Northstar Trailers SPORTSTAR III - Manual (Page 4)

This trailer requires inverted assembly. (Assembled upside-down). Start by turning
the trailer frame upside-down so the trailer deck is facing the ground. Use a table
robust enough to support the weight of the trailer frame and high enough to elevate
the frame to waist-height, or place the corners of the frame on buckets, or use
sawhorses to elevate each end.
CAUTION: This trailer is heavy. More than one person is required to flip the trailer
frame and assembly this trailer. Personal injury may occur if you try to assemble this
trailer alone.
STEP 1: LEAF SPRING & AXLE ASSEMBLY
a.
Flip the trailer frame (1) upside-down, and place the frame on a waist-high
table or other elevated supports in order to facilitate assembly.
b.
Position the leaf-spring (7) on the frame’s spring casing (welded to the
frame) so the eye in the leaf-spring is positioned toward the front of the
trailer and aligns with the bolt eyehole in the spring casing.
c.
Fasten the leaf-spring to the casing with 3 ½” pin-bolt (D) and a large nut (H)
by inserting the bolt through the leaf-spring and through the eyeholes in the
casing. (Leave tension loose to allow play when aligning the axel; you will
securely tighten bolts in step “i”.)
d.
Secure the hooked end of the leaf-spring to the casing by running a 3 ½” pin-
bolt (D) through the eyeholes of the leaf-spring casing and over the flat side
of the leaf-spring. Fasten the bolt with a large nut (H).
e.
Lay the axel (8) on top of the leaf-springs, and align the holes in the axel
knobs with the posts on the leaf-springs. The axle will lie snug on top of the
springs.
FASTEN AXLE TO LEAF SPRINGS
f.
Take two U-bolts (A) and slide them over the axle, so the bolts hang over the
axle and on both sides of the leaf-springs. Attach the spring-plate (B) to the
U-bolts using the small locknuts (V), and then tighten the locknuts to finger-
tightness.
g.
Once all of the locknuts are on the U-bolts, tighten the locknuts in alternating
sequence in order to ensure an even, level plate pressure.
h.
Continue to tighten the locknuts until the spring-plate just begins to bend
and conform to the shape of the leaf-spring. (Approximately 35 ft-lbs of
torque).
i.
Securely tighten the bolts from step “c” and “d”. After tightening the bolts,
insert a cotter-pin (M), then secure the cotter-pin by bending at least one leg
to 90 degrees.