Burley Pre-2004 d'Lite User manual

Pre-2004 d’Lite, Lite
& Pre-2005 Encore
Handlebar & Stroller Wheel Supplement
To be used in conjunction with 2003 or previous model
year Burley trailer Owner’s Instruction & Safety Manual.
Table of Contents Page
I. Introduction 2
II. Preparation for Installation 3
III. Handlebar Installation 3
IV. Using the Handle 6
V. Mount Wheel Assembly 7
VI. Using the Walk ‘n Roller Wheel 9
VII. Installing the Brake 9
VIII. Safety Guidelines 11
IX. Maintenance 12
Warranty 12

2
Burley Walk ‘n Roller Manual; models 2003 and earlier
I. Introduction
Congratulations!With theWalk’n Roller option you are able to stroll or jog with your
kids – using your Burley d’Lite,Burley Lite,or Burley Encore trailer!.You can enjoy
years of maintenance-free cycling and strolling together,all in one neat package.
Every effort has been made to ensure that your purchase is of top quality and
proven design,ready to provide you with many years and thousands of miles of
happy,safe trailering.
TheWalk n’Roller has been designed to empower you to bicycle and stroll,all in the
same trip.You can bike with your Burley as a trailer to a store or a scenic park,lock
your bike and quickly convert the trailer to a stroller,without tools.The conversion
from trailer to stroller,and stroller to trailer,is done without removing anyWalk n’
Roller components.
Before using your converted Burley trailer,carefully read sections III toVIII of this
supplement for essential information regarding daily use,safety guidelines,and
maintenance.If you have any questions ,we encourage you to contact your Burley
dealer.
When loaning or selling your trailer,supply the new user with both this
Supplement and the original Owner’s Instruction & Safety Manual for your trailer.
They must familiarize themselves with all sections,especially with Safety Guidelines
and Safety Checklists prior to use.
If you do not have a copy of the appropriate manual,contact Burley at
www.burley.com or call [phone]

3
Burley Walk ‘n Roller Manual; models 2003 and earlier
II. Preparation for Installation
TheWalk’n Roller requires the assembly and attachment of 3 components:
handlebar,parking brake,and stroller wheel.These are covered in sections III,V,and
VII.Each section has its associated part list so that you may confirm that you have
received all the parts needed. If any parts are missing contact Burley,do not proceed
with installation.
Tools Required:
7/16 inch wrench No. 2 Phillips screwdriver
Torque wrench No. 3 Phillips screwdriver
Extension Some adhesive tape
7/16 inch socket
Note: The No 2 Phillips screwdriver has a shaft diameter of ¼ inch or less
and is most useful here for making bolts holes through fabric. The No. 3
driver has a larger shaft (almost 1/3 inch) and is the better fit for tightening
the bolts of this assembly.
ThelocationsoftheWalkn’Roller
components are seen on the left.
#1 is the handle assembly,#2 is
the wheel assembly,and #3 is
the brake.
The directions around the trailer
are in reference to the normal
direction of motion,front being
forward.
III. Handlebar Installation
Parts included for the Handlebar Assembly:
(1) Padded handle with safety tether (1) Handle Receiver –Right side
(1) Roll Bar plastic replacement hinge (1) Handle Receiver – Left side
(1) Roll Bar plastic replacement catch (4) ¼” by 1-1/8” Phillips head bolts
(4) ¼” locking nuts (2) ¼ inch standard nuts
(1) ¼ “ jam locking nut (hinge)
Note: Standard nuts are larger width, across the hex and do not possess
a nylon locking ring. The locking nuts have a nylon ring built in. A jam nut
is thinner, requiring less height on the bolt. In assembly, when replacing
similar parts, use the new nuts provided.
1
2
3
Left
Right
Front
Back

4
Burley Walk ‘n Roller Manual; models 2003 and earlier
NOTE: if you have a 2004 Encore,this step is not necessary.
Locate the replacement parts for the roll bar catch and hinge,and their counterparts
on the trailer (see the figure,top of next page).The“catch”is located on the trailer’s
right,the“hinge”is on the left.
First remove the old hinge from the left side of the trailer by removing the hex head
bolt that attaches the roll bar. Then remove the Phillips head screw that holds the
hinge to the frame.Save both the hex head and Phillips bolts for installing the new
hinge.
Fasten the new hinge onto the
trailer’s left side using the #3
driver,the existing Phillips head
bolt and the new standard nut
provided.The nut will fit snugly
into the hex shape recess in
the center of the part.Tighten
securely.

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Burley Walk ‘n Roller Manual; models 2003 and earlier
Replace the roll bar into the
new hinge.Use the pre-existing
1.5 inch hex bolt from the old
hinge and the new jam locking
nut provided.Tighten until
the end of the bolt is flush or
slightly protrudes beyond the
nut.
On the right side,remove the old
catch from the frame saving the
Phillips head bolt.Install the new
catch using the existing Phillips
head bolt and new standard nut
provided.Tighten securely.
Locate the pair of handle receiver
mounting holes on the bottom of
both the hinge and catch (See 1 and
2 on diagram to the left).
Carefully punch or cut a hole
through the trailer fabric,small
enough to allow a bolt to pass
through to the mounting holes.
(This can be done with the No.2 Phillips driver.) The fabric is rip resistant to prevent
the hole from growing
1
2
Check that the new roll bar catch and hinge parts and the
roll bar is properly installed. Check the attachment points for
loose elements. Failure to do so could result in serious injury.

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Burley Walk ‘n Roller Manual; models 2003 and earlier
Insert the Handle receivers,on right and left side using 1-1/8”bolts and locking
nuts provided.The right and left receivers are side specific.Be sure to mount the
receiver that directs the handle upward toward the back.
IV. Using the Handle
Install the handle from the rear of the trailer. The trailer must be in the running,
unfolded position. The handle needs to be removed to fold the trailer.It may remain
on while towing the trailer behind a bicycle.
The handle height is adjusted by inserting the handle with the bend upward for
high,or flipped over with the bend downward,for low (see image below).
To insert the handle,depress the button on both sides,simultaneously,while
inserting into the receivers.
The receivers have an oval hole,as shown,for the button to protrude through when
inserted.The button locks the handle into the receiver. Be sure that both buttons
are protruding through the hole in the receivers.This will prevent the handle from
coming out during use.

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Burley Walk ‘n Roller Manual; models 2003 and earlier
V. Mount Wheel Pivot Assembly
Parts Included for the Pivot wheel Assembly Attachment:
(1) 1/4 x 2”hex bolt (1) PivotWheel Assembly
(3) 1/4”locking nuts (3) 1/4 x 1”hex bolts
(3) 5/8”washers
Temporary Hitch Removal
Before installing theWheel Pivot Assembly,the hitch has to be removed from the
end of the tongue. Loosen and remove the securing bolt,#1 in the drawing on the
next page.
• As you remove the bolt,notice how it secures the hitch though the hitch
connector (#2) and the safety strap (#4).
• Save the hitch and the d-ring (#3) for reinstallation. The locking nut (#5) and the
bolt (#1) can be discarded. A longer bolt is provided for the next step.
Always check the handle attachment before using. Be sure
that handle is properly installed with buttons protruding in the
locked position. Failure to do this could lead to loosening of
handle, loss of control, and serious injury.
3
1
2
4
5

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Burley Walk ‘n Roller Manual; models 2003 and earlier
Re-Assembly with the Pivot Wheel
• Slide the wheel pivot assembly over the end of the tongue so that the hole in the
tongue lines up with the hole in the top as shown below.
• Line the hitch connector hole #4 with those same two holes.
• Run the 2-inch bolt provided through the d-ring,and then through the Wheel
pivot assembly,tongue hitch connector.
• Push the bolt through the hole at the bottom,visible in the cavity underneath,and
then secure with the new locking nut provided (tighten to 6 ft-lbs).The end of the
bolt should be flush or completely pass through the end of the nut.
• Place the 1-inch bolt (#2) using 2 washers as shown and a locking nut.
• Then place the other 1-inch bolt (#3) through one washer and the remaining hole.
• On the underside of #3 place the safety strap and a locking nut.
• Tighten to 6 ft-lbs using the torque wrench. The end of the bolt must be flush with
or completely pass through the nut.
When installed the hitch is re-attached by the bolt
that goes through the tongue (and hitch’s flexible
coupling);the safety strap is anchored,and the
d-ring is on top.
Note: If using the Burley Alternative Hitch,
the flexible coupling is attached in the same
manner, using the bolt through the tongue.
The safety strap is anchored in the same way,
to the wheel assembly clamp bolt.
23
5
4
1

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Burley Walk ‘n Roller Manual; models 2003 and earlier
VI. Using the Walk n’ Roller Wheel
The wheel has two positions.One is for use as a trailer,“bike”position.The other is for
use as a stroller,“stroll”position. Before changing engage the parking brake.
To rotate the wheel,loosen the knob,#1.
This will loosen the triangular pivot clamp,#2,enough to rotate.Then rotate to either
the“bike”or “stroll”position as needed. Then tighten the knob.
Do not attempt to hitch the trailer to the bike with the wheel in“stroll” position.
VII. Installing the Brake
Note: If you have a 2004 Encore,this step is unnecessary.
Parts Needed for Brake Installation:
(1) brake assembly (1) ¼”x 1.5”hex head bolt(1) ¼”nut
Locate the gap in the trailer fabric that is behind the right wheel.The gap exposes a
1 inch diameter,aluminum main frame tube that runs along the inside of the wheel.
Undo the clamp in the brake assembly by removing the 1.5 inch long hex head bolt.
Bolt must go through hole in flexible coupling. Otherwise,
hitch could come loose causing an accident resulting in
injury or death.
1
2

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Burley Walk ‘n Roller Manual; models 2003 and earlier
Clamp the brake assembly onto the frame tube as
shown.The clamp should be oriented so that the bolt
runs underneath the main frame tubing.
Fasten with the bolt
and nut through
the clamp,but do
not tighten.
Adjust the brake by sliding backward or
forward as needed before tightening.
You will need to pull the brake handle
backward to move the brake to engaged
position (see next image).
With the brake in engaged position,handle back,
slide the brake forward until the post is just touching
the tire. Mark this position on the frame.Then rotate
the handle forward to disengage the brake,and
slide the brake forward about ¼ from the mark.Now
tighten the bolt.
Once tightened,engage the brake
to verify its function.The brake post
should push into the tire about ¼
inch,or half the diameter of the post.