Owner’s Instruction Manual Trailercycle Bike Conversion Kit Burley Compatible with 2012 and newer Piccolo and Kazoo
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.
4 3 1 2 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 1.
1 Detent engaged in frame hole 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). 2.
1 2 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.
2 5 6 4 7 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.
6 1 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.
5 1 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). 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.
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.
Maintaining Your Burley: • Inspect chain, chainring and rear cog(s); replace if worn. • Clean and lubricate pivot points on derailleur (Piccolo only), wipe excess lubricant to prevent dirt buildup. • Inspect derailleur cable for fraying and replace as necessary (Piccolo only). • Adjust shifting as necessary (Piccolo only). • Ensure that chain is not loose (Kazoo only); tighten chain by moving hub back if needed. • Check wheel for trueness; inspect for cracks at spoke hole or sidewall.
Burley Limited Warranty: The Burley Plus is warranted from the date of purchase against defects in materials and workmanship as follows: frame and fork for five years, other components for one year, excluding normal wear items such as tires, tubes, brake pads, etc. Your original dated sales or delivery receipt showing the date of purchase is your proof of purchase.
Burley Design 1500 Westec Drive Eugene, OR 97402 USA P. 541.687.1644 800.423.8445 F. 541.687.0436 burley@burley.com Burley.
