Burley d'lite User manual

Owner’s Instruction and Safety Manual
d’LITE™
LADY BUG™
SOLO™
ENCORE™
CUB™
BEE™

Table of Contents
Introduction Pg. 3
Hardware Bag Contents and Tool Lists Pg. 6
Unfolding Your Trailer Pg. 7
Mounting the Reflectors Pg. 8
Attaching the Wheels Pg. 9
Installing and Operating the Tongue Pg. 10
Attaching the Handle Pg. 12
Installing the Cub Parking Brake Pg. 13
Using the Parking Brake Pg. 14
Installing the Safety Flag Pg. 14
Installing the Cover Pg. 14
Using the Padded Seat, Shoulder Harness,
XII.Reclining Seat and Helmet Pocket Pg. 16-18
Hitching Your Burley to Your Bicycle Pg. 19
Maintenance and Storage Pg. 21
Parts Lists and Diagrams Pg. 22-27
Warranty Pg. 28
Congratulations!
Your Burley®trailer is 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
miles of happy, safe trailering.
Because some of the features and guidelines for using
your Burley merit close attention, it is very important that you familiar-
ize yourself with the trailer by reading this entire manual before use. If
you have any questions, please contact your Authorized Burley Dealer or
check our website at www.burley.com.
IMPORTANT:

BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL 3
Introduction
Your Burley is shipped 95% factory-assembled. You need only to mount the
reflectors, install the tongue, attach the wheels, handle, brake, 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. Before
trailering, be sure you have a thorough understanding of the safety harness
and of trailer hitch operation. Practice folding and unfolding your trailer.
Make sure the trailer wheels and hitch are securely attached.
Any reference to left or right is made in the direction of travel,
as if you were sitting in the child seat looking forward.
NOTE:
Safety Guidelines
Bicycling with a trailer is different from bicycling without one, in ways which
aren’t always obvious. It is essential that you read and understand all of the
following safety guide lines—in addition to the warnings and instructions in
the following sections—prior to using your trailer. Contact your Authorized
Burley 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 the safety guidelines in this manual
could result in accident and serious injury or death.
WARNING
Use a Well-Maintained Bicycle and Trailer
Use a bicycle which is in good working condition with good brakes. A fre-
quent safety check of your bicycle is essential. Inspect and maintain your
trailer as outlined in the “Safety Check Lists” of this manual. Have your
Authorized 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 for children and/or
cargo is 100 lbs. (40 kg. in Europe). When placing children 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.

4BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Starting and Stopping
Because of the trailer’s additional weight, a bicycle pulling a trailer will be
slower to start and stop, and because of its length, requires more time to
cross streets or paths. Your entire vehicle is heavier and less responsive.
Think ahead and anticipate stops, turns and starts. Note that your trailer ex-
tends further out on the left; allow for this difference when turning, passing
pedestrians or approaching obstacles, such as posts on bike paths. Experi-
ment with a loaded trailer in an uncongested area to become familiar with
how your heavier, longer vehicle responds.
Prevent Trailer Tip Over
Like automobile and motorcycle trailers, bicycle trailers can tip over. Do not
pull your trailer over curbs or hit holes or other road obstructions. Instruct
children not to bounce or lean, which can cause a shift of weight. Do not
make high-speed turns or descents when pulling the trailer. Always corner
with caution at 5 mph or less, as the trailer cannot lean into a turn the way
a bicycle can. Do not travel faster than 15 mph—all road irregularities and
your slower reaction time are greatly magnified.
Trailers can tip over, causing damage to trailer and serious injury to
cyclist or passengers. AVOID causes of tip over, especially:
WARNING
• Children leaning or bouncing
• Hitting potholes, curbs, other
road obstructions
• Taking turns too fast
• Sudden swerving
• Off-banked turns
• Improper wheel installation
• Improper tire inflation
No Motorized Vehicles
Never pull your Burley trailer with a motorized vehicle, as the increased ac-
celeration and speed could damage the trailer or cause it to tip over.
Always Use Your Cover
To protect your children from flying debris, always use your cover. Never leave
children unattended in direct sunlight, as heat buildup in the trailer can
cause serious harm. Open or close the vinyl window and periodically check
to make sure your children are comfortable.

BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL 5
Wear Helmets
Numerous studies have shown that head injury is the leading cause of bi-
cycling fatalities. Helmets prevent or reduce bicyclists’ head injuries; it is
essential that both cyclist and passengers use approved bicycling helmets
at all times.
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 or knobbies. We recommend using only tires with street
tread.
Know Your Trailer Hitch
Clamp the hitch securely to the bicycle frame, and check for a tight attach-
ment each time you use the trailer. Refer to “Hitching Your Burley to Your
Bicycle” and “Maintenance and Storage” sections of this manual for proper
installation, use and maintenance of your hitch.
Use Your Flag
Always use the safety flag—it will help make you more visible to motorists and
other cyclists.
Protect Your Children
Use the shoulder harness, lap belt, and child helmets on your children 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 the shoulder straps, especially for sleeping
children. Make sure children cannot put a finger into the wheel spokes.
Observe Age and Height Restrictions
The trailer seat is intended only for children old enough to wear a helmet
and sit upright and alone. Adequate neck strength is required to hold his/her
head upright while trailering. A physician should evaluate anyone who is of
questionable developmental age for trailering. Never carry a child whose sit-
ting height (with helmet) is above the roll bar, because their chance of injury
is significantly higher in the event of a tip over.

6BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Hardware Bag Contents and Tool List
Hardware Bag Contents: Tools Required:
All: Warranty Card, Burley Owner’s
Instruction & Safety Manual
d’Lite™, Encore™, Solo™, Lady Bug™:
(2) red reflectors Phillips screwdriver
(2) clear reflectors
(2) reflector brackets
(4) hex head screws
(1) hitch
Bee™:
(2) red reflectors
(2) hex head reflector screws
(2) 1” plastic reflector brackets Phillips screwdriver
(1) hitch
Cub™:
(1) Cub Brake Assembly Two No. 2 Phillips screwdrivers
(3) #10 x 5/8 Phillips pan screws
(3) #10 spring washers
(3) #10 x 1” fender washers
(1) hitch
Note: European models have an additional light hardware bag.
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.
IMPORTANT:

BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL 7
Unfolding Your Burley Trailer
To unfold your trailer, rotate the front tube upward and the rear tube back
until they meet on the two plastic saddles. Then rotate the two frame locks
to snap onto the rear tube. The frame locks should connect adjacent to, and
to the outside of, the two plastic saddles.
d’Lite™, Encore™, Lady Bug
™
, Cub™– After the frame locks are locked in place,
attach the hooks on the seat sides to the D-rings by the windows inside the
trailer.
Solo™only – After the frame locks are locked in place, clip the female buckle
ends on the two seat side straps into the male buckle ends on the inside of
the frame.
Check that the frame locks are properly engaged before using the
trailer. Failure to do so can result in serious injury.
WARNING
Frame locks snapped
into closed position
onto rear tube.
Rear
Front
Seat clips attach
to the top of the
frame.
Seat clips

8BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Mounting the Reflectors
Cub™: Factory-installed Bee™: Rear Reflectors Only
All other models:
FRONT: Clear front reflectors are mounted horizontally to both sides of the
trailer fabric front. “TOP” is marked on the reflector front. Locate the grom-
mets on the trailer fabric front, insert the screw into the reflector back through
the grommet, and tighten snugly. Repeat for the other side.
REAR: Red reflectors are mounted horizontally to both sides of the rear of the
main frame tube, with the reflectors extending out past the sides.
1. Snap the posts on the red reflectors into the openings in the reflector
brackets, and with the provided screw, screw the pieces together.
2. Loosen the black screw next to the clamp (A) on the reflector bracket.
Slide the bracket clamp onto the rear side section (B) of the main
frame tube. Make sure the reflector side marked TOP is to the top.
3. Tighten screw snugly, making sure reflector extends out past the trailer
side. Repeat for the other side.
Make sure both reflectors face outward. Incorrectly installed reflectors
can reduce visibility at night and cause an accident or serious injury.
WARNING
A
B
C
Mounts
horizontally
to frame

BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL 9
Attaching the Wheels
First, verify that the tires are inflated to 30-35 P.S.I. Tip the trailer frame
onto its rear end. 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. Tighten the thumb
nut, so that you feel resistance halfway though tightening the lever. Once the
wheel is fully seated in the hollow axle, position the quick-release lever so
that it is aimed to the rear of the trailer in the “CLOSED” position (the lever
is marked for OPEN or CLOSED positions). Repeat for the other wheel. Note:
wheels are not centered on the axle.
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. Improp-
erly installed wheels can fall off, causing an accident or serious injury.
WARNING
Quick-release
lever in unlocked
“Open” position
Quick-release
lever in locked
“Closed” position

10 BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Installing and Operating the Tongue
d’Lite™, Encore™, Solo™, Lady Bug™
Tip the trailer onto its rear end. Slide the tongue through the LEFT front
tongue receptacle. Depress the safety button to allow it to slide back through
the rear tongue receptacle. Line up the rear hole on the tongue with the
hole in the rear tongue receptacle. Insert the pin through both holes. Once
inserted, rotate the pin’s spring clip to engage the pin underneath the tongue
receptacle. Always check to ensure the tongue is properly installed before
using your trailer.
Never operate the trailer without the tongue retaining pin locked in
place. An unlocked tongue can loosen or detach, and cause accident
resulting in serious injury.
WARNING
Cub™
Slide the tongue through the two plastic tongue receptacles on the LEFT side
of the trailer 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.
2. Secure it and lock
the pin by rotating it
toward the rear of the
trailer as shown.
3. Slip the retaining pin
though the forward hole
in the tongue and lock
in place. Refer to the
illustration showing the
locked position. Firmly
pull on the tongue to
ensure that it is secure.
Front Tongue
Mount
Pin
Rear Tongue
Mount
Button
Trailer Pin
Hole
Stroller Pin
Hole
1
2
3
Forward hole in tongue

BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL 11
Bee™
Tip the trailer onto its back end. Slide the tongue onto the
pivot pin at the left front. Secure the tongue as follows:
1. 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.
2. Push the lock pin fully into the
front tongue receptacle.
3. Rotate the lock pin and locate
the hole in it, between the
receptacle and the trailer frame.
Anchor the lock pin by inserting
the hair pin cotter all the way
into the hole in the lock pin.
Never operate the trailer without the tongue lock pin and hairpin
cotter locked in place. An unlocked tongue can loosen or detach,
and cause accident, resulting in serious injury.
WARNING
The tongue pin is captured between the tongue receptacle
and the lip of the poly shell. It should never be completely removed from
the tongue receptacle. The tongue pin must be locked into place before
using the trailer. If the pin is not properly locked, the trailer could separate
from the bicycle, resulting in an accident or serious injury. The retaining
pin is a backup for the tongue pin. Under no circumstances should the
trailer be towed with only the retaining pin engaged.
IMPORTANT:
Pin in
locked
position OPEN CLOSED
Retaining Pin
3. Anchor Lock Pin
with Hairpin Cotter
4. Anchor Lock
Pin with
Hairpin Cotter
1. Slide
Tongue
onto
Pivot Pin
2. Rotate Tongue
into Place
5. Lock Pin and Hairpin
Cotter Locked in Place
(viewed from underside)

12 BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Attaching the Handle
d’Lite™, Encore™, Solo™, Lady Bug™, Cub™
(Bee™: no handle)
Your trailer comes with a handle which allows for easier maneuvering of the
trailer when it’s not attached to your bicycle. The handle is also an important
part of the optional Burley Jogger Kit™and the optional Burley Stroller Kit™,
which are available at your Authorized Burley Dealer.
To install the handle, slide it into the lower handle bar receivers and tighten
the knobs. (The upper handlebar receivers have spacers in them for the
optional Burley Rollbar, available from your Burley dealer.) To change the
position, remove the handle from the handle bar receivers, flip it over and
reinstall it as described above.
Handlebar
Flag
Rollbar
Accessory
(optional)
Flag Installation
Hole
Knob
Handlebar
Installation

BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL 13
Installing the Cub™Parking Brake
The trailer should be fully unfolded and the tongue removed.
1. Put the trailer on its nose on the floor with the roll cage leaning against
a wall or table. Sort the contents of the hardware bag.
2. Facing the underside of the bucket, locate the rear row of six molded
depressions (see illustration). Holes are drilled in the first, third and
sixth depressions (numbered from the left). See illustration.
3. Put a spring washer and then a fender washer on a mounting screw.
Repeat for the other two screws.
4. 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. Let the brake arms hang down. Hold the center post
and screw it into place with a Phillips screwdriver.
5. 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.
6. 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 screw/spring washer/fender stacks.
7. 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.
8. Take care to keep the far left post
from rotating as you tighten its mounting
screw so that the brake return spring
does not distort.

14 BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Using the Parking Brake
For All Trailers Except the Bee™
Engage the parking brake by pushing the handle to the right. This pushes
the brake arms outward so that the tip of each brake engages the inside of
each tire. Exercise caution when disengaging the brake, as it may spring to
the left.
To disengage
the brake, move
the handle to
the RIGHT.
Simply move the
handle to the
LEFT to engage
the brake.
Installing the Safety Flag
Bee™Only:
On the outer left side of the trailer, insert the safety flag pole through the
webbing loop and into the flag pocket.
All Other Models:
Insert the safety flag pole into the hole in the top of the LEFT handle bar re-
ceiver. (See handle bar illustration on page 12 for location of correct hole.)
DO NOT USE YOUR TRAILER WITHOUT THE SAFETY FLAG.
Installing the Cover
Bee™:
Snap the cover snap buttons to the
snap posts on the top of the frame.
Attach the cover’s Velcro hook strips
to the Velcro loop strips on the trailer
body. Then hook the rubber O-rings
over the back and front frame ends. To
stow the window, unhook the O-rings
from the trailer front. Roll the window
up and secure it by inserting it into the
elastic loops at the top.
Cover Snap Button

BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL 15
Cub™:
Snap the two front snap buttons
to the two snap studs under the
front rim corners. Attach the male
buckles on the rear cover corners to
the female buckles below the side
windows.
All Other Models:
Slip D-rings on the front cover corners over the outer hooked corners of the
front tongue receptacles. Attach male buckles on rear cover corners to fe-
male buckles below the side windows. To stow the front window (all models
except the Bee), unzip it, roll it up and insert the loop Velcro ends of the
elastic straps into the hook Velcro holders on the cover top. The Adjustable
Sunshade slides up and down as needed.
Buckle
Snap Buttons
D-RINGS:
d’Lite™
Ladybug™
Solo™
Encore™

16 BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Padded Seat & Shoulder Harness, Child Seat
Recliner, and Recessed Helmet Pocket
(d’Lite™, Solo™, Lady Bug™, Cub™)
To Install Seat Pad:
Attach the seat pad Velcro hook strips to the loop Velcro strips on the seat.
To Install Shoulder Harness Pad:
Insert the shoulder straps into the shoulder harness pad as shown in the
drawing at the right. The shoulder straps should
be oriented so that the FLAT parts of the male
buckles are facing toward each other.
Using the Child Seat Recliner
The child seat can be reclined for
added comfort by making the following
adjustments:
1. Loosen the tension on the straps (A)
attached to the top of the frame.
2. Loosen the tension in the helmet
pocket straps (B).
Using the Recessed
Helmet Pocket
(d’Lite™, Solo™, Lady Bug™, Cub™)
The helmet pocket, which is designed
to provide added room for the back
side of a child’s helmet, can be
modified by loosening/tightening the
helmet pocket straps (B)
as required.
Using the Child Seat Divider
(d’Lite™, Lady Bug™only)
This feature keeps two passengers from sliding to the center of the seat.
Connect center crotch strap O-ring to snap hook located on the front splash
guard. Adjust strap tension with the plastic slider on the crotch strap.
NOTE: Use the Seat Divider feature only when transporting two passengers.
BA

BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL 17
Using the Seat Harness
Only passengers who are able to wear a helmet and sit
upright, unassisted should ride in a child trailer. Adequate neck strength
is required by passengers to hold their heads upright while trailering. A
physician should evaluate anyone who is of questionable developmental
age for trailering.
IMPORTANT:
Single Passenger, Solo™:
1. Make sure the seat pad and shoulder harness are
installed as indicated in the previous section.
2. Position the child in the center of the seat.
3. Snap shoulder straps into the Y-buckle, with the
buckle positioned at the child’s sternum.
4. Make sure the shoulder straps are adjusted so that
the child cannot move too far forward in the seat.
5. Fasten and adjust the lap belt so that it is snug.
Single Passenger, All Other Models:
1. Unclip the center support strap (with O-ring).
2. Remove both shoulder harnesses (if applicable) from the shoulder
straps. Unclip the Y-buckle if necessary. Store one of the shoulder
harnesses in a safe place. Leave outboard shoulder straps dangling.
3. Remove the two center shoulder straps by unthreading them from the
ladder locks.
4. Trade the position of the shoulder straps and re-insert the straps into
the ladder locks as shown in the illustration to
the right. The flat parts of the male portion of
the Y-buckle should face toward the center.
5. Install one shoulder harness assembly in the
center position as shown at above left.
6. Seat the child in the center of the seat.
7. Snap shoulder straps into the Y-buckle, with the
buckle positioned at the child’s sternum.
8. Make sure the shoulder straps are adjusted so
that the child cannot move too far forward in the seat.
9. Fasten and adjust the lap belt so that it is snug.
Ladder Lock

18 BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Two Passengers, All Models (Except Solo™):
For two children, use both shoulder harnesses and two outer crotch straps.
1. If your trailer was set up for single-child use, reverse the process above in
the Single Passenger section. Set up the restraint system for two children,
with the male portion of each Y-buckle facing the center of each
seating position.
2. Attach the center support strap with the O-ring.
3. Seat the first child on one side of
the trailer.
4. Snap shoulder straps into the Y-buckle,
with the buckle positioned at the child’s
sternum.
5. Make sure the shoulder straps are adjusted
so that the child cannot move too far
forward in the seat.
6. Repeat for the second child.
7. Fasten and adjust both lap belts so they
are snug.
Child and cyclist must wear helmets when trailering. Helmets
can prevent or significantly reduce head injury in event of accident.
The junction of Y-buckle must be positioned at child’s sternum to work
correctly. Belts or buckles positioned near your child’s neck can cause
discomfort or serious injury. Check child periodically to ensure that
he/she has not slipped from correct seated position.
WARNING

BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL 19
Hitching your Burley to Your Bicycle
The Burley standard trailer hitch was designed to quickly and safely attach
to virtually all types of bicycles. It is attached to the left rear dropout (the
non-chainring side) of your bicycle.
1. Remove the quick release lever assembly from your bike and set it aside.
2. Line up the hole on the flat side of the hitch upper arm with the left
rear dropout hole.
3. Reassemble the quick release assembly through the hitch and dropout,
but don’t tighten it yet.
4. Slide the hitch receiver end of the tongue between the two hitch side
arms, and line up the holes. The hitch should clear any racks, bags, or
fittings you have on your bicycle. If there is any interference, contact
your Authorized Burley Dealer.
5. Open the retaining pin and insert the pin through the holes.
6. Rotate the pin’s spring clip and close the pin.
7. Now tighten the quick release lever, with the lever pointing to the rear
of the bike. When properly adjusted, you will feel resistance halfway
through tightening the lever (when the lever is pointing straight out
away from the bike).
8. Wrap the safety strap around the inside of the chain stay twice and then
over the hitch body. Fasten the hook to the D-ring on the underside of
the tongue end.
The quick release lever must be in
the closed position. Do not operate
the trailer without the hitch safety
strap properly installed. A dangling
safety strap can contact spokes
and damage the rear wheel or
cause an accident resulting in
serious injury. The hitch must
not interfere with racks, bags,
or fittings. Inspect the hitch and
tongue frequently for damage or
loose fasteners. Interfering parts
or damaged hitch can cause an
accident resulting in serious injury.
WARNING
Safety strap wrapped
around chainstay
Hook fastened to
D-ring under tongue

20 BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Safety Checklists
Before Each Ride:
❏Wheels tightly attached
❏Tire pressure at 30–35 P.S.I.
❏Hitch properly secured with safety strap in place
❏Locked retaining pins for tongue and roll bar
❏Maximum load 100 lbs. (40 kg. in Europe)
❏Bicycle safety check, especially brakes and tires
❏Helmets for children and rider
❏Safety flag 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 (Bee only)
❏Inspect frame tubing and hardware for cracks, damage, or loose parts
❏Inspect tires for wear and cracks
❏Inspect wheels for trueness and cracks
❏Inspect wheel bearings for wear
❏Inspect fabric parts, child seat, and harness for rips, abrasion, or miss-
ing or damaged hardware
❏Contact Authorized Burley Dealer for repairs/replacement of any
damaged or worn-out parts