Burley Tandem Supplement User manual

Contents
Section Page
I. Introduction 2
II. Sizing 2
III. Starting Up 3
IV. Operating Tips 4
A. Use of Quick-Release Mechanism 4
B. Tightening Seat Post Clamps 6
C. Tightening Adjustable Stoker Stem 6
D. Correct Choice of Gears 7
V. “Top Technique” 7
VI. Safety 8
VII. Maintenance Schedule 10
Warranty 12
Tandem Supplement
To be used in conjunction with the Bicycle Product
Suppliers Association Multi-Speed Bike Manual.

2
Burley Tandem Suppplement
I. Introduction
Congratulations!You’ve made a smart choice in selecting a Burley tandem.We
believe that your new tandem will offer you years of top-quality performance,
comfort,and pleasure.To show our confidence,we offer a lifetime warranty on the
frame and fork,and a 180-day warranty for other original equipment parts (see
warranty for details).
Fill out the following for your own records:
Date of Purchase _______________________________________________________
Retailer Purchased from _________________________________________________
City,State _____________________________________________________________
Model _____________________ Serial # __________________________________
Please verify that you have received the following information with your new Burley
tandem:
Bicycle Product Suppliers Association Multi-Speed Bike Manual.
BurleyTandem Supplement.This supplement will provide information specific to
your Burley tandem.To ensure your safety,read this supplement prior to using your
tandem.
Warranty Card.To help us serve you better,take a couple of minutes to fill out and
return the enclosed warranty registration card. If you have any questions or are
missing any of the above items,we encourage you to contact your Burley dealer.
IMPORTANT: Keep your Tandem Supplement for future reference. If
you loan or sell your tandem, be sure to provide these instructions
and allow enough time for the riders to read them carefully.
II. Sizing
The Captain
Most important,the frame should not be too big for the captain.If in doubt,too
small is better than too big.The captain must have straddle clearance over the top
tube,because he/she will need to be able to to stop the bike and keep it upright
while the stoker remains clipped into both pedals.On mountain tandems,make
sure the captain's frame size is two to three inches smaller than on a road tandem to
allow for a higher bottom bracket and additional straddle clearance.
(Located on the front bottom bracket)

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Burley Tandem Suppplement
On tandems with a sloping top tube,you have another reason to buy small.The
sloping top tube increases the effective size of the frame,because the head tube is
higher than the seat lug where the frame size is measured.
The Stoker
Size matters less for the stoker.The stoker has two concerns:seat position and hand
position.Because the stoker can mount and dismount as you would mount and
dismount a horse or motorcycle (while the captain holds the bike upright),straddle
clearance is much less critical.So if need be,the stoker's seat can be low,close to the
top tube.At the other extreme,the stoker's seat can go as high as long seatposts
want to place it.If you are planning to spend a lot of your time off-road,the stoker
should probably have standover clearance adequate for an emergency bailout.
The stoker's hand position is determined by the stoker stem and handlebars.
Assuming that the captain's seat is not bottomed out,it is no problem to move the
handlebars up or down.The adjustable stoker stem offers a number of inches of
fore-aft adjustment for the stoker's handlebars.On a single bike,adjusting an off size
frame in this way would screw up the fore-aft weight distribution and and result in
sub-standard handling.This is not the case on the rear of a tandem.If you can get the
seat-to-crank-spindledistancethat fits your body,the other factorswill fall intoplace.
III. Starting Up
The Captain
Shift the tandem into a suitably easy gear.Now straddle the top tube.Next,grab the
handlebars,lock both brakes,and place both feet firmly on the ground,straddling
the top tube.Keep your legs spread wide,so the pedals can move around between
them.The bike is now held securely in an upright position.Invite the stoker to climb
on board.
The Stoker
The easiest way is for the stoker to stand on one side of the bike and position a foot
on the near pedal.He/she can then use that pedal as a step and gently swing the
other leg over the seat,as if mounting the back of a motorcycle.If the stoker is not
comfortable with this approach have the stoker step over the top tube with one foot
on the ground (as he/she would on a single bike.) Once both feet are clipped in,the
stoker can backpedal to get situated.When the stoker is ready,he/she rotates the left
(or right if you prefer) pedal to the top of the pedal stroke.The captain now clips into
that pedal.
Now it is time to shove off.The captain should stand on the raised pedal to start the
bike rolling.Put the other foot (that is not currently clipped in) on top of the other
pedal and complete a few pedal revolutions to get the tandem rolling.Now the
captain may clip their other foot in.

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Burley Tandem Suppplement
IV. Operating Tips
A. Correct Use of the Quick-Release Mechanism
Whether transporting your bike or changing a flat,Burley tandems feature quick-
release mechanisms which enable you to easily remove and replace the wheels.As
long as the quick-release is secured properly,the wheel cannot come off.Be sure you
have a thorough understanding of the quick-release mechanism before riding your
tandem.Ask your Burley dealer for a demonstration if you have anything less than a
thorough understanding of the quick-release mechanism.
The quick-release mechanism consists of five parts as shown in the illustration
below.Be aware that the quick-release mechanism is a cam action device,not a nut
and bolt device.At the end of the quick-release lever (inside lever cap) is an eccentric
cam,which provides fail-safe wheel installation when properly tightened with the
wheel in the bicycle frame dropout.
Installing the Front Wheel
With the quick-release lever in the OPEN position (concave side facing outward),
insert the wheel’s axle up to the top of the slot in the front fork end.You may need to
release the front brake straddle cable to fit the wheel into place.Be sure to place the
hub axle all the way into the slot (dropout),centered between the fork blades.The
lever must be on the left side of the bike.
With the lever sticking straight out (at a 90-degree angle to the bicycle),hand-
tighten the cone-shaped adjusting nut at the opposite end until it is snug.Move
the lever to the CLOSE position,parallel to the fork.With the adjusting nut properly
tightened,you should feel some resistance to this motion;it will require a firm push
with the heel of your hand to close the lever.If you do not feel such resistance,return
the quick-release lever to the OPEN position,turn the adjusting nut clockwise one
full turn,and again move the quick-release lever to the CLOSE position.
Drawings after Retseck/Bridgestone, B. Gleason
Skewer Lever Cap
Adjusting
Nut
Quick-
Release
Lever
Spiral
Springs

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Burley Tandem Suppplement
IMPORTANT: Do not tighten the wheels by holding the adjusting nut
and rotating the quick-release lever. The cam action device will
only safely tighten the wheels by following the above instructions.
If you can easily close the lever,the adjusting nut is not tight enough.Open the
quick-release lever and turn the nut clockwise a half turn.Check again for resistance.
Repeat this step if necessary until firmly applied pressure closes the lever.Do not
overtighten the lever (more than 45 lbs.of force),as you may stretch or fracture the
skewer.The front quick-release lever should lie alongside the fork blade when closed
to avoid snagging or accidental opening.
Installing the Rear Wheel
Make sure the chain is shifted onto the smallest chainwheel.Pull the rear derailleur
to the rear of the bike and place the wheel into the rear fork dropouts,with the rim
centered between the seat stay and chain stay.You may need to release the rear
brake straddle cable to allow the wheel to fit into place.Tighten the rear quick-
release skewer as described for the front wheel.Be sure that the lever is on the left
side of the bike so it does not interfere with the chain or the wheel.
A Final Check
Make sure both wheels are securely locked in place in the fork dropouts.To check
for proper front wheel attachment,raise the front wheel of the tandem off the
ground by lifting the front of the frame with one hand.With the other hand,strike
the top of the tire with a firm downward blow.The wheel should not move in the
dropouts.Test the rear wheel by attempting to move it forwards and downwards
out of the dropouts.It should not move in the dropouts.Be sure to reconnect the
brake straddle cables if you released them to install the tire.Check brakes for proper
operation before each ride.

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Burley Tandem Suppplement
Make sure wheels are held securely; you should not be able to
rock or shift wheels. Never ride with the levers in OPEN position.
Improperly installed wheels can fall off, causing accident and
harmful or fatal injury.
B. Tightening the Seat Post Clamps
IMPORTANT: If one of your seatpost clamps is taller than the other,
install the taller one on the captain’s (front) seat post.
Your Burley tandem comes with removable seat
post clamps.When installing the seat post clamps or
adjusting seat post height,note that the slot in the
seat tube must align with the slot in the seat post
clamp (see illustration at right).
IMPORTANT: Always keep a thin film of lightweight grease on your
seat posts to prevent corrosion and to make adjustment easier.
Also,do not tighten the seat post clamp if the seat post is inserted only to where you
can still see the minimum insertion line.Likewise,do not tighten the clamp if the
seat post is inserted so deeply in the seat tube as to obscure the tapered upper edge
of the seat post.The clamp should only be tightened below this tapered portion of
the seat post,and above the minimum insertion line.
C. Tightening the Adjustable Stoker Stem
If your bike is equipped
with an adjustable stoker
stem,note that there are
two bolts securing the
alloy stem.To adjust the
stem,loosen both bolts
(see illustration),slide the
alloy stem in or out,and
then securely tighten the binder bolt and stem bolt as shown with the appropriate
wrenches.Verify that the handlebars will not rotate.Make sure the insert does not
extend past the maximum extension line.
Do not extend past
maximum extension
line
Tighten
expander bolt
on alloy insert
Tighten binder
bolt on ChroMoly
sleeve

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Burley Tandem Suppplement
A stem with insert pulled out past maximum extension line or with
loose adjustment bolts could cause handlebars to suddenly twist or
detach and result in harmful or fatal injury.
D. Correct Choice of Gears
Your Burley tandem is equipped with 24 or 27 speeds.The chain ring and cog
combinations from which you select yield a wide range of gears with minimal
duplication.Note that you should avoid using the small-small (inner front/outer rear)
and large-large (outer front/inner rear) chain ring and cog combination.Here are
three good reasons why:
1.Use of these combinations exceeds the capacity of some derailleurs.This is
generally true on most derailleur systems,but is especially true on tandems that
use wide-range gearing.
2.These extreme combinations distort the chain sideways,causing extra wear on the
chain and gears.
3.Small-small and large-large combinations are generally duplicates of other gear
combinations.
V. “Top Technique”
The Captain
Captains have a big responsibility with the possibility of big rewards.Here are a few
tips towards receiving that reward:
1. Break your stoker in gently.Demonstrate braking,turning, and descending so
that the stoker knows what those manuevers feel like.Give your stoker time to
get used to the back of the tandem.Everything feels a little bit different back
there.
2. Be smooth,predictable,and precise in your manuevers.
3. Set a tone for the ride that your stoker will appreciate.A stoker can't enjoy riding
the way that they like unless the captain cooperates.
4. Be sure that you anticipate the need to shift.Failure to do this can bog down your
tandem and lead to a short "hike" on a steep hill.
5. Make a special effort to carve a straight line when you ride.If there is an
unavoidable bump in the road,be sure to yell "Bump!" so that the stoker has
time to prepare for it.
6. Let your stoker know your intentions.Give verbal commands like "Braking,"
"Shifting," and "Coasting" until your stoker learns your riding style.

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Burley Tandem Suppplement
6. Claim a little bit more of the road when you ride.This will keep your stoker from
feeling too claustrophobic.
4. Be a little cautious.Your biggest obligation is to make the ride pleasurable for the
stoker.In the long run,you will both enjoy riding more if you make that your first
priority.
The Stoker
It will take a little pratice to follow behind like a perfect stoker.Here are a few tips to
get started:
1. Make sure that you decide upon the style of riding with the captain.This will
ensure that there are no surprises as to the length or intensity of the ride.
2. When the captain pedals,so do you.When he/she stops,your legs go limp;the
captain may need to lift the inside pedal to bank steeply around a corner.
3. Lean into the turns,but not too much.With time you will learn the right amount
for any type of maneuver.
4. Don't make unexpected moves.It could cause the bike to veer a foot or more
to the left or right.Don't try to see the road ahead.If you do you will move your
body in such a way that fights the captain's efforts to balance the bicycle.
5. Don't wiggle while clipped in at stoplights.You risk throwing the captain off
balance and falling over.
6. RELAX.And have fun!
VI. Safety
Portions of the following section on safety are reprinted with permission from a pamphlet
entitled “Cycling Safely in Traffic,” Copyright 1990, Bicycling Magazine.
Cycling Safety in Traffic
If you’re a cyclist who’s been rattled by your initial experiences with motor traffic,this
might sound crazy:The solution is to make life easier for drivers.
Here are ten easy ways to share the road peacefully and,above all,keep friendly
drivers friendly.These tips are particularly effective for cyclists who are still
developing their confidence,fitness,and bike-handling ability.
1. Keep right—This most basic rule of sharing the road is the one that cyclists are
most casual about.If there’s a wide,clean shoulder,use it.Barring potholes,storm
grates,parked cars,glass,gravel,and other hazards,most of the time it’s easier
(and safer) to stay to the right.
2. Use common sense about riding two or more abreast—Sure,it’s enjoyable
to ride side by side with a companion and carry on a conversation.But road
and traffic conditions may be such that vehicles back up behind and then pass
dangerously when they could otherwise slip safely by.It’s usually best to restrict
side-by-side riding to quiet,secondary roads.

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Burley Tandem Suppplement
3. Don’t force vehicles to repass you needlessly—You’re riding along a narrow,
busy road and motorists are having trouble getting by.There are a dozen cars
waitingat the next red light,all of whichhavealready patiently overtaken you.Do
you maintain your place in line,or do you zip past everyone on the right so you’ll
get the jump when the light changes? If you do the latter,you might gain 50 feet
and save a few seconds,but you’ll also probably create 12 anti-bicyclists when
they get caught behind you again.
4. Ride predictably—Maintain a straight line when you’re cruising,and use hand
signals when turning or changing lanes.If you ride erratically,it’s difficult for
drivers to know when to pass.
Hand signals are a courtesy and an important part of safe cycling.Motorists
feel more comfortable dealing with cyclists who communicate their intentions.
Use the same hand signals that motorists use,except for a right turn,which is
indicated by pointing with your right arm.
5. Avoid busy roads—It’s surprising how often you see cyclists on a busy highway,
ruffling the delicate feathers of already edgy commuters.An alternate route
doesn’t have to be a residential street with stop signs every block or a glass-
littered,jogger-strewn bike path.Examine a detailed map of your area and you’ll
probably find a relatively quiet road that takes you where you want to go.
6. Make yourself visible—In conditions where motorists might not readily
see you (an overcast day,for example),it’s a courtesy and plain good sense to
wear brightly colored clothes.Drivers will never blame themselves when they
almost pull into your path after a too-casual look.Unfair,yes;but you can greatly
enhance your safety by dressing to be seen.
7. Be careful about“provocative”actions—At a red light,even friendly drivers
are likely to be irritated by a cyclist riding in circles in front of them.Many view it
as a challenge to their right-of-way,even when none is intended.
8. Return the favor—Cyclists come to appreciate little unexpected courtesies
from motorists.For instance,we all nod a thank you to the driver who has the
right-of-way but waves us through anyway,returning the favor.You might,for
example,motion a driver to make his turn in front of you if you’ll be slow getting
under way.Who knows?That driver might look a bit more favorably on the next
cyclist down the road.
9. Obey traffic laws—Probably nothing irritates motorists more than watching a
cyclist blithely sail through a stop sign or light with barely a reduction in speed.If
we want to be treated with courtesy and respect by motorists,acting as if we’re
superior won’t make it happen.And legally,we’re bound by the same laws as
drivers in all states.
10. Brake with caution—Be especially careful when riding in wet weather when
traction of the tires is impaired by wet roads.

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Burley Tandem Suppplement
Rules of the Road
These are the keys to increasing your safety in the midst of motor vehicles.
• Always ride on the right.Go with the flow of traffic,never against it.
• Be predictable.Maintain a straight line,change direction without swerving,and
use hand signals when turning.
• Obey all traffic laws.If you want to be safe in traffic you have to act like traffic.
• Pay attention.Use your eyes and ears as warning devices,alerting you to
potential hazards in time to take action.
• Assert yourself.Don’t let vehicles creep by and force you into parked cars or the
curb.You have a legal right to the lane,so take as much as you need for safety.
• Ride defensively.Expect a car to pull out from the side street or turn left in front
of you.If you anticipate the worst it will rarely happen.
• Be visible.Wear bright colors and put reflectors and reflective tape on your
bicycle.
• Shout.It’s the quickest,most effective way to let a motorist know that he or
she is putting you in danger,or to alert an inattentive pedestrian that you are
approaching.
VII. Maintenance Schedule
It is essential that you keep your Burley tandem properly maintained.Shortcuts or
missed maintenance checks often result in a failure that can leave you stranded,
or worse,result in accident and serious injury.For your safety and tandeming
enjoyment,follow the maintenance schedule as shown on page 11.
We strongly recommend that you have your Burley dealer or other trained bicycle
mechanic perform all adjustments,repairs,and maintenance.This is especially true
for brakes and wheels.If you attempt any adjustments,repairs,or maintenance,you
will need to refer to a bicycle technical service manual (available from most bike
shops),or do the work under the supervision of a trained bicycle mechanic.
When Your Tandem is New
Tandem wheels undergo considerably greater stress than single-bike wheels.
Attention to tandem wheels during the initial 500 miles of riding will reduce long-
term maintenance.We strongly recommend you return your tandem to the dealer
for wheel tensioning and truing after the first 200 miles of riding or as soon as you
notice an out-of-true condition or loose spokes.
It is also advisable to have the wheels checked again at 500 miles.These are also
appropriate intervals for the dealer to perform a mechanical check-over including
brake and derailleur adjustments,bearing checks,and other safety-related tune-up
procedures.It is not recommended to begin a major tour (loaded or otherwise) on a
tandem that has not been through a break-in period.

11
Burley Tandem Suppplement
Before Each Ride
• Check tire pressure.Fill to the maximum pressure on the sidewall,using an
accurate gauge.Caution:do not overinflate.
• Check and tighten all mounting screws and hardware.
• Make sure gears are properly adjusted.
• Clean and lubricate chains periodically.
• Check brakes,and adjust if necessary.
• Verify that the timing chain is properly tensioned.
• Check headset adjustment.
• Secure your tool kit and pump in place.
• Verify that the tires and wheels are in good condition.
• Make sure the quick-release levers for the wheels are secure and properly
positioned.See section IIA of this manual for information on quick-release levers.
See your Burley dealer for a hands-on demonstration if you aren’t absolutely sure
how to operate your quick-release levers.
Mid-Season Maintenance
This should be done every 1,000 miles or 4–6 months.If you are riding high mileage
(over 100 miles per week) or in rain or off-road,you will need to perform this
maintenance every 2–3 months.In addition to your“Before Each Ride”inspection:
• Inspect all brake and derailleur cables for fraying and replace as necessary.
• Check and tighten fixing bolts for crank arms to 18–20 ft.-lb.Also check and
tighten chainring bolts.
• Inspect pedals,toe clips,and straps for cracks or loose parts.
• Verify that seats are properly positioned and securely tightened.
• Check and adjust hub brake (if applicable).
• Check and tighten all nuts and screws on your bike.
• Clean and lubricate pivot points on shifters,derailleurs,brakes and levers;wipe
excess oil to prevent dirt buildup,and keep oil clear of brake and rim surfaces.
• Inspect and replace any worn brake pads.
• Carefully inspect tires for cracks;if in doubt,replace your tires.
• Check wheels for trueness;inspect for cracks at the spoke hole or sidewall.Retrue
or replace as necessary.
• Remove seatposts from seat tubes and apply a thin film of lightweight grease on
your seat posts to prevent corrosion and to make adjustment easier.
• Clean and wax your bike’s finish.Good products for cleaning powder coat finishes
include:
• Simple Green
• Mild soap and water
• Vinegar and water
• A good quality car wax generally works well,but remove
excess wax within five minutes after applying.

Burley Bicycle Limited Warranty
Burley will repair or replace any original equipment parts it
determines to be defective for a period of 180 days from
date of purchase at no charge; the frame and fork have a
lifetime warranty. The owner of a Burley bicycle must present
his/her bicycle for repair, within the warranty period, at an
authorized Burley dealer, together with an original sales
receipt or similar proof of purchase. This warranty applies
only to the original owner and is non-transferable. Burley
cannot be responsible for failure due to improper assembly,
modification of parts or instructions, neglect, abuse,
accident, and/or normal wear. The warranty does not cover
any bikes used for rental, competition, or commercial use.
Burley neither assumes nor authorizes any person to assume
any other liability in connection with Burley bicycles, and
there are no oral agreements or warranties collateral
to or affecting this agreement. Any implied warranty of
merchantability or fitness for a particular purpose is limited in
duration to the duration of this warranty.
Some states do not allow limitation on how long an implied
warranty lasts, so the limitation may not apply to you. This
warranty gives you specific legal rights and you may also
have other rights which vary from state to state.
Copyright © 2004 by Burley Design Cooperative
“Burley” is a registered trademark of Burley Design Cooperative
rev.04/04
Printed on recycled paper
Burley Design Cooperative • 4020 Stewart Rd. • Eugene, OR 97402
[phone] • [phone] • Fax [phone]
www.burley.com • email: [email protected]