury or death.

Use Well-Maintained Bicycle and Trailer
Use a bicycle which is in good working condition, with good brakes. A frequent safety check of your bicycle is essential. Inspect and maintain your trailer as outlined in section “IX. Safety Checklists” of this manual. Have your Burley dealer maintain and inspect your bicycle and trailer if you are not qualifi ed to do so.

Starting and Stopping
Because of the trailer’s additional weight, a bicycle pulling a trailer will be slower to start up and stop, and because of its length, it requires more time to cross streets or paths. Your entire vehicle is heavier and less responsive. This means you should think further ahead in anticipating stops, turns, and starts. Note that your trailer extends out further on the left; allow for this difference when turning, passing pedestrians, or approaching ob sta cles (like posts on bike paths). We recommend you spend some time experimenting with a loaded trailer in an uncongested area to become familiar with how your heavier, longer vehicle responds.
Prevent Trailer Tip Over
Just like automobile and motorcycle trailers, bicycle trailers can tip over. To avoid overturning: Do not pull your trailer over curbs or hit holes or other obstructions in the road. Do not make high-speed turns or descents when pulling the trailer. Always corner with caution at 5 m.p.h. or less, as the trailer cannot lean into a turn the way a bicycle can. Do not under any circumstance travel fast er than 15 m.p.h.—all road irregularities and your slowness to re-act are greatly mag ni fied.

WARNING: Trailers can tip over causing damage to trailer and serious injury to cyclists. AVOID causes of tip over, especially:

• Hitting potholes, curbs, and other road obstructions
• Taking turns too fast
• Sudden swerving
• Off-banked turns
• Improper wheel instation
• Improper tire infl nation

Fit, Alert, Adult Pilot
To safely pull a trailer, you need to be a fi t, experienced cyclist. You must be alert, have good sight and hearing, and have adequate strength in your legs, arms, and hands. Never let a child or adolescent pull your trailer because it is likely that they lack the necessary physical ability and judgment.

No Headphones or Other Distraction
Do not bicycle with headphones, radios, or other distractions. You must be able to hear surrounding traffi c, and concentrate on safe bicycling at all times.
No Motorized Vehicles
Your Burley Flatbed is only in tend ed for use with pedal-powered cycles; never pull it with a motorized vehicle, as the increased acceleration and speed could damage the trail er or cause the trailer to tip over.
Avoid Riding in Traffi c
We recommend against riding in traffi c. If you must ride in traffi c, do not pull your trailer on highways or busy streets. Never assume that you will be given the right-of-way, even if it is legally yours. Use care when pulling your trailer on bike routes or along bike lanes, especially at intersections.
Ride on Clean, Paved Surfaces
Your Burley Flatbed is not intended for off-road use. Any bumps or
irregularities could cause a tip-over and serious injury to the bicyclist or damage to the trailer and/or its contents. Cross over railroad tracks, curb cutouts, and road grooves at 90˚. Riding parallel or at an acute angle to such obstacles can cause a crash.
Riding When It’s Slippery
Be especially careful in wet, rainy, or freezing conditions. Your ability to
control and stop your bicycle when towing a trailer is greatly impaired. In wet conditions apply your brakes periodically to be sure the rims and brake pads are clear of the water. Avoid forceful braking which can cause dan ger ous skid ding. Ride slowly and allow a greater margin of safety when starting, stopping ping, and turning.
Do not ride on surfaces where sand, gravel, ice, oil, or other slippery substances are present; if you must pass over slippery surfaces, walk your bike and trailer.

Navigating Curbs, Stairs, and Escalators
Never tow your trailer over curbs; the rider must dismount and walk over
any curbs. If you must traverse stairs, prevent a hazardous loss of control: carefully roll your trailer and bike, in de pen dent ly, up or down the stairs. Never take your bike or trailer on escalators.

Use Cautiously with Pets
Your trailer is not designed to secure pets. A cat or other small pet can be towed if they are in a pet carrier secured to the trailer frame. Do not exceed 100 lbs. Never tow an excitable dog in your trailer, as it may lunge or try to jump out causing tip-over or other accidents.

Avoid Riding at Night
Make every effort to schedule your rides so you are not pulling a trailer at night. Because your ve hi cle is long er and heavi er you will be less able to react to unseen hazards. Automobile drivers may not be accustomed to your longer vehicle and may not react to it appropriately. If you must ride at night, wear bright, refl ective clothing, use a bright headlight and a red blinking taillight on your bike. Do not operate without properly attached re fl ec tors; replace cracked or missing refl ectors.

Wear Helmets
Numerous studies have shown that:

• Head injury is the leading cause of bicycling fatalities; and,
• Helmets prevent or reduce bi cyclists’ head injuries.

For safety, it is essential that cyclists use approved bicycling helmets at all times. Don’t take chances.

Proper Wheels and Tires are Essential
Use only the fac to ry-supplied wheels, and keep them properly maintained. In fl ate tires to 30–35 P.S.I. and check pressure before each use. Do not use high er-pres sure tires, as the trailer will be bouncy and prone to tip over with light loads. We only recommend tires with street tread. Do not use knobbies. For stability, dished wheels must be offset to the outside of the trailer (with tires close to the outer frame, providing a wider track).

Know Your Trailer Hitch
Clamp the hitch securely to the bicycle frame, and check for a tight attachment each time you use the trailer. Refer to sections “V. Hitching the Burley Flatbed to Your Bicycle” and “VII. Trailer Main te nance and Care” of this man u al for proper installation, use and main te nance of your hitch.

Follow the Rules of the Road
Bicycles are vehicles and are required to observe all rules of the road. Always signal turns and stops; ride with both hands on the handlebars except when signaling. Scan ahead for dangerous situations, and anticipate turning traffi c. Watch out for parked cars and opening doors. Never run stop signals, and never ride against oncoming traffi c. On bike paths, give an audible warning when passing pe des trains from behind. If you are not aware of your local and state bi-cycle regulations, contact your nearby police or motor- vehicles offi ce for more information. Refer to the owner’s manual of your lead bicycle for safe cycling information.

Have Fun Defensively
Besides being practical and easy to use, the Burley Flatbed allows people and children to get outdoors for some fun together, rain or shine. The fact that you’re getting exercise and fresh air at the same time is an added benefi t! So, whether you’re going down to the corner store, across town on a picnic, or off for an extended vacation, enjoy your Burley Flatbed and remember . . . ALWAYS RIDE DEFENSIVELY!

Safety Checklists

Before Each Ride, Ensure the following:

• Wheels tightly attached
• Tire pressure 30–35 P.S.I.
• Hitch properly secured with safety strap in place
• Locked safety pin for tongue
• Maximum load 100 lbs.
•  Bicycle safety check, especially brakes, and tires

Monthly Checklist

• Inspect tongue and hitch for damage, scratches, or loose fasteners
• Inspect frame tubing and hardware for cracks, damage, or loose parts
• Inspect tires; worn out or cracked tires can lead to blowout
• Inspect wheels for trueness and cracks
•  Inspect wheel bearings for wear
• Contact authorized Burley dealer for repairs/replacement of any damaged or worn out parts

IMPORTANT: Refer to section “VII. Trail er Main te nance and Care” of this manual for additional periodic maintenance. Un less you are a qualifi ed bicycle me chan ic, contact your Burley dealer for repairs and maintenance.

Parts List and Drawing

Note: Subassemblies are indented. Inquire for additional parts.

Your serial number is located on the bottom of the Left Inner Frame in front of the Wheel Dropout. Please have your serial number ready when requesting replacement parts.

About Burley Design Cooperative

Burley has been supplying products to the bicycle industry since 1975. Burley products are designed and manufactured at our Eu gene, Oregon shop. As worker- owners of our cooperatively owned business, we bring a un com mon degree of personal pride and attention to our work. Use our products with confidence and satisfaction!

Burley Trailer Limited Warranty

Burley will re-pair or replace any original equipment parts it deters mine to be defective for the life of the trailer. The owner of a Burley trailer 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 only to the original owner and is nontransferable. Burley can not be responsible for failure due to improper as sem bly, modification of parts or instructions, neglect, abuse, accident, and/or normal wear. The warranty does not cover any trailers used for rental, com petition, or com mercial use. Burley neither assumes nor authorizes any person to assume any other liability in connection with Burley trailers, and there are no oral agreements or war ran ties col lat er al to or affecting this agreement.
This war ran ty gives you specifi c legal rights and you may also have other rights which vary from state to state.

Burley Design Cooperative
4020 Stewart Rd. • Eugene, OR 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 and “d’Lite” is a trademark of Burley Design Cooperative

References

• Burley | Bike Trailers & Strollers

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