Burley RECUMBENT User manual

Recumbent
Bicycle
Owner’s
Instruction
&SafetyManual
Section Page
I. Introduction 2
II. ImportantSafety&
OperatingInformation 3
III. SizingAdjustments 5
IV. AssemblyInstructions&
WheelbaseConversion 9
V. SuspensionTuning 15
VI. Accessories&
Trailercycle/TrailerTowing 16
VII. FastenerTorqueSpecifications 17
VIII. HelpfulHintsforNoviceRiders 18
IX. Warranty 19
Contents

2
I. Introduction
Congratulations! You have made a smart choice in selecting a Burley recumbent.
Your new recumbent has been engineered to provide years of top quality perfor-
mance, comfort and enjoyment. To show our confidence, we offer a lifetime war-
ranty on the frame and fork and a 180-day warranty for other original equipment
parts. [See warranty for details.)
Complete the following for your own records:
Date of Purchase: _______________________
Purchased From: _______________________________________________
(Retailer name and location)
Model: ________________________ Serial #: ________________________
(located on right-rear dropout)
Verify that you have received the following information with your
new Burley recumbent:
• Burley Adult Owners Manual for Multi-Speed Bicycles
• Recumbent Owners Manual Supplement (This manual)
• Warranty Card
IMPORTANT:ReadtheBurleyAdultOwnersManualandOwnersManual
Supplementthoroughlyforimportantsafety,maintenanceandoperatinginforma-
tion.KeeptheBurleyOwners ManualandOwnersManualSupplementfor future
reference. If you loan or sell your bicycle, be sure to provide these instructions and
allow enough time for new riders to read them carefully.
CHECK YOUR BRAKE CABLE ENGAGEMENT: Before you begin every
ride, or move the steering mast fore/aft, depress the front and rear
brake levers to ensure proper brake cable engagement. Failure to
do so could result in brake cables that are not properly engaged
which could in turn result in an accident and serious injury or death.
If you have questions or concerns about the length of your brake
cables, contact your local dealer for assistance.

II. Important Safety & Operating
Information
Caution to New Recumbent Riders: The riding position and weight distribution
onrecumbentsisquitedifferentthanonaverage“upright”bicyclesandcontributes
to unique handling characteristics. Starting up from a standstill, turning at low
and high speeds, and cornering and braking in wet weather will all be somewhat
different from other bicycles. It is recommended that you become thoroughly
acquainted with the handling and performance of your recumbent before riding
among automobile traffic or other cyclists.
BECOME FAMILIAR WITH HANDLING CHARACTERISTICS: Your Burley
recumbentbicyclewillhandledifferentlyfrom otherbicycles.Donot
ride this bicycle among automobile traffic or other cyclists before
you are thoroughly familiar with its handling characteristics. Failure
to do so could result in accident and serious injury or death.
The addition of accessories, such as racks, trailers and trailercycles can affect the
handling of your recumbent. Add these accessories only after you are thoroughly
acquainted with your recumbent. Practice riding with these accessories in an open
area free of automobile traffic.
PRACTICE USING ACCESSORIES: The handling characteristics of your
recumbent will change with the addition of loaded racks, a trailer or
a trailercycle. Only add these accessories after you are completely
familiar with the handling of your recumbent. Failure to do so could
result in an accident and serious injury or death.
Seat frame
Rear shock
Suspension
pivot
Seat
base
Tilt and height-adjustable
steering mast
3

4
Rider Maximum Weight Restriction
All Burley recumbents are engineered for a maximum rider weight of 275 lbs.
(125 kg).
DESIGNED FOR MAXIMUM RIDER WEIGHT OF 275 LBS.: All Burley
recumbents are engineered for a maximum rider weight of 275 lbs.
(125 kg). Individuals heavier than 275 lbs. (125 kg) should not ride
thesemodels.Failuretoheedthiswarningmayresultinaframefailure
which could cause an accident resulting in serious injury.
Wheel/Heel Overlap
Most recumbent bicycles exhibit some amount of front wheel-to-foot overlap
when turning. This condition is described as the potential for the riders foot to
come in contact with some part of the front wheel while pedaling and cornering
simultaneously. This condition is often noticed during low speed cornering, when
the front wheel steering angle is greatest.
It is important to become familiar with the extent of wheel-to- foot overlap, if any,
with your recumbent bicycle. To familiarize yourself with this condition, test ride
your bicycle in a safe, open space such as an empty parking lot.
IMPORTANT: It is important to learn where front wheel-to-foot overlap can oc-
cur so that you will know how to avoid it. To avoid overlap, learn the technique
of coasting through sharp turns.
AVOID WHEEL-TO-HEEL OVERLAP: Most recumbent bicycles exhibit
someamount offrontwheel-to-footoverlap.A footcomingintocon-
tactwiththefrontwheelmaycauseyoutolosecontrolofthebicycle,
and may cause an accident resulting in serious injury or death.
Handlebars and Forks
SomeBurley recumbent models areequippedwitha special lightweight handlebar.
This handlebar is designed specifically for recumbent bicycles and MUST NOT
BE USED ON ANY OTHER BICYCLE.
Handlebars of this type are identified by a warning label at the center of the bar.
This warning label will be covered by the handlebar stem when installed on the
bicycle. The warning label will be visible and obvious when the handlebar is re-
moved from the handlebar stem.

5
DO NOT USE YOUR HANDLEBAR WITH ANY OTHER BICYCLE: Some
Burley recumbent models are equipped with a special lightweight
handlebar, identified by a warning label at the bar center. These
handlebars are designed specifically for recumbent bicycles and
MUST NOT BE USED ON ANY OTHER BICYCLE. Use of these handlebars
on other bicycles may result in a failure, which could cause an ac-
cident resulting in serious injury.
Some Burley recumbent models feature front forks with a protective plastic strip
at the top of the right side fork leg. This strip is designed to prevent scratching or
gougingdamagetotheforkfromthedrivechain.Itisveryimportantthattheseforks
are not allowed to become scratched or gouged and that damage to the surface of
the fork from the drive chain is prevented. It is very important that the protective
strip is replaced if it becomes warn or damaged. See your dealer or call Burley
Customer Service if you have questions about the fork in your bike.
REPLACE PROTECTIVE STRIP ON FORK WHEN DAMAGED: Some Burley
recumbent models feature front forks with a protective plastic strip
at the top of the right-side fork leg. Damage to the surface of these
forks could lead to the development of cracks, which could even-
tually cause the fork to fail. A fork failure will cause an accident that
could result in serious injury or death.
III. Sizing Adjustments
Important Sizing Information for Proper Riding Position
Recumbent bicycle sizing and fit criteria are different from upright bicycles. It is
veryimportanttocarryoutthenecessaryadjustmentstobesureyourrecumbentfits
you properly. A bike that does not fit properly is unsafe. It will be uncomfortable
and difficult to control.
FIT AND SIZE IMPORTANT: If your bicycle does not fit properly, you
maylose control and fall. Ifyour new bikedoesn’t fit, ask your dealer
to size it properly before you ride. Failure to do so may cause an
accident, resulting in serious injury or death.
Refer to the photo on page 6 for proper recumbent cycling riding position. Seat
fore-aft position and handlebar position affect your comfort, safety and ability to
control the bike.

6
Seat Track Adjustment
Theseatassemblyisfixedtotheseattrack
via quick-release mechanisms. It can be
easilymovedbyopeningthequick-release
levers and sliding the seat on the track.
The seat quick-release mechanisms must
be fully closed before riding. If you have
any questions about the proper operation
of the quick-release mechanism, refer to
SectionIV.Tech,B.3,oftheBurleyAdult
OwnersManualforMulti-SpeedBicycles
or have your dealer provide instruction.
Undernocircumstancesshouldthebicycle beridden withoutthe seatquick-release
mechanisms properly adjusted and fully closed. If the quick-release mechanisms
are not closed with adequate force, the seat assembly may slide on the seat track.
When the quick-release mechanisms are closed properly, the seat assembly WILL
NOT SLIDE ON THE SEAT TRACK.
If the seat assembly is allowed to slide on the seat track, it will not slide off the
bike frame. Socket head bolts and special washers are installed at the rear of the
seat track to prevent the seat assembly from coming off. These important safety
features should not be removed from the bicycle.
CLOSE QUICK-RELEASE MECHANISM AND ADJUST PROPERLY: Riding
yourbicyclewithseatquick-releasemechanismsopenorimproperly
adjusted can cause you to lose control, resulting in serious injury or
death.
Seat Fore-Aft Adjustment
Step1.SeatAdjustment—Whilesittingonthe bicycle, have an assistant hold you
upright or lean against a wall. Pedal backwards in the freewheeling direction to
position yourself on the seat and pedals. Stop pedaling with the crankarms parallel
to the ground. There should be a slight bend to the knee of the leg on the forward
pedal. If your leg is completely straight, the seat is positioned too far back on the
seat track. If the bend at the knee is too great, the seat is positioned too far forward
on the seat track.
Step 2. SeatAdjustment Check—Confirm the correct bend of your leg by again
sitting on the bike with the crankarms oriented parallel to the ground. Place the
heel of your foot on the center of the forward pedal. Your leg will be absolutely
straightwhentheseatisadjustedthecorrectdistancefromthepedals.Thistechnique
should provide a slight bend at the knee when the ball of your foot is centered on
the pedal.

7
Steering Mast Adjustments
Thesteeringmastassemblyfeaturesseparatehandlebarheightandtiltangleadjust-
ments. These adjustments will allow you to set the handlebars at the appropriate
height and distance from your body. The correct adjustment will result in a 90°
bend at the elbow (see photo on page 6).
Steering Mast Height Adjustment
1. Loosen the binder clamp at the bottom of the steering mast upper tube.
2. Adjust the handlebars to the desired height and tighten the binder bolt.
IMPORTANT NOTE: There is a minimum required insertion of the steer-
ing mast lower tube into the steering mast upper tube. This minimum
insertion is required for proper strength of the steering mast assembly.
Under no circumstances should the steering mast height adjustment
be set so that the MINIMUM INSERTION mark on the lower tube is vis-
ible beneath the upper tube.
ADJUST STEERING MAST PROPERLY: The MINIMUM INSERTION mark on
the steering mast lower tube must not be visible below the steering
mast upper tube AT ANY TIME. If the steering mast height adjustment
is set beyond the MINIMUM INSERTION mark, the steering mast may
become damaged or break, which could cause you to lose control
and fall, causing serious injury or death.
CHECK YOUR BRAKE CABLE ENGAGEMENT: Before you begin every
ride, or move the steering mast fore/aft, depress the front and rear
brake levers to ensure proper brake cable engagement. Failure to
do so could result in brake cables that are not properly engaged
which could in turn result in an accident and serious injury or death.
If you have questions or concerns about the length of your brake
cables, contact your local dealer for assistance.
Steering Mast Tilt Range Adjustments
It is a good idea to check the tightness of your steering mast pivot bolt before and
aftereveryride.The steering masts on all 2004 recumbents (in this manual referred
to as Type 2 steering masts) have only the rearward tilt range setting adjustment.
Set the rearward tilt setting of the steering mast to the desired position by adjusting
the adjustment bolt as described above.
Some Type 2 offset stems feature a removable forward stop bolt. This bolt serves

8
tolimittheextenttowhichthe
steering mast can be folded
forward. If threaded inward
(clockwise) completely or
removed, the steering mast
can be folded completely flat
torestonthebikeframe.With
theseatassemblyremovedand
the steering mast folded flat,
the bike may be easier to load
into some vehicles.
Once the seat and steering
mast adjustments have been
performed, the bike is ready
to ride. However, there are
other seat adjustments that may increase comfort and allow you to customize the
fit of your bike.
Fine Tuning Seat Adjustments for Comfort
Seat Back Recline Adjustment
The seat back recline is adjustable to several different position settings. Newer
riders may prefer a more upright setting. Experienced and performance-oriented
riders may prefer a fully reclined seat back.
To adjust the degree of seat back recline:
1. Note the position of the seat assembly on the seat track.
2. Open both seat quick-release mechanisms.
3. Note the position of the plastic seat slider blocks in the range of adjustment holes
provided.Note howmoving thesliderblocks todifferentadjustment holeschanges
the recline angle of the seat frame.
4. Slide the seat fully rearward and remove seat assembly from the frame.
5. Hold the seat in your lap or place it on a suitable work surface or table.
6. Remove both seat quick-release mechanisms, being careful not to lose the self-
centering springs.
7. Install the quick-release mechanism with plastic slider blocks and self-centering
springs in the desired recline adjustment holes.
8. Install the seat assembly on the bike by sliding the seat onto the seat track from the
rear (opposite of removal). Slide the seat frame to its original position on the seat
track.
9. Close both seat quick-release mechanisms. (Refer to Section IV. Tech B.3, of the
Burley Adult Owners Manual for Multi-Speed Bicycles for proper quick-release
mechanism operation.)
Seat Bottom Fine Tuning Adjustments
Seat Bottom Fore-Aft and Tilt Range Adjustments: The fore-aft and tilt range
Type 2 Steering Mast
Rear Tilt
Adjustment
Bolt
Adjustment
Lock Nut
Forward Tilt
Stop Bolt
Steering Mast
Lower Tube
Offset Stem

adjustments enable you to change the distance of the seat bottom from the seat
back, as well as the tilt angle of the
seat bottom relative to the seat back.
Theseadjustmentswillenhanceyour
comfort on the bike.
Changing the seat bottom fore-aft
and tilt range adjustments requires a
6mm hex wrench and a 13mm open
end or box end wrench.
1. Loosen the seat bottom fixing
bolts.
2. Slide the seat bottom to the desired fore-aft position within the seat frame side
plates.
3. Adjust the tilt angle range to the desired setting by raising or lowering the nose of
the saddle.
4. Tighten the seat bottom fixing bolts to 150-200 in/lb on a Corbin®seat bottom
and 80-100 in/lb on a Burley©Seat bottom.
IV. Assembly & Wheelbase Conversion
Instructions
NOTE: Burley recumbents MUST BE FULLY ASSEMBLED by your dealer.
ThefollowingassemblyinformationisintendedprimarilyfortheDealer
Technician performing this assembly.
Forward Steerer Tube Locking Collar
Some Burley recumbent models have a convertible wheelbase feature (identified
by linkage steering with two headsets). Please review the following information
regarding the forward Steerer Tube Locking Collar.
Bikes with the convertible wheelbase feature utilize threadless (Aheadset™) style
headset bearing assemblies, as well as one locking collar not included with typical
threadless headsets. This locking collar is designed to act as both the spacer for
the headset assembly and as a secondary retention device for the steerer tube. As
with typical threadless headset assemblies, first adjust the bearing preload of the
headset bearings and then tighten the locking collar bolt. The M5 bolt of the clamp
should be tightened to 50–75 in/lb.
IMPORTANT:Thelockingcollarisonlyusedinthemediumwheelbase
[MWB] setting [see wheelbase conversion instructions].
Linkage Assembly
Forbikeswiththeconvertiblewheelbasefeatureandlinkagesteering,pleasereview
the following linkage assembly information.
9
Seat Tilt
Adjustment
Holes
Seat Bottom
Fixing Bolt
Seat Bottom
Seat Back
Side Plate

1. The linkage rod attaches the rear steerer to the front fork. Notice that one end
of the linkage rod has the bearing and nuts tightened against each other with no
gap. The other end has a gap and the nuts are tight.Also notice that the hardware
necessary to attach the linkage rod to the brackets is installed on the linkage as-
sembly. To install the linkage rod, you will need to remove the hardware.
2. Attach the side of the linkage rod with NO gap to the bracket on the fork using
an M6 x 25mm bolt. IMPORTANT: The linkage rod must be installed to the
bottom face of the mounting brackets on the fork and rear steerer tube. Place two
flat washers between the bearing and the fork bracket. Tighten the bolt to 90-100
in/lb.
3. Adjust the linkage rod length so that the fork is centered and facing forward and
the bracket of the rear steerer is perpendicular to the main frame of the bike.
4. Using a 10mm wrench, tighten one nut on the linkage rod against the bearing
(11mm wrench). Tighten the other nut against the linkage rod.
5. Attach the linkage rod to the bottom face of the rear steerer bracket with one flat
washer between the bracket and the bolt head and one flat washer between the
bearing and the nut. Tighten the assembly to 90-100 in/lb. Wheelbase Conver-
sion
Wheelbase Conversion
Some Burley recumbent models can be configured as either a short wheelbase
[SWB] or medium wheelbase [MWB] recumbent. This feature provides two
distinctly different handling characteristics. In the SWB setting, the bike delivers
a quick-handling, sporty ride. In the MWB setting, the bike has a slightly slower
steering feel and is smoother over bumps.
Please review the following procedure to perform the wheelbase conversion on
bikes with this feature. Such bicycles are assembled in the Medium Wheelbase
(MWB) setting at the factory, hence these instructions cover the conversion from
MWB to Short Wheelbase (SWB).
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