KING TOUR-PAK® WRAP-AROUND LIGHT KIT
J037912008-07-11
GENERAL
Kit Number
68172-06
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
REMOVAL
WARNINGDisconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
| 1. | Disconnect the battery, negative (-) cable first, or remove the main fuse. | |||||||||
| 2. | See Figure 10. Cut out the two-sided template (1) as indicated. | |||||||||
| 3. | If motorcycle is radio equipped, separate antenna cable from terminal at antenna base. Remove nut, lockwasher and ground ring terminal from antenna terminal. Remove phillips head screw from the antenna base. Remove mast and antenna base. Remove mast from antenna base. | |||||||||
| 4. | Shield threads of antenna terminal stud with strip of light cardboard. Remove terminal with pliers around cardboard strip. Save terminal and mast for installation. | |||||||||
| 5. | See Figure 13. Remove two bolts and owner's manual pouch. Save bolts for installation. Remove metal plate and six bolts from bottom of Tour-Pak and set aside. Align template as follows: a. Place centerline template (4) along rear top edge of Tour-Pak (1) with curved end against one corner. b. Mark centerline at top edge of Tour-Pak. c. Reverse centerline template and mark center with curved end against opposite corner. d. If centerlines overlap, mark center one half the distance between the two lines. e. Place a carpenter's square against lip at top of Tour-Pak and draw a 3-1/2 in (89 mm) centerline down from the center mark. | 
Figure 1. Mounting Templates |
INSTALLATION
| 1. | Attach template to Tour-Pak as follows: a. Attach four pieces of masking tape to top edge of hole template (2). The hole template is reversible with one side marked left and one side marked right. b. Mount template (2) (left side out), at left side with top edge against the underside of the lip of Tour-Pak and large square end flush with centerline. See Section "AA" in Figure 2. c. Tape top of template to Tour-Pak with last tab bent around corner. Remember all tabs are against the underside of the top lip of Tour-Pak. d. While holding template tightly around corner of Tour-Pak, trace outline of cut-out area (portion with diagonal lines) with felt tip pen or grease pencil. | 
Figure 2. Mounting Templates - Section View A-A | ||||||||||||||||||||||||||||||
| 2. | Remove template and repeat Steps 5 and 6 on right side of Tour-Pak. Mount template on right side of Tour-Pak (right side out) in same manner described in Step 5. Trace outline of cut-out area. NOTE Use a hand saw equipped with a fine tooth hacksaw blade, for marking opening. Do not use power tools, as a high speed reciprocating blade can set up stress cracks. File or sand smooth any irregular or rough edges where a crack may originate. | |||||||||||||||||||||||||||||||
| 3. | Drill a 1/2 in (13 mm) hole in each corner of both designated cut-out areas. Cut out the marked openings with a handsaw. | |||||||||||||||||||||||||||||||
| 4. | See Figure 3. Remove left lamp socket (2) from lamp housing (1) by pressing locking tab and rotating down in direction of wire leads. Remove right lamp socket (2) from lamp housing (1) by pressing locking tab and rotating up in direction of lead wires. Place lamp housing (1) in openings and press in tightly around both corners. Check that there is clearance between each opening and lamp housing around entire perimeter. Verify top of lamp housing does not interfere with side hinges or buckles on outside of Tour-Pak. If there is interference, the housing will not fit correctly. Enlarge any interference area with a file. | |||||||||||||||||||||||||||||||
| 5. | See Figure 4. Measure down from the top edge of Tour-Pak 3 in (76 mm) at centerline. Mark a reference point. Measure down 1-3/4 in (45 mm) from top edge of Tour-Pak and make a horizontal line at three places, one at center, one 6 in (152 mm) left of center, and one 6 in (152 mm) right of center. | |||||||||||||||||||||||||||||||
| 6. | Mount lamp housing on Tour-Pak and align top center hole over the 3 in (76 mm) mark at centerline. Align the top edge of lamp housing with the three horizontal lines 1-3/4 in (45 mm) down from top edge of Tour-Pak. Using the lamp housing as a template, mark the six hole locations. Punch a pilot hole in the center of each hole and drill a 1/4 in (6 mm) hole at each location. NOTE If there is to be an antenna mounted to the Tour-Pak, a 1/2 in (13 mm) hole is drilled 9-3/4 in (248 mm) to the left of centerline, down 1-1/2 in (38 mm) from lip. If existing antenna hole does not align with antenna hole in lamp housing, drill new hole as described and seal any portion of existing hole that extends beyond lamp housing with silicone. | 
Figure 3. Wrap-Around Light Assembly 
Figure 4. Centering and Squaring Lamp Housing | ||||||||||||||||||||||||||||||
| 7. | See Figure 5. Lay lamp housing down with back facing up. Lay a bead of silicone sealant into grooves at top and bottom of lamp housing at areas shown. Seat long piece of rubber seal (1) in silicone at top groove in housing (2). Seat short piece of rubber seal (3) in silicone at bottom groove in housing (2). | |||||||||||||||||||||||||||||||
| 8. | See Figure 6. Mount housing with holes aligned in Tour-Pak. If Tour-Pak has Harley-Davidson decal at back, which partly shows outside of lamp housing, remove paper from back of solid black trim strip. Mount trim strip on Tour-Pak under lamp housing flush with the two lower edges of housing. | |||||||||||||||||||||||||||||||
| 9. | See Figure 3. Insert the six hex screws (3) through holes in lamp housing (1) and Tour-Pak (9). From inside Tour-Pak, install a flat washer (5) on each screw and install on an acorn nut (4). Tighten each nut (4) snugly, but do not tighten to where heads of screws turn inside square seat in lamp housing. | |||||||||||||||||||||||||||||||
| 10. | See Figure 7. At inside of Tour-Pak, insert clip into slot in lamp housing with curved portion against side of Tour-Pak. Push clip or tap with rubber hammer until shoulder of lip is flush with lamp housing. | |||||||||||||||||||||||||||||||
| 11. | Fill area between lamp housing and opening in Tour-Pak with silicone sealant around entire perimeter. | 
Figure 5. Mounting Sponge Rubber Seal  Figure 6. Applying Trim Strip | ||||||||||||||||||||||||||||||
| 12. | See Figure 3. Strip paper backing from Harley-Davidson nameplate (6) and press into place over screw heads at lamp housing (1). | |||||||||||||||||||||||||||||||
| 13. | See Figure 8. Obtain wiring harness from kit. See Figure 9. Lay harness in the bottom of Tour-Pak with the two lights aiming toward the rear corners of Tour-Pak and the end with the large connector located towards the left front corner of Tour-Pak. Attach clips to base to retain wire harness. Align three tabs on left light socket with slots in lamp housing. Gently push light socket inward and turn clockwise until it clicks. Wires should end up facing toward center of Tour-Pak. Repeat for right side. | |||||||||||||||||||||||||||||||
| 14. | If Tour-Pak has side marker lights with a wiring end connector, connect side marker lights to Tour-Pak wiring harness. Discard side marker lights harness. | 
Figure 7. Clip Installation and Sealing Housing 
Figure 8. Wiring Harness 
Figure 9. Wire Harness Routing | ||||||||||||||||||||||||||||||
| 15. | See Figure 12. Replace metal plate. | |||||||||||||||||||||||||||||||
| 16. | See Figure 10. If vehicle is radio equipped, the antenna terminal (3) is connected to the antenna adapter (2). Insert adapter so tapped hole aligns with hole in housing and install terminal removed from antenna base into tapped hole in antenna adapter. Place ground wire (4) ring terminal and lockwasher onto threaded terminal and install on nut. Tighten nut. Install mast onto threaded end of adapter. Tighten mast with adjustable wrench across flats. Push antenna cable socket onto antenna terminal. If the vehicle is not radio equipped, the adapter hole is sealed with plastic plug (1) furnished in kit. | |||||||||||||||||||||||||||||||
| 17. | Secure Tour-Pak to the vehicle and complete electrical connections into wiring harness to vehicle. | 
Figure 10. Antenna Adapter and Hole Plug 
Figure 11. Antenna Cable and Connector  Figure 12. Metal Plate | ||||||||||||||||||||||||||||||
| 18. | See Figure 11. Connect Tour-Pak light harness connector to unused connector bundled with antenna cable inside Tour-Pak. | |||||||||||||||||||||||||||||||
| 19. | See Figure 14. Install Tour-Pak liner. | |||||||||||||||||||||||||||||||
| 20. | Press liner (1) firmly into place on Tour-Pak bottom (2). | |||||||||||||||||||||||||||||||
| 21. | Install owner's manual pouch inside Tour-Pak with two bolts previously removed. | |||||||||||||||||||||||||||||||
| WARNING Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) | ||||||||||||||||||||||||||||||||
| 22. | Connect battery, positive (+) cable first or install main fuse. | |||||||||||||||||||||||||||||||
| WARNING 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) | ||||||||||||||||||||||||||||||||
| 23. | Install seat using original hardware. |  Figure 13. Remove Owner's Manual Pouch 
Figure 14. Install Tour-Pak Liner |
SERVICE PARTS
Figure 15. Service Parts: King Tour-Pak Wrap Around Light Kit
Table 1. Service Parts: King Tour-Pak Wrap Around Light Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Template (not shown) | 50002-01 | 12 | Seals, rubber (long and short, installed on lamp housing) | 58382-89 | |
2 | Liner, Tour-Pak (not shown) | 53278-06 | 13 | Cable assembly (shown installed on lamp housing) | 70648-00A | |
3 | Wrap around light subassembly (includes items 4-22) | Not Sold Separately | 14 | Adapter, antenna (2) | 76260-89 | |
4 | Lamp housing assembly | Not Sold Separately | 15 | Nut, acorn (6) | 90844-80 | |
5 | Plug (2) | 90493-83 | 16 | Silicone sealant | 99710-88 | |
6 | Screw, hex (6) | 4930 | 17 | Sealed splice, red (3) | 70585-93 | |
7 | Washer, flat (6) | 6716 | 18 | Sealed splice, blue (2) | 70586-93 | |
8 | Strap, cable (6) | 10006 | 19 | Harness, adapter | 70307-97 | |
9 | Trim, solid black (not shown) | Not Sold Separately | 20 | Wires, blue (2) (not shown) | Not Sold Separately | |
10 | Clip, housing (2) | 58380-89 | 21 | Wires, black (2) (not shown) | Not Sold Separately | |
11 | Nameplate (shown installed) | 58381-89 | 22 | Clip, wire (6) (not shown) | 10102 |