KARAVAN TRAILERS, INC.
100 KARAVAN DR. P.O. BOX 27 FOX LAKE, WI 53933
PHONE (920) 928-6200 FAX (920) 928-6201

ACTION REQUIRED
PRODUCT SERVICE BULLETIN
For Immediate Distribution
Dear Bayliner Dealer:
When a Karavan model USTM-6000-TDB10-78 is packaged under a Bayliner model
Element XR7 we’ve discovered there is too great of a distance between the outboard
motor skeg (motor tilted UP/tow position) and the trailer taillights. This distance is
greater than certain state laws allow.
We have created a new bunk kit which will include another set of taillights mounted to
the end of the carpeted bunk. With the new bunk kit installed, the distance between the
outboard motor skeg (motor tilted UP/tow position) and the trailer taillights will be an
acceptable distance.
IF YOU HAVE RECENTLY SOLD THIS BOAT/TRAILER PACKAGE IT IS
VERY IMPORTANT THE OWNER(S) ARE URGENTLY CONTACTED.
Action Required To Start Claim and Initiate Bunk Kit Part Order:
1.
2.
3.
4.

Fill out an online warranty claim on our website, www.karavantrailers.com.
Click on the link in the center of the home page “Submit A Warranty Claim”.
You will be directed to the Warranty Claim Form page, click “Dealer/Distributor”
Enter VIN of trailer, click “Yes” if boat/trailer package is unsold. If you click
“No” and the trailer has not been warranty registered, you will be directed to
complete a warranty registration for the trailer. Once that is complete you will be
allowed to continue with your warranty claim.
5. Fill in all information fields. In “Problem” field enter “XR7 Warranty Bulletin”.
In the “Diagnosis” field enter “Replace bunk assemblies”. Select “Yes” for
replacement parts needed and enter the following part numbers: 15898-J-BL for a
painted trailer Qty 1 OR 15898-J-GL for a galvanized trailer Qty 1.
NOTE: IF YOU HAVE ANY SPECIAL REQUESTS OR INFORMATION YOU
WOULD LIKE TO TELL US, SAY WHAT YOU WOULD LIKE IN THE
“DIAGNOSIS” FIELD.
6. Click Submit – You will receive an email confirmation (with a claim number)
after submission, this will be sent to the email address you entered in the claim.
Once we receive your claim we will ship the required bunk assemblies to your facility.

After you’ve completed the repair we will need a copy of your closed repair order, please
reference your claim number. This action will allow us to close your claim and send
warranty labor reimbursement (the parts will be sent to you at no charge and the freight
will be prepaid). Send via email: [email protected] or fax: 920-928-6201
Attn: Warranty.
Repair Required/Reimbursement:
1. Remove Boat From Trailer
2. Remove existing bunk assemblies
3. Drill two ¾” holes at the designated points on the rear cross member
4. Install new bunk assemblies (bunk assemblies are pre-wired)
5. Install taillights to end of bunk assemblies
6. Plug bunk assembly wire harness to main wire harness on both sides of trailer
7. Test lighting
8. Place boat back on trailer
You will receive a detailed, step by step instruction sheet explaining the repair. This will
ship with the parts.
Reimbursement is 3 hours of labor at our warranty labor rate of $65.00 per hour. 3 hours
is based on our flat rate times plus and additional hour for plugging in the new wire
harness. Total labor reimbursement $195.00. (Shop labor rates are paid when state law
requires).

If you have any questions please contact ChiAnna Harvey, Karavan Warranty Manager.
[email protected] or 920-928-6200 x333.