harley tour pack spoiler

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HARLEY DAVIDSON TOUR-PAK SPOILER LIGHT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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Installation 1. If the motorcycle was previously equipped with a Tour-Pak Spoiler Light, disconnect the light wires from the motorcycle. 2. Remove the Tour-Pak Spoiler from the Tour-Pak and disassemble original light or chrome trim (as equipped). Save the original mounting hardware for later installation. 3. Attach light assembly to spoiler using 10-24 x 7/8 in. long screws. 4. See Figure 1. Route light wires through 3/8 in. hole in Tour-Pak lid. Attach spoiler to Tour-Pak lid using original hardware removed in step 2. 5. See Figure 1. Attach the wires to the inside of the Tour- Pak with adhesive backed clips as shown. Route wires out front left corner of Tour-Pak bottom and support wires inside Tour-Pak bottom with the remaining adhesive backed clips as needed. Wires will exit out the bottom of the Tour-Pak through the antenna cable grommet. NOTE On Chopped Tour-Paks drill a 3/8 in. hole in the front left corner of the Tour-Pak bottom. Route the spoiler light wires through this hole for connection to the main motorcycle wiring. 6. On 1994 and later models, proceed to step 7 for wire connection instructions. On 1993 and earlier models, go to step 11 for wire connection instructions. WIRING INSTRUCTIONS FOR 1994 AND LATER MODELS 7. Remove the seat and locate the accessory circuit connector. Route the light wires along the frame and secure with cable straps from kit. 8. Refer to the Deutsch connector section in a 1994 or later FLT Service Manual and assemble the spoiler wires into the socket connector half supplied with the LED assembly. The wire terminals shall be inserted in the connector half as follows: WIRE COLOR CODECONNECTOR CAVITY Blue 1 Red/yellow 2 Sealing plug 3 Black 4 9. Remove the plug from the accessory connector located under the seat (connector number [4A] in wiring diagram in Service Manual). Connect wire from spoiler. Turn on ignition switch and test the spoiler light operation with taillight and brake light. 1 WARNING Always connect the positive battery cable first. If the positive cable should contact the ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury. 10. Reattach battery

HARLEY DAVIDSON CONTOURED TOUR-PAK LUGGAGE RACK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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INSTALLATION NOTE The location of the Tour-Pak spoiler has a direct relationship to the location of Tour-Pak mounted luggage rack. The spoiler template will locate the Tour-Pak spoiler in the correct position for the luggage rack so that the spoiler may be added in the future. It is recommended that the spoiler be installed first. See Figure 1. 1. Identify if the installation of a Tour-Pak mounted spoiler is desired in the future. Use the template if the spoiler will be installed. Cut the template along the appropriate line. Carefully place template on top of Tour-Pak lid, aligning edges of template with top surface of Tour-Pak. Tape template in desired location. 1 is 00579 1. Check clearance between rack and spoiler Figure 1. Tour-Pak Rack and Spoiler NOTE Position top rack with upright section toward rear of motorcycle. To avoid contact with the passenger backrest pad, do not mount the top rack in too far forward a position. 2. See Figure 2. Place the four mounting pads (1) onto the four mounting supports on top rack (2). Carefully center the rack on the lid and position the rack rear supports 5/8 inch to 3/4 inch (16 mm to 19 mm) in front of the emblem on the Tour-Pak lid, as shown. 1 is 00636 1.5/8 in. – 3/4 in. (16 mm – 19 mm) Figure 2. Locate Holes From Emblem 3. Use a grease pencil to temporarily mark the positions of the four mounting pads on Tour-Pak cover. NOTE Apply masking tape to the Tour-Pak cover painted surface at the four points where the top rack mounting holes will be drilled. The tape can be marked for hole location, and will help prevent the paint from being chipped during the drilling procedure. 4. Carefully remove top rack/mounting pad assembly. Place a strip of masking tape over each grease pencil mark on the Tour-Pak cover. Once again, position top rack/mounting pad assembly on Tour-Pak cover in the desired mounting location. 5. Using a soft lead pencil on the masking tape strips, trace a circle around each mounting pad. Remove top rack/mounting pad assembly. Use a ruler to mark the exact center of each circle drawn on the tape strips. NOTE Remove all contents from within the Tour-Pak to avoid possible contact with the moving drill bit during the following drilling procedure. 6. Drill starter holes using a 1/16 inch drill bit. Drill the finished holes for the mounting screws using a 9/32 inch drill bit. Remove masking tape strips. 7. Apply a small amount of silicone sealant around each mounting hole on interior surface of Tour-Pak cover

HARLEY DAVIDSON ULTRA CLASSIC AND ELECTRA GLIDE CLASSIC TOUR PACK ADJUSTMENT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-04-2012

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1. Open the Tour Pack and remove all of the contents. 2. Remove map bag and inner pack liner. Pack liner comes out quite easily once map bag is removed. 3. Remove the 4 bolts inside the tour pack that are located on top of the metal support plate that hold the tour pack to the luggage rack. Have your assistant hold the pack in place before removing the last bolt. 4. Gently tip the tour pack forward to expose the supporting luggage rack under the pack. 5. While your assistant holds the pack up, place the two adjusting bars on top of the supporting luggage rack. Use the 4 flat head screws supplied with the kit to mount the bars snugly to the support rack (see fig. 1). 6. Reposition the tour pack over the threaded holes in the adjusting bars at the 2″ or 3″ position and bolt it in place snugly (see fig. 2). 7. Replace the trunk liner and map case and the installation is complete

HARLEY DAVIDSON PREMIUM TOUR-PAK LUGGAGE RACK KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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INSTALLATION Template Positioning (Rack Installation WITH SPOILER only) The location of the luggage rack has a direct relationship to the location of the Tour-PakĀ® Spoiler. The template (7) included in this kit will locate the luggage rack in the correct position for the current or future installation of a Tour-Pak Spoiler. NOTE A template is not required if installing rack without spoiler. 1. If a spoiler is already installed, or if the installation of a Tour-Pak-mounted spoiler may be desired in the future, cut the template along the appropriate line. 2. Carefully place the trimmed template on top of the Tour- Pak, aligning the edges of the template with the top surface of the Tour-Pak lid. Tape the template to the lid in the desired location. The template will help to properly locate the rack so that a spoiler may be added in the future. Rack Installation on Tour-Pak 1. ALL installations: Open the lid, and remove all loose contents from the Tour-Pak. 2. See Figure 1. Slip the mounting pads (2) onto each of the mounting bosses (B) of the luggage rack (1). NOTES Kit 53665-87: Position rack with wide upright toward rear of vehicle. Kit 91793-85: Position rack with upright toward rear of vehicle. Carefully center the rack from left to right, and position the rack squarely on the lid for best appearance. Do not mount the rack too far forward to avoid contact with the backrest pad. 3. Position the rack on the Tour-Pak lid in the desired loca- tion. 4. Carefully raise the rack, and place masking tape (A) on the Tour-Pak lid where the four mounting bosses contact the cover. 5. Lower the rack onto the tape in the location chosen in Step 3. Using a soft lead pencil on the masking tape strips, trace a circle around each mounting boss. Remove the rack, and use a ruler to mark the exact center position of each mounting boss on the tape. 6. Drill four 1/16 inch (1.5 mm) diameter pilot holes through the masking tape and Tour-Pak lid at each mounting boss center position. Use a 9/32 inch (7 mm) diameter bit to drill the finish holes. 7. Remove the masking tape

HARLEY DAVIDSON TOURING DETACHABLE TOUR-PAK RACK INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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INSTALLATION NOTE See Figure 3. When installing Tour-Pak to Rack in the following Steps, note that holes on Rack provide two positions for mounting Tour-Pak in desired location. 1. Place Tour-Pak on support tube and open lid. NOTE See Figure 3. In the following step, the longer bolts (6) are used for 2005 and earlier (King only) and Chopped Tour-Paks while the shorter bolts (5) are used for Leather Tour-Pak and 2006 and later King Tour-Paks. 2. See Figure 3. Obtain bolt (5 or 6), two flat washers (3), concave spacer (4) and hex lock nut (2) from kit. Align rear center hole in Tour-Pak with same hole in support tube (8). Slide bolt with flat washer through Tour-Pak, through support tube, then through concave spacer (with concave side facing support tube). At bottom of support tube, install washer (3) and nylock cap nut (2). With concavity on spacer inline with the rail, hold nut and tighten bolt until snug. 3. Obtain bolts (5 or 6), two flat washers (3), concave spacer (4) and hex lock nut (2) from kit. Align top support tube (8) with detachable tour-pak rack holes (four). Slide bolts with flat washer through Tour-Pak, through support tube, through concave spacer (with concave side facing support tube) then through rack. At bottom of detachable tour-pak rack, install washer (3) and nylock cap nut (2). With concavity on spacer inline with the rail, hold nut and tighten bolt until snug. NOTE Always install the mounting bolts from inside the Tour-Pak. If the bolts are installed upside down, then the ends of the bolts can tear the molded liner and scratch objects, such as helmets, stored inside the Tour-Pak. 4. Repeat Step 3 and install hardware to the remaining three holes in Tour-Pak and mounting rack. 5. In a crosswise pattern, alternately tighten the five bolts to 96-120 in-lbs (10.8-13.5 Nm) . Be sure that concavity on each spacer is inline with the rail and has not rotated out of position. INSTALLATION-TOUR-PAK AND RACK 1. Follow the instructions included in the docking point kit and install docking points. 2. See Figure 1. While standing behind the motorcycle, place the front Tour-Pak rack notches into the front docking points (1). Make sure the notches seat fully into the front docking points. 2 1 is04025 1. Front Docking Point 2. Rear Docking Point Figure 1. Docking Point Bracket 3. See Figure 1 and Figure 2. Position the latches over the rear docking points (2). Check to be sure the latches fit into the neck of the rear docking points as shown in figure 2. This may require some gentle squeezing or spreading of the rack

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