Burley ALTERNATIVE HITCH User manual

This manual covers assembly and application of the Burley line of Alterna-
tive Hitches. The Alternative Hitch allows the use of Burley trailers on
bicycles that will not accommodate the standard Burley hitch. Follow the
instructions specific to your particular model. Enjoy your cycling!
NOTE: There are two distinct versions of the safety strap for the Alternative
Hitches. The standard safety strap is designed for bicycle frames with both
seat and chain stays, the other is designed for bicycles with mono-stay
frames. Follow the instructions below for fitting either version.
If any of these instructions are not clear or if the hitch does not fit the bicycle
properly, call Burley Customer Service at 1-800-423-8445.
A qualified Burley dealer must install the Burley Alternative Hitch. Failure
to install the Alternative Hitch correctly could result in an accident and
serious injury.
Burley Alternative Hitch
Contents
Section
I. Preparing the Burley Trailer 2
IIa. Installing Burley Quick-Release Alternative Hitch 3
IIb. Installing Burley Nutted, Solid Axle Alternative Hitch 6
III. Attaching the Burley Trailer to the Alternative Hitch 7
IV. Maintaining the Alternative Hitch 9
Nutted
Solid Axle
9.5mm

Long QR
140 x 160mm

Short QR
126 x 135mm

Nutted
Solid Axle
10.5mm

Copyright © 2002 by Burley Design Cooperative
“Burley” is a registered trademark of Burley Design Cooperative
Printed on recycled paper rev 5/03
Burley Design Cooperative • 4020 Stewart Rd. • Eugene, OR 97402 USA
[phone] • fax [phone]

2
I. Preparing the Burley Trailer
If you have purchased a new Burley trailer with the Alternative Hitch as
original equipment, proceed beyond to Section II.
1) To remove the standard Burley hitch from the hitch coupler, insert a 1/
8" hex key into the socket head and, while holding the 3/8" nylock nut
with a wrench, rotate the hex wrench counterclockwise.
2) The Burley QR Alternative Hitch includes a 1 3/4" long, 1/4 x 20 bolt,
nylock nut and D-ring.
The Alternative Hitch is packaged with a standard length safety strap to
accommodate frames with both seat and chain stays, (follow steps 3 and 4).
Longer safety straps with D-loops (required for mono-stay frames), are
available from Burley as an accessory (follow steps 5 and 6).
If you are not sure what type of frame configuration you have, call Burley
Customer Service at 1-800-423-8445.
3) From the top of the tongue, insert the bolt through the metal grommet
at the end of the standard length safety strap and through the tongue.
The bolt must pass through the hole in the black elastomer coupler
inside of the tongue (Figure 4).
4) Install the D-ring and new nylock nut on the bottom of the bolt and
tighten securely. When finished, pull and twist the elastomer coupler
to ensure that the bolt has correctly engaged the elastomer and tongue.
FIGURE 1 1/4" Shouder
Bolt
Tongue
Coupler Bolt
Trailer
Tongue
3/8" Nylock Nut
Safety Strap
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For Mono-Stay Bicycles:
5) From the top of the tongue, insert the bolt through the D-ring clip at the
endofthelongsafetystrap,andthetongue.Theboltmustpassthrough
the hole in the black elastomer coupler inside of the tongue (Figure 5).
6) Install the new nylock nut on the bottom of the bolt. Tighten securely.
When finished, pull and twist the coupler to ensure that the bolt has
captured the coupler.
Burley’s standard and Alternative Hitches are engineered exclusively for
Burley trailers. Use of any Burley hitch on a non-Burley trailer may result
in an accident and serious injury or death.
FIGURE 2
Burley Quick-Release
Alternative Hitch
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IIa. Installing the Quick-Release
Alternative Hitch
The Burley Quick-Release Alternative Hitch is a rugged and precise quick-
release assembly that acts as a secure trailer hitch. The Quick-Release
alternative hitch is available in two lengths. The short length fits bikes with
a rear hub over locknut dimension (O.L.D.) between 126mm and 135mm
(most single bikes). The long length fits bikes with an O.L.D. between
140mm and 160mm (most tandem bikes). Please note that drop-out
thickness will vary between bike frames.
Carefully identify your O.L.D. measurement to determine safe use of the
Burley QR Alternative Hitch. If you are not sure how to calculate O.L.D.,
please call Burley Customer Service at 1-800-423-8445.
For the Solid Axle Alternative Hitch:
1) Checkthe nut tightness frequently. Remember to carry the appropriate
tools to remove the hitch and rear wheel in the event that you may have
a flat tire.
For All Models:
1) At a minimum, have an authorized Burley dealer examine your
Alternative Hitch once a year.
2) The Alternative Hitch is not user-serviceable. Should your hitch need
to be repaired or rebuilt, it must be returned to your Authorized Burley
dealer.
If your Burley Alternative Hitch becomes scratched, marred, or bent, return
the hitch to your Burley dealer for inspection. Scratches, mars, and bends
may lead to hitch failure and serious injury or death.
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NOTE: The quick-release skewer must insert a minimum of 11mm into the
adjusting nut to function properly. The Alternative Hitch replaces the quick-
release mechanism on the rear wheel. The consumer MUST be thoroughly
informed on how to safely operate this and traditional quick-release
mechanisms. Proper adjustment of the quick release must be checked
before every ride.
Failure to properly secure the quick-release mechanism of the Alternative Hitch
may lead to an accident resulting in serious injury or death.
1) Remove the entire quick-release assembly from the rear wheel of the
bicycle. Set aside.
2) Install the wheel between the dropouts. Make sure that the left dropout
is snug against the axle lock nut. Measure the distance that the wheel
axle is recessed in the left dropout. If the axle is recessed less than
1.5mm from the exterior face of the dropout, the Alternative Hitch
body cannot engage the dropout properly. You must then remove the
wheel and file or grind the hollow axle end. Repeat the measurement
and file or grind as necessary to ensure that the axle end is recessed
1.5mm from the exterior face of the dropout.
Never install the Alternative Hitch on a bicycle with an axle end less than
1.5mm from the face of the left side dropout. An axle less than 1.5mm from
the dropout face will prevent the Alternative Hitch from engaging the
dropout properly and lock the wheel in the frame, possibly resulting in an
accident and serious injury.
3) Loosen and remove the nut and the single quick-release spring from
the Alternative Hitch quick-release assembly.
4) Insert the skewer of the Alternative Hitch into the hollow axle from the
non-drive side of the wheel as you would a traditional quick-release
skewer. (Caution: DO NOT install a quick-release spring on the hitch
side of the quick-release assembly.)
5) Install the single quick-release spring on the “nut” (drive) side of the
quick-release assembly. Thread the adjusting nut onto the skewer.
6) The quick-release lever is marked for “open” (concave) and “closed”
(convex) positions (Figure 3).
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Never install an Alternative Hitch with standard length safety strap on a
mono-stay bicycle. Mono-stay bicycles require an Alternative Hitch with
long safety strap that allows the safety strap to be secured around the
mono-stay and above the left side cantilever brake stud. Failure to properly
attach the appropriate safety strap on a mono-stay bicycle can lead to the
trailer separating from the bicycle, resulting in serious injury or death.
After completing the Safety Checklist printed on the trailer seat, you are
ready to ride.
IV. Maintaining the Alternative Hitch
For the Quick Release Alternative Hitch:
1) Check quick-release tension frequently. The composite “ears” are
connected to the metal hitch body with a retaining clip. The quick-
release lever is secured to the Alternative Hitch body with an “E-type”
retaining clip.
This retaining clip is attached to the end of the quick-release shaft opposite
the quick-release lever handle. Do not disassemble this retaining clip or
your Alternative Hitch mechanism or quick-release mechanism.
Inspect the retaining clips each time you tighten or release the Alternative
Hitch quick release. Do not use your bicycle with the Alternative Hitch if the
retaining clips are missing or not securely engaged. Failure to maintain the
quick-release mechanism may result in an accident resulting in serious
injury or death.

O
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Never install a quick-release spring on the hitch (non-drive) side of the
Alternative Hitch. The spring will interfere with complete engagement of
the hitch, which could result in an accident and serious injury.
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7) Secure the assembly by rotating the quick-release lever in a counter-
clockwise direction so that the lever profile presents a concave profile
facing inward toward the rear wheel. The lever will meet progressively
more resistance (like a traditional quick-release). Use the nut to adjust
the quick-release lever for a snug fit (finger tight).
8) Openandreadjustas necessary until the wheel is tightly clamped. Give
a final check to the tightness of the wheel by grabbing the rim and
attempting to move the wheel in the dropout.
If you are unfamiliar with the use of quick-release levers, contact your
authorized Burley dealer for a demonstration.
NOTE: Confirm that the wheel is centered in the frame and adjust the
brakes as necessary.
9) Inspect the amount of threads protruding from the nutted end of the
quick-release skewer. The threaded rod is very sharp and can cause
injury if extending beyond the nut. If the threads extend 4mm or more
out of the nut, you will have to cut the quick release skewer down to
a shorter length.
a) Mark the skewer threads 2-4mm from the end of the nut with a
permanent marker, remove the nut and single spring, and set aside. As
an option, count the number of threads needed to cutdowntheskewer
to size and use this figure as a guide after removing the skewer.
FIGURE 3
Closed
Position
Open
Position
Nut or
Adjusting nut
(choose one)
Quick-release
lever
4) Coil the free end of the long safety strap around the non-drive side stay.
Wrap to shorten excess strap length as needed. (Figure 6).
5) Secure the strap end by running the strap through the D-buckles above
the cantilever stud (or other permanent frame projection) and around
the stay—not around the cantilever stud (Figure 6).
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NOTE: The mono-stay strap comes with a clip and D-ring which should be
attached to the top of the tongue under the head of the tongue coupler bolt.
FIGURE 6
Cantilever Brake Stud
To Alternative
Hitch
FIGURE 5
Safety
Strap
Lock Pin
Bail Wire
Black Elastomer Coupler
NOTE: Generous safety strap length enables the strap to be tightened
securely around non-drive side stay. Coil excess free end of strap around
non-drive side stays and tuck end under coiled strap to avoid contact with
wheel hub and spokes.

6
b) Slide out the skewer and thread on a nut (to chase the threads after
cutting) beyond the cutting line. Use a M5x0.8P nut; this is the standard
metric size for most bike racks and accessories.
c) Placetheskewerin a vice andusingasuitablemetal cutting blade, cutthe
skewer down to the appropriate length.
d) File the end until smooth and back the nut off the skewer to chase the
threads.
Install the skewer following the aforementioned instructions.
NOTE: The stock Burley Quick-Release Alternative Hitch has been designed
to fit a specific range of bicycle geometries. Cutting the skewer down to fit a
particular model may inhibit the skewer from safely retaining the wheel on a
different model. Be sure to scrutinize each bicycle you may want to use the
hitch on for minimum requirements as defined in this manual.
IIb. Installing the Burley Solid Axle
Alternative Hitch
The Solid Axle Alternative hitch replaces the non-drive (left) side axle nut
on your solid axle hub. Burley has (2) versions of the Solid Axle Hitch
available—a 9.5mm x 26 TPI nut and a 10.5mm x 26 TPI nut for your
convenience and flexibility.
NOTE: Your solid axle must protrude no less than 14mm and no more than
22mm from your drop-out to use the Alternative Hitch. Failure to install your
original equipment serrated washer may cause your axle to rotate, causing
internal gear hub malfunction.
1) Remove your axle nut by turning the nut counterclockwise. Do not
remove the washer if provided as original equipment on your bike.
2) Identify the correct nut diameter needed for your axle.
3) Insert a 6mm hex wrench between the ears into the hex receiver and
tighten the nut assembly by turning the wrench clockwise. Follow the
hub nut tightening torque recommendations provided by the hub
maker. As a guideline, 14.75-ft. lbs. is a common axle nut torque.
III. Attaching the Burley Trailer to the
Alternative Hitch
For Frames with Seat and Chain Stays:
1) Insert the exposed end of the black elastomer coupler into the compos-
ite “ears” of the Alternative Hitch (Figure 4).
2) Align the hole in the black elastomer coupler with the holes in the hitch
ears and insert the lock pin with attached safety strap (Figure 4).
3) Snap the lock pin closed by pressing the bail wire over the pin end
(Figure 4).
4) Wrap the end of the safety strap over the chain stay of the bicycle frame
and attach it to the D-ring on the trailer tongue (Figure 4).
For Frames with Mono Stays:
1) Insert the exposed end of the elastomer coupler into the composite
“ears” of the Alternative Hitch.
2) Align the hole in the black elastomer coupler with the holes in the hitch
ears and insert the lock pin with attached safety strap (Figure 5).
3) Snap the lock pin closed by pressing the bail wire over the pin end
(Figure 5).
Lock Pin
FIGURE 4
Snap Hook
Safety
Strap
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