Burley Plus Trailercycle Bike Conversion Kit Setup guide

Owner’s Instruction Manual
Trailercycle Bike Conversion Kit
Compatible with 2012 and
newer Piccolo and Kazoo
Burley

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

1.
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
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2.
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).
1
Detent engaged
in frame hole

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

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).
7. Tighten both stem binder bolts to 8 N·m (70 in-lb).
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4 7
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4.

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).
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5.

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).
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5
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.

8.
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.