On Small Trailers Only: Actuator Installation

Large Trailer Owners skip to Page 2

I. Installation of Rod, Spring and Ball Joint (Tie Rod) in Tow Bar

Apply a small dab of grease on the Rod and slide the rod through the tow

bar from the inside towards front of tow bar.

The threads should be at the very front.

From the front, slide the spring over the rod. Then screw the jam

nut all the way onto the threads.

Screw the ball joint onto the rod as far as you can with your hand.

With one 9/16 inch wrench (or adjustable

wrench) hold the jam nut in place. With a

second 9/16” wrench (or adjustable

wrench), tighten the ball joint firmly

against the jam nut.

2. Actuator

Slide the hole of the Actuator over the inside lip of the tow

bar’s sternum. Tighten the actuator’s screw with the 5/32

hex key. Over time, occasionally re-check to ensure the

screw stays tight.

See picture for screw’s location. The indent in the actuator

will face the ball-end of the rod.

To see a YouTube video, google CycleTote Adding Brakes

1

Tools needed:

Regular and Phil-

lips screwdriver,

On small trailer:

2 small wrench-

es. (9/16 or ad-

justable)

Ball Joint Spring on Rod

Underside of Tow bar

Safety Strap

Actuator Jam Nut

Sternum

Cables

Indent

Anchor Rod

Hole

Actuator Parts

Tighten

Screw

Brake Actuator

top view

Rod

Cable in

housing

Ferrules rest

in Anchor

Ferrule

Parts:

2 wheels with

Sturmey Arch-

er hubs.

Cables

Cable housing

Brake adjuster

Ferrules

Actuator

Spring

Ball joint

Jam nut

Safety strap

5/32 hex key

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Install Wheels

Each hub is marked with an L (left) or R (right). Left and right is facing from

the rear of the trailer forwards as though you were sitting inside.

As you install each wheel, ensure that the axle goes all the way to the rear

of the drop out slot. Notice that the brake arm will be held in place against

the main frame with a Brake Arm Clip. Tighten axle nuts enough to keep

brake in place but not so much that the brake arm cannot rotate.

Slide the brake arm clip over the brake arm aligning between the black

lines provided on the main frame. The brake arm is the longer of the two

black pieces attached to the hub. Tighten the Brake Arm Clip with a screw

driver. Tighten Axle Nuts.

Repeat the process on the other side. The left and right brake hubs are ori-

ented differently when installed. Since the hubs are identical, they are in

reverse positions from each other rather than mirror images.

The left wheel hub will look like the illustration LEFT SIDE. The right hub will

have the brake arm parallel to the main frame and the brake adjuster on

the lower side, as shown in the illustration RIGHT SIDE.

Cables and Cable Housing

The cables (sliver wire) are inside the Cable housing (black plastic)

The front end of the brake cable housing is encased with a ferrule.

Nestle the Ferrule in the Anchor (of the Brake Actuator). Keep it from

getting caught on the edge. As you attach the cable to the brake, the Fer-

rules will want to pull away from their Anchors. Check frequently as you

finish the assembly to see that they have stayed snugged into the Anchor

(of the Brake Actuator).

On the hub (center) of the wheel, attach cables to wheels by attaching the

brake Adjuster and the pinch bolt.

1. Clip the anchor bolt (of the Brake Adjuster) into the brake arm

notch.

2. Squeeze the brake lever towards the brake arm and slide the pinch

bolt into the brake lever notch .

Fine Tune Brakes Using Brake Adjuster

The brakes need to be adjusted so that both wheels stop as the same time, and

release at the same time. If the tow bar isn’t attached to the trailer, attach it

now.

Tip the trailer to get the wheels off the ground. ( Or set the trailer on a bucket or

bench that lifts the wheels off the ground. )

With your hand, start both wheels spinning.

Press the ball joint (on the tow bar) in slowly. Watch to see if the wheels

stop together or one stops first.

If they stop together, the brakes are balanced.

Pinch

Bolt

Drop out

No Gap

Brake Arm Clip

Brake Adjuster

Locknut Anchor Bolt Barrel

Screw

Left Side

Squeeze the Lever Brake adjuster

in notch

Axle Nut

Front of

trailer

If not, use the brake adjuster assemblies to adjust each wheel.

1. Loosen the locknut

2. Turn the barrel screw (of the Brake Adjuster Assembly)

clockwise to make the wheel brake more quickly (counter-

clockwise to make it brake more slowly).

3. Tighten the Locknut against the anchor bolt.

4. Repeat until adjusted.

Over time, periodically check and re-adjust the brakes as needed.

Brake Cables ties

Arrange the brake cables so that the bends in the cable make the biggest loops possible. Avoid sharp turns. Then attach the cable

to the tow bar and frame with the zip ties provided. Cut off the ends of the ties once everything is set.

Brake Cables for use with the optional Jog Handle Attachment

Run the brake cable down the jog handles and along the top of the trailer sides. Then loop it around and back into the wheels.

Arrange the brake cable so that the bends make the biggest loops possible. Avoid sharp turns. Attach the cables with the ties

provided. Along the handle and onto the main frame just in front of the wheels. When appropriate, the cable can run through the

Velcro loops on the fabric.

Trouble Shooting

Brakes are too loose , jerky, or no braking:

To remedy this problem use the Brake Adjuster Assembly. Loosen the lock nut, then loosen (turn counter-clockwise) the

barrel screw (in the Brake Adjuster Assembly). Spin the wheels and compress the ball joint in. Adjust until fixed. If the problem

persists, with the barrel screw fully loosened, undo what you just did (Barrel Screw and Lock Nut).

Then adjust the pinch bolt (at the Brake Lever).

1. The top unscrews. Turn it a few times to loosen the cable in the pinch bolt.

2. Move the pinch bolt along the cable 1/2 inch.

3. Re-tighten the pinch bolt.

Now use the Brake Adjuster, as described above, to fine tune.

Once adjusted correctly, tighten the locknut against the brake adjuster to keep it in place.

Presta Valve Adapter

If the inner tube uses a Presta valve, we have included an adapter (small brass piece in the bag of parts) that allows you to use a conventional Schrader bicycle tire pump. The adapter gets screwed onto the inner tube's stem before inflating the tire. 1. Remove black cap from stem. 2. Unscrew the top brass fitting on the stem until it is loose. 3. Screw the large end of the adapter onto the valve stem (over the brass fitting). 4. Inflate with air. 5. Remove the adapter. 6. Re-tighten the top brass fitting on the stem. 7. Replace the Presta black valve cap on the stem.

3

Squeeze

the Lever

Brake adjuster

in notch

Right Side Front of

trailer

Brass

Fitting-

open

Brass Adapter

Clip