KING TOUR-PAK WRAP AROUND LIGHT UNIT
J027702008-10-01
GENERAL
Kit Number
68012-88E
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
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
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
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)
| 1. | Disconnect the negative battery cable (-) following the instructions in the owner's manual. | |||||||||||||||||||||
| 2. | Locate the two-sided template (part number 50002-01) printed on a 11 x 17 inch sheet of poster board. Cut out the template as indicated. | |||||||||||||||||||||
| 3. | If the motorcycle is radio equipped, separate the antenna cable from terminal at antenna base. Remove the nut, lockwasher and ground ring terminal from antenna terminal. Remove phillips head screw threaded into antenna base. Remove mast and antenna base. Detach mast from antenna base by turning counterclockwise with adjustable wrench across flats. | |||||||||||||||||||||
| 4. | See Figure 10. Shield threads of antenna terminal stud with strip of light cardboard. Remove terminal with pliers across cardboard strip. Save terminal and mast for later installation. | |||||||||||||||||||||
| 5. | See Figure 1. Open Tour-Pak top and remove all loose contents. Remove Tour-Pak. Align the template as follows: a. Place center line 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 center line 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 square against lip at top of Tour-Pak and draw a 3 in (76 mm) line down from the center mark. | 
Figure 1. Mounting Templates | ||||||||||||||||||||
| 6. | Attach the template to the 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. Looking at the rear of the Tour-Pak, mount template (2) (left side out), at left side with top edge against lip of Tour-Pak and large square end flush with centerline. c. Tape top of template (3) to Tour-Pak with last tab bent around corner. All tabs must be against 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. | |||||||||||||||||||||
| 7. | Remove the template and repeat Steps 5 and 6 on the right side of the Tour-Pak. Mount the template on the right side of Tour-Pak (right side out) in same manner described in Step 4. Trace outline of cut-out area. NOTE Use only 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. | |||||||||||||||||||||
| 8. | Carefully drill a 1/2 in (13 mm) hole in each corner of both designated cut-out areas. With a hacksaw blade mounted in handle or keyhole saw with fine hacksaw blade, cut out the marked openings. | |||||||||||||||||||||
| 9. | See Figure 2. Carefully remove any pockets that are installed to backside of Tour-Pak and discard. | 
Figure 2. Remove Pocket from Tour-Pak | ||||||||||||||||||||
| 10. | See Figure 3. Remove left lamp socket from lamp housing (1) by depressing locking tab and rotating downward in direction of wire leads. Remove right lamp socket (2) from lamp housing by depressing locking tab and rotating upward in direction of lead wires. Place lamp housing (1) in openings and press in tightly around both corners. Check to be sure there is clearance between each opening and lamp housing around entire perimeter. If there is interference, the housing will not fit correctly. Enlarge any interference area with a file. | 
Figure 3. Wrap-Around Light Assembly | ||||||||||||||||||||
| 11. | See Figure 4. Measure down from lip at top of Tour-Pak a distance of 2-3/4 in (70 mm) (3) at centerline. Mark a reference point. Measure down 1-1/2 in (38 mm) (2) from lip 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. | |||||||||||||||||||||
| 12. | Mount lamp housing on Tour-Pak and align top center hole over the 2-3/4 in (70 mm) mark at centerline. Align the top edge of lamp housing with the three horizontal lines 1-1/2 in (38 mm) down from top edge of Tour-Pak. Using the lamp housing as a template, mark the six hole locations. Prick punch 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, downward 1-1/4 in (32 mm) (1) 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. | |||||||||||||||||||||
| 13. | See Figure 5. Lay lamp housing down with back facing upward. Cut off lip of silicone applicator and thread onto it the top for the silicone tube furnished in kit. Lay a bead of silicone sealant into grooves at top and bottom of lamp housing at areas shown. Seat long piece of sponge rubber seal (1) in silicone at top groove in housing (2). Seat short piece of sponge rubber seal (3) in silicone at bottom groove in housing (2). | 
Figure 4. Centering and Squaring Lamp Housing 
Figure 5. Mounting Sponge Rubber Seal | ||||||||||||||||||||
| 14. | See Figure 6. Mount housing with holes aligned in Tour-Pak. If Tour-Pak has a Harley-Davidson decal at the 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. | |||||||||||||||||||||
| 15. | See Figure 3. Insert the six hex screws (3) through holes in lamp housing (1) and Tour-Pak (9). From inside Tour-Pak, place a flat washer (5) on each screw and install 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. | |||||||||||||||||||||
| 16. | See Figure 7. At inside of Tour-Pak, insert clip (2) 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. | 
Figure 6. Apply Trim Strip 
Figure 7. Clip Installation and Sealing the Housing | ||||||||||||||||||||
| 17. | Fill area between lamp housing and opening in Tour-Pak with silicone sealant around entire perimeter. | |||||||||||||||||||||
| 18. | See Figure 3. Strip paper backing from Harley-Davidson nameplate (6) and press into place over screw heads at lamp housing (1). | |||||||||||||||||||||
| 19. | See Figure 8. Obtain wiring harness from kit. 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 black connector located towards the left front corner of Tour-Pak. 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. | |||||||||||||||||||||
| 20. | See Figure 9. If Tour-Pak has side marker lights with a wiring end connector, connect side marker lights to Tour-Pak wiring harness. If side marker lights do not have a connector, remove the Tour-Pak side light lenses. Unhook the Tour-Pak wiring harness from rearmost bulb, making note of posts to which black wires are connected. Pull wires back into Tour-Pak and cut them off as close to metal plate (3) in bottom of Tour-Pak as possible. | |||||||||||||||||||||
| 21. | Feed a blue and black wire through Tour-Pak and attach wire ring terminal to bulb socket post. Make sure black wire is attached on the post where the original black wire in Step 19 was removed. Inside Tour-Pak, install socket housing onto blue and black wire and connect side marker lights to the Tour-Pak harness. | |||||||||||||||||||||
| 22. | 1997 and later models: Attach connector on new wrap around light harness to mating connector in Tour-Pak. Discard adapter harness. Continue to Step 29. | |||||||||||||||||||||
| 23. | 1980 to 1996 models: See Figure 8. Attach adapter harness (4) to wrap around light harness by snapping together mating connectors. Cut off plug end of existing wiring harness, located in front of Tour-Pak, as close to metal plate (3) in bottom of Tour-Pak as possible. See Figure 9. Retain end. | |||||||||||||||||||||
| 24. | 1994 to 1996 models: Remove plug from wire harness end that was cut in Step 22, by gently prying away orange cap with a thin flat blade screwdriver. Pull back retaining tabs inside plug using small flat blade screwdriver and pull out wires. Discard three cut wire stubs. Insert wires from adapter harness back into plug in the following manner: - Blue wire: Cavity A - Red/Yellow wire: Cavity B - Black wire: Cavity C Make sure all wires have clicked into place by gently pulling on each wire. Wires should be "locked" in place. Insert orange cap back into plug until it snaps into place. Continue to Step 29. | |||||||||||||||||||||
| 25. | 1980 to 1993 models: Cut three metal sockets off adapter harness as close to metal ends as possible. Strip 1/4 in (6 mm) of insulation off of each of the three wires, leaving bare wire ends. Continue to Step 26 or 27, depending on your model year. | |||||||||||||||||||||
| 26. | 1991 to 1993 models: Strip 1/4 in (6 mm) of insulation off of wire ends of plug that was cut from in Step 21. Connect to other end of wire that passed through hole drilled in Step 22 using red butt splices included with kit by inserting wires into red shrink wrap butt splice. Continue to Step 29. a. Butt Splice Procedure: Insert wires to be connected into red or blue butt splice connector from kit. b. Crimp butt splice to wires with wire crimper. Tug gently on wires to verify they are properly crimped. c. Using heat gun, heat middle portion of butt splice shrink wrap until liquid flows into each end of the cavity on butt splice. Heat ends until plastic shrinks to wires. d. Let cool for 1-2 minutes before handling to allow liquid to properly set. |
WARNINGBe sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)
- Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/explosion resulting in death or serious injury.
- Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed.
- Always keep hands away from tool tip area and heat shrink attachment.
| 1 | Light (2) |
| 2 | Black wire (2) |
| 3 | Blue wire (2) |
| 4 | Adapter harness (for 1996 and earlier) |
| 5 | Attaches at front of Tour-Pak |
Figure 8. Wiring Harness
| 1 | Rear of Tour-Pak |
| 2 | Side marker light bulb wires |
| 3 | Metal plate |
Figure 9. Inside Tour-Pak/Metal Plate
| 27. | 1986 to 1990 models: Strip 1/4 in (6 mm) of insulation off of wire ends of plug that was cut in Step 21. With red butt splice from kit, connect black wires together and connect blue wires together. Cut a piece of 18 gauge wire long enough to reach from Tour-Pak to motorcycle wiring harness brake light wire, located under seat. Connect one end of wire to red/yellow wire using a red butt splice from kit. Splice remaining end of wire to brake light wiring harness, located under seat, using a blue butt splice from kit by: cutting brake light wire, inserting one end of wire into end of butt splice connector, inserting remaining end of wire and new wire into remaining end of splice. Crimp wires. Continue to Step 29. | |||||||||||||||
| 28. | 1980 to 1985 models: For ground wire, cut a length of wire long enough to reach from Tour-Pak to a suitable fastener threaded into a metal frame member under seat. Splice one end to black wire on Tour-Pak using butt splice from kit. Crimp ring terminal on other end and secure it to fastener on frame member. Cut two more wires long enough to reach from Tour-Pak to brake light and running light wires under seat and splice them to wires, as described in Step 25. | |||||||||||||||
| 29. | See Figure 10. If the vehicle is radio-equipped, the antenna terminal is connected to the antenna adapter furnished with the kit. Insert adapter so tapped hole aligns with hole in housing thread terminal removed from antenna base into tapped hole in antenna adapter. Place ground wire ring terminal followed by lockwasher onto threaded terminal and thread on nut. Tighten nut. Thread 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 furnished in kit. | |||||||||||||||
| 30. | Secure Tour-Pak and complete electrical connections into wiring harness to vehicle. NOTE Early models have the lid tether anchored to the Tour-Pak bottom at various locations. If installing this liner on models that have a tether location that does not align with the cutout in the liner, it will be necessary to cut a notch in the liner to allow clearance for the tether. Locate the placement of the tether and cut a notch in the liner that creates enough clearance for the tether. | |||||||||||||||
| WARNING After installing Tour-Pak, pull upward to be sure it is locked in position. While riding a loose Tour-Pak can shift causing loss of control, which could result in death or serious injury. (00572b) | ||||||||||||||||
| 31. | See Figure 11. Remove the adhesive backing from the hook and loop strip (2) and press the strip into place on the Tour-Pak bottom (3). Press the liner (1) firmly into place. | |||||||||||||||
| 32. | Install the owner's manual pouch. | |||||||||||||||
| 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) | ||||||||||||||||
| 33. | Connect battery, positive cable first. | |||||||||||||||
| 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) | ||||||||||||||||
| 34. | Install seat using original hardware. | 
Figure 10. Antenna Adapter and Hole Plug 
Figure 11. Install Liner |
SERVICE PARTS
Figure 12. Service Parts: King Tour-Pak Wrap-Around Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Template (not shown) | 50002-01 |
2 | Tour-Pak liner (not shown) | 53278-97 |
3 | Wrap-around light subassembly (includes Items 4 through 22) | Not Sold Separately |
4 | Lamp housing assembly | Not Sold Separately |
5 | Plug (2) | 90493-83 |
6 | Screw, hex (6) | 4930 |
7 | Washer, flat (6) | 6716 |
8 | Cable strap (6) | 10006 |
9 | Trim, solid black (not shown) | Not Sold Separately |
10 | Clip, housing (2) | 58380-89 |
11 | Nameplate (shown installed) | 58381-89 |
12 | Rubber seals -Seal, long rubber -Seal, short rubber | 58382-89 |
13 | Cable assembly | 70648-00 |
14 | Adapter, antenna (2) | 76260-89 |
15 | Nut, acorn (6) | 90844-80 |
16 | Silicone sealant | 99710-88 |
17 | Butt splice, red (3) | 70585-93 |
18 | Butt splice, blue (2) | 70586-93 |
19 | Adapter harness | 70307-97 |
20 | Wire, blue (2) (not shown) | Not Sold Separately |
21 | Wire, black (2) (not shown) | Not Sold Separately |
22 | Socket housings (2) (not shown) | 73152-96BK |