Burley Plus Trailercycle Bike Conversion Kit Owner's Instruction Manual

Owner’s Instruction Manual

Trailercycle Bike Conversion Kit

Burley

Compatible with 2012 and

newer Piccolo and Kazoo

Table of Contents

1. Burley Plus Overview and Required Tools

2. Frame Assembly

3. Wheel Installation

4. Handlebar Assembly

5. Rear Brake Installation

6. Front Brake Installation

7. Before You Ride

8. Safety Guidelines

9. Maintaining Your Burley & Torque Specifications

10. Warranty

Important

Before using your trailercycle bike conversion kit, please familiarize yourself with

this Burley manual. See Burley Bike Manual for complete instructions on bike use

and maintenance. For questions and additional information, please contact your

authorized Burley dealer or visit www.burley.com

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Burley Plus Overview:

1. Front frame & fork assembly

2. Wheel assembly

3. Front brake assembly (short cable)

4. Rear brake assembly (long cable)

5. Parts bag

Additional Parts (not included): 1 Trailercycle frame, 1 handlebar

Required Tools (not included):

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

1.

1

Detent engaged
in frame hole

Frame Assembly:

1. Loosen frame coupling bolts and trailercycle, push detent button and remove towbar.

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

2.

1

2

Wheel Installation:

1. Place wheel into fork, with axles in fork dropout slots, as shown above.
Make sure axle nuts and retention washers are on the outside of the forks.

2. Begin tightening axle nuts and insert the bent tab of the retention washer into the
small hole in the fork.

3. Tighten both axle nuts to 34 N·m (300 in-lb).

3.

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2

5

6

Handlebar Assembly:

1. On trailercycle, remove handlebar by removing bolts in trailercycle stem faceplate.

2. On Burley Plus bicycle, remove stem face plate, place handlebar into stem and
replace face plate, as shown above. Center handlebar and tighten face plate bolts
to 5-6 N·m (45-55 in-lb).

3. When gear shifter is present (Piccolo), before step 2, route cable under frame and
secure to the right-most cable guide.

4. Loosen both stem binder bolts, shown above.

5. Turn handlebar and stem to align with front wheel.

6. Tighten stem cap bolt to 4-8 N·m (35-70 in-lb).

4.

7. Tighten both stem binder bolts to 8 N·m (70 in-lb).

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1

Rear Brake Installation:

1. Install rear brake caliper (has longer cable) onto frame behind seatpost, as shown above.

2. Align caliper so that rim is centered between brake pads, and tighten nut to 8-10 N·m (70-85 in-lb).

3. If necessary, adjust brake pads so that they are in line with sides of rim and do not contact tire
during brake operation.

4. Route brake cable through frame triangle, crossing to the left side of frame, and attach to
left-most cable guide near frame coupling.

5. Continue to route cable, staying left of head tube and swinging to right side handlebar.

6. Attach brake lever assembly to the right handlebar with 2 allen bolts, as shown
above, tighten to 6 N·m (55 in-lb).

5.

5

1

Front Brake Installation:

1. Install front brake caliper (has shorter cable) onto front of fork, as shown above.

2. Align caliper so that rim is centered between brake pads, and tighten nut
to 8-10 N·m (70-85 in-lb).

3. If necessary, adjust brake pads so that they are in line with sides of rim and do not
contact tire during brake operation.

4. Route cable up to the left handlebar.

5. Attach brake lever assembly to the left handlebar with 2 allen bolts, as shown above,
tighten to 6 N·m (55 in-lb).

6.

Before You Ride:

Check before each use:

• Child weighs less than 100 lbs (45 kg).

• Frame coupling bolts are fully tightened.

• Handlebars, seat, and wheels are secured.

• Tires are inflated to recommended pressure on tire sidewall.

• Rider is wearing helmet.

• Safety flag and reflectors are in place.

• Bicycle is in good working order, especially brakes and tires.

Check monthly:

• Inspect bike for loose fasteners.

• Inspect pedals for smooth operation.

• Ensure chain is clean and lubricated.

• Check and tighten all hardware, especially frame coupling bolts, according to fastener
torque specifications table.

• Inspect frame tubing and hardware for cracks, damage, or loose parts.

• Inspect tire for cracks or worn spots.

• Repair or replace any damaged or worn-out parts.

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

7.

Safety Guidelines:

• Burley bicycles are designed for children ages 4-10 with sufficient coordination to pedal and
adequate strength to hold on to the handlebars tightly. If your child is physically or mentally
impaired, consult your physician as to whether your child can safely ride.

• Rider must wear helmet.

• Adjust the seat and handlebar to the correct heights for each rider. Ensure that the minimum
insertion mark, or at least 2 1/2” (64 mm), on the seat post remain inside the frame.

• DO NOT exceed weight limit by attaching a rack, panniers, or other cargo to the bicycle.

• DO NOT attach a trailer to the bicycle.

• Keep the tire inflated to pressure recommended on the tire sidewall. Check pressure before each
use. Do not use higher-pressure or knobby tires. Be sure axle nuts are properly tightened.

• DO NOT use off-road.

• DO NOT use at night without proper lights on bicycle.

• Avoid rocks, curbs, hard braking, and sudden swerving.

It is recommended that a qualified bicycle mechanic does a safety check of the bicycle before use.

Always comply with local regulations when using the bicycle on public roadways. Obey all local
requirements for lighting. The red reflector that came with the trailercycle must remain attached
and visible at all times.

Use good judgement when deciding if weather, road, or traffic conditions are safe to use a Burley.

Failure to comply with the instructions and safety guidelines in this manual could result in serious
injury or death of the passenger or rider.

8.

Maintaining Your Burley:

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

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

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

• Adjust shifting as necessary (Piccolo only).

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

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

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

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

• Repair or replace any worn-out parts.

Fastener Torque Specifications:

Correct tightening torque of threaded fasteners is very important to your safety. Always
tighten fasteners to the correct torque. In case of a conflict between the instructions in
this manual and information provided by a component manufacturer, consult with your
dealer or the manufacturer’s customer service representative for clarification. Bolts
that are too tight can stretch and deform. Bolts that are too loose can move and fatigue.
Either mistake can lead to a sudden failure of the bolt.

Always use a correctly calibrated torque wrench to tighten critical fasteners on your
bike. Carefully follow the torque wrench manufacturer’s instructions on the correct way
to set and use the torque wrench for accurate results.

Bike Component Torque values N·m (in-lb) page

Frame coupling bolts 6-8 N·m (53-70 in-lb) 2

Wheels Axle Nuts: 29-44 N·m (260-390 in-lb)

QR: Resistance from halfway to full closure

Stem/steerer clamp Threadless Headset Stem Cap Bolt: 4-8 N·m (35-70 in-lb)

Threadless Stem Double Binder Bolt: 6-9 N·m (50-85 in-lb)

Handlebar clamp/faceplate 5-6 N·m (45-55 in-lb) 4

Brake/control lever clamps Brake lever clamp: 3-8 N·m (30-70 in-lb)

Twist Shifter clamp: 6-8 N·m (53-70 in-lb)

Brake mounting bolts 8-10 N·m (70-85 in-lb) 5-6

Pedals 23-39 N·m (200-350 in-lb)

Seat post clamp 4-6 N·m (35-60 in-lb)

QR: Resistance from halfway to full closure

Seat rail clamp 20-39 N·m (174-347 in-lb)

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5-6

9.

Burley Limited Warranty:

The Burley Plus is warranted from the date of purchase against defects in materials and
workmanship as follows: frame and fork for five years, other components for one year, excluding
normal wear items such as tires, tubes, brake pads, etc. Your original dated sales or delivery receipt
showing the date of purchase is your proof of purchase.

If a defect in materials or workmanship is discovered during the Limited Warranty period, we will,
at our sole option, repair or replace your product at no cost to you. This warranty is only valid in
the country in which the product was purchased.

The Limited Warranty extends only to the original retail purchaser of this product and is not
transferable to anyone who obtains ownership of the product from the original purchaser.

The Limited Warranty does not cover claims resulting from misuse, failure to follow the
instructions, installation, improper maintenance and use, abuse alteration, involvement in an
accident, and normal wear and tear. The Limited Warranty does not cover products which are
used in rental operations and Burley will not be liable for any incidental or commercial damages
relating to such use.

TO THE GREATEST EXTENT PERMITTED BY LAW, THIS LIMITED WARRANTY IS EXCLUSIVE
AND IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR ORAL, INCLUDING BUT NOT LIMITED
TO ANY EXPRESS OR IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. The duration of any implied warranties, including any implied warranty
of merchantability or fitness for a particular purpose that may exist during the express warranty
period are expressly limited to the limited warranty period.

10.

Some states and countries do not allow limitations on how long an implied limited warranty lasts;
therefore, the above limitation and exclusions may not apply to you.

THE CUSTOMER’S EXCLUSIVE REMEDY FOR BREACH OF THIS LIMITED WARRANTY OR OF
ANY IMPLIED WARRANTY OR OF ANY OTHER OBLIGATION ARISING BY OPERATION OF LAW
OR OTHERWISE SHALL BE LIMITED AS SPECIFIED HEREIN TO REPAIR OR REPLACEMENT,
AT OUR SOLE OPTION. IN ANY EVENT, RESPONSIBILITY FOR SPECIAL, INCIDENTAL AND
CONSEQUENTIAL DAMAGES IS EXPRESSLY EXCLUDED.

Some states do not allow the exclusion of limitation of incidental or consequential damages, so
the above limitation of exclusion may not apply to you.

This Limited Warranty gives you specific legal rights, and you may have other rights that vary from
state to state or country.

For warranty service or replacement part information for the USA or Canada, please contact
Burley directly by calling 800-311-5294 or emailing [e-mail]. For warranty service or
replacement part information outside of the USA and Canada please contact the place of purchase
for warranty service. Please be prepared to provide the product model, serial number and a
description of the warranty issue.

Some replacement parts may be available for purchase after this limited warranty expires. Please
visit us at www.burley.com or call us at 541-687-1644 for more information.

Burley Design
1500 Westec Drive
Eugene, OR 97402 USA
P. 541.687.1644 800.423.8445 F. 541.687.0436
[e-mail] Burley.com

Copyright ©2012 by Burley Design LLC
“Burley” is a registered trademark of Burley Design LLC
New 03/12 Plus Manual 2012 Rev 0