Honda GL1800 Trailer Hitch Standard & Deluxe Vertical Receiver Hitch System PDF Installation Instructions

1. Place the motorcycle on its centerstand on level ground. Remove the four bolts in the seat handles with a 6mm Allen head socket and remove the seat. NOTE: The rubber bushings inside the seat may fall out during removal; Make sure they are in place upon reassembly.
2. Remove both side covers.
3. Remove the (5) five bolts in the rear fender (license plate panel, between saddlebags) with a 5mm Allen head socket. Remove the rear fender. NOTE: The fifth bolt is behind the license plate.
4. Remove the (3) three bolts in the passenger floorboard holder cover with a 5mm Allen head socket. Remove the cover and repeat for other side.
5. Remove the (2) bolts in the rear saddlebag guard with a 12mm socket. Remove the saddlebag guard and repeat for other side.
6. Remove the bolt in the muffler hanger using a 12mm socket. Repeat for other side.
7. Loosen, but do not remove, the muffler clamps using a 6mm Allen head socket. Rotate the mufflers down slightly to allow the hitch hoop to slide between the mufflers and the saddlebags.

Remove the lower front bolt of the saddlebag subframe; located behind the saddlebag guard you removed earlier, using a 12mm socket. Install the supplied 8mm x 35mm bolt using a 13mm socket. Thread the bolt all the way into the frame and tighten this bolt to your service manuals specification. You will attach a nut to this bolt later. Repeat for other side.
9. Loosely assemble the hoop sides and the receiver center section using the supplied 3/8-16 x 1’ bolts and nylock nuts. NOTE: Looking from the rear of the bike, the receiver center section should have the embossed “Bushtec” on the top left. The left hoop side should have the single bend with strut hole on top and the right hoop side should have three bends with the strut hole on top also. Install the supplied hardware with the bolts running from t he inside to the outside. Do not tighten yet.

10. Slide the hoop in from the rear of the bike, above the mufflers and below the saddlebags. NOTE: You may want to cover the exhaust tips to prevent scratching them. Have your assistant hang the front of the hoop sides onto the bolts that you installed in the last step and make sure that they pass through the holes in the front of the hoop. Loosely attach an 8mm standard nut to the bolts to keep the hoop in place. The hoop will now hang freely. Install the (2) two U-bolts around the subframe, through the “ears” on the hoop sides (it may be necessary to spread the U-bolts slightly to fit around the subframe tube). Install the backing plates and ¼”-20 Nylock nuts onto each U-bolt. Do not tighten at this time.
NOTE: The threaded ends of the U-bolts should be facing the ground with the backing plate and Nylock nuts on the bottom of the hoop ears.

11. CAUTION: COMPLETE THIS STEP ONE SIDE AT A TIME. Remove the bolt in the top of the saddlebag subframe using a 12mm socket and wrench. NOTE: This is the bolt at top-rear of the main frame, just in front of the trunk, under the seat. Install the supplied 5/16”-18 x 2-½” bolt and ¼” washer from the outside of the frame to the inside. Slide the strut down and in-between the saddlebag and inner fender with the angled end on top, and the straight end pointing towards the rear. With the bolt in place, slide the supplied 3/8” spacer and then the strut onto the bolt, followed by another ¼” flat washer and Nylock nut. From the outside in, you should see the bolt, washer, subframe, mainframe, spacer, strut, washer and nut.

Attach the bottom end of the strut to the tab on the hoop platform using the (2) two supplied 5/16-18 x 3/4” bolts and nylock nuts. The strut should be on the inside of the hoop tabs with the bolt running from the inside out. Do not tighten at this Assembly of all the hitch components is now complete. You must tighten all components
1. Tighten the (4) four 3/8-16 x 1” bolts at the receiver section flanges using a 9/16” socket and wrench.
2. Align (center) the receiver center section left and right then tighten the (4) four ¼”-20 Nylock nuts on the U-bolts on both hoop sides using a 7/16” wrench until there is an equal length of thread showing on each U-bolt.
4. Tighten the (2) two lower strut bolts using a ½” socket and wrench. NOTE: The struts should be on the inside of the hoop platform tabs.
5. Apply the manufactures recommended amount of blue Loctie 242 or similar removable threaded lock onto the (2) two supplied 8mm nuts and install them onto the bolts you installed earlier at the front of the hoop. Tighten these nuts using a 13mm wrench.

WIRING INSTRUCTIONS
NOTE: If your trailer is equipped with combined turn signal and brake lights and/ or a 4 pin harness, a Trailer Light Converter will be required to complete the installation. NOTE: The isolator package you receive with your new hitch comes with generic wiring instructions. The instructions you are holding are more specific to the Honda GL1800 although wire routing, connections and isolator location is left up to the individual installer. These instructions are a guide through the procedure. If you purchased this hitch with a new BUSHTEC trailer, you will have received a 4’ bike side wire harness with the trailer. If you need a new harness, they are available from the factory at an additional cost. If you are using this hitch with anything other than a BUSHTEC trailer, you will need to purchase the appropriate plug and sufficient length of wiring to reach the isolator package from your local parts store or your trailers manufacturer.

NOTE: The rear fender should still be off of the motorcycle. However, you may need to put the fender back into position to gauge the distance of wire you will need exposed as described below. If you need or want to install the fender, you will need to remove the receiver head, install the fender (without the screws) then reinstall the receiver head. This will help in familiarizing yourself with the hidden hitch.
1. (BUSHTEC APPLICATION) Attach the plug body of the bike side harness within 2- 3 inches of the hitch pin using wire ties, electrical tape or a fastener of your choice.
2. (ALL OTHER APPLICATIONS) Attach your plug body in a suitable location that, once connected to the trailer, allows sufficient movement in the trailer harness. (I.e. Too long or to short, the harness will drag the ground or disconnect respectively)
3. Run the bike side harness up the left side of the bike to the underside of the trunk. Fasten the harness so that it does not interfere with the movement of the trailer, exhaust pipe, rear tire or get in the way of reassembling your motorcycle.
4. Plug the supplied subharness into the supplied relay package using the 4 pin connector. The subharness will plug in between the factory Honda 2-pin and 3-pin connectors underneath the trunk for the saddlebag and trunk lighting. Locate the black rubber boot which covers the connectors. Slide it to the side.
5. Locate the red Honda 3-pin connector with the ORANGE wire. Disconnect the two halves and connect the subharness 3-pin connectors with the BROWN wire to each end. NOTE: Make sure that you plug both ends of the connectors into both sides of the subharness.
6. Locate the blue Honda 3-pin connector with the LIGHT BLUE wire. Disconnect the two halves and connect the subharness 3-pin connectors with both the GREEN and YELOW wires.
7. Locate the red Honda 2-pin connector. Disconnect the two halves and connect the subharness 2-pin connector.
8. Position the relay block on the shelf created by the rear inner fender. Clean the surface with the supplied wipe and mount using the double sided adhesive tape on the relay block. NOTE: Do not use the Honda 5 amp accessory circuit for 12V connection of the trailer relay block. It is not capable of handling the load. Route the large red and black wires to the battery under the trunk and along the left upper frame rail. Connect the black wire to the battery ground terminal using the supplied eyelet connector. NOTE: Remove the 30 amp main fuse from the fuse holder prior to establishing battery connections.
9. Connect the supplied fuse holder to the battery positive terminal. Now connect the free side of the fuse holder to the red wire from the relay block.
10. Use the supplied black plastic split loom to cover the power and ground wires as needed.
11. (BUSHTEC APPLICATION) The BUSHTEC harness contains a Sixth wire (the black wire), which operates the interior light. BUSHTEC recommends combining the black wire with the green running light wire so that the interior light operates only when the running lights are functioning, otherwise you may drain your battery if the light is left on. If you wish to be able to operate the interior light at any time without turning on the ignition, you will need to connect the black wire of the trailer harness directly to the positive (+) terminal of the battery with the appropriate inline fuse (not supplied).

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