Northstar Trailers SPORTSTAR I - Manual (Page 5)

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 (8) 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 (G)
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 (G).
e.
Lay the axel (9) on top of the leaf-springs, and align the holes in the axel 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 (C), 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 (K), then secure the cotter-pin by bending at least one leg
to 90 degrees.