Surly Dummy User manual

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Hi there. Thanks for spending your hard-earned cash on this Surly product. Surly stuff is designed to be useful and durable.
We’re confident it will serve you well for years to come.
Surly Dummy Rails were designed to support our Dummy Deck and Dummy Bags. They fit all longtail frames
(including the Big Dummy) using Xtracycle’s design standards.
Our Dummy Deck bolts directly to the Dummy Rails using M5 metric hardware, unifying and stiffening the entire system.
We include 20mm-long stainless steel flanged button head machine screws with the Dummy Rails for this application.
The threaded deck-attachment bosses, located along the tops of the Dummy Rails also serve as spacers. These 5mm-tall
standoffs create space between the rails and the deck for bag straps, Junk Straps, webbing, and cords.
Threaded bosses, located at the rear of each rail, provide a mounting location for a water bottle cage or other accessories such
as lights, cameras, action, pumps, flags, horns, light saber scabbards, disco balls, spittoons, cornucopias, etc.
Our Dummy Bags were designed to be fully compatible with our direct-mount rail and deck system. Non-Surly bags may
or may not be compatible with our system, due to the placement of the threaded bosses on the rails.
We highly recommend you have your Dummy Rails installed by a competent professional bicycle mechanic.
WARNING: Cycling can be dangerous. Bicycle products should be installed and serviced by a professional mechanic.
Never modify your bicycle or accessories. Read and follow all product instructions and warnings including information
on the manufacturer’s website. Inspect your bicycle before every ride. Always wear a helmet.
• Check with your bicycle’s manufacturer to verify proper fit, mounting points, bicycle cargo load capacity, and
compatibility for carrying cargo. Do not exceed the bicycle manufacturer permissible load
For additional safety information about all Surly products visit: surlybikes.com/safety
Dummy & Big Fat Dummy Rail Instructions
Surly Dummy Rails are compatible with Surly Dummy Bags, the Surly Dummy Deck, and the Surly Big Fat Dummy Deck.
Surly Big Dummy Rails also fit all longtail frames using Xtracycle’s design standards.
NOTE: Big Fat Dummy Rails are designed to be compatible with a maximum wheel size of 26 x 5.25˝. Big Dummy Rails are
designed to be compatible with a maximum wheel size of 26 x 2.5˝.
Dummy & Big Fat Dummy Rail Compatibility and Intended Use
RETAILER: These instructions MUST BE provided to the end user.
3
Jumps and drops
are intended to
be less than
61cm (24″)
ASTM F2043 INTENDED USE: CONDITION 3
This is a set of conditions for operation of a bicycle that includes Condition 1 and Condition 2 as well as rough
trails, rough unpaved roads, and rough terrain and unimproved trails that require technical skills. Jumps and
drops are intended to be less than 61cm (24˝). Please see link to Bike Owner’s Manual on surlybikes.com/safety
for complete list of riding condition descriptions.
BIG DUMMY
BIG FAT DUMMY
RETAILER: These instructions MUST BE provided to the end user.
2
ASTM F2043
Drops are
intended to be
limited to 15cm
(6″) or less.
INTENDED USE: CONDITION 2
This is a set of conditions for the operation of a bicycle that includes Condition 1 as well as unpaved and gravel
roads and trails with moderate grades. In this set of conditions, contact with irregular terrain and loss of tire contact
with the ground may occur. Drops are intended to be limited to 15cm (6˝) or less. Please see link to Bike Owner’s
Manual on surlybikes.com/safety for complete list of riding condition descriptions.
WARNING: FAILURE TO READ AND FOLLOW ANY OF THESE SAFETY WARNINGS COULD CAUSE A CRASH AND SERIOUS INJURY
• The maximum load weight for the Dummy Cargo System is 200 lb (90 kg) 75 lb per bag plus 50 lb max load for the deck. Check
with other manufacturer’s systems to determine if they are compatible with the Dummy Cargo System maximum load weight.
What you load and how you load it makes a big difference in how a bike like this handles! Use caution with unusually heavy,
long,or large cargo
• Do not modify the luggage carrier in anyway. Hardware included with the rack must be used. Do not use hardware
included on your bike
• Only carry live cargo if you are using Surly Rail Collars
• Position reflectors and lights so that they are not obstructed when the rack is loaded
• The bicycle may behave differently (particularly with regard to steering and braking) when the luggage carrier is loaded
• Make sure your load is evenly balanced and secure before every ride ride; always secure loose straps or cords or anything else
that may get caught in the wheel prior to riding
For additional safety information about all Surly products visit surlybikes.com/safety
Safety
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If you lack proper tools, knowledge, or patience to get the job done right, visit your friendly local bike mechanic for assistance.
Spare parts are available in the event that you break or lose something.
Your new Dummy Rails require little maintenance. Periodically check the tightness of the hardware. Spray a little oil inside
the tubes on occasion, if you’re prone to riding in wet conditions.
WARNING: Improper installation of bolts may lead to product failure, causing serious injury. Do not exceed specified torque
values. Periodically inspect bolts and retighten if required.
Frequently check to make sure that all of the rack hardware is properly torqued per these instructions. Check to make sure
that the rack mounting bolts are properly tightened and secure the rack to the bicycle frame. Periodically check for any signs
of cracking or failure and discontinue use if rack is damaged.
Ongoing Maintenance
Installation
Tools Needed
Parts Included
1. Apply a small amount of grease to the exterior surface
of each rail tube where the rail will be inserted into
the longtail vertical frame tubes.
2. Insert the front part of the rail (the end without bottle
cage bosses) into the front vertical Big Dummy frame
tube. It will go into the frame 15mm before the rear
part of the rail can be inserted. Apply light downward
pressure to both ends of the rail, alternating between
the front and rear, until both ends hit their dead stops
and are fully seated in the frame.
3. You are now ready to install the Dummy Bags and the
Dummy Deck onto the rails.
• (8) M5 x 0.8 x 20mm stainless flanged button head socket cap screws
(for Dummy or Big Fat Dummy Deck installation, see Deck Instructions for proper assembly)
• Grease
This Surly product is warranted against defects in materials and workmanship for one year from the date of retail purchase of the product,
subject to the limitations detailed below. Save your dated receipt for proof of purchase.
This warranty does NOT cover the following:
• Damage due to improper assembly or follow-up maintenance or lack of skill, competence or experience of the user or assembler
• Products that have been modified, neglected, used in competition or for commercial purposes, misused or abused, involved in accidents
or anything other than normal use
• Installation of components, parts or accessories not originally intended for or compatible with Surly product as sold
• Damage or deterioration to the paint, surface finish, aesthetics or appearance of the product
• Normal wear and tear
• Labor required to remove and/or refit and re-adjust the product within the bicycle assembly
This limited warranty is expressly limited to the repair or replacement of a defective product, at the option of Surly, and is the sole remedy of
the warranty. This limited warranty applies only to the original purchaser of the Surly product and is not transferable. This warranty applies
only to products purchased through an authorized dealer or distributor. In no event shall Surly be liable for any loss, inconvenience or damage,
whether direct, incidental, consequential, or otherwise resulting from breach of any express or implied warranty or condition, of merchantability,
fitness for a particular purpose, or otherwise with respect to our products except as set forth herein.
This limited warranty gives the consumer specific legal rights, and those rights and other rights may vary from place to place. This limited
warranty does not affect your statutory rights.
TO THE EXTENT NOT PROHIBITED BY LAW, THESE WARRANTIES ARE EXCLUSIVE AND THERE ARE NO OTHER EXPRESS OR IMPLIED
WARRANTIES OR CONDITIONS INCLUDING WARRANTIES OR CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Limited Warranty
OTHER PRODUCTS:
Give us a call for a free catalog or visit our website to check out all our stuff–you won’t be disappointed.
CONTACT US:
SURLY
Phone: [phone]
Web: www.surlybikes.com
E-mail: [email protected]
Where We Is: 6400 W. 105th St., Bloomington, MN 55438 USA
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