Burley Cub Product manual

Owner’s Instruction and
Safety Manual
child trailer
Burley Cub™
Push
Burley Cub™ model shown
Stroll
Bike
Ski
Jog
Contents
Owner’s Instruction
and Safety Manual
Burley Cub™
3 Introduction
3 Safety Guidelines
3 Parts Bag Contents
3 Tools Required
4 Installing and Using Parking Brake
4 Opening and Closing Your Trailer
5 Attaching the Seat
5 Installing Wheels
6 Installing Tow Bar
6 Installing Handle Bar and Roll Bar
7 Mounting Lights
7 Installing Cover
7 Installing Safety Flag
8 Installing Seat Pads
8 Installing Shoulder Harness Pads & Crotch Strap Pads
8 Using Seat Harness
9 Using Seat Recliner
9 Hitching Trailer to Your Bicycle
10 Safety Checklists
10 Maintenance and Storage
10 Replacement Parts List
11 Replacement Parts Diagram
12 Warranty
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
[email protected] to register your warranty information.
IMPORTANT
ITISVERYIMPORTANTFORYOUTOFAMILIARIZEYOURSELFWITH
YOURBURLEYBYREADINGTHISENTIREMANUALBEFOREUSE.
IF YOU HAVE ANY QUESTIONS, PLEASE CONTACT YOUR
AUTHORIZED BURLEY DEALER ORVISITWWW.BURLEY.COM.
Introduction
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
WARNING
BICYCLINGWITHATRAILER,ANDBICYCLINGINGENERAL,CAN
BE HAZARDOUS. FAILURE TO OBSERVE ANY OF THE SAFETY
GUIDELINESINTHISMANUALCOULDRESULTINANACCIDENT
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 with 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). Load children and/or
cargo securely in the center of the trailer, forward of the
axle and as low as possible.
4. The trailer 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 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 hot 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
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 repairs.
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) Handle bar receiver sets:
(2) handle bar receiver pairs, (2) knobs, (4) lock nuts
Tools Required:
(1) No. 2 Phillips screwdriver
(1) 5mm hex key wrench
(1) 13mm open end wrench
BURLEY CUB OWNER’S INSTRUC TION AND SAFE T Y MANUAL
WARNING
Screws/Spring
Washers/Flat
Washers
TRAILERS CANTIP OVER, CAUSING DAMAGETOTRAILER AND
SERIOUSINJURYTOPASSENGERS.AVOIDCAUSESOFTIPOVER,
ESPECIALLY:
• CHILDREN LEANING OR BOUNCING
• HITTING POTHOLES, CURBS, OTHER ROAD OBSTRUCTIONS
• TAKING TURNS TOO FAST
• SUDDEN SWERVING
• IMPROPER WHEEL INSTALLATION OR TIRE INFLATION
Brake
Released
1
2
3
4
Brake
Engaged
5
Installing and Using Parking Brake
1. Tilt trailer onto its nose and lean it against a wall.
2. Place brake assembly’s center post in hole #3 in bucket
bottom. Handle grip must clear bucket. Let brake
arms hang down. Hold center post and screw it into
place. Figure 1
3. Place a spring washer and fender washer on each
mounting screw. From inside of bucket, loosely thread
screw/spring washer/flat washer stack through hole and
into brake assembly center post. Do not tighten at
this point.
4. Line up brake assembly arms with outer holes #1 and #6,
and using screw/spring washer/flat washers, fasten them
from inside of bucket.
5. Using one tool on inside of bucket and one on outside,
tighten screws firmly until spring washers are fully
flattened between screw heads and flat washers. To
prevent brake return spring from distorting, use care when
tightening left screw.
6. Engage parking brake by pushing handle to the right.
Exercise caution when disengaging brake, as it may spring
to the left.
6
Center
Post
FIGURE 1: Rear underside of trailer
Front
Rear
FIGURE 2
Opening and Closing Your Trailer
1. Rotate front tube upward and rear tube back until they
meet on plastic saddles. Figure 2
2. Rotate frame locks and snap onto rear tube. Figure 3
3. To close trailer, unclip seat buckles on back of seat and
reverse opening process.
Plastic Saddles
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
BEFOREUSINGTHETRAILER.FAILURETODOSOCANRESULTIN
SERIOUS INJURY.
FrameLocks
FIGURE 3
BURLEY CUB OWNER’S INSTRUC TION AND SAFE T Y MANUAL
Attaching the Seat
1. Behind seat, fasten buckle sections together on upper and
lower straps and adjust as needed. Photo 1
2. Before closing trailer, unfasten buckles behind seat. Photo 1
UpperFrameTube
IMPORTANT
ALWAYS KEEP SEAT ATTACHMENTS FASTENED
WHILE TRAILERING.
UpperandLowerStrapBuckles
photo 1: Back of Cub seat shown
Installing Wheels
1.
2.
3.
4.
Push rubber button on outside of wheel hub.
Fully insert axle into axle receiver and release
button. Photo 2
Pull firmly on wheel to check that axle is fully seated.
Verify that tires are inflated to pressure marked on tire
side wall.
Button
WARNING
MAKE SUREWHEELS ARE HELD SECURELY,WITHWHEEL AXLE
ASSEMBLY FULLY INSERTED INTO TRAILER RECEIVER. YOU
SHOULDNOTBEABLETOROCKORSHIFTWHEELS.IMPROPERLY
INSTALLEDWHEELSCANFALLOFF,CAUSINGANACCIDENTOR
SERIOUS INJURY.
photo 2
BURLEY CUB OWNER’S INSTRUC TION AND SAFE T Y MANUAL
Installing Tow Bar
1. Slide tow bar through both tow bar mounts on 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 rear.
4. Insert retaining pin through front tow bar holes, and lock
hoop securely.
FrontTowBarHole
Lock
Pin
WARNING
NEVEROPERATETRAILERWITHOUTRETAININGPINLOCKEDIN
PLACE. AN UNLOCKED TOW BAR CAN LOOSEN OR DETACH,
CAUSING AN ACCIDENT RESULTING IN SERIOUS INJURY.
RetainingPin
RearTowBarMount
Figure 4: Side view of trailer
Trailer Rear
Installing Handle Bar and Roll Bar
PHOTO 3: Inner Receiver
il e
r
1. Install inner handle bar receivers and roll bar with 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 rear, slide handle bar into lower handle bar receivers
and tighten knobs securely. To change height position, flip
handle bar over. Photo 4
Rear Assembly
Frame
Fro
nt
of
Tra
LockNuts
Screws
Handle Bar
Knob
InnerHandle
Bar Receiver
Roll Bar
OuterHandle
BarReceiver
figure 5: Roll bar installtion
Handle Bar
Tighten Knob
PHOTO 4: Tighten knob clockwise
BURLEY CUB OWNER’S INSTRUC TION AND SAFE T Y MANUAL
Mounting Lights
FrontofTrailer
Note:Clear light is mounted facing foward, on side closest to
traffic. Red light is mounted facing rear, on side closest
to traffic.
1. Remove clips and screws from back of 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
RedLight
Roll Bar
Clear Light
PHOTO 5
Installing Cover
Front
Trailer
1. At top of trailer frame, fit openings on cover sides around
handle bar 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.
Opening
HandlebarMount
Buckle
PHOTO 6
Installing Safety Flag
Insertingflagpoleinhandlebarreceiver
Insert flag pole into hole in top of LEFT handle bar
receiver. Photo 7
IMPORTANT
DO NOT USE TRAILER WITHOUT SAFETY FLAG.
PHOTO 7
BURLEY CUB OWNER’S INSTRUC TION AND SAFE T Y MANUAL
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 pad.
Using Seat Harness
One Passenger:
Note: In two-passenger trailers, use inner shoulder straps and
middle crotch strap.
1. Place child in center of 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 seat.
HarnessPads
3. Fasten and adjust lap belt snugly. Figure 6
IMPORTANT
SINGLE PASSENGER MUST BE SEATED IN CENTER POSITION.
Lap Belt
Figure 6
Two passengers:
Note:For two children, use both shoulder harnesses and two
outer crotch straps.
1. Seat first child on one side of seat.
Harness
Pads
Harness
Pads
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 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
BEFOREUSE.ONLYUSETHISSEATIFYOURCHILDISCAPABLEOF
SITTINGUPRIGHTALONE.FAILURETODOSOCOULDRESULTIN
ACCIDENT AND SERIOUS INJURY OR DEATH.
BURLEY CUB OWNER’S INSTRUC TION AND SAFE T Y MANUAL
OuterCrotch
Strap
Figure 7
LapBelts
OuterCrotch
Strap
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
IMPORTANT
DO NOT SLIDE SHOULDER STRAP ASSEMBLIES ABOVE
WEBBING STOPS.
ForTaller
Children
Helmet
PocketArea
Using Seat Recliner
For added comfort when children are sleeping, make the
following adjustments to recline seat:
1. Loosen tension on lower horizontal strap on seat back.
2. Loosen tension on helmet pocket straps on upper back of
seat. Photo 9
3. To return seat to upright position, reverse steps 1 & 2, and
make sure upper seat strap is also tightened securely.
Horizontal
Elastic
ForShorter
Children
photo 8
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 bike.
2. Match hole on flat side of hitch upper arm to left (nonchain ring side) 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 hitch.
4. Slide flex connector between hitch side arms, and match
holes.
5. Open 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 lever pointing to rear of 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 trailer from bicycle, unfasten clip from D-ring
and remove retaining pin.
Loosenfor
reclining
photo 9
QuickRelease
Nut
Hitch
Hitch
Nut
Figure 8: Nutted axle assembly
Safety strap
wrappedtwice
aroundchainstay
Figure 9: Quick release assembly
HitchUpperArm
QuickReleaseLever
RetainingPin
WARNING
QUICK RELEASE LEVER MUST BE IN CLOSED POSITION AND
HITCHSAFETYSTRAPPROPERLYINSTALLED.NUTTEDAXLES
MUSTBETIGHTENEDSECURELY.HITCHMUSTNOTINTERFERE
WITHRACKS,BAGSORFITTINGS.INSPECTHITCHANDTOWBAR
FREQUENTLYFORDAMAGEORLOOSEFASTENERS.DAMAGEDOR
IMPROPERLYINSTALLEDHITCHESORINTERFERINGPARTSCAN
CAUSE ACCIDENTS RESULTING IN SERIOUS INJURY.
Tightento
returnseat
toupright
poisition
FlexConnector
Hookfastenedto
D-ringundertowbar
Figure 10
BURLEY CUB OWNER’S INSTRUC TION AND SAFE T Y MANUAL
Safety Checklists
2009 Cub Replacement Parts and Diagram
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
Diagram #
Cub
Part #
1
960041
Forged Standard Hitch
2
960009
Safety Flag
1 year
3
950003
Handle Bar Clamp Kit
5 years
4
250066
Handle Assembly w/Tether
lifetime
5
950120
Pad Set (2 seat pads, 2 pair of harness pads &
2 crotch pads)
1 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 - flex
connector/
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
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 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 hitch flex connector
can become brittle and possibly break, causing an accident
resulting in serious injury.
Fabric Care
Hand wash fabric parts with mild soap or detergent and warm
water. For heavy soiling, use a nylon bristle 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 out 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.
Cover window may crack if trailer is stored below 32°F (0°C).
Replace any damaged parts.
10
BURLEY CUB OWNER’S INSTRUC TION AND SAFE T Y MANUAL
Description
Warranty
lifetime
Recommended Accessories
• Stroller Kit
• Storage Cover
• Baby Snuggler
• Handle Bar Console
• Alternative Hitches
• Soft Suspension Kit
Pleasegotowww.burleygear.comforupdatedproductpartslist,diagramsandavailableaccessories
BURLEY CUB OWNER’S INSTRUC TION AND SAFE T Y MANUAL
11
Burley Trailer Limited Warranty
Burley trailers are warranted from date of purchase against defects in materials and workmanship under normal use and
service. Burley will repair or replace parts it determines to 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 trailer for repair at
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 can not 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 trailer 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.
BU R LEY DES IG 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