Highlander AirTrek PDL Series: full user manual

Compact. Lightweight. Ready to go. The Highlander AirTrek PDL series — Highlander 100, Highlander 120, Highlander 140T — is Cajo's inflatable SUP-kayak hybrid lineup. Premium features in a lightweight, packable frame. Compatible with the Traverse Pedal Drive or third-party fin drives. Sets up fast, travels light, stows easily in a trunk, RV, or gear closet.

This article is the structured summary of the full Highlander User Manual. Download the printable PDF below.

Lineup at a glance

Model	Dimensions	Configuration
Highlander 100	10' × 39" × 6"	Solo
Highlander 120	12' × 39" × 6"	Solo
Highlander 140T	14' × 44" × 6"	Tandem

Features (shared across the line)

• Inflatable SUP-kayak hybrid for compact performance
• Compatible with Traverse or fin pedal drives
• Ultra-stable platform for stand-up fishing or paddling
• Equipped with ultra-comfortable high-low Treklite seat
• 4-piece paddle that converts between SUP and kayak use
• ×4 integrated gear tracks for rigging accessories
• ×3 stern anchor pole, rudder, or motor mounts
• Packs into a travel bag with roller wheels

What's in the box (accessories overview)

Every Highlander ships with:

• Zip Backpack (with roller wheels)
• Double-Action Pump
• Treklite Seat — adjustable, removable
• AirTrek Pod — structural mount for the Traverse PDL drive
• Fin Set ×3 — one center fin, left and right side fins
• Seat Tie-Down Straps ×4
• Delta Grip Bungee Clips ×4
• Cargo Bungee Cord
• Repair Kit — patch material, glue, and applicator
• AirTrek Lite Paddle — 4-piece convertible

Safety guidelines

The Highlander is built tough, but it's still an inflatable — and inflatable watercraft carry inherent risk. Read these before launch.

Mandatory

• Wear a personal flotation device (PFD) at all times
• Read instructions first
• Fully inflate all air chambers before use
• Respect the number-of-users rating (1 for 100/120, up to 2 for 140T)
• Respect max load capacity: 286 lbs (130 kg)
• Stay within safe distance to shore: 150m (492 ft)
• Swimmers only — non-swimmers must not use the board

Prohibited

• Do not use in white water
• Do not use in breaking waves
• Do not use in offshore current
• Do not use in offshore wind
• Not for children 14 years old and below

Pressure & equipment warnings

• Operating pressure: 12 psi minimum, 15 psi maximum. Over inflation voids warranty.
• Working pressure rating: 15 psi (1.0 bar). Design max.
• No protection against drowning. PFD is non-negotiable.
• Do not use air compressors — voids warranty (over-inflation risk).

For the full operating walkthrough, see Highlander AirTrek: inflate, paddle, deflate, pack.

Hull components (referenced across all 3 sizes)

Every Highlander has the same major component layout. The 140T tandem doubles the seat zone.

• Fore Keel (bow) + Aft Keel (stern)
• Carry Handle (×4 on 100/120, ×6 on 140T) — bow, stern, and gunwales
• D-Ring for cargo bungee attachment
• Cargo Bungee + Delta Bungee Clips for gear tie-down
• AirTrek Window + AirTrek Pod — center deck, where the Traverse PDL drive installs
• EVA Deck Pad — high-traction standing zone
• Gear Mount — accessory mounting plates
• Seat Strap D-Rings — for attaching the Treklite Seat
• Rod Straps + Paddle Straps — for stowing tackle and paddle while on the water
• Rudder Line Fastener — hook-and-loop guides for the rudder line
• Power-Pole Micro Anchor Mount + Traverse Rudder / Power-Pole Micro Anchor Mount — stern, for anchor or rudder install
• Air Valve — primary inflation valve (Halkey-Roberts)
• Fins — center + left + right (slide-in)

AirTrek Pod & Window installation

The AirTrek Pod is the structural mount for the Traverse PDL drive on inflatables. The AirTrek Window is a removable cover.

Insert AirTrek Pod:

1. Lightly inflate the ISUP to approximately 25% first.
2. Insert the AirTrek Pod with the "FRONT" arrow pointing toward the bow.
3. Continue inflation to full operating pressure (12-15 psi).

Traverse Pedal Drive installation (sold separately)

The Highlander AirTrek series can be fitted with the optional Traverse PDL foot pedal drive for hands-free propulsion.

1. Remove window — Unscrew the AirTrek Window from the Pod and remove it.
2. Install — Screw the Traverse PDL Drive mounting collar onto the AirTrek Pod using the provided hardware.
3. Next steps — With the watercraft inflated, follow the Traverse Pedal Drive and Rudder System installation instructions included with those kits — see Traverse Pedal Drive manual and Traverse Rudder System manual.

Fin installation

Slide-in fin system. No tools required.

1. Slide the large center fin into the fin box.
2. Insert the push-in pin to secure.
3. Repeat for left and right side fins.

Treklite Seat attachment

1. Loop the mounting strap around the seat frame and pass the clip through the loop.
2. Clip the seat strap to the nearest D-Ring that's at least 6 inches from the seat.
3. Repeat for all 4 seat straps.
4. Tighten the seat strap using the tension buckles.

Full Treklite Seat detail: Treklite Kayak Seat manual.

Inflation overview

1. Open the valve cap by twisting counter-clockwise. Ensure the valve is clear of debris, sand, or dirt.
2. Push valve button in and turn 90°.
3. UP position — valve button popped up = inflation mode.
4. Attach pump hose to the pump and secure it tightly.
5. Connect to the valve, twist 45° clockwise to lock.
6. Save effort — as pressure builds, keep arms extended and bend your knees to power for less fatigue.

Dual-action pump has two modes:

• Double action mode (top cap shows "2") — fast inflation, pumps the board up to 7-10 psi.
• Single action mode (top cap shows "1") — easier pumping for the final psi.

Note: Gauge will not respond until reaching 4 psi. Just keep pumping for 2-3 minutes.

Fast Inflation — Keep pumping until you reach the 12-15 psi operating range. Max 15 psi.

After inflation, return the valve cover and tighten in a clockwise direction to lock in place.

Electric pumps: can be used to inflate up to 80-90%, but the remaining pressure should be achieved using the hand pump to avoid over-inflation. Air compressors are prohibited.

Full inflation walkthrough: Highlander AirTrek inflate, paddle, deflate, pack.

Deflation & pack-down

1. Valve open — twist counter-clockwise. Valve button to DOWN position.
2. Deflate by hand — roll the board from nose to tail to squeeze the air out.
3. Remove AirTrek Pod — prior to rolling and packing.
4. Roll — Tightly roll the board from nose to tail and use the provided strap to secure.
5. Pack — Pack the rolled ISUP into the backpack with the disassembled paddle and folded seat. Do not overtighten the zipper.

Paddle assembly

The AirTrek Lite Paddle is a 4-piece convertible — SUP single blade or kayak double blade.

• Hold position — correct vs. incorrect grip shown in the manual. The paddle blade faces forward for proper stroke.
• Clamp system — Adjust tightness by rotating the hasp to reduce any play.
• After use — Always drain the water left in the paddle shaft.

ISUP board care

8 maintenance fundamentals:

1. Cleaning — Freshwater and mild soap after each use.
2. Keep it dry — Dry completely before storage to avoid mold.
3. Frequent use — Long-term storage may cause adhesive failure. Use the board.
4. Regular maintenance — Check for cracks, scrapes, or other issues; repair if necessary.
5. No air compressor — Voids warranty.
6. No dragging — Sharp debris may puncture.
7. Avoid direct sunlight — Keep under shade when not in use with a working pressure no more than 50-60% of max (so under ~9 psi shade-storage).
8. Avoid temperature extremes — Store between 0–40°C (32–104°F).

Patch/repair procedure

The Highlander ships with a repair kit. Full step-by-step in Highlander patch and repair.

Quick summary:

• Supplies: AQUASEAL® glue (recommended), acetone or M.E.K., hairdryer, brush, tape, spatula or spoon, towel
• Procedure: Clean → outline patch → apply tape → apply glue (both sides, 1-minute set) → apply patch → heat-bond with hairdryer
• Cure: Allow glue to cure with the board un-inflated for 24 hours prior to use

FAQ (from the manual)

Q: How much air should I pump, and how long does it take? A: Maximum pressure is 15 psi. Higher risks over-inflation and damage. Inflation time depends on size — 5 to 10 minutes.

Q: When detaching the pump, air starts releasing from the valve. How do I stop this? A: The valve spring pin has been left in the deflating position. Push down and turn the pin until it lifts up into the inflation position. Air will stop releasing.

Warranty

2-year limited warranty on the board material against major defects in material or workmanship. Standard exclusions apply (commercial / rental use, modifications, normal wear, puncture damage, heat / sunlight damage, improper handling and storage, surf and wave breakage, motor installation beyond rated capacity, etc.).

For the full warranty terms, see the PDF or How to file a warranty claim.

Download the full PDF

The Highlander User Manual PDF contains all illustrations and per-model diagrams.

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Related links

• Highlander AirTrek: inflate, paddle, deflate, pack
• Highlander inflation pressure — 12-15 psi operating, 10 psi storage max
• Highlander single-chamber design
• Highlander patch and repair
• Highlander 100 vs. 120 vs. 140T
• Can the Highlander inflatable use a fin drive?
• Traverse Pedal Drive manual
• Traverse Rudder System manual
• Treklite Kayak Seat manual
• Cajo User Care