Burley HP 4489 User's Manual

Burley HP 4489 User's Manual
Hardware Bag Contents & Tool List
II. Attaching the Wheels
III. Install Rear Reflectors
IV. Setting Up & Folding
Your Burley Nomad
V. Hitching Your Nomad to the Bicycle
VI. Trailer Maintenance and Care
VII. Safety Guidelines
VIII.Safety Checklists
IX. Parts Lists and Drawings
You’ve just purchased a Burley® trailer, the leading choice of discriminating 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 thousands
of miles of happy, safe trailering.
IMPORTANT: Because some of the features and guidelines for using the Burley
Nomad merit close attention, it is very important that you familiarize yourself with
the trailer by reading this manual all the way through before use. If you have any
questions, we encourage you to contact your Burley dealer.
This manual is written sequentially to assist initial assembly. Your Burley Nomad is
shipped 95% factory-assembled. You need only to mount the reflectors, install the
tongue, attach the wheels, side panels, roll bar and safety flag, and snap the cover
into place. Once you’ve read the safety guidelines, you’re ready to go. Initial assembly
should take 10-15 minutes. Subsequent setting up and knockdown can easily be
done in a couple of minutes, no tools required.
Before trailering, be sure you have a thorough understanding of the safety harness
and of trailer hitch operation. Practice folding and unfolding your trailer; it can easily
be done quickly, no tools required. 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, refering 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 Nomad, supply the new user with this manual.
They must familiarize themselves with all sections—especially sections “VII.
Safety Guidelines” and “VIII. Safety Checklists” prior to use. It is essential that they
understand the differences between riding a bicycle with a trailer and without one. It
is also essential that they understand correct wheel attachment, setup, knockdown,
safety flag, cover, and hitch. Never loan your trailer if it is in need of maintenance or
Burley Nomad Owner’s Instruction and Safety Manual
I. Hardware Bag Contents and Tool List
IMPORTANT: Please verify that you have received all of the contents listed. Do not
proceed with assembly if any parts are missing; contact Burley immediately for
replacement parts.
Hardware Bag Contents
Rear reflectors:
(2) Reflector bracket
(2) Self-tapping Phillips screw, bracket
(2) Rear reflector, red
(2) Self-tapping slotted screw, reflector
Roll-bar hardware:
(2) Roll-bar knob
Tools Required:
Phillips screwdriver
Flat blade screwdriver
Burley Checklist
Warranty Card
Burley Nomad Owner’s Instruction & Safety Manual
NOTE: Alloy spoked wheels come with reflectors already installed.
II. Attaching the Wheels
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. With the quick-release lever in the
"OPEN" position, insert the wheel axle assembly completely into the hollow trailer
axle, making sure that the horizontal shaft goes all the way into the axle.
NOTE: The spoked wheels install with the inset side of the hub facing
Quick-release lever
in unlocked “OPEN”
Quick-release lever
in locked “CLOSED”
Burley Nomad Owner’s Instruction and Safety Manual
Wheel axle assembly inserts into hollow trailer axle
Once the wheels are fully seated in the hollow axle, the quick-release laver should
be positioned so that it is aimed to the rear of the trailer in the “CLOSED” position
(the lever is marked for OPEN or CLOSED positions). The wheel quick-release/axle
assembly comes preadjusted from Burley.
Make sure wheels are held securely, with wheel shaft fully inserted
into the hollow axle. You should not be able to rock or shift wheels.
Improperly installed wheels can fall off, causing an accident or
serious injury.
With wheels mounted, both reflectors must face outward. Check to
see that both reflectors have been installed correctly. Incorrectly
installed reflectors can reduce visibility at night and cause an
accident or serious injury.
Install Rear Reflectors
In the hardware bag, you’ll find the parts needed to install the rear reflectors:
Reflector bracket
Self-tapping Phillips screw, bracket
Rear reflector, red
Self-tapping slotted screw, reflector
Burley Nomad Owner’s Instruction and Safety Manual
The reflector brackets mount on the outside of
each side panel, 2.5” up from the plastic connector on the side panel. The holes for the mounting
screws are covered by the fabric.
First, insert the screw into the reflector bracket and
drive the Phillips-head self-tapping screws through
the fabric into the holes provided to mount the
bracket. (Don’t worry; this won’t harm the fabric.)
Then mount the red reflectors onto the brackets with the slotted-head, self-tapping reflector
mounting screws. The bracket should be mounted
as shown in the illustrations.
Setting Up and Folding Your Burley
Setting up or folding your Burley Nomad is accomplished in a few easy steps
involving the side rails, the roll bar and cover, the tongue, and the safety flag.
Install Side Rails
Ensure that all four of the plastic side-panel hold-downs (C-shaped) on the main
frame are flipped to the outside of the Burley Nomad (see illustration). Slide each
side rail down over the 2" tall aluminum side rail guides at the front and rear of each
side of the main frame.
Take care that you put the proper side panel assembly on each side, each with the
trademark “Burley” facing outward. Next, snap each side-panel assembly into place
with the plastic side-panel hold-downs at the front and rear of each side as shown
on next page. The large end of the side rails face forward.
Burley Nomad Owner’s Instruction and Safety Manual
All four side-panel hold-downs must be snapped in place before
using trailer. Otherwise side rails can shift or collapse resulting in loss
of cargo.
Side Rail
Side Rail
Side Rail Guide
Side Panel Hold-Down
(Snapped in Place)
Side Panel Hold-Down
(Flipped Open)
Side Rail
Side Rail
Side Rail Guide
Side Panel Hold-Down
(Flipped Open)
Burley Nomad Owner’s Instruction and Safety Manual
Side Panel Hold-Down
(Snapped in Place)
Install Tailgate and Splashguard
Snap the tailgate into place as shown in the illustration below. Start by ensuring there is
sufficient slack in the 1” webbing to allow you to loop the webbing over the side panel
and lock it into place in the corresponding side release buckle sewn to the inside of
the side panel. Repeat for the other side of the tailgate. In a similar fashion, attach the
front splashguard to the front side panels. The tailgate and splashguard are adjustable
to accommodate any size or amount of cargo you wish to carry in your Nomad. Simply
tighten or loosen the 1” webbing as required. For normal cargo carrying modes, the
tailgate and splashguard should be adjusted so they are tight to minimize the entry
of water and dirt.
Burley Nomad Owner’s Instruction and Safety Manual
Install Roll Bar and Cover
1. Locate the two roll-bar knobs in the hardware bag, and the tonneau cover.
2. Lay the cover over the side rails so that it is right side out and oriented so the
end with “Burley” and “Nomad” is at the front of the trailer.
3. Next, slip one of the roll-bar knobs through one of the grommets on the cover.
Slide roll bar through the casing in the top of the mesh divider.
4. Align one end of the roll bar with its corresponding hole on the side rail. Thread
the roll-bar knob through one side rail, and tighten it into the roll bar (see illustration below).
5. Similarly, thread the second roll-bar knob through the other grommet on the
cover, align the roll bar with the hole in the other side rail, and screw this roll-bar
knob into the roll bar.
6. Carefully check that both roll-bar knobs are screwed tightly into the roll bar.
Complete the cover installation by pulling on one of the B-tabs and looping the rubber
O-ring on the trailer frame as shown below. Finish this for each of the three remaining
B-tab/O-rings. Additionally, ensure that the cover extends over the top of each side
panel (see illustration below).
Side Rail
Cover Grommet
Roll Bar
Roll Bar Knob
Trailer Frame
Burley Nomad Owner’s Instruction and Safety Manual
Install Tongue
To facilitate tongue installation, tip your Burley Nomad frame onto its back end. If
you are working on a rough or dirty surface, lay down a cloth or other protective
barrier. Installing your Burley Nomad tongue involves four simple steps (see the
following illustrations):
Slide the tongue onto the pivot pin at the left front.
Remove the hairpin cotter and lock pin from the front tongue receptacle, rotate
the tongue up into place, and snap it into the two plastic tongue receptacles.
Secure the tongue by pushing the lock pin fully into the front tongue receptacle.
Rotate the lock pin and locate the hole in it which will be between the
receptacle and the trailer frame. Anchor the lock pin by inserting the hairpin
cotter all the way into the hole in the lock pin.
Never operate trailer without tongue lock pin and hairpin cotter
locked in place. Unlocked tongue can loosen or detach and
cause accident resulting in serious injury.
1. Slide Tongue
onto Pivot Pin
4. Anchor Lock Pin
with Hairpin Cotter
2. Rotate Tongue into Place.
3. Secure Tongue
with Lock Pin
5. Lock Pin and Hairpin
cotter Locked in Place
(viewed from underside).
Burley Nomad Owner’s Instruction and Safety Manual
Installing the Safety Flag
Insert the flag into the webbing strip on the outside of the
left panel.
Folding Your Burley Nomad
Folding your Burley Nomad is basically the reverse of
setting it up. Familiarize yourself with setting up the trailer
as outlined in this section above.
To knock down your trailer:
Remove the safety flag.
Remove the tongue by pulling out the hairpin cotter
and lock pin and reversing the process previously described.
Unscrew the roll bar knobs. Stow the roll bar and the cover in the bottom of the
Burley Nomad along with the tongue. Screw the Roll Bar Knobs back into the
Roll Bar for storage.
Release the four side-panel hold-downs. Remove the side-panel assemblies and
lay them between the wheels on top of the main frame.
Remove wheels.
IMPORTANT: Read and study sections “V. Hitching the Burley Nomad
to Your Bicycle,” “VII. Safety Guidelines,” and “VIII. Safety Checklists”
before using your Burley Nomad.
Hitching Your Burley Nomad to the
The trailer hitch was designed to quickly and safely attach to virtually all types of
bicycles. It is inserted in front of the left rear dropout of your bicycle.
Loosen the knob on the eyebolt until the two arms are spread fully apart.
Slip the lower hitch arm under the chain stay (A) and the upper arm above the
seat stay (B). (See illustration next page.)
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 firmly clamped against the stays.
Wrap the safety strap around the inside of the chain stay, over the hitch body,
and back to the D-ring at the end of the tongue.
Burley Nomad Owner’s Instruction and Safety Manual
Make sure that the cone is wedged securely into the stays. The knob should be fingertight; do not overtighten. The hitch should not move, but should allow the bicycle
complete movement, including lying it down on the ground. It should clear any
racks, bags, or fittings you have on your bicycle. If there is any interference, contact
your Burley dealer.
IMPORTANT: Remove trailer from your bicycle when it’s not in use to
prevent deforming the plastic hitch.
Do not operate trailer without hitch safety strap properly installed. A
dangling safety strap can contact spokes and damage rear wheel
or cause an 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
loose fasteners. Interfering parts or damaged hitch can cause an
accident resulting in serious injury.
Burley Nomad Owner’s Instruction and Safety Manual
Do not use or store trailer at temperatures below 32˚ Fahrenheit as
hitch rubber flex connector can become brittle and possibly break,
causing an accident resulting in serious injury.
VI. Trailer Maintenance 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
five 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,
The Burley Nomad tongue pivot requires periodic lubrication to enable ease of
movement and prevent rust. Lubricate using a light machine oil once a year for
normal use, and every three months for heavier use—i.e., frequent tongue removal
or use in wet or salty conditions.
Fabric/Shell Care
Your Burley Nomad is manufactured from tough, durable 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 avoid mildew.
Polyester fabric will eventually fade, especially when exposed to direct sunlight. 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
Burley Nomad Owner’s Instruction and Safety Manual
VII. Safety Guidelines
Bicycling with a trailer is different from bicycling without one, in ways which 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 understand its proper, safe use. Contact your dealer or Burley if
any of these instructions are unclear.
Bicycling with a trailer, and bicycling in general, can be hazardous.
Failure to observe any of section “VII. Safety Guidelines” could
result in accident and serious injury or death.
Use A 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 “VIII. Safety Checklists” of this manual. Have your Burley dealer maintain
and inspect your bicycle and trailer if you are not qualified to do so.
Loading Your Trailer
Do not overload the trailer. Maximum trailer load limit is 100 lbs. When placing cargo
into the trailer, keep the load centered or forward of the axle. Pack the load as low as
possible and make sure items cannot shift around.
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 obstacles (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.
Burley Nomad Owner’s Instruction and Safety Manual
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 circumstances travel faster than 15 m.p.h.—all road
irregularities and your slowness to react are greatly magnified.
Trailers can tip over causing damage to trailer and serious injury to
cyclist or passengers. AVOID causes of tip over, especially:
Hitting potholes, curbs, other road obstructions
Taking turns too fast
Sudden swerving
Off-banked turns
Improper wheel installation
Improper tire inflation
Fit, Alert, Adult Pilot
To safely pull a trailer, you need to be a fit, experienced cyclist. You must be alert,
have good sight and hearing, and adequate strength in your legs, arms, and hands.
Never allow a child or adolescent to pull your trailer because it is likely that they lack
the necessary physical ability and judgement.
No Headphones or Other Distractions
Do not bicycle or stroll with headphones, radios, or other distractions. You must be
able to hear surrounding traffic, and concentrate on safe bicycling at all times.
No Motorized Vehicles
Your Burley Nomad is only intended for use with pedal-powered cycles; never pull it
with a motorized vehicle, as the increased acceleration and speed could damage the
trailer or cause the trailer to tip over.
Burley Nomad Owner’s Instruction and Safety Manual
Avoid Riding in Traffic
We recommend against riding in traffic. If you must ride in traffic, do not pull your
trailer on highways, busy streets, or on streets unsafe for bicycling with children.
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
Ride on Clean, Paved Surfaces
Your Burley Nomad is not intended for off-road use. Any bumps or irregularities
could cause tip over and serious injury to the bicyclist or damage to the trailer.
Cross over railroad tracks, curb cutouts, and road grooves at 90˚. Riding parallel or at
acute angle to such obstacles can cause a crash, resulting in serious injury.
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 water. Avoid
forceful braking which can cause dangerous skidding. Ride slowly and allow a
greater margin of safety when starting, stopping, 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; rider must dismount and walk over any curbs. If
you must traverse stairs, prevent a hazardous loss of control: disconnect the trailer
from the bike; carefully roll your trailer and bike, independently, 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. A sedate dog can be towed
seated on the trailer floor: add carpet for comfort, always use a cover. Never tow an
excitable dog in your trailer, as it may lunge or try to jump out causing the trailer to
tip over or other accident.
Avoid Riding at Night
Make every effort to schedule your rides so you are not pulling a trailer at night.
Because your vehicle is longer and heavier you will be less able to react to unseen
hazards. Automobile drivers may not be accustomed to your longer vehicle and may
Burley Nomad Owner’s Instruction and Safety Manual
not react to it appropriately. If you must ride at night, wear bright, reflective clothing,
use a bright headlight and a red blinking taillight on your bike. Do not operate
without properly attached reflectors; replace cracked or missing reflectors.
Wear Helmets
Numerous studies have shown that:
Head injury is the leading cause of bicycling fatalities; and,
Helmets prevent or reduce bicyclists’ head injuries.
Proper Wheels and Tires are Essential
Use only the factory-supplied wheels, and keep them properly maintained. Inflate
tires to 30–35 P.S.I. and check pressure before each use. Do not use higher-pressure
tires, as the trailer will be bouncy and prone to tip over with light loads. We only
recommend tires with street tread.
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 “VII. Hitching the Burley Nomad to Your
Bicycle” and “VIII. Trailer Maintenance and Care” of this manual for proper installation,
use and maintenance of your hitch.
Use Your Flag
Always use the safety flag—it’s an essential safety device. The moving flag will help
make you more visible to motorists and other cyclists.
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 signalling.
Scan ahead for dangerous situations, and anticipate turning traffic. Watch out for
parked cars and opening doors. Never run stop signals, and never ride against
oncoming traffic. On bike paths, give audible warning when passing pedestrians
from behind. If you are not aware of your local and state bicycle regulations, contact
your nearby police or motor-vehicles office 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 Nomad allows people to get
outdoors for some fun together, rain or shine. So, whether you’re going down to
the corner store, across town on a picnic, or off for an extended vacation, enjoy your
Burley Nomad and remember . . . ALWAYS RIDE DEFENSIVELY!
Burley Nomad Owner’s Instruction and Safety Manual
VIII. 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
√ Roll bar, tongue, and side rails securely attached
√ Maximum load 100 lbs.
√ Bicycle safety check, especially brakes and tires
√ Safety flag and cover in place
Monthly Checklist
√ Inspect tongue and hitch for damage, scratches, or loose fasteners
√ Inspect tongue pivot for smooth operation
√ 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
√ Inspect fabric canopy and harness for rips, abrasion, or missing/damaged hardware
√ Repair or replace any damaged or worn-out parts
IMPORTANT: Refer to section “VI. Trailer Maintenance and Care” of
this manual for additional periodic maintenance. Unless you are a
qualified bicycle mechanic, contact your Burley dealer for repairs and
Burley Nomad Owner’s Instruction and Safety Manual
Parts Lists & Drawings
Note: Subassemblies are indented.
(1)Preassembled Main Frame Assembly
(1)Front Main Frame, 1" Aluminum Tube
(1)Rear Main Frame, 1" Aluminum Tube
(1)Left Frame, 1" Aluminum Tube
(1)Right Frame, 1" Aluminum Tube
(1)Bag Holder, 3/4" Aluminum Tube
(1)Axle Assembly
(1)Fabric Bottom Bag
(1)Front Tongue Receptacle, Plastic
(1)Rear Tongue Receptacle, Plastic
(4)Side-Panel Hold-Down
(1)Lanyard w/Lock Pin & Hairpin Cotter to Hold Tongue
(1)Pivot Pin for Tongue
(2)Front Side-Rail Guide
(2)Rear Side-Rail Guide
(2)Rear Reflector Assembly
(1)Roll Bar, 3/4" Aluminum Tube
(1)Mesh Pocket Panel
(2)Roll-Bar Knob
(2)Side panel
(1)2-Piece Safety Flag
(2)16" Alloy Spoked Wheel, Tire, & Tube Assembly
(1)Tonneau Cover
(1)Tongue Assembly
(1)Hitch Safety Strap
Optional Accessories (not shown)
Nomad Carry Bag
Nomad Cargo Rack
Burley Nomad Owner’s Instruction and Safety Manual
4 10
Burley Nomad Owner’s Instruction and Safety Manual
About Burley Design Cooperative
Burley has been supplying products to the bicycle industry since 1975. Burley products
are designed and manufactured at our Eugene, Oregon shop. As worker-owners of our
cooperatively owned business, we bring an uncommon degree of personal pride and
attention to our work. Use our products with confidence and satisfaction!
Burley Trailer Limited Warranty
Burley will repair or replace any original equipment parts it determines 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 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 trailer
used for rental, competition, or commercial use.
Burley neither assumes nor authorizes any person to assume any
other liability in connection with Burley trailer or jogger, and there
are no oral agreements or warranties collateral to or affecting this
This warranty gives you specific 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 © 2003 by Burley Design Cooperative
“Burley” is a registered trademark of Burley Design Cooperative
Printed on recycled paper
Rev2: 12/03
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