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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
2
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
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