Burley d'lite, 1-Wheel Stroller Kit User manual

Burley d'lite, 1-Wheel Stroller Kit User manual
Pre-2004 d’Lite, Lite
& Pre-2005 Encore
Handlebar & Stroller Wheel Supplement
To be used in conjunction with 2003 or previous model
year Burley trailer Owner’s Instruction & Safety Manual.
Table of Contents
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
Introduction
Preparation for Installation
Handlebar Installation
Using the Handle
Mount Wheel Assembly
Using the Walk ‘n Roller Wheel
Installing the Brake
Safety Guidelines
Maintenance
Warranty
Page
2
3
3
6
7
9
9
11
12
12
I. 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
2
Burley Walk ‘n Roller Manual; models 2003 and earlier
II. 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 confirm 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 fit for tightening
the bolts of this assembly.
Left
1
Front
Back
Right
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.
2 The directions around the trailer
3
are in reference to the normal
direction of motion, front being
forward.
III. 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.
3
Burley Walk ‘n Roller Manual; models 2003 and earlier
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 figure, 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 fit snugly
into the hex shape recess in
the center of the part. Tighten
securely.
4
Burley Walk ‘n Roller Manual; models 2003 and earlier
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 flush 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).
1
2
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
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.
5
Burley Walk ‘n Roller Manual; models 2003 and earlier
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 specific. Be sure to mount the
receiver that directs the handle upward toward the back.
IV. 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 flipped 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.
6
Burley Walk ‘n Roller Manual; models 2003 and earlier
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.
V. Mount Wheel Pivot Assembly
Parts Included for the Pivot wheel Assembly Attachment:
(1) 1/4 x 2” hex bolt
(1) Pivot Wheel Assembly
(3) 1/4” locking nuts
(3) 1/4 x 1” hex bolts
(3) 5/8” washers
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.
1
3
5
2
4
7
Burley Walk ‘n Roller Manual; models 2003 and earlier
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.
1
2
3
4
5
• 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 flush 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 flush 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 flexible
coupling); the safety strap is anchored, and the
d-ring is on top.
Note: If using the Burley Alternative Hitch,
the flexible 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.
8
Burley Walk ‘n Roller Manual; models 2003 and earlier
Bolt must go through hole in flexible coupling. Otherwise,
hitch could come loose causing an accident resulting in
injury or death.
VI. 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.
2
1
VII. 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.
9
Burley Walk ‘n Roller Manual; models 2003 and earlier
Clamp the brake assembly onto the frame tube as
shown. The clamp should be oriented so that the bolt
runs underneath the main frame tubing.
Fasten with the bolt
and nut through
the clamp, but do
not tighten.
Adjust the brake by sliding backward or
forward as needed before tightening.
You will need to pull the brake handle
backward to move the brake to engaged
position (see next image).
With the brake in engaged position, handle back,
slide the brake forward until the post is just touching
the tire. Mark this position on the frame. Then rotate
the handle forward to disengage the brake, and
slide the brake forward about ¼ from the mark. Now
tighten the bolt.
Once tightened, engage the brake
to verify its function. The brake post
should push into the tire about ¼
inch, or half the diameter of the post.
10
Burley Walk ‘n Roller Manual; models 2003 and earlier
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.
VIII. Safety Guidelines
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 significantly 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”.
11
Burley Walk ‘n Roller Manual; models 2003 and earlier
IX. Maintenance
Grease the wheel-pivot assembly twice a year (monthly under
wet, dirty, salty conditions). Use a standard grease gun with multipurpose (thick brown, or green) grease and insert into the hole on
pivot casing (1). Wipe clean all the old grease that flushes out. This
can be done by your local bike shop or gas station while you wait.
1
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, modification
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 specific 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
rev: 10/04
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