Burley Cub Instruction Manual

Cub
Owner’sInstruction&SafetyManual
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

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Burley Cub Owner’s Instruction and Safety Manual
Congratulations!
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 Cub 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 ques-
tions, 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-assembled.You will need to mount the reflectors,install the
tongue and brake,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 folding 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 in less than a minute,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,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 themselves with all sections—especially sections“IX.Safety Guidelines”
and“X.Safety Checklists”prior to use.It is essential that they understand the differ-
ences between riding a bicycle with a trailer and without one.It is also essential that
they understand correct wheel attachment,setup,folding,and use of the harness,
safety flag,cover,and hitch.Always ensure that both adult and child are wearing
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
contents listed. Do not proceed with assembly if any parts are
missing; contact Burley immediately 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
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 INTOTHE HOLLOW
TRAILER AXLE,MAKING SURETHAT THE HORIZONTAL SHAFT GOES ALL THEWAY
INTOTHE AXLE.
Quick-release
lever in unlocked
“open” position
Quick-release
lever in locked
“closed” position Wheel axle assembly inserts
into hollow trailer axle
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)

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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 pread-
justed from Burley.
NOTE: All wheels, including optional spoked alloy wheels, must
be mounted with the recessed side of the hub facing out-
ward.
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.
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 flush 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.
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 flag pole through the loop of ½”webbing on the outside of the
trailer and into the flag pocket at the bottom left hand corner of the trailer as shown
below. DO NOT USEYOURTRAILER WITHOUTTHE SAFETY FLAG IN PLACE.
1
2
3
Forward hole in tongue
Retaining Pin
Safety Pin
OPEN LOCKED

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Burley Cub Owner’s Instruction and Safety Manual
IV. Unfolding & Folding Your Burley Cub
Unfolding your Burley Cub
Your Burley Cub is designed with a durable
polyethelyne bucket,lightweight alumi-
num frame with roll cage,and bright-col-
ored polyester software. Setting it up or
folding it down is accomplished in a few
easy steps as follows:
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.
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.
Frame locks
snapped into
closed position
onto rear tube.
Frame Lock

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Burley Cub Owner’s Instruction and Safety Manual
InstallingtheCover
To install the cover,unfold it and
snap the top two snaps first. 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 snap-
ping the B-tabs over the edge of
the frame rails.
FoldingandStowingtheFrontWindow
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 theVelcro holders on the top of the trailer.
UsingtheAdjustableSunscreen
Your Burley Cub is equipped with an adjust-
able 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 neces-
sary. 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 floor 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.
B-tabs
Adjustable
Sunscreen

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Burley Cub Owner’s Instruction and Safety Manual
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 firmly,until the spring washers are fully flattened 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.
123
456
Brake
Released
Brake
Engaged

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Burley Cub Owner’s Instruction and Safety Manual
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 flag.
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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Burley Cub Owner’s Instruction and Safety Manual
The straps and sliding buckles sewn to the backrest of the child seat are part
of a self-adjusting system that keeps the shoulder straps at the correct height
for children of various sizes.When you tighten the shoulder harness,the sliding
buckles allow the shoulder belts to come across the top of the child’s shoulders,
creating a snug fit.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 SectionVI 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 flat parts of
the male portion of theY-buckle should face
toward the center.
4. Install one shoulder harness assembly in the
center position as shown
below.See SectionVI for details on installing
the shoulder harness.
5. Seat the child in the center of the seat.
6. Snap in the shoulder straps at theY-buckle.
Ensure that theY-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.
Ladder Lock