Burley HD 4485-86-87, HD 4435-36-37 User Manual

Cub

Owner’s Instruction & Safety Manual

Contents

Section Page

Introduction 2
I. Hardware Bag Contents & Tool List 3
II. Attaching the Wheels 3
III. Installing the Tongue & Safety Flag 4
IV. Unfolding & Folding your Burley Cub 6
V. Using the Seat Harness 9
VI. Padded Seat & Shoulder Harness 12
VII. Hitching the Burley Cub to Your Bicycle 13
VIII. Trailer Maintenance and Care 14
IX. Safety Guidelines 16
X. Safety Checklists 21
XI. Parts List & Drawing 22

Warranty 24

Congratulations!

You’ve just pur chased a Burley® trailer, the lead ing choice of dis crim i nat ing bi cy cle
trailer own ers world wide. Every ef fort has been made to ensure your pur chase is of
top quality and proven design, ready to provide you with many years and thou sands
of miles of happy, safe trailering.

IMPORTANT: Because some of the features and guidelines for
using the Burley Cub merit close attention, it is very im por tant
that you fa mil iar ize 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.

Introduction

This manual is written sequentially to assist initial assembly. Your Burley Cub is
shipped 95% factory-as sem bled. You will need to mount the refl ec tors, install the
tongue and brake, attach the wheels, side panels, roll bar and safety fl ag, and snap
the cover into place. Once you’ve read the safety guidelines, you’re ready to go. Initial
as sem bly should take 10-15 minutes. Sub se quent setting up and folding can eas i ly
be done in a couple of minutes, no tools re quired.

Before trailering, be sure you have a thor ough understanding of the safety harness
and of trailer hitch operation. Practice folding and un fold ing your trailer; it can easily
be done in less than a minute, no tools required. Check to see that the trailer wheels
and hitch are securely at tached. We again request that you read this manual from
start to fi nish before use, referring 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 sitting in the child seat looking forward.

When Loaning or Selling Your Trailer

If you loan or sell your Burley Cub, supply the new user with this manual. They must
familiarize them selves with all sec tions—especially sections “IX. Safety Guidelines”
and “X. Safety Check lists” prior to use. It is es sen tial that they understand the differ­ences between riding a bicycle with a trailer and without one. It is also essential that
they understand correct wheel at tach ment, setup, folding, and use of the har ness,
safety fl ag, cover, and hitch. Always ensure that both adult and child are wear ing
helmets. Never loan your trailer if it is in need of maintenance or repair.

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Burley Cub Owner’s Instruction and Safety Manual

I. Hardware Bag Contents and Tool List

IMPORTANT: Please verify that you have received all of the
con tents listed. Do not pro ceed with as sem bly if any parts are
missing; contact Bur ley im me di ate ly for replacement parts.

Hardware Bag Contents

(1) Cub Brake Assembly (1) Brake Hardware Bag
(3) #10 x 5/8 Philips pan bolts (3) #10 split washers
(3) #10 x 1” fender washers (1) 4 x 6 plastic bag
(1) 6 x 18 plastic bag

Tool List

7/16” wrench Torque wrench Extension
7/16” socket Two no. 2 Phillips screwdrivers
1/4” pin punch and hammer, or 1/4” drill bit and hand drill (see page 8)

II. Attaching the Wheels

First, verify that the tires are infl ated 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.

Quick-release
lever in unlocked
“open” position

Quick-release
lever in locked
“closed” position

Wheel axle assembly inserts
into hollow trailer axle

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Burley Cub Owner’s Instruction and Safety Manual

Once the wheels are fully seated in the hollow axle,
the quick-relase lever 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.

NOTE: All wheels, including optional spoked alloy wheels, must
be mounted with the recessed side of the hub facing out­ward.

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 refl ectors must face outward.
Check to see that both refl ectors have been installed correctly.
Incorrectly installed refl ectors can reduce visibility at night and
cause an accident or serious injury.

III. Installing the Tongue & Safety Flag

Installing the Tongue

The tongue attaches to the left side of the trailer. When installed, the tongue bends
to the right, which places the hitch near the center line of the trailer. Slide the
tongue through the two plastic tongue receptacles until the end of the
tongue is fl ush with the back edge of the rear tongue receptacle.

Secure the tongue as follows:

1. Slide the retaining pin
in the rearward receptacle through
the hole provided in the tongue.

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Burley Cub Owner’s Instruction and Safety Manual

2. Secure it and lock the pin by
rotating it toward the rear of the
trailer as shown in the drawing on
the right.

3. Slip the safety pin though the
forward hole in the tongue and
lock in place. Refer to the illustra
tion showing the locked position
of the safety pin. Firmly pull on the
tongue to ensure that it is secure.

Forward hole in tongue

2

Retaining Pin

Safety Pin

3

1

OPEN

LOCKED

Important: The tongue retaining pin is captured between
the tongue receptacle and the lip of the poly shell. It should
never be completely removed from the tongue receptacle.

Tongue retaining pin must be locked into place before using
trailer. If pin is not properly locked, trailer could separate from
bicycle, resulting in an accident or serious injury. Safety pin is a
backup for the retaining pin. Under no circumstances should the
trailer be towed with only the safety pin engaged.

Installing the Safety Flag

Insert the safety fl ag pole through the loop of ½” webbing on the outside of the
trailer and into the fl ag pocket at the bottom left hand corner of the trailer as shown
below. DO NOT USE YOUR TRAILER WITHOUT THE SAFETY FLAG IN PLACE.

Burley Cub Owner’s Instruction and Safety Manual

5

IV. Unfolding & Folding Your Burley Cub

Unfolding your Burley Cub

Your Burley Cub is designed with a durable
polyethelyne bucket, lightweight alumi­num frame with roll cage, and bright-col­ored polyester software. Setting it up or
folding it down is accomplished in a few
easy steps as follows:

Frame Lock

To unfold, rotate the front tube
upward and the rear tube back
until they meet on the two black
plastic saddles as shown at right.
Then rotate the two frame locks to
snap onto the rear tube as shown.
The frame locks should connect
adjacent to, and to the outside of
the two plastic saddles.

Frame locks
snapped into
closed position
onto rear tube.

Check that the frame locks are properly engaged before using
trailer. Failure to do so can result in serious injury.

Installation and Use of the Cover

Your Big Screen 2-in-1 Cover is held in place by eight snaps at the rear, top, and two
sets in the front. Always use your cover to keep debris out (and toys inside) of the
trailer when it’s in use.

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Burley Cub Owner’s Instruction and Safety Manual

Installing the Cover

To install the cover, unfold it and
snap the top two snaps fi rst. Next,
pull the cover toward the back of
the trailer and snap the two rear
snaps. Finally, using the B-tabs in
front, pull the cover taut by snap­ping the B-tabs over the edge of
the frame rails.

B-tabs

Folding and Stowing the Front Window

Folding and stowing the front window is quick and easy. Begin by unzipping the
window. Next, fold the window in half toward the back of the trailer. Then roll the
window up toward the top of the trailer. Hold the window in place by inserting the
elastic straps into the Velcro holders on the top of the trailer.

Using the Adjustable Sunscreen

Adjustable
Sunscreen

Your Burley Cub is equipped with an adjust­able sunscreen to keep your kids in the shade
during bright, sunny days. To move the
Adjustable Sunscreen, simply pull on the tabs
to move it up or down on the trailer as neces­sary. If more visibility is required, pull the
sunscreen up in the middle. This is depicted
in the illustration at right.

Parking Brake Installation and Operation

The roll cage should be fully unfolded; remove the Big Screen 2-in-1 Cover; remove
the tongue, and leave the wheels in running position.

1. Put the trailer on its nose on the fl oor with the roll cage leaning against a wall
or table. If you are working on a rough or dirty surface, lay trailer on a cloth or
other protective barrier.

2. Facing the underside of the bucket, identify the rear-most row of six molded
depressions (see illustration on page 8). These depressions have 1/4” dimples
molded into their centers.

Burley Cub Owner’s Instruction and Safety Manual

7

3. Use a 1/4” pin punch and a hammer to pop out three dimples - the ones in
depressions 1, 3, and 6 (as numbered in the illustration on page 9). If you are
lacking a pin punch, use a 1/4” drill bit in a hand drill to drill out those dimples.

4. Clean the slugs and/or burrs from the resulting holes where they enter the
inside of the bucket.

5. Put a spring washer on a mounting screw, and put a fender washer on the screw.
These parts are found in the hardware bag.

6. Place the brass center post of the brake assembly in the number 3 depression
so that the black vinyl grip on the brake handle clears the rear of the bucket and
let the brake arms hang down. Hold the center post and screw in place with a
Phillips screwdriver.

7. Reach inside the bucket and thread the screw/spring washer/fender washer
stack through the punched hole and into the brake assembly center post. Don’t
tighten it yet.

8. Swing each of the two brake assembly arms into place in turn, so their posts
enter their respective depressions, and fasten them from the inside of the
bucket with the scew/springwasher/fender stacks.

9. Using two screwdrivers, one inside the bucket and one outside, tighten the
mounting screws fi rmly, until the spring washers are fully fl attened between the
mounting screw heads and fender washers.

10. Be careful to keep the left-most post from rotating as you tighten its mounting
screw so as not to distort the brake return spring.

Brake
Released

1

2

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Burley Cub Owner’s Instruction and Safety Manual

3

Brake
Engaged

4

5

6

Your assembly of the Cub parking brake is complete. Now reattach the tongue and
you are ready to go!

Using the Parking Brake

Once installed, the parking brake is engaged by pushing the handle to the right,
which pushes the brake arms outward so that the tip of each brake engages the
inside of each tire. This can be done with your hand or foot. When disengaging the
brake, it may spring to the left, so exercise caution.

Folding Your Burley Cub

Folding your Burley Cub is basically the reverse of unfolding it. Familiarize yourself
with unfolding the trailer as outlined in section IV, on page 6. To fold your trailer:

1. Remove the safety fl ag.

2. Remove the tongue by pulling out the safety pin and lock pin and reversing

the process described previously.

3. Remove the wheels and store them in a safe place with the handle.

4. Remove the cover and store in a safe place.

5. Unclip the safety clips at the top rear of the frame.

6. Push the rear part of the trailer forward and down while simultaneously

pushing the top of the trailer down.

We recommend reinserting the safety pins in their receptacles
for storage or transport to avoid snagging.

You can partially fold your Burley Cub as needed. Your options are to fold only the
top, remove only the tongue and hitch, remove the quick release wheels, or any
combination of the above. Do not operate your trailer in a partially folded condition.

V. Using the Seat Harness

Only passengers who are able to wear a helmet and sit
upright, unassisted should ride in a trailer. Adequate neck
strength is required to hold head upright while trailering. A
physician should evaluate anyone who is of questionable
developmental age for trailering.

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9

The straps and sliding buckles sewn to the backrest of the child seat are part
of a self-ad just ing sys tem that keeps the shoulder straps at the correct height
for children of various sizes. When you tighten the shoulder har ness, the sliding
buckles allow the shoulder belts to come across the top of the child’s shoulders,
cre at ing a snug fi t. In addition, the sliding buckles keep the straps from falling
off of the shoulders.

IMPORTANT: Always fasten and adjust the two buckles behind
the child seat when using the trailer.

Single Passenger:

1. Remove both shoulder harnesses from the
shoulder straps (see Section VI for details
on removing the shoulder harness). Unclip
the Y-buckle if necessary. Store one of the
shoulder harnesses in a safe place. Leave
outboard shoulder straps dangling. Do not
unthread the straps from the ladder locks in
this step.

2. Remove the two center shoulder straps by
unthreading them from the ladder locks.

3. Trade the position of the shoulder straps
and re-insert the straps into the ladder locks
as shown in the illustration. The fl at parts of
the male portion of the Y-buckle should face

Ladder Lock

toward the center.

4. Install one shoulder harness assembly in the
center position as shown
below. See Section VI for details on installing
the shoulder harness.

5. Seat the child in the center of the seat.

6. Snap in the shoulder straps at the Y-buckle.
Ensure that the Y-buckle is adjusted so that it
is at the child’s sternum.

7. Ensure that the shoulder straps are adjusted
so that the child is comfortably kept from
moving too far forward in the seat.

8. Fasten and adjust lap belt so that it is snug.

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Burley Cub Owner’s Instruction and Safety Manual

Two Passengers

For two children, use both shoulder harnesses and two outer crotch straps.

1. Ensure that the restraint system is set up for two children so that the male

portion of each Y-buckle is facing the center of each seating position. If
your trailer was set up for single-child use, reverse the process above in the
Single Passenger section.

2. Attach the center support strap.

3. Seat the fi rst child on one side of the trailer.

4. Snap in the shoulder straps at the Y-buckle. Ensure that the Y-buckle is

adjusted so that it is at the child’s sternum.

5. Ensure that the shoulder straps are adjusted so that the child is comfortably

kept from moving too far forward in the seat.

6. Repeat for the second child.

7. Fasten and adjust the lap belt so that it is snug.

Ladder Lock

Junction of Y-buckle must be po si tioned at child’s ster num to work
correctly. Belts or buckles positioned near your child’s neck can
cause dis com fort or se ri ous injury. Check child pe ri od i cal ly to
ensure that he/she has not slipped from correct seated position.

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11

Child and cyclist must wear helmets when trailering. Helmets can
prevent or signifi cantly reduce head injury in event of accident.

VI. Padded Seat & Shoulder Harness

The seat in your Burley Cub is designed to provide the utmost comfort for your
children. From a padded seat and shoulder harnesses to room for your children’s
helmets to fl ow-thru mesh to keep your children cool, the Burley Cub is the most
comfortable trailer on the market.

Seat Pad and Shoulder Harnesses

The seat pads and shoulder harnesses in your Burley Cub are made of a durable
spacer weave fabric for ventilation to keep your children cool, and a high tech foam
material to provide the padding necessary for a comfortable ride. If the seat pad
and/or shoulder harnesses become dirty, they can be easily removed and hand­washed with mild soap and water. If it is extremely hot, the shoulder harnesses can
be removed to provide maximum fl ow-thru ventilation. Installing the seat pad and
shoulder harnesses is quick and easy. Simply follow the steps below.

Seat Pad

1. Ensure that shoulder straps and lap

belt are not in the way of the seat
pad during installation.

2. The seat platform and seat pad each

have two strips of Velcro material as
shown at right. Install the front part of
the seat pad so that the square edges
of the pad face match up with the front
of the seat.

3. Attach the top part of the seat pad to

the seat to complete the process.

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Burley Cub Owner’s Instruction and Safety Manual

Shoulder Harness Pad

Insert the shoulder straps into the
shoulder harness pad as shown in the
drawing at right. The shoulder straps
should be oriented so that the FLAT
parts of the male buckles are facing
toward each other.

VII. Hitching the Burley Cub to Your Bicycle

The trail er hitch was designed to quick ly and safe ly at tach to vir tu al ly all types of
bi cy cles. It is in sert ed in front of the left rear drop out of your bicycle.

Hitching the Trailer to Your Bicycle

1. Loos en the knob on the eye bolt un til the two arms are spread fully apart.

2. Slip the low er hitch arm un der the chain stay (A) and the up per arm above the
seat stay (B).

3. Wedge the hitch cone all the way back into the an gle formed by the stays at the
wheel.

4. Tight en the knob un til the arms are fi rm ly clamped against the stays. Wrap the
safe ty strap around the in side of the chain stay, over the hitch body, and back to
the D-ring at the end of the tongue.

B

A

Make sure that the cone is wedged se cure ly into the stays. The knob should be
fi nger-tight; do not overtighten. The hitch should not move, but should al low the
bi cy cle com plete move ment, in clud ing ly ing it down on the ground. It should clear

Burley Cub Owner’s Instruction and Safety Manual

13

any racks, bags, or fi t tings you have on your bi cy cle. If there is any in ter fer ence,
con tact your Burley dealer.

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

Do not operate trailer without hitch safety strap prop er ly installed.
A dangling safety strap can contact spokes and damage rear
wheel or cause an ac ci dent re sult ing in se ri ous injury.

Hitch must seat properly into stays and not interfere with racks,
bags, or fi ttings. In spect hitch and tongue frequently for damage or
loose fasteners. Interfering parts or damaged hitch can cause an
ac ci dent resulting in se ri ous injury.

Do not use or store trailer at temperatures below 32˚ Fahrenheit
as hitch rubber fl ex con nec tor can become brittle and pos si bly
break, caus ing an accident re sult ing in serious injury.

VIII. Trailer Main te nance and Care

Storing Your Burley Cub

We build trailers to last, and often see fi fteen-year-old trailers in use, but even a
Burley trailer will not last forever. When not in use, the trailer shold be stored out of
the sunlight, as extended exposure will cause deterioration of the polyethylene shell,
hitch and fabric.
Your polyethylene shell will need to be replaced if it becomes damaged or cracked.
Periodically inspect all parts of your Burley Cub using section “X. Safety Checklists.”

Hitch and Tongue Maintenance

Your trailer is designed for low maintenance and easy care. Clean and grease the
eyebolt threads on the hitch pe ri od i cal ly to ensure that the eyebolt knob can be
properly tightened.

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Burley Cub Owner’s Instruction and Safety Manual

Because of ultraviolet deg ra da tion, 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,
scratch es.

When ordering a replacement hitch, you must specify that your Burley trailer is
equipped with a square tongue. Trailers with round tongues require a different
hitch.

Fabric Care

Your Burley Cub is manufactured from a tough, durable polyester. The fabric is
coated for wa ter proof ness and is highly resistant to fading. It can be easily cleaned
with any mild soap or deter gent and warm water. For more per sis tent 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.

Polyester fabric will eventually fade, especially when ex posed 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 dam age
the fabric. The fabric is an important part of your trailer’s structure, and provides a
safety envelope for child pas sen gers. Re place any fabric that is ripped, scuffed, or
oth er wise damaged.

Burley offers a durable polyester storage cover to protect your Cub from the ele­ments when it is not in use. Contact your Burley dealer for details.

Trailer with damaged or ripped fabric components can permit
harmful contact between child and spinning spokes or moving
pavement, and cause serious injury. Replace damaged
components.

Suspension Elastomer Maintenance

Periodically inspect suspension elastomers for wear, cuts, or damage. Should you
need them, replacements are available from your authorized Burley dealer and are
easily installed.

Burley Cub Owner’s Instruction and Safety Manual

15

IX. Safety Guidelines

Bicycling with a trailer is different from bi cy cling without one, in ways which aren’t
always obvious. It is therefore essential that you read and un der stand all of the
fol low ing safety guide lines—in addition to the warn ings and in struc tions in the
previous sec tions—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 in struc tions are un clear.

Bicycling with a trailer, and bicycling in general, can be
hazardous. Failure to ob serve any of section “IX. Safety
Guidelines” could result in an ac ci dent and serious injury or death.

Use Well-Maintained Bicycle and Trailer

Use a bicycle which is in good working con di tion, with good brakes. A frequent
safety check of your bicycle is essential. Inspect and maintain your trailer as out lined
in section “X. Safety Check lists” of this manual. Have your Burley dealer main tain and
inspect your bicycle and trailer if you are not qualifi ed to do so.

Loading Your Trailer

Do not overload the trailer. Maximum trailer load limit for children and/or cargo is
100 lbs. When placing chil dren or 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. Loose, heavy objects can injure passengers in event of a sudden stop or
tip over.

Starting and Stopping

Be cause 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 an tic i pat ing 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 ex per i ment ing with a loaded trailer in an uncongested area to become familiar
with how your heavier, longer vehicle responds.

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Burley Cub Owner’s Instruction and Safety Manual

Prevent Trailer Tip Over

Just like automobile and mo tor cy cle trailers, bicycle trail ers can tip over. To avoid
over turn ing: Do not pull your trail er over curbs or hit holes or other obstructions
in the road. In struct children not to bounce, rock, or lean, which can cause a shift of
weight. Do not make high-speed turns or descents when pulling the trail er. 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 cir cum stanc es travel fast er than 15 m.p.h.—all road
ir reg u lar i ties and your slow ness to re act are greatly magnifi ed.

Trailers can tip over causing dam age to trailer and serious injury to
cyclist or pas sen gers.

AVOID causes of tip over, es pe cial ly

• Children leaning or bounc ing

• Hitting potholes, curbs, other
road ob struc tions

• Taking turns too fast

• Sudden swerving

• Off-banked turns

• Improper wheel in stal la tion

• Improper tire infl ation

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 hear ing, and adequate strength in your legs, arms, and hands.
Nev er allow a child or adolescent to pull your trailer be cause it is likely that they lack
the necessary phys i cal abil i ty and judgement.

No Headphones or Other Distraction

Do not bicycle or stroll with head phones, radios, or other dis trac tions. You must be
able to hear surrounding traffi c, and con cen trate on safe bicycling at all times.

No Motorized Vehicles

Your Burley Cub is only in tend ed for use with pedal-pow ered cy cles; never pull it
with a motorized vehicle, as the in creased ac cel er a tion and speed could damage the
trail er or cause the trailer to tip over.

Burley Cub Owner’s Instruction and Safety Manual

17

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 high ways, busy streets, or on streets unsafe for bicycling with chil dren.
Never assume that you will be given the right-of-way, even if it is legally yours. Your
child is a pre cious load; his or her safety should not be en trust ed to a car driver
whose attention or regard for bike riders is un known. Use care when pulling your
trailer on bike routes or along bike lanes, es pe cial ly at intersections.

Ride on Clean, Paved Surfaces

Your Burley Cub is not intended for off-road use. Towing a child off road can be
especially dan ger ous. Any bumps or ir reg u lar i ties could cause tip over and serious
in ju ry to the bicyclist or pas sen ger, or damage to the trailer. Cross over railroad
tracks, curb cut outs, and road grooves at 90˚. Riding parallel or at acute angles to
such obstacles can cause a crash.

Riding When It’s Slippery

Be especially careful in wet, rainy, or freezing conditions. Your abil i ty to control and
stop your bi cy cle when towing a trailer is greatly im paired. In wet con di tions apply
your brakes periodically to be sure the rims and brake pads are clear of water. Avoid
forceful braking which can cause dan ger ous skid ding. Ride slowly and allow a
greater margin of safety when starting, stop 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; rider must dismount and walk over any curbs. If
you must traverse stairs, prevent a hazardous loss of control: have the children get
out of the trailer and disconnect it from the bike; carefully roll your trail er 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. A sedate dog can be towed
seated on the trailer fl oor: add carpet for comfort, always use a cover, and 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 accident.

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 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

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Burley Cub Owner’s Instruction and Safety Manual

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. Similarly, put a red
blinking light in the light-holder tab sewn onto the back of your cover so you can
be more easily seen. Do not operate without properly attached re fl ec tors; replace
cracked or missing refl ectors.

Always Use Your Cover

Affi x your Big Screen 2-in-1 Cover to protect your child from fl ying debris when
pulling your trailer. Never leave a child unattended in direct sunlight because heat
buildup in the trailer can cause serious harm. Open or close the vinyl cover depend­ing on the weather, to help keep your child cooler or warmer. Check pe ri od i cal ly to
ensure that they are comfortable.

Cool Weather Use

When the temperature is 60-70˚ or colder you may be com fort able without heavy
clothing because your pedaling effort helps keep you warm. How ev er, when you
consider the child’s inactivity sitting in the trailer—coupled with a potential wind­chill factor—an extra sweater or jacket may be needed for them to keep from
getting too cold.

Wear Helmets

Numerous studies have shown that:

• Head injury is the leading cause of bicycling fatalities; and,

• Helmets prevent or reduce bi cy clists’ head injuries.

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

Proper Wheels and Tires are Essential

Use only the factory-sup plied wheels, and keep them properly main tained. Infl ate
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. Do not use knobbies. For stability, dished wheels
must be offset to the out side 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 “VII. Hitching the Burley Cub to Your Bicycle”
and “VIII. Trailer Main te nance and Care” of this man u al for proper in stal la tion, use and
main te nance of your hitch.

Burley Cub Owner’s Instruction and Safety Manual

19

Use Your Flag

Always use the safety fl ag—it’s an essential safety device. The moving fl ag will help
make you more visible to motorists and other cyclists.

Protect Your Child

When pulling a child, use the shoulder harness, lap belt, and a child helmet at all
times. Always fasten the seat belt so that each child is held securely. For maximum
stability and safety, seat a single child in the center of the trailer. Periodically check
placement of shoulder straps, especially for a sleeping child. Check that a child can­not put a fi nger into the wheel spokes. Also, be aware that children get thirsty when
riding in the trailer. Bring plenty of water, especially on longer rides; keep a full water
bottle in the trailer where your children can easily quench their thirst when they
desire.

Observe Age and Height Restrictions

The trailer seat is intended only for children old enough to wear a helmet and sit
upright alone. Your child must have adequate neck strength to hold his or her head
up while trailering. Check with your pediatrician if you are unsure about your child’s
ability to sit upright and hold his or her head up. Never carry a child whose sitting
height (with helmet) is above the roll bar, because their chance of injury is signifi ­cantly higher in the event of tip over.

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 sit u a tions, and an tic i pate turning traffi c. Watch out for
parked cars and opening doors. Never run stop sig nals, and never ride against
oncoming traffi c. On bike paths, give au di ble warn ing when pass ing pe des tri ans
from behind. If you are not aware of your lo cal and state bi cy cle reg u la tions, 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 Cub allows adults 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 Cub and remember . . . ALWAYS RIDE DE FEN SIVE LY!

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Burley Cub Owner’s Instruction and Safety Manual

X. 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 pins for tongue and roll bar
√ Maximum load 100 lbs.
√ Bicycle safety check, es pe cial ly brakes and tires
√ Helmets for children & rider
√ Safety fl ag in place
√ Both seat buckles in rear of seat are securely fastened

Monthly Checklist

√ Inspect tongue and hitch for damage, scratches, or loose fasteners
√ Inspect tongue pivot for smooth operation: tongue should fold and unfold

freely; lubricate brass bushing if necessary

√ 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, child seat, and harness for rips, abra sion, or missing or

damaged hardware
√ Contact authorized Burley dealer for repairs/replacement of any damaged or

worn out parts

IMPORTANT: Refer to section “VIII. Trailer Main te nance and
Care” of this manual for additional periodic maintenance.
Unless you are a qualifi ed bicycle mechanic, contact your

Burley dealer for repairs and maintenance.

Burley Cub Owner’s Instruction and Safety Manual

21

XI. Parts List and Drawing

Note: Subassemblies are indented; inquire for additional parts

1. (1) Polyurethane Shell

2. (2) Front Refl ec tor (clear)

3. (2) Rear Refl ector (red)

4. (2) Suspension Elastomer

5. (1) Pair Side Panel Hold Down (left and right)

6. (1) Tongue Retaining Pin

7. (1) Pair Tongue Receptacle (front and rear)

8. (1) Safety Pin & Tether

9. (1) Front Roll Bar, 7/8” Aluminum Tube

10. (2) Frame Locks

11. (2) Front Roll-Bar Hinge (plastic)

12. (1) Rear Roll bar, 7/8” Aluminum Tube

13. (2) Rear Roll Bar Hinge (plastic)

14. (2) Roll Bar Saddle (plastic)

15. (1) Tongue and Hitch Assembly

16. (1) Tongue, 1 1/8” Square Aluminum

17. (1) Hitch with Hitch Knob & Ball

18. (1) Hitch Safety Strap

19. (1) Clip & D-Ring

20. (1) Rubber Flex Connector (not available without hitch)

21. (1) Pair Fabric Side-panel Assembly, with Vinyl Windows

22. (1) Seat pad

23. (2) Shoulder Pads

24. (1) Flow-Thru Seat Back with Harness

25. (4) Shoulder Strap

26. (3) Crotch Strap

27. (1) Lap Belt

28. (1) Buckle for Lap Belt

29. (2) Plastic Wheel, Each with (2) Wheel Bearing

30. (2) Wheel Refl ector (clear) with Self-Tapping Screw

31. (1) Swing Arm Assembly

32. (2) Hollow Axle

33. (2) Wheel Axle Assembly

34. (2) Quick-Release Lever

35. (1) Two-Piece Safety Flag

36. (1) Big Screen 2-in-1 Cover

37. (1) Adjustable Sunscreen

Options (at addditional cost):
Walk ’n Roller Stroller Kit (not shown)

Alloy-Wheel Option

Trailer Storage Cover

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Burley Cub Owner’s Instruction and Safety Manual

37

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15

17

18

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Burley Cub Owner’s Instruction and Safety Manual

About Burley Design Cooperative

Burley has been supplying products to the bi cy cle in dus try since 1975. Burley prod­ucts are designed and man u fac tured at our Eu gene, Oregon shop. As worker-own ers
of our cooperatively owned busi ness, we bring an un com mon degree of personal
pride and attention to our work. Use our products with confi dence and satisfaction!

Burley Trailer Limited Warranty

Burley will re pair or replace any original equipment parts
it de ter mines to be defective for the life of the trailer. The
owner of a Burley trailer must present the trailer for repair at
an au tho rized Burley deal er, to geth er with an original sales
re ceipt or similar proof of pur chase. This war ran ty applies only
to the original owner and is nontransferable. Burley can not be
re spon si ble for failure due to improper as sem bly, mod i fi ca tion
of parts or in struc tions, ne glect, abuse, ac ci dent, and/or
nor mal wear. The warranty does not cover any trailers used for
rental, com pe ti tion, or com mer cial use.

Burley neither assumes nor authorizes any per son to assume any other
liability in connection with Burley trail ers, and there are no oral agree­ ments 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

[phone] • Fax [phone] • www.burley.com

Copyright © 2004 by Burley Design Cooperative

“Burley” is a registered trademark of Burley Design Cooperative.

rev3: 02/04