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 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