Bushtec Turbo+2 User manual

Owners Manual
for
♦Turbo+2
♦Roadstar
♦Quantum Sport
♦Quantum “GL”
Bushtec Mfg. & Sales, Inc.
P.O. Box 459 * 180 Mt. Paran Rd.
Jacksboro, TN 37757
[phone] * [phone] Fax
www.bushtec.com* [email protected]

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TABLE OF CONTENTS
INHTSA Notification Statement…………………………………………...3
II Steps for Determining Correct Load Limit………………………………3
1. Safe Towing Guidelines…………………………………………………..…5
2. Loading & Tongue Weights………………………………………………...6
3. Lid Latch Operation, Opening & Closure.……………………………..…7
4. Attaching Trailer to Motorcycle…………………………………………...9
5. Maintenance………………………………………………………………..10
6. Suspension Operation……………………………………………………...16
7. Tongue Stand, Mounting & Operation…………………………………...17
8. Cooler Pacakge, Mounting & Operation…………………………………17
9. Garment Bag or Accessory Lid Bag………………………………………19
10. Stone Protector Bra, Removal & Installation……………………………19
11. Luggage Rack, Lid Mounted……………………………………………...20
12. Interior Light………………………………………………………………20
13. Wire Harness Color Codes………………………………………………..20
14. Specifications……………………………………………………………....21
15. Certification Label Location (VIN #)…………………………………….21
16. Lighting and Access……………………………………………………….22
17. Heim Joint, Adjustment & Replacement………………………………...23
18. General Information……………………………………………………....24
19. General Finish Care……………………………………………………….24
20. Warranty……………………………………………………………………25

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NHTSA NOTIFICATION STATEMENT
If you believe that your vehicle has a defect that could cause a crash or could cause injury
or death, you should immediately inform the National Highway Transportation Safety
Administration (NHTSA) in addition to notifying Bushtec Manufacturing & Sales, Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that
a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
However, NHTSA cannot become involved in individual problems between you, your
dealer, or Bushtec Manufacturing & Sales, Inc.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-
327-4236 (TTY: 1-800-424-9153),or go to http://www.safercar.gov; or write to:
Administrator, NHTSA, 400 Seventh Street, SW, Washington, DC 20590. You can also
obtain other information about motor vehicle safety from http://www.safercar.
STEPS FOR DETERMINING CORRECT LOAD LIMIT
(1) Locate the statement “The weight of cargo should never exceed XXX kg or XXX
lbs.” on your trailer’s placard (located on tongue next to VIN).
(2) This figure equals the available amount of cargo and luggage load capacity.
(3) Determine the combined weight of luggage and cargo being loaded on the
vehicle. That weight may not safely exceed the available cargo and luggage load
capacity.

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NO MOTORCYCLE MANUFACTURER HAS APPROVED OR ENDORSED
BUSHTEC MFG. & SALES, INC., ITS PRODUCTS, TRAILERS, OR HITCHES.
USE OF A TRAILER OR TRAILER HITCH ON ANY MOTORCYCLE COULD
VOID YOUR WARRANTY AND MAY INCRESE YOUR CHANCES OF INJURY
IN AN ACCIDENT SITUATION.
The following notations distinguish important information:
NOTE: A NOTE provides key information to make procedures easier or clearer.
CAUTION: A CAUTION indicates special procedures that must be followed to avoid
damage to the motorcycle, trailer, or accessories.
WARNING: A WARNING INDICATES SPECIAL PROCEDURES THAT MUST
BE FOLLOWED TO AVOID INJURY TO A MOTORCYCLE OPERATOR OR
OTHERS.
BUSHTEC Manufacturing and Sales, Incorporated reserves the right to make changes in
design and specifications, and/or to make additions to or improvements in its products
without imposing any obligations upon itself to install them on products previously
manufactured.
This owner’s manual contains information applicable to newly constructed Bushtec
Performance Sport Trailers, procedures, hitches, parts and accessories pertaining thereto.
It is designed as a tool for information, education, and reference. While we make every
effort to make it as comprehensive as possible, it may not answer all your questions or
not contain information pertaining to older trailers. If this manual does not address your
questions or particulars regarding your trailer, please contact us by phone, fax, or e-mail.
We thank you for your purchase of a Bushtec trailer and want to keep you satisfied for
many miles. Remember this-we can fix anything but we can’t fix it if we do not know it
is broken.

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1. SAFE TOWING GUIDELINES
All of the employees at BUSHTEC wish to thank you for your purchase of the finest
touring cargo trailer made in the world. Please take a few moments to review the
contents of your owner’s manual to insure thousands of trouble-free miles of use.
Remember that this is only a guide and should be supplemented with your own regard for
safe operation.
CAUTION: FAILURE TO PERFORM WHEEL BEARING SERVICE AS
DESCRIBED HEREIN MAY CAUSE THE TRAILER TO TRACK UNDESIRABLY
AND WILL VOID WARRANTY!!!
WARNING: TOWING A TRAILER BEHIND A MOTORCYCLE INCREASES THE
LIKELIHOOD OF INJURY OR DEATH TO BOTH OPERATOR AND PASSENGER
DUE TO INCREASED RISK AND EXPOSURE. FAILURE TO OBSERVE AND
FOLLOW;
(A) ALL RULES OF THE ROAD AND LAWS OF THE LAND,
(B) MAINTENANCE AND OPERATION INSTRUCTIONS ASSOCIATED
WITH THIS TRAILER,
(C) POSTED SPEED AND ROAD CONDITION WARNINGS,
(D) SAFE RIDING PRACTICES AND PROCEDURES,
WILL FURTHER INCREASE THE RISK OF INJURY OR DEATH TO OPERATOR
AND PASSENGER.
We are aware of no current state or federal guidelines for pulling a trailer with a
motorcycle. We suggest when pulling and loading a trailer that you do not exceed the
manufacturers Gross Vehicle Weight limits.
When pulling a trailer with a motorcycle, extra distance must be allowed for stopping.
When cornering, use slower speeds and a wider angle of attack.
Use extra caution at all times, particularly if the road surface is wet or slippery.
Splitting lanes with a trailer is HIGHLY discouraged and is ILLEGAL in many states.
Behind most touring motorcycles, your mirrors are wider than your BUSHTEC trailer.
BUSHTEC supports the Motorcycle Safety Foundation. If you have never taken a
course, BUSHTEC highly recommends it! Contact the MSF office nearest you.

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2. LOADING AND TONGUE WEIGHTS
Tongue weight is a much-discussed aspect of trailer use. Too much is bad, not enough is
bad, so how do you determine the happy medium? Point in fact dictates that a trailer will
wander if tongue weight is not sufficient to give the trailer “direction”. Without
“direction”, all trailers will wander behind the tow vehicle and cause handling problems.
Insufficient tongue weight will result in erratic trailer handling. Excessive tongue weight
will cause coupler fatigue, hitch fatigue or failure and increased wear and tear on the tow
vehicles mechanical components.
Trailer Industry standards suggest a ratio of 10% to 15% of the trailers gross vehicle
weight (GVW-base weight of trailer and its cargo) be applied to the coupler as an ideal
tongue weight. This weight is routinely measured by using a bathroom scale or fish
scale, weighing the applied load at the ball or coupler. This weighing exercise must
allow that the coupler is at the installed or operational height to determine the actual
tongue weight during use.
Loading of cargo is a major function in determining tongue weight. Load placement and
distribution must be executed carefully and thoughtfully, with added consideration given
to additional weight in and on accessory items such as coolers and luggage racks.
Adding or subtracting load must be accomplished with the same care and thought as the
original loading was given, and tongue weight rechecked!
WARNING: ALWAYS LOAD CARGO SO THAT HEAVIEST ITEMS ARE
LOWEST AND DISTRIBUTED FRONT TO REAR. NEVER PUT THE HEAVIEST
ITEM AT THE REAR OF THE TRAILER, AS THIS WILL INCREASE THE
TRAILERS TENDENCY TO SWAY. LOADING THE TRAILER IN EXCESS OF
THE GVWR (gross vehicle weight rating) IS DANGEROUS AND COULD CAUSE
SERIOUS PERSONAL INJURY OR DEATH.
WARNING: IF THE TRAILER FAILS TO HANDLE IN A SAFE AND
PREDICTABLE MANNER, STOP! DO NOT OPERATE THE TRAILER UNTIL
YOU HAVE DETERMINED AND CORRECTED THE CONDITION OR PROBLEM.

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3. LID LATCH OPERATION, OPENING & CLOSURE
CAUTION:Do not slam the lid on any Bushtec trailer. All Bushtec trailers feature soft
closure lid systems. Slamming of the lid to close the trailer can result in damage or
breakage and failure of operation of the latch system.
NOTE: It is possible to lock the keys inside of your Bushtec trailer. Check that keys are
not inside the trailer prior to closing the lid.
TURBO+2
To Open: Push downward on the recessed logo area of the lid while pushing the lock
button in. While the lock button remains fully depressed, lift upward on the lid.
To Close: DO NOT SLAM. Bring the lid down and allow to set on the latch. Push lid
closed, the latch should snap and lid should not be able to be lifted open.
To Lock: Insert key into keyhole and rotate. Press button and check.
NOTE: Lock must be unlocked in order to open the lid on Turbo+2 model. It is possible
to lock the keys in the trailer. Check that you have your keys before closing the lid.
ROADSTAR
To Open: Push downward on the lid handle while pushing the lock button in. While the
lock button remains fully depressed, lift upward on the lid.
To Close: DO NOT SLAM. The latch features a two-stage rotary mechanism. Close the
lid and push down gently. This will engage the first stage. Then push down firmly to
engage the second stage, which will click. Pull up on handle to check lid is securely
closed. When the latch in fully engaged, the lid should have no movement.
To Lock: Insert key into keyhole and rotate. Push button to check.
CAUTION: The second stage of the latch must be engaged to keep the lid securely
closed.
QUANTUM
To Open: Push down on the back of the lid behind the third brake light or over either
foot of the aerowing if the trailer is equipped with the aerowing. This is to remove spring

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tension on the latch. Pull out on the paddle handle until the latch releases, hold, and lift
the lid.
NOTE: Due to spring tension generated by the seal, it may feel as though the paddle
handle is fully extended but the lid will not open. Pull out further on the paddle handle
and the latch will release.
To Close: DO NOT SLAM. The latch features a two-stage rotary mechanism. Bring lid
down and push gently to engage the first stage of the latch. Place your hand on the rear of
the lid behind the third brake light if equipped with the standard lid. If the trailer is
equipped with the aerowing, place the palms of your hands over the feet of the wing,
NOT the middle of the wing. Push down firmly until the second stage engages, which
will click. The lid should have no movement and should not be able to be lifted open
when the latch is properly closed
To Lock: Insert key into keyhole and rotate. Check paddle.
CAUTION: If the Quantum is equipped with the aerowing option, DO NOT push down
on the center of the wing. Push down over the feet of the wing, as marked. Failure to do
so could result in the wing cracking.
NOTE: All BUSHTEC Trailers have an extremely airtight seal. Opening and closing
the lid requires pushing down on the lid to remove tension created by lid seal
compression.
CAUTION: Do not allow plastic bags near the gas lid props, such as grocery bags.
Plastic can work its way into the seals and cause them to leak.

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4. ATTACHNG TRAILER TO MOTORCYCLE
NOTE: When connecting the trailer to the motorcycle, be sure that the trailer is loaded,
and that tongue weight and wheel alignment has been checked.
CAUTION: If the trailer is equipped with a tongue stand make sure it is in the upright
stowed position.
LOCKING HITCH PIN: (Smooth body, barrel style key)
Place the hole in captured ball of the heim joint over the hitch pin. Place the key into the
lock, hold the lock and turn the key ¼ turn clockwise to unlock. Place the lock on top of
the pin down against heim joint ball and turn the key ¼ turn counterclockwise to lock.
Remove the key. Lift up on the lock to insure lock is engaged on the pin. Cover keyhole
with supplied rubber cap which is designed to keep the keyway free of debris.
After securing the trailer to the motorcycle, connect the wiring harness, preferably run the
harness over the top of the chassis neck. Secure the safety chain to the safety chain
mount. Check all connections for completeness.
NOTE: The heim joint must be approximately perpendicular to the hitch pin or the lock
will not seat properly. If the lock does not seat, rotate the heim joint so that it is
perpendicular to the pin.
CAUTION: Failure to use the supplied rubber cap will result in dirt and debris settling
into the keyhole. This may prevent you from being able to insert the key and remove the
lock.
WARNING: IF THE TRAILER IS NOT SECURELY ATTACHED TO THE
MOTORCYCLE, IT COULD UNCOUPLE FROM THE MOTORCYCE. THE KEY
CAN BE REMOVED FROM THE LOCK REGARDLESS OF WHETHER OR NOT
THE LOCK IS ENGAGED ON THE HITCH PIN.
CAUTION:When the trailer is not in use, do not leave the lock on the hitch pin.
Remove it and store off of the hitch pin until its next use. Leaving the hitch lock in place
during operation without the trailer attached could lead to premature hitch lock fatigue
and/or failure.

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5. MAINTENANCE
The following section is broken into subsections, BEFORE EACH USE, AFTER 50
MILES, AFTER 500-1000 MILES, AT 2500 MILES AND EVERY 2500 MILES,
REMOVAL FROM STORAGE, and MISCELLANEOUS. Each operation will take a
maximum of 10 minutes to perform and will aid in the longevity of your investment.
BEFORE EACH USE AFTER 50 MILES AFTER 500- 1000 MILES AT 2500 AND EVERY 2500 MILES REMOVAL FROM STORAGE MISC.
COUPLER CONDITION
X X X
GENERAL HARDWARE INSPECTION
X X X
LUBRICATE HEIM JOINT
X X
LUBRICATE 360 DEGREE SWIVEL
X X
LUBRICATE SUSPENSION COLLARS
X X
CHECK TIRE PRESSURE AND WEAR
X X X
TONGUE HARDWARE
X X X
WHEEL SERVICE
X
COUPLER CONDITION
Check that the captured ball in the front of the heim joint moves freely without binding,
but does not have excessive play. Check that the 360-degree swivel has full movement

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with moderate resistance. There should be no fore and aft play in the swivel assembly.
When the trailer is attached, check your hookup to insure that the coupler is secure, your
lights are plugged in and that your safety chain is attached.
GENERAL HARDWARE INSPECTION
TOOLS REQUIRED
7/16, ½, 9/16 inch wrenches
Visually inspect all components for structural integrity, fitment, and completeness.
Check all hardware and fittings for proper tension.
HEIM JOINTLUBRICATION
TOOLS REQUIRED
Cartridge Grease Gun
Lubricate the captured ball via the zerk fitting in the side of the heim joint using good
quality grease designed for automobile use. Turn the captured ball while lubricating.
Inspect the heim joint for wear, that the captured ball is free, and that the heim is not
bent.
NOTE: The zerk fitting in the heim joint is NOT equipped with a check ball. Upon
removal of the grease gun, grease may backflow out of the zerk fitting. Allow to purge
and wipe off excess.
CAUTION: The heim joint can be bent if the captured ball is forced to travel beyond its
rotational limit. Approach steep incline changes (driveway to street) at an angle to allow
the swivel portion of the coupler to engage the change rather than the captured ball.
360-DEGREE SWIVEL LUBRICATION
TOOLS REQUIRED
Cartridge Grease Gun
7/8 inch Wrench
Lubricate the grease fitting on the underside of the tongue forward of the safety chain,
using a good quality grease designed for automobile use. While greasing the swivel,

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continuously turn the swivel using the 7/8-inch wrench placed on the heim joint to allow
grease to penetrate the mechanism.
NOTE: YOU MUST ROTATE THE HEIM JOINT ASSEMBLY CONTINUOUSLY
WHILE PUSHING GREASE INTO THE FITTING. FAILURE TO ROTATE WILL
NOT ALLOW GREASE TO PENETRATE SWIVEL ASSEMBLY.
SUSPENSION LUBRICATION
Lubricate the six sway bar collars on the underside of the chassis. Place 2-3 drops of a
good quality Teflon-based lubricant on each edge of each of the six points. Super Lube,
DuPont Multi-Use with Teflon or Dri-Slide are preferred lubricants. Super Lube is
available from BUSHTEC.
NOTE: Do not use any type of wheel bearing or lithium grease, chain lube or WD-40
for suspension lubrication. These lubricants will attract dirt and, because of their
viscosity, will not allow the suspension to operate properly.
TIRE PRESSURE
TOOLS REQUIRED
Calibrated Tire Gauge
Adjust 3.00x16 tires to 35 PSI cold, regardless of load. Improper inflation will increase
rolling resistance and decrease fuel mileage, as well as increase tire wear. Spin-balance
wheels annually or every 10,000 miles, whichever comes first. Failure to re-balance will
shorten tire life and result in irregular wear.

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CAUTION: Low tire pressure can cause undesired handling and will shorten tire life.
TONGUE HARDWARE
TOOLS REQUIRED
7/16, ½, 9/16 inch wrenches.
Check the tension on the two bolts which secure the tongue to the main chassis tube.
Check the two nuts on the third body support clamp at front of body and the two nuts
securing the third body support plate to the body. This is especially important with the
addition of the cooler package.
WHEEL SERVICE
TOOLS REQUIRED
15/16-inch wrench
Cartridge Grease Gun
Wire Brush
Medium Duty Threadlock (blue or green)
1. Refer to section regarding hub cover removal for instructions according to wheel
type.
2. Remove the 5/8-inch nylock axle nut from the spindle using a 15/16-inch wrench.
3. Lift trailer and pull out on hub to remove wheel.
4. Inspect integrity of wheel bearings by placing one finger into each bearing, lift wheel
and spin. If any binding, grinding, or looseness is detected, the bearing needs to be
replaced.
5. Clean the spindle threads with a wire brush to remove old Threadlock.
6. Place a light coat of good quality automotive grease on the unthreaded portion of the
axle shaft for water displacement and corrosion resistance.
7. Reinstall the wheel onto the axle shaft, with the balanced side facing in. Place two to
three (2-3) drops of medium duty (blue or green) Threadlock onto the axle threads.
NEVER USE RED THREADLOCK.
CAUTION: Do not allow the Threadlock to bond the wheel bearing to the spindle or
penetrate the wheel bearing. Excessive Threadlock can damage the internals of the
bearing.

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8. Install the axle nut and tighten with the wrench until it comes into contact with the
wheel bearing. At this point the wrench will not want to turn any further with
minimal force. Turn the wrench an additional 1/16 to 1/8 of a turn to place a preload
on the wheel bearing. On the standard cast mag wheel, this is ½ to ¼ the distance
between two spokes.
9. Spin the wheel to insure that it spins freely and does not stop abruptly. If the wheel
stops abruptly, the axle nut is too tight. Grab the top of the wheel and attempt to
move it in and out, to check for lateral play. If the wheel exhibits lateral play, the
axle nut is too loose.
WARNING: DO NOT APPLY EXCESS PRELOAD. EXCESS TORQUE WILL
RESULT IN WHEEL BEARING FAILURE. THE WHEEL MUST NEVER HAVE
ANY LATERAL MOVEMENT.
10. Reinstall hub covers. Refer to section regarding hub cover for installation
instructions according to wheel type.
NOTE: Bushtec uses a single row, dual sealed roller bearing which is a 6203 series.
This bearing has a 5/8 inch (15.875 mm) ID. When purchasing replacement bearings
from a source other than Bushtec, specify the ID to assure that it is the correct bearing.
CAST WHEEL HUB COVER, CHROME HEX STYLE
TOOLS REQUIRED
5/64” Allen wrench

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Removal: Using 5/64” Allen wrench, loosen the three Allen head set screws two to three
turns. Pull hub cover off of wheel hub.
Installation: Check that the setscrews do not protrude inside hub cover. Place hub cover
over hub of wheel and push on until three internal stops make contact with the hub face.
Using the 5/64” Allen wrench, tighten the three Allen head set screws in an alternating
pattern until snug against the hub of the wheel.
CAUTION: Do not overtighten! Make sure setscrews are snug against hub and pull on
cover to check proper tensioning. Spin the wheel to make sure the hub cover is on
straight and does not contact any other parts.
FORGED WHEEL HUB COVER
TOOLS REQUIRED
3/16” Allen wrench
Removal: Using 3/16”Allen wrench, loosen the single Allen head set screw until almost
removed from hub cover. Pull hub cover off of wheel hub.
Installation: Check that the setscrew does not protrude inside hub cover. Place hub cover
over hub of wheel and push on until fully seated against hub face. Using the 3/16”Allen
wrench, tighten the single Allen head set screw until snug against the hub of the wheel.
CAUTION: Do not overtighten! Make sure setscrew is snug against hub and pull on
cover to check proper tensioning. Spin the wheel to make sure the hub cover is on
straight and does not contact any other parts.
REMOVAL FROM STORAGE
Perform the designated services according to the chart.
MISCELLANEOUS
Tires should be checked for signs of weathering, checking, cracking, or irregular wear. If
tires exhibit any of the above signs or have less than 1/8 inch of tread on the middle of
the tread face, the tires should be replaced.

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6. SUSPENSION OPERATION
The BUSHTEC air suspension should be inflated so as to maintain a constant vertical
alignment of the wheel with the road surface, regardless of pressure. As your cargo loads
change, it may be necessary to increase or decrease the suspension air pressure and roll
the trailer to determine the correct wheel alignment.
Operation: Inflate the suspension so that the wheels are in the “positive camber” position
(wheels cambered out at top). Place cargo load inside trailer, establishing proper tongue
weight. While walking the trailer forward simultaneously release air until the wheels are
properly aligned. On Roadstar, Quantum, Quantum “GL”, and most Turbo+2 models,
proper wheel alignment is achieved with a straight up wheel alignment, or neutral
camber. On Turbo+2 models equipped with the Aerowing aerodynamic lid wing, proper
alignment is achieved when the wheels are slightly cambered out at the top to account for
downforce generated by the Aerowing at speed (2-4 degrees).
Top pair shows positive
camber.
Center pair shows correct
neutral camber.
Bottom pair shows
negative camber.
CAUTION: The BUSHTEC air suspension is a high pressure/ low volume system and
should NEVER be adjusted with gas station air systems. These systems typically run
unregulated line pressure, making it difficult to control airflow. We recommend the use
of the PROGRESSIVE AIR PUMP with GAUGE, available from BUSHTEC.
NOTE: Always roll the trailer after inflation changes to determine the motive position of
the wheels. Pressure is an irrelevant measure of suspension inflation, and should only be
used for a reference. The suspension system is capable of 150 PSI.
WARNING: OPERATION OF THE TRAILER WITHOUT SUFFICIENT
SUSPENSION AIR PRESSURE (NEGATIVE CAMBER) MAY CAUSE DAMAGE

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TO THE SUSPENSION COMPONENTS AND ROUGH HANDLING
CHARACTERISTICS. OVERINFLATION WILL CAUSE JUMPY HANDLING AND
TRACKING IN ADDITION TO THE DANGER OF AIR SHOCK SEAL FAILURE
AND THE INABILITY TO MAINTAIN AIR PRESSURE IN THE SUSPENSION.
NOTE: Suspension operation will be stiff during the first 500 to 1000 miles making
adjustment touchy. Stiffness will subside after 500 to 1000 miles.
7. MOUNTING AND OPERATION OF TONGUE STAND
TOOLS REQUIRED
½ inch Wrench
Mounting: The tongue stand should be mounted so that the end of the leg in the retracted
position is no lower than the bottom bend in the chassis neck. The higher it can be
mounted, the more clearance you will achieve, but it should not be so high that the trailer
can be attached to the motorcycle while on the centerstand and the tongue stand down.
Operation: To stow the tongue stand, pull downward on the leg until the pin is clear of
the notch and push backward until the pin engages the notch at the upper rear. To deploy
the stand, pull the leg toward the back of the trailer until the pin clears the rear notch and
fold the leg downward until the pin engages the bottom notch.
8. MOUNTING AND OPERATION OF COOLER PACKAGE
TOOLS REQUIRED
½ inch Wrench
Mounting: Mount the cooler rack with the stepped support facing towards the rear of the
trailer. On all 1998 and later Turbo+2 trailers, all Quantum, and Roadstar models, the
front clamp should fit around the neck just behind the skid hoop on the underside of the
tongue. Place clamp around chassis neck from underside, place saddle over top of neck
with clamp end through holes. Next, set rack over clamp assembly with clamp ends

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through holes on rack and secure with nuts. Install clamp assembly in the same order-as
above for back end of rack. Level rack and tighten nutsevenly in an alternating pattern,
until snug. Check that rack is secure. After installing the rack, place the cooler and cover
on the rack and snap the cover down around the rack. On pre-1998 Turbo and Ultimate
trailers, install cooler rack so that with the cooler in place and the trailer lid open, there is
approximately a ½ to 1-inch gap between the cooler and lid. Carefully open the trailer lid
to insure that the trailer lid or luggage rack does not rub on the cooler cover. If the cooler
is too close, loosen the cooler rack hardware and move it away from the front of the
trailer body until proper clearance is achieved.
CAUTION: The cooler and the lid cannot be opened at the same time on some Turbo
trailers.
CAUTION: When backing the motorcycle with the trailer attached, it is possible to
“jackknife” and cause the cooler to make contact with the rear end of the motorcycle.
Have someone watch the back of the motorcycle during these operations.
Cooler Operation: To open the cooler, lift the top skirt over the zipper. Grab the zipper
by the tassel and pull all the way around front and to the opposite side rear. Fold back
cover and open cooler lid by lifting on lid recess at front. To close, close cooler lid and
fold cooler cover over top to cooler. Grab tassel by zipper and pull all the way around
the front and to the opposite side rear. Fold down skirt on top of cooler cover.
CAUTION: Failure to close cooler cover can result in damage to finish by cover.
Drain Operation
To Remove: Lift the brass handle until it is straight up, and lift plug out.

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To Install: Place plug in drain hole and fold handle over. This compresses the plug
between the top and bottom plates and causes the plug to expand. You should not be able
to pull the plug out of the hole easily with the handle folded over.
To Adjust: If the drain leaks, adjust as follows; with lever folded so that it points
upward, hold the rubber body and metal plate at the bottom of the drain. Tighten handle
by turning clockwise, like a bolt 1/8 to ¼ of a turn at a time. If the handle cannot be
folded down, the handle needs to be loosened by turning counterclockwise 1/8 to ¼ turn
at a time.
9. GARMENT BAG (TURBO+2, QUANTUM, and QUANTUM “GL”) LID BAG
(ROADSTAR)
TURBO+2, QUANTUM, and QUANTUM “GL” GARMENT BAG
The garment bag is secured to the steel lid frame via snaps on the garment bag around its
perimeter. All of the snaps except for the top center snap on the garment bag are standard
snaps. The top center snap is a locking snap, identified by the writing “PUL THE DOT”
on the face. The locking snap is installed bottom first and removed top first.
ROADSTAR LID BAG
The Roadstar Lid Bag is secured to the steel lid frame via snaps on the lid bag around its
perimeter. All of these snaps are standard snaps.
10. REMOVAL AND INSTALLATION OF STONE PROTECTOR BRA
TURBO+2 AND ROADSTAR
These models each have 2 locking snaps, one on each side of the bra. The locking snap is
identified by the writing “PULL THE DOT” on the face of each locking snap stud. On
the Turbo+2 and Roadstar with Standard fenders, the locking snap is removed bottom
first and installed top first. On the Roadstar with the GT fenders, the locking snap is
removed front first and installed rear first. The locking snap goes on and comes off over
the snap stud at an angle.
The stone protector bra fits tightly on all models and is made more pliable by warming
the bra prior to installation. This can be accomplished by laying the bra in the sun.
CAUTION: The stone protector bra should be removed when washing the trailer
regularly to remove debris and grit from between the paint and vinyl. Failure to do so
may result in abrasion and damage to the painted finish.

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11. LUGGAGE RACK
TURBO+2
The luggage rack for the Turbo+2 consists of 4 rails. The luggage rack has a maximum
weight rating of 75 pounds, spread evenly over the 4 rails.
QUANTUM
The luggage rack for the Quantum consists of 4 rails. The luggage rack has a maximum
weight rating of 75 pounds, spread evenly over the 4 rails.
ROADSTAR
The luggage rack for the Roadstar consists of a chrome tubular steel rack. The luggage
rack has a maximum weight rating of 25 pounds.
12. INTERIOR LIGHT
The interior light is run via its own wire in the primary harness. During a typical
installation, it is connected into the running lights on the motorcycle. This way, if the
light is left on but the ignition is turned off, the light will go off. The light can be hooked
to the accessory terminal or directly to the battery, but must be fused and adds
opportunity for battery drain if the light is left on.
CAUTION: The interior light should be turned off when not in use to avoid unnecessary
battery discharge.
WARNING: IF LEFT ON FOR EXTENDED PERIODS, THE INTERIOR LIGHT
LENS CAN BECOME EXTREMELY HOT. DO NOT TOUCH THE LENS AND DO
NOT ALLOW ITEMS TO MAINTAIN CONTACT WITH THE LENS, AS THEY
MAY MELT OR BE DAMAGED.
13. WIRE HARNESS COLOR CODES
Following are the primary wiring harness functions identified by color.
GREEN: RUNNING & TAILLIGHTS
WHITE: CHASSIS OR BATTERY GROUND
BLUE: BRAKE LIGHTS
YELLOW: RIGHT TURN SIGNAL