This document is an owner's manual for Bushtec Performance Sport Trailers, specifically covering the Turbo+2, Roadstar, Quantum Sport, and Quantum "GL" models. It provides comprehensive information on the safe operation, maintenance, and specifications of these motorcycle trailers.
Function Description:
Bushtec Performance Sport Trailers are designed to be towed behind motorcycles, providing additional cargo and luggage capacity for touring. They are engineered to offer stable and predictable handling when properly loaded and maintained. The manual emphasizes that no motorcycle manufacturer has approved or endorsed Bushtec products, and using a trailer may void a motorcycle's warranty and increase the risk of injury in an accident.
Important Technical Specifications:
The manual includes a "Specifications" section detailing key measurements and capacities for each model:
- Base Weight (LBS):
- Roadstar: 125 lbs
- Turbo+2: 125 lbs
- Quantum Sport & "GL": 150 lbs
- Cargo Area Dimensions (inches) (narrowest interior points):
- Height:
- Roadstar: 18 inches
- Turbo+2: 16 inches
- Quantum Sport & "GL": 16 inches
- Length:
- Roadstar: 38.5 inches
- Turbo+2: 43 inches
- Quantum Sport & "GL": 45 inches
- Width:
- Roadstar: 23 inches
- Turbo+2: 23 inches
- Quantum Sport & "GL": 23 inches
- Maximum Cargo Dimensions (inches) (widest exterior points):
- Height:
- Roadstar: 24 inches
- Turbo+2: 23 inches
- Quantum Sport & "GL": 24 inches
- Length:
- Roadstar: 52 inches
- Turbo+2: 54 inches
- Quantum Sport & "GL": 54 inches
- Width:
- Roadstar: 40 inches
- Turbo+2: 38 inches
- Quantum Sport & "GL": 38 inches
- Volume (Cubic Feet):
- Roadstar: 21 cubic feet
- Turbo+2: 25 cubic feet
- Quantum Sport & "GL": 26 cubic feet
- Overall Length (inches):
- Roadstar: 87 inches
- Turbo+2: 87 inches
- Quantum Sport & "GL": 89 inches
- Load Capacity (GVWR - Gross Vehicle Weight Rating):
The manual also specifies that Bushtec uses a single-row, dual-sealed roller bearing (6203 series) with a 5/8 inch (15.875 mm) ID for the wheels. The suspension system is capable of 150 PSI.
Usage Features:
- Load Limit Determination: Users are instructed to locate the cargo load capacity on the trailer's placard (next to the VIN on the tongue) and ensure the combined weight of luggage and cargo does not exceed this figure.
- Safe Towing Guidelines: Emphasizes increased stopping distance, slower speeds and wider angles for cornering, caution on wet/slippery surfaces, and discourages lane splitting. It also recommends adhering to all rules of the road, maintenance instructions, posted warnings, and safe riding practices.
- Loading and Tongue Weights: Recommends a tongue weight ratio of 10% to 15% of the trailer's Gross Vehicle Weight (GVW). Heaviest items should be loaded lowest and distributed front to rear to prevent sway. Loading in excess of GVWR is dangerous.
- Lid Latch Operation:
- Turbo+2: Push down on the recessed logo area while pushing the lock button, then lift the lid. Close gently, allowing the latch to snap. Lock by inserting and rotating the key.
- Roadstar: Push down on the lid handle while pushing the lock button, then lift the lid. Close gently, engaging the two-stage rotary mechanism until it clicks. Lock by inserting and rotating the key.
- Quantum: Push down on the back of the lid (behind the third brake light or over aerowing feet if equipped) to release spring tension, then pull out the paddle handle and lift the lid. Close gently, engaging the two-stage rotary mechanism until it clicks. If equipped with an aerowing, push down over the feet of the wing, not the center.
- All models feature soft-closure lid systems, and slamming the lid is cautioned against. Keys can be locked inside.
- Attaching Trailer to Motorcycle: Involves placing the heim joint's captured ball over the hitch pin, locking the pin with a barrel-style key, connecting the wiring harness (preferably over the chassis neck), and securing the safety chain. The heim joint must be approximately perpendicular to the hitch pin for proper lock seating. A rubber cap is provided for the keyhole to prevent debris.
- Suspension Operation: The Bushtec air suspension should be inflated to maintain constant vertical wheel alignment. Pressure is adjusted by increasing or decreasing air and rolling the trailer to determine correct alignment. On Roadstar, Quantum, and most Turbo+2 models, neutral camber (straight up wheel alignment) is ideal. Turbo+2 models with an Aerowing require slight positive camber (wheels cambered out at the top) to account for downforce. Gas station air systems are not recommended for adjustment; a Progressive Air Pump with Gauge is suggested.
- Tongue Stand Operation: To stow, pull the leg down until the pin clears the notch, then push backward until the pin engages the upper rear notch. To deploy, pull the leg toward the back until the pin clears the rear notch, then fold the leg downward until the pin engages the bottom notch.
- Cooler Package Operation: The cooler rack mounts with the stepped support facing the rear. The front clamp fits around the chassis neck behind the skid hoop. The cooler and lid cannot be opened simultaneously on some Turbo trailers. When backing, watch to prevent "jackknifing" and cooler contact with the motorcycle. To open the cooler, lift the top skirt, pull the zipper, fold back the cover, and lift the lid.
- Garment Bag/Lid Bag: Secured to the steel lid frame via snaps. Turbo+2, Quantum, and Quantum "GL" models have a locking snap ("PUL THE DOT") as the top center snap. Roadstar models use standard snaps.
- Stone Protector Bra: Fits tightly and can be made more pliable by warming. Turbo+2 and Roadstar models have two locking snaps on each side.
- Luggage Rack Weight Ratings:
- Turbo+2: 75 pounds (spread evenly over 4 rails)
- Quantum: 75 pounds (spread evenly over 4 rails)
- Roadstar: 25 pounds (chrome tubular steel rack)
- Interior Light: Wired into the motorcycle's running lights for automatic shut-off with ignition. Can be connected to an accessory terminal or battery, but requires fusing and risks battery drain if left on. The lens can become extremely hot if left on for extended periods.
- Wire Harness Color Codes:
- GREEN: Running & Taillights
- WHITE: Chassis or Battery Ground
- BLUE: Brake Lights
- YELLOW: Right Turn Signal
- BROWN: Left Turn Signal
- BLACK: Interior Light
Maintenance Features:
The manual outlines a detailed maintenance schedule:
- Before Each Use:
- Coupler Condition: Check for free movement without binding, and no excessive play.
- Check Tire Pressure and Wear.
- After 50 Miles:
- General Hardware Inspection.
- After 500-1000 Miles:
- Lubricate Heim Joint.
- Lubricate 360 Degree Swivel.
- Lubricate Suspension Collars.
- Tongue Hardware.
- Wheel Service.
- At 2500 Miles and Every 2500 Miles:
- Coupler Condition.
- General Hardware Inspection.
- Lubricate Heim Joint.
- Lubricate 360 Degree Swivel.
- Lubricate Suspension Collars.
- Check Tire Pressure and Wear.
- Tongue Hardware.
- Wheel Service.
- Removal From Storage:
- Perform all designated services.
- Miscellaneous:
- Tires: Check for weathering, checking, cracking, or irregular wear. Replace if tread is less than 1/8 inch in the middle.
Detailed Maintenance Procedures:
- Coupler Condition: Ensure the captured ball moves freely without binding and the 360-degree swivel has full movement with moderate resistance, no fore and aft play.
- General Hardware Inspection: Visually inspect all components for structural integrity, fitment, and completeness. Check all hardware and fittings for proper tension. Tools required: 7/16, 1/2, 9/16 inch wrenches.
- Heim Joint Lubrication: Lubricate the captured ball via the zerk fitting using a cartridge grease gun and automotive grease. Turn the ball while lubricating. Inspect for wear and ensure it's not bent. The zerk fitting is not equipped with a check ball, so grease may backflow. Caution: Avoid bending the heim joint by forcing the ball beyond its rotational limit, especially on steep inclines.
- 360-Degree Swivel Lubrication: Lubricate the grease fitting on the underside of the tongue using a cartridge grease gun and automotive grease. Continuously turn the swivel with a 7/8-inch wrench on the heim joint while greasing to ensure penetration.
- Suspension Lubrication: Apply 2-3 drops of a good quality Teflon-based lubricant (e.g., Super Lube, DuPont Multi-Use with Teflon, or Dri-Slide) to each edge of the six sway bar collars on the underside of the chassis. Do not use wheel bearing grease, lithium grease, chain lube, or WD-40.
- Tire Pressure: Adjust 3.00x16 tires to 35 PSI cold, regardless of load. Spin-balance wheels annually or every 10,000 miles. Low pressure can cause undesired handling and shorten tire life.
- Tongue Hardware: Check tension on the two bolts securing the tongue to the main chassis tube, and the two nuts on the third body support clamp and plate. Tools required: 7/16, 1/2, 9/16 inch wrenches.
- Wheel Service:
- Remove hub cover.
- Remove the 5/8-inch nylock axle nut with a 15/16-inch wrench.
- Lift trailer and remove wheel.
- Inspect wheel bearings for binding, grinding, or looseness; replace if detected.
- Clean spindle threads with a wire brush.
- Apply a light coat of automotive grease to the unthreaded portion of the axle shaft.
- Reinstall wheel with balanced side facing in. Apply 2-3 drops of medium duty Threadlock (blue or green) to axle threads (NEVER use red Threadlock). Caution: Do not allow Threadlock to bond to or penetrate the wheel bearing.
- Install axle nut and tighten until it contacts the bearing, then an additional 1/16 to 1/8 turn to preload. For standard cast mag wheels, this is 1/2 to 3/4 the distance between two spokes.
- Spin wheel to ensure free movement and no abrupt stops. Check for lateral play by moving the top of the wheel in and out. No lateral movement should be present. Warning: Do not apply excess preload to avoid bearing failure.
- Reinstall hub covers.
- Hub Cover Removal/Installation:
- Chrome Hex Style (Cast Wheel): Loosen three Allen head set screws (5/64" Allen wrench) 2-3 turns to remove. For installation, ensure screws don't protrude, push cover until internal stops contact hub face, then tighten screws in an alternating pattern until snug.
- Forged Wheel: Loosen single Allen head set screw (3/16" Allen wrench) until almost removed to pull cover off. For installation, ensure screw doesn't protrude, push cover until fully seated, then tighten screw until snug.
- Caution: Do not overtighten set screws.
- Taillight & Turnsignal Bulb Replacement:
- Turbo+2 & Roadstar: Loosen and remove screws holding the lens from the outside of the trailer.
- Quantum Sport: Open trailer, remove taillight recess cover, twist out bulb base holders from the back.
- Quantum "GL": Open trailer, remove taillight recess cover, remove three nuts from light housing studs, carefully remove housing, twist out bulb holders. Reapply sealant upon reinstallation.
- Third Brake Light: Use a small pointed probe to remove red caps covering securing screws. Loosen and remove two Phillips head screws to access the lens. Check insert position before reinstallation.
- Heim Joint Adjustment/Replacement: (Only if joint turns freely or has fore/aft play). Tools required: 15/16" wrench, 7/8" wrench, wire brush, medium strength Threadlock.
- Hold heim joint with 7/8" wrench, turn jam nut (between joint and tongue) clockwise until it stops. Turn heim joint counterclockwise to remove it.
- Clean exposed threads with a wire brush.
- Apply 2-3 drops of new Threadlock to threads, install heim joint by hand, turn clockwise until 1-2 threads are visible between joint and jam nut.
- Turn jam nut counterclockwise until it meets the heim joint and tighten against each other.
- Check for no fore/aft play and rotation under moderate hand pressure. Tension is adjusted by varying jam nut tightness.
General Finish Care:
- For the first 90 days, no wax should be used as the paint is curing.
- Use automotive wash solutions, not dishwashing liquids, which can break down paint oils and waxes.
- For painted (basecoat-clearcoat) and standard white gelcoat finishes, waxes and polishes designed for clearcoat finishes are recommended.
- Remove the stone protector bra regularly when washing to prevent debris abrasion.
- Chrome surfaces: Clean with soap and water and nonabrasive chrome cleaners. Avoid abrasive cleaners.
- Vinyl materials: Wash both sides with soap and water, allow to dry before reinstallation. Use vinyl treatments sparingly. Keeping them clean and dry ensures longevity.
- Three (3) Year Warranty: Covers hard parts (air shocks, gas lid props, wheels, wheel bearings, fiberglass, paint, electrical harness, light housings, non-soft trim) against defects in materials and workmanship under normal use.
- Limited Lifetime Warranty: Covers the chassis (main frame, A-arm assemblies, sway bar, body mounts) against defects in materials and workmanship under normal use for the duration of ownership by the original retail purchaser.
- One (1) Year Warranty: Covers Bushtec trailer hitches and trailer accessories (soft goods, luggage racks, bumpers, other accessory items) against defects in materials and workmanship under normal use.
- Exclusions: Tires and tubes (warranted by their manufacturers), defects from abnormal use (negligence, accident, abuse, misuse, neglect, overload), unauthorized repairs/alterations, acts of God, or normal wear items.
- Transportation Costs: Excluded from warranty coverage.
- Prior Written Consent: Required for repairs to qualify for reimbursement. Defective parts must be sent prepaid to Bushtec.
- Warranty Registration: The signed warranty registration card must be postmarked within 30 days of purchase to validate the warranty. Failure to do so voids all express warranties.
- Limitations: Bushtec's sole responsibility is to repair or replace parts at its factory. Maximum liability is limited to the original purchase price of the trailer (less taxes, freight, shipping, registration fees, labor, non-attached accessories).
- Disclaimers: All other express and implied warranties (including merchantability and fitness for a particular purpose) are disclaimed or limited to the stated warranty periods.
- Claim Procedure: Within five days of discovering a problem, contact the Bushtec dealer (if purchased from one) or Bushtec Manufacturing & Sales, Inc. (if purchased directly). All claims must be registered in writing. Defective parts must be returned within 30 days of approval. Bushtec will not reimburse for repairs without prior written approval. Repairs made at the factory are warranted for one year; outside repairs are not.
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