BURLEY BURPLTR Plus Trailercycle Bike Conversion Kit Owner’s Manual

BURPLTR Plus Trailercycle Bike Conversion Kit
**Owner’s Manual

**

Owner’s Instruction Manual
Trailercycle Bike Conversion Kit Burley
Compatible with 2012 and newer Piccolo and Kazoo

Important

Before using your trailer cycle bike conversion kit, please familiarize yourself with this Burley manual. See Burley Bike Manual for complete instructions on bike use and maintenance. For questions and additional information, please contact your authorized Burley dealer or visit www.burley.com

Burley Plus Overview:

1. Front frame & fork assembly
2. Wheel assembly
3. Front brake assembly (short cable)
4. Rear brake assembly (long cable)
5. Parts bag
   Additional Parts (not included): 1 Trailercycle frame, 1 handlebar

Required Tools (not included):

4mm & 5mm hex keys, 10mm & 15mm wrenches

Frame Assembly:

1. Loosen frame coupling bolts and trailer cycle, push detent button and remove towbar.
2. Insert the end of Burley Plus front frame tube into frame coupling and align so that the detent button engages in the detent hole in the frame as shown above. Progressively tighten clamp bolts, alternating between bolts every 1-2 N·m until both bolts are at 6-8 N·m (53-70 ft-lb).

Wheel Installation:

1. Place wheel into a fork, with axles in fork dropout slots, as shown above. Make sure axle nuts and retention washers are on the outside of the forks.
2. Begin tightening axle nuts and insert the bent tab of the retention washer into the small hole in the fork.
3. Tighten both axle nuts to 34 N·m (300 in-lb).

Handlebar Assembly:

1. On trailer cycle, remove handlebar by removing bolts in trailer cycle stem faceplate.
2. On the Burley Plus bicycle, remove the stem face plate, place the handlebar into the stem, and replace the face plate, as shown above. Center handlebar and tighten face plate bolts to 5-6 N·m (45-55 in-lb).
3. When gear shifter is present (Piccolo), before step 2, route cable under frame and secure to the right-most cable guide.
4. Loosen both stem binder bolts, as shown above.
5. Turn the handlebar and stem to align with the front wheel.
6. Tighten stem cap bolt to 4-8 N·m (35-70 in-lb)
7. Tighten both stem binder bolts to 8 N·m (70 in-lb)

Rear Brake Installation:

1. Install rear brake caliper (has longer cable) onto frame behind Seatpost, as shown above.
2. Align the caliper so that rim is centered between brake pads, and tighten the nut to 8-10 N·m (70-85 in-lb).
3. If necessary, adjust brake pads so that they are in line with the sides of the rim and do not contact the tire during brake operation.
4. Route brake cable through the frame triangle, crossing to the left side of the frame, and attach to the left-most cable guide near frame coupling.
5. Continue to route the cable, staying left of the head tube and swinging to the right side handlebar.
6. Attach brake lever assembly to the right handlebar with 2 Allen bolts, as shown above, and tighten to 6 N·m (55 in-lb).

Front Brake Installation:

1. Install the front brake caliper (which has a shorter cable) onto the front of the fork, as shown above.
2. Align caliper so that rim is centered between brake pads, and tighten the nut to 8-10 N·m (70-85 in-lb).
3. If necessary, adjust brake pads so that they are in line with the sides of the rim and do not contact tire during brake operation.
4. Route cable up to the left handlebar.
5. Attach brake lever assembly to the left handlebar with 2 Allen bolts, as shown above, and tighten to 6 N·m (55 in-lb).

Before You Ride:

Check before each use:

• The child weighs less than 100 lbs (45 kg).
• Frame coupling bolts are fully tightened.
• Handlebars, seats, and wheels are secured
• Tires are inflated to recommended pressure on the tire sidewall.
• The rider is wearing a helmet.
• Safety flags and reflectors are in place
• The bicycle is in good working order, especially the brakes and tires.

Check monthly:

• Inspect the bike for loose fasteners.
• Inspect pedals for smooth operation.
• Ensure the chain is clean and lubricated.
• Check and tighten all hardware, especially frame coupling bolts, according to the fastener torque specifications table.
• Inspect frame tubing and hardware for cracks, damage, or loose parts.
• Inspect tire for cracks or worn spots.
• Repair or replace any damaged or worn-out parts.

Contact your authorized Burley dealer for the replacement of any damaged or worn-out parts. See Burley Bike Manual for complete instructions on bike use and maintenance.

Safety Guidelines:

• Burley bicycles are designed for children ages 4-10 with sufficient coordination to pedal and adequate strength to hold on to the handlebars tightly. If your child is physically or mentally impaired, consult your physician as to whether your child can safely ride.
• The rider must wear a helmet.
• Adjust the seat and handlebar to the correct heights for each rider. Ensure that the minimum insertion mark, or at least 2 1/2″ (64 mm), on the seat post remains inside the frame.
• DO NOT exceed the weight limit by attaching a rack, panniers, or other cargo to the bicycle.
• DO NOT attach a trailer to the bicycle.
• Keep the tire inflated to the pressure recommended on the tire sidewall. Check pressure before each use. Do not use higher-pressure or knobby tires. Be sure axle nuts are properly tightened.
• DO NOT use off-road.
• DO NOT use at night without proper lights on the bicycle.
• Avoid rocks, curbs, hard braking, and sudden swerving.

It is recommended that a qualified bicycle mechanic does a safety check of the bicycle before use. Always comply with local regulations when using bicycles on public roadways. Obey all local requirements for lighting. The red reflector that came with the trailer cycle must remain attached and visible at all times.
Use good judgment when deciding if weather, road, or traffic conditions are safe to use a Burley. Failure to comply with the instructions and safety guidelines in this manual could result in serious injury or death of the passenger or rider.

Maintaining Your Burley:

• Inspect chain, chainring, and rear cog(s); replace if worn.

• Clean and lubricate pivot points on the derailleur (Piccolo only), and wipe excess lubricant to prevent dirt buildup.

• Inspect derailleur cable for fraying and replace as necessary (Piccolo only).

• Adjust shifting as necessary (Piccolo only).

• Ensure that chain is not loose (Kazoo only); tighten chain by moving hub back if needed.

• Check the wheel for trueness; inspect for cracks at the spoke hole or sidewall.
  Return or replace if necessary.

• Verify that the bottom bracket spins smoothly and doesn’t exhibit any play; tighten fixing bolts for crank arms.

• Disassemble bearings in hitch and hub and repack with grease if needed.

• Repair or replace any worn-out parts.

Fastener Torque Specifications:
Correct tightening torque of threaded fasteners is very important to your safety. Always tighten fasteners to the correct torque. In case of a conflict between the instructions in this manual and information provided by a component manufacturer, consult with your dealer or the manufacturer’s customer service representative for clarification. Bolts that are too tight can stretch and deform. Bolts that are too loose can move and fatigue. Either mistake can lead to a sudden failure of the bolt.
Always use a correctly calibrated torque wrench to tighten critical fasteners on your bike. Carefully follow the torque wrench manufacturer’s instructions on the correct way to set and use the torque wrench for accurate results.

Burley Limited Warranty:

The Burley Plus is warranted from the date of purchase against defects in materials and workmanship as follows: frame and fork for five years, other components for one year, excluding normal wear items such as tires, tubes, brake pads, etc. Your original dated sales or delivery receipt showing the date of purchase is your proof of purchase.
If a defect in materials or workmanship is discovered during the Limited Warranty period, we will, at our sole option, repair or replace your product at no cost to you. This warranty is only valid in the country in which the product was purchased.
The Limited Warranty extends only to the original retail purchaser of this product and is not transferable to anyone who obtains ownership of the product from the original purchaser.
The Limited Warranty does not cover claims resulting from misuse, failure to follow the instructions, installation, improper maintenance, and use, abuse alteration, involvement in an accident, and normal wear and tear. The Limited Warranty does not cover products that are used in rental operations and Burley will not be liable for any incidental or commercial damages relating to such use.
TO THE GREATEST EXTENT PERMITTED BY LAW, THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR ORAL, INCLUDING BUT NOT LIMITED TO ANY EXPRESS OR IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The duration of any implied warranties, including any implied warranty of merchantability or fitness for a particular purpose that may exist during the express warranty period, are expressly limited to the limited warranty period.
Some states and countries do not allow limitations on how long an implied limited warranty lasts; therefore, the above limitation and exclusions may not apply to you.
THE CUSTOMER’S EXCLUSIVE REMEDY FOR BREACH OF THIS LIMITED WARRANTY OR OF ANY IMPLIED WARRANTY OR OF ANY OTHER OBLIGATION ARISING BY OPERATION OF LAW OR OTHERWISE SHALL BE LIMITED AS SPECIFIED HEREIN TO REPAIR OR REPLACEMENT, AT OUR SOLE OPTION. IN ANY EVENT, RESPONSIBILITY FOR SPECIAL, INCIDENTAL, AND CONSEQUENTIAL DAMAGES IS EXPRESSLY EXCLUDED.
Some states do not allow the exclusion of limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
This Limited Warranty gives you specific legal rights, and you may have other rights that vary from state to state or country.
For warranty service or replacement part information for the USA or Canada, please contact Burley directly by calling 800-311-5294 or emailing burley@burley.com. For warranty service or replacement part information outside of the USA and Canada please contact the place of purchase for warranty service. Please be prepared to provide the product model, serial number, and a description of the warranty issue.
Some replacement parts may be available for purchase after this limited warranty expires. Please visit us at www.burley.com or call us at 541-687-1644 for more information.

Burley Design
1500 Westec Drive
Eugene, OR 97402 USA
P. 541.687.1644 800.423.8445 F. 541.687.0436
burley@burley.com
Burley.com
Copyright ©2012 by Burley Design LLC
“Burley” is a registered trademark of Burley Design LLC
New 03/12 Plus Manual 2012 Rev 0

References

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

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