COLOR-MATCHED CHOPPED TOUR-PAK KITS
J005942008-07-18
GENERAL
Kit Number
53111-XX
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Separate purchase of a Detachable Tour-Pak Mounting Rack Kit or an Original Equipment Tour-Pak Mounting Rack Kit is required.
Separate purchase of a Lock Kit (53194-07) is required.
WARNINGRider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
Installation
Installation on 1997 and later FLHR, FLHT and FLTR Models with a 3-Hole Original Equipment Solid Mounted Luggage Rack
- Drill hole location (2) using a 3/8 inch drill bit.
- Position the Tour-Pak on mounting rack and secure with three 5/16-18 inch bolts.
Installation on 1997 and Later FLHR, FLHT and FLTR Models with a 5-Hole Original Equipment Solid Mounted Luggage Rack
- Drill hole location (2) and (3) using a 3/8 inch drill bit.
- Position the Tour-Pak on the mounting rack and secure with the five bolts, spacers, and nuts supplied with the Tour-Pak Mounting Rack Kit. See the instruction sheet for specific installation procedure.
Installation on 2009 and Later FLHR, FLHT and FLHX Models with 4-Hole Original Equipment Rack or 4-Hole Detachable Rack
- Drill hole location (1) using a 5/16 drill bit.
- See Figure 2.Position the Tour-Pak on the rack with the mounting spacer (30) positioned under the front mounting holes, in between the Tour-Pak and the rack.
- Secure with bolts (29).
WARNINGDo not exceed Tour-Pak weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00401c)
NOTE
Do not exceed 25 pounds (11.3 kg) maximum in Tour-Pak.
| 1 | 2009 and later solid and detachable luggage racks |
| 2 | 2008 and earlier 3-hole or 5-hole with solid luggage racks |
| 3 | 2008 and earlier 5-hole solid luggage rack |
| 4 | Front of Tour-Pak |
Figure 1. Mounting Hole Locations in Bottom of Tour-Pak
SERVICE PARTS
Figure 2. Service Parts: Chopped Tour-Pak
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Screw, 6-32 x 3/8 in. (2) | 3595 |
2 | Tour-Pak bottom | Not Sold Separately |
3 | Screw, 6-32 x 9/16 in. (4) | 3597 |
4 | Screw, 6-32 x 3/4 in. (2) | 3598 |
5 | Bolt, 1/4-20 x 3/4 in. (4) (Loose) | 3574 |
6 | Spring washer (2) | 6970 |
7 | Plain washer, No. 6 (2) | 6029 |
8 | Hinge pin (2) | 8500A |
9 | Nameplate - USA | 14251-90 |
Nameplate (for FLTRSE3 Models) | 54048-09 | |
10 | Cover gasket | 53415-83 |
11 | Hinge, cover - upper (2) | 53426-87 |
12 | Bumper (2) | 53429-93 |
13 | Mat, Tour-Pak bottom | 53109-96 |
14 | Hinge, lower (2) | 53447-87 |
15 | Backing plate, brace | 53478-80 |
16 | Pad (2) | 53486-85 |
17 | Bracket, cable mounting | 53563-82 |
18 | Cable brace, cover | 53564-97 |
19 | Bracket, cable mounting | 53570-89 |
20 | Spacer (2) | 53615-85 |
21 | Catch, lower | 53616-85 |
22 | Tour-Pak cover (XX is color code) | 53112-96XX |
23 | Body, catch (2) | 90649-85 |
24 | Catch, upper (2) | 90663-95 |
25 | Backing plate (2) | 90688-85 |
26 | Label, load limit | 90821-74A |
27 | Backing plate (8) | 90964-63 |
28 | Bolt, 5/16-18 hex head, (3) (loose) | 2871W |
29 | Bolt, 1/4-20 x 1.0 in (4), (loose) | 2551W |
30 | Spacer (loose) | 11875 |
Kit 53194-07 - Lock kit (purchased separately): Includes items A through G. Refer to lock kit instruction sheet for complete assembly and installation instructions. | ||