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HARLEY DAVIDSON SOFTAIL DETACHABLE TWO-UP TOUR-PAK LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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TOUR-PAK LUGGAGE INSTALLATION TO RACK 1. Open the lid and, if necessary, remove all items from inside the Tour-Pak luggage.  Remove the rubber mat from the luggage floor. 2. If holes ARE NOT pre-drilled in the floor of the luggage,       see Figure 1. To prevent damage to the leather while drilling, place blocks of wood underneath the Tour-Pak luggage at the drilling sites.  Use the four inboard holes (3) in the metal base of the luggage (2) as a guide, and carefully drill four 11/32 inch (9 mm)  holes through the floor of the luggage. 1 2 3 is04249 1. Front of motorcycle 2. Tour-Pak 3. Drill four 11/32 inch (9 mm) diameter holes Figure 1.  Drill Attachment Hole Locations in Tour-Pak NOTE See Figure 3. When installing the luggage to the rack in the following steps, note that holes in the luggage rack (2) provide forward (A) and rearward (B) positions for mounting the lug- gage. 3. Place the luggage on the luggage rack.  Align the holes in the luggage mounting plate with the forward or rearward holes in the rack. 4. ALL applications: Obtain the hex head cap screws (9), lock nuts (11) and plain washers (10) from the kit. Place a washer over the threads of each screw, and insert the screw threads, from the inside, through the Tour-Pak luggage mounting plate and floor, and into the holes in the rack. NOTE Always install the mounting screws from inside the luggage.  If the screws are installed from the bottom, the screw ends can tear the rubber mat and scratch objects, such as helmets, stored inside the luggage. 5. From the underside of the rack, install a washer and lock nut onto the threads of each screw.  In a crosswise pattern, incrementally tighten each screw to 19 ft-lbs (25 Nm) . 6. Install the rubber mat into the luggage.  Close and latch the lid. 7. If not already in place, install the Detachable Docking Hardware Kit to the vehicle per the instructions in that kit

HARLEY DAVIDSON XR1200 LUGGAGE RACK KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2011

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Kit 53976-08 (XR1200 Passenger Upright Kit) is available for separate purchase. Contact your Harley-Davidson dealer for more information. Kit Contents See Figure 2 and Table 1. REMOVAL 1. Remove pillion and seat following the instructions in the appropriate Service Manual. 2. Remove the seat base following the instructions in the appropriate Service Manual. 3. See Figure 1. Remove the turn signal mounting screws (3) and discard. Allow the turn signal to hang by the harness until lower bracket installation. 4. Remove the rear fender support strut screws (6) and dis- card. INSTALLATION 1. See Figure 2. Install lower luggage rack mount bracket with screws (9), flat washers (10) and nuts (8). Bracket will mount around nut (Item 2 in Figure 1). Tighten to 19 ft-lbs (26 Nm) . 2. Install screws (7) and nuts (8) through the rear fender support strut and the lower luggage rack mount bracket. Tighten to 19 ft-lbs (26 Nm) . 3. Route the turn signal wire harnesses through the groove in the bracket. Install new turn signal mounting screws (11). Tighten screws to 3-5 ft-lbs (4-7 Nm) . 4. Install seat base following the instructions in the appropriate Service Manual. 5. Install upper luggage rack mount bracket (4) with original equipment seat base screws in the lower holes (A). Do not tighten at this time. 6. Install screws (3) into slotted holes in the upper luggage rack mount bracket (4) and flange nuts (6). Slide the upper bracket as far back in the slots as possible. Tighten screws (3) to 10 ft-lbs (13.5 Nm) 4 1 1 2 5 6 3 is05250 1. Lower luggage rack mount bracket screw (4) 2. Nut (2) 3. Turn signal mounting screw (4) 4. Upper luggage rack mount bracket 5. Luggage rack 6. Rear fender support strut screw (2) Figure 1. Luggage Rack Installation NOTE If installing the Passenger Upright Kit (part number 53976-08) (available separately), do not install spacers (2) and screws (3) in front holes. 7. Install luggage rack (1) aligning the holes with the holes in the upper luggage rack mount bracket. Install spacers (2) and screws (3) in holes. Tighten to 6-10 ft-lbs (8-13.5 Nm) . After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 8. Install pillion and seat following the instructions in the appropriate Service Manual. Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a

HARLEY DAVIDSON TOUR-PAK KIT INTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION 1. Remove the rubber mat from the bottom of the Tour-Pak. 2. See Figure 1 and Table 1 to determine the proper hole configuration to attach the Tour-Pak to your luggage rack. Holes will be drilled as explained in Step 3 in the hole location for your luggage rack. Table 1. Luggage Rack and Hole Configurations Hole Configura- tion Luggage Rack C (3 holes) Stock 1997 B (4 holes) Detachable luggage rack 53107-96 A (5 holes) Luggage rack 53118-97A and luggage rack 53118-98 A (5 holes) Stock 1998 and later racks A (5 holes) Detachable Tour-Pak rack 53276-04 B (4 holes) Solo detachable Tour-Pak rack 53655-04 B (4 holes) Detachable Tour-Pak rack 53066-00B B (4 holes) Solo detachable Tour-Pak rack 53559-04A A (5 holes) Solo detachable Tour-Pak rack 53260-02 -J03631 1 of 3 B 1 A C 2 2 2 is00163 1. Front of motorcycle 2. Bottom view of Tour-Pak interior (rubber mat removed) Figure 1. Hole configurations for Tour-Pak attachment NOTE Drilling holes in Tour-Pak without wood underneath each hole site may result in the leather becoming damaged during the drilling process. 3. Place blocks of wood underneath the Tour-Pak where the holes will be drilled to prevent damage to the leather while drilling. Use the pre-drilled holes in the metal base as a guide and carefully drill the holes through the leather in the proper location using a 11/32 inch drill bit. 4. See Figure 2. For detachable luggage racks (53107- 96, 53066-00B and 53276-04): Install black cover tube to the front bar (1) of the luggage rack, as shown. This tube is used to provide a cleaner look. The black cover tube is not for use with other luggage racks. 5. Attach Tour-Pak to rack using the mounting screws provided in the Luggage Rack kit. Put bolt through from inside of Tour-Pak. Tighten screws to specifications found in the Luggage Rack kit. 6. Place the black rubber mat on the bottom of the Tour-Pak. 7. If luggage rack was removed, reattach to motorcycle according to kit instructions or Service Manual instructions

HARLEY DAVIDSON FXSTD PASSENGER BACKREST AND LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) INSTALLATION Passenger Upright 1. Unscrew the captive screw fastening the seat rear bracket to the fender. 2. Remove the rubber plugs from the three holes in the rear fender where the passenger upright installs. 3. See Figure 2. Fasten the studplate (2) to the fender (A) with the backing plate (3) and three flange locknuts (4). 4. See Figure 1. Fasten the passenger upright (3) to the studplate (1) with three flange locknuts (2). 5. Insert the seat front bracket into the frame, then fasten the seat rear bracket to the fender. NOTE The seat must be temporarily bowed up in the center to fit the seat rear bracket through the slot in the passenger upright. 6. Kit 51144-02 only. See Figure 2. Carefully clean the lower hole (B) on the passenger upright (1) with isopropyl alcohol to remove any grease or dirt. Remove backing from adhesive emblem (5) and press the emblem firmly in to place. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 1 4 3 2 is03890 1. Stud plate 2. Locknut, flange (3) 3. Passenger upright 4. Backrest pad Figure 1. Passenger Upright, Backrest Pad and Luggage Rack Installation NOTE When temporarily removing the passenger upright, the mounting and backing plates may be left in place to simplify passenger-upright re-installation. Thread the flange nuts back onto studs to store the nuts. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) Backrest Pad See Figure 2. Fasten the backrest pad (7) to the passenger upright (1) using the button-head screw (6) as shown. Luggage Rack NOTE See Figure 2. Fasten the luggage rack (8) to the backrest with the backrest pad (7) removed from the studplate (2). -Fasten the luggage rack (8) to the passenger upr ight (1) using the luggage-rack mounting plate (11), button-head screw (12)

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HARLEY DAVIDSON SOFTAIL SPORT LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-02-2011

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INSTALLATION NOTE Cover the rear fender with a clean shop towel to prevent scratching. Damage to the finish could result. 1. See Figure 1. Remove the four button-head TORX screws attaching the sissy bar (5) to the sideplates (4). Discard the screws 2. Remove the sissy bar and set it aside. For Rigid-Mount Sideplates only: Loosen, but do not remove, the hardware securing the sideplates to the motorcycle. 3. Position the luggage rack between the sideplates. Reinstall the sissy bar into the sideplate channels. 4. Apply Loctite 271 (Red) to the flat head TORX screws (2) from the kit, and insert through the holes in the luggage rack (1), sideplate, and sissy bar. Tighten the screws to 8-10 ft-lbs (10.8-13.6 Nm) . For Rigid-Mount Sideplates only: Apply Loctite 271 (Red) to the screws securing the sideplates to the motorcycle, and tighten to 21-27 ft-lbs (28.5-36.6 Nm) . 5. Remove the backing strip from the two rubber bumpers (3) and install onto the luggage rack. a. Align the notches in the bumper with the bottom edge of the channel on the sideplate. b. Wrap the bumper up the side of the luggage rack channel and across the bottom of the sissy bar. When properly installed the bumpers will cover the lower flat head screws, and will bend around the lower edge of the channel. Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) NOTE Maximum luggage rack weight capacity is ten pounds (4.5 Kg)

HARLEY DAVIDSON LUGGAGE RACK BAG INSTALLATION INTSRUCTIONS

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

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INSTALLATION 1. Set the rack bag on top of the luggage rack with the main pocket opening facing the rear of the vehicle. 2. See Figure 2, Figure 3 and Figure 4. Determine which luggage rack is installed on the vehicle. 3. See Figure 1. Open the hook-and-loop closures in the appropriate locations for the installed luggage rack. 4. Fasten the closures around the bars of the luggage rack and pressing the hook-and-loop ends together. 5. Give the rack bag a final pull to verify the pack is securely attached. 1 2 3 4 7 5 6 is05516 1. Rear left closure 2. Rear center closure 3. Rear right closure 4. Front left closure 5. Front center closure 6. Front right closure 7. Rain cover storage Figure 1. ook-and-Loop Closure Locations 1 2 3 4 5 6 is05513 Figure 2. Premium Rack Closure Locations -J00861 1 of 2 1 3 4 6 is05514 Figure 3. Air Wing Rack Closure Locations 2 5 4 6 is05515 Figure 4. Contoured Rack Closure Locations USAGE Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) •Combined load of top rack and Tour-Pak® must not exceed 25 lbs (11.3 Kg). Overloading the motorcycle will cause unstable handling and reduced braking efficiency, which could result in death or serious injury. See Figure 1. Open the hook-and-loop flap on the rain cover storage pocket (7) and wrap the tethered rain cover around the bag.

HARLEY DAVIDSON SISSY BAR LUGGAGE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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INSTALLATION Improper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00095a) Harley-Davidson cannot test and make specific recommendations regarding every accessory or combination of accessories sold, the rider must assume responsibility for safe operation of the motorcycle when installing accessories or carrying additional weight. Use the following guidelines when equipping a motorcycle or carrying passengers and cargo. •The Gross Vehicle Weight Rating (GVWR) is shown on the information plate located on the frame steering head. GVWR is the sum of the weight of the motorcycle and accessories and the maximum weight of the rider and cargo that may be carried safely. Do not pull a trailer with this motorcycle. Do not exceed the GVWR as indicated on the frame label. •Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize the change in the motorcycle’s center of gravity. Distribute weight evenly on both sides of the vehicle and do not load bulky items too far behind the rider or add weight to the handlebars or front forks. •Do not exceed the maximum load (indicated on the label inside) in the bag. Do not exceed the capacity of the luggage rack. •Be sure cargo is secure and will not shift while riding. Periodically recheck the load. •Ensure that the bag strap buckles are secure •Large surfaces, such as fairings, windshields, backrests and luggage racks, can affect handling. These items should be designed and approved by Harley-Davidson specifically for the motorcycle model and be properly installed. 1. Disconnect the quick-disconnect buckle on the bottom mounting strap, and undo the D-ring fasteners on the back straps. Add enough slack to the straps to wrap around the luggage rack and backrest pad. 2. See Figure 1. Center the bag on the luggage rack with the closure buckles facing the back of the motorcycle. Bring the mounting strap on the bottom of the bag around the underside of the luggage rack

HARLEY DAVIDSON DETACHABLE PASSENGER BACKREST LUGGAGE RACK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-04-2011

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INSTALLATION 1. See Figure 1. If not already assembled in package, assemble V-logo onto each mounting bracket (2 and 3) using #4-40 thread-forming screws (5). 2. Position luggage rack between sideplates of detachable passenger backrest assembly. 3. Thread button head screws (7) through washers (6), then through holes in luggage rack support and passenger backrest sideplate and into mounting brackets (2 and 3). Apply LOCTITE 243 (Blue) to screws (7) before installation. Finger tighten. 4. Tighten button head screws to 19 ft-lbs (26 Nm) . NOTE The backrest shown in Figure 1 is not included in this kit and must be purchased separately. -J01851 1 of 2 SERVICE PARTS 8 1 7 6 3 2 4 5 is04290 Figure 1. Service Parts: Detachable Passenger Backrest Luggage Rack Kit Table 1. Service Parts Table Part Number Description (Quantity) Item Part Number Description (Quantity) Item 2711 Screw, #4-40 thread-forming, steel, zinc plated (4) 5 Not sold separately Passenger backrest rack kit 1 94066-90T Washer, chrome (4) 6 53046-00 Bracket, mounting, right side (includes items 4 and 5) 2 94392-92T Button head screw, hex socket, chrome (4) 7 53045-00 Bracket, mounting, left side (includes items 4 and 5) 3 Not Sold Separately Warning label 8 Not sold separately V-logo (2) 4

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-Pak® 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 CHROME 4-CHANNEL LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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INSTALLATION Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) NOTE Maximum luggage rack weight capacity is ten pounds (4.5 Kg). Luggage Rack Assembly 1. See Figure 1. Locate inner channels (1) by rounded cuts (2) on one end. Lay inner channels side by side on a flat table with the cutout end flush with the edge. Verify that the cutouts face outside in opposite directions. 2. See Figure 2. Place the backrest support slide bars (1) inside the inner channels with the tapped holes on the cutout end of the inner channels. 3. Separate spacers by their length, two 5/16 inch, four 3/4 inch and six 1-1/16 inch. Set two 5/16 inch spacers aside, they will be used later. 4. Position the four 3/4 inch spacers (2) inside the backrest support slide bars.