1. | Refer to the Service Manual, and follow the instructions given to remove the seat. | |||||||||||||||||||||
WARNING Disconnect 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) | ||||||||||||||||||||||
2. | See BATTERY; DISCONNECTION AND REMOVAL in the Service Manual, and remove the battery from the vehicle. NOTE The Tour-Pak does not have to be removed from the vehicle to perform this installation. | |||||||||||||||||||||
3. | Open the Tour-Pak lid and remove all items from the Tour-Pak base. |
Figure 1. Template Placement (Type 1 Tour-Pak) | ||||||||||||||||||||
4. | Models equipped with mat:Models equipped with liner:if the Tour-Pak interior has a MEDIUM GRAY, GLOSSY finish
(Type 1 Tour-Pak): Do not remove the liner at this time. if the Tour-Pak interior has a MATTE BLACK finish (Type 2
Tour-Pak): a. Remove the mat. b. See Figure 5. Obtain the Hands Free Phone Interface Module (1), harness (6) and alcohol wipe (2) from the kit. c. Connect the Hands Free harness connector to the module. d. With the connector at the bottom, center the module on the left side wall of the Tour-Pak between the two hinges. For King Tour-Pak: The top of the module should be below the top edge, and the connector should not contact the floor of the Tour-Pak base. For Chopped Tour-Pak: The top of the module may rise above the top edge of the Tour-Pak base, but the connector should not make contact with the floor of the Tour-Pak base. Mark the module mounting area on the Tour-Pak wall. e. See Figure 1. Obtain the template (1) from the kit. f. Follow the directions on the template. Place the template as shown on the left side of the Tour-Pak, lining up the top and left edge of the template with the top edge and the raised feature toward the rear of the liner. Fit the bottom of the template to the raised rib on the floor of the liner. g. Tape the template to the top edge of the liner, in the locations marked AREA 1 and AREA 2. h. Cut along the dashed line near the bottom of the template, and discard the lower portion. i. Tape the template to the liner in the two locations marked TAPE. j. Trace around the rectangular cutout area of the template onto the liner. k. Open the map pocket, and remove the acorn nuts with flat washers. Remove the map pocket and liner. Use a utility knife to cut out the marked area on the liner side wall. l. Open the map pocket, and remove the acorn nuts with flat washers. Remove the map pocket and liner. m. See Figure 2. Locate the recessed feature (shaded area) on the outside left wall of the liner (1). n. Measure down 3-3/8 in. (86 mm) (3) from the top of the recess (2), and mark a horizontal line (5) across to both vertical sides of the recess. Mark vertical lines upward to meet the sides of the recess (4) and clearly define the 3-3/8 in. x 6-3/8 in. (86 x 162 mm) area to be cut out. o. Use a utility knife to cut out the marked area on the liner side wall. |
Figure 2. Cutting the Opening in the Liner (Type 2 Tour-Pak)
Figure 3. Hands Free Interface Harness Drilling Location (Type 1 Tour-Pak) | ||||||||||||||||||||
5. | If the Tour-Pak is drilled for wiring at the lower left
forward edge: Proceed to Step 6. If the Tour-Pak IS NOT drilled for wiring at the lower left
forward edge, AND:if the Tour-Pak interior has a MEDIUM GRAY, GLOSSY finish
(Type 1 Tour-Pak):if the Tour-Pak interior has a MATTE BLACK finish (Type 2
Tour-Pak): a. See Figure 3. Measure and determine the center (1) of the support plate (2) that covers the floor of the Tour-Pak. b. Lay a strip of 2 in. (51 mm) wide masking tape from the front to about half-way back down the approximate center of the support plate. c. Very carefully measure again, and mark the center of the support plate at the front of the tape strip, and again near the back. Draw a straight line through the two marks. d. Facing the tape, measure 7-1/2 in. (190 mm) from the center line to the left side floor of the Tour-Pak. e. Lay a strip of 2 in. (51 mm) wide masking tape on the Tour-Pak floor in front of the support plate at the 7-1/2 in. (190 mm) distance from the center line, from the support plate to the front wall. f. Very carefully measure again, and mark the tape 7-1/2 in. (190 mm) from the center line, near the front wall and again near the support plate. Draw a line between the two marks. g. Measure forward 5/8 in. (16 mm) from the front edge of the support plate, and draw a short line across the line drawn in the step above. h. Mark the center of the crossed lines with a center punch, then drill a 1/8 in. (3 mm) guide hole through the Tour-Pak floor. i. Lay a strip of 2 in. (51 mm) wide masking tape on the outer surface of the Tour-Pak floor, centered on the guide hole. Poke a hole in the tape at the guide hole. j. From the underside of the Tour Pak drill a 3/4 in. (19 mm) hole from the outside of the Tour-Pak to the inside. k. Remove the tape. Lightly sand to remove burrs and sharp edges. Clean the inside and outside Tour-Pak surfaces of tape residue with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. l. See Figure 4. Measure and determine the center (1) of the inside front Tour-Pak wall. m. Lay a strip of 2 in. (51 mm) wide masking tape from top to bottom over the approximate center of the inside front Tour-Pak wall. n. Very carefully measure again, and mark the center near the top of the tape strip. Measure and mark the center near the bottom of the strip. Draw a line from the top mark to the bottom mark. o. Facing the tape, measure 6-3/8 in. (162 mm) from the center line to the left side front Tour-Pak wall. Do not follow the curve of the wall, but measure straight across. See Figure 4 inset. p. Lay a strip of 2 in. (51 mm) wide masking tape from the bottom to approximately half way up the inside front Tour-Pak wall at the 6-3/8 in. (162 mm) distance from the center line. q. Very carefully measure again, and mark the tape 6-3/8 in. (162 mm) straight across from the center line, near the top of the tape strip and again near the bottom of the strip. Draw a line from the top mark to the bottom mark. r. For King Tour-Pak: Measure down 7-19/32 in. (193 mm) from the top edge of the Tour-Pak. For Chopped Tour-Pak: Measure down 4-19/32 in. (117 mm) from the top edge of the Tour-Pak. Draw a short horizontal line across the vertical line. s. Mark the center of the crossed lines with a center punch, then drill a 1/8 in. (3 mm) guide hole through the Tour-Pak front wall. t. Lay a strip of 2 in. (51 mm) wide masking tape on the outer surface of the Tour-Pak front wall, centered on the guide hole. Poke a hole in the tape at the guide hole. u. From the outside of the Tour Pak drill a 3/4 in. (19 mm) hole through the guide hole to the inside. v. Remove the tape. Lightly sand to remove burrs and sharp edges. Clean the inside and outside Tour-Pak surfaces of tape residue with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. |
Figure 4. Hands Free Interface Harness Drilling Location (Type 2 Tour-Pak) | ||||||||||||||||||||
6. | ALL models: Re-install the rubber mat or molded liner into the Tour-Pak base. | |||||||||||||||||||||
7. | Models with mat AND hole drilled in Tour-Pak front
wall:Models with liner OR hole drilled in Tour-Pak floor: a. Proceed to Step 8. b. Trace the outline of the drilled hole to transfer the size and exact location onto the mat or liner. c. Remove the mat or liner. d. Use a small knife to open a hole in the mat or liner to line up with the wiring hole. e. Re-install the mat or liner | |||||||||||||||||||||
8. | See Figure 5. Obtain the Hands Free Phone Interface Module (1) and alcohol wipe (2) from the kit. | |||||||||||||||||||||
9. | Use the wipe to thoroughly clean the mounting surface of the Hands Free Module and the inner surface of the Tour-Pak base in the module mounting area (8). |
1 | Hands free phone interface module |
2 | Alcohol wipe |
3 | Hands free phone interface antenna |
4 | Adhesive tape (two-sided) |
5 | Dual-Lock mounts (2) |
6 | Hands free phone interface harness |
7 | Grommet |
8 | Cleaned area on the Tour-Pak side wall |
10. | Obtain the antenna (3) and two-sided adhesive tape (4) from the kit. Peel the white liner from the tape, and apply the tape squarely onto the antenna body. | |
11. | Peel the clear liner from the tape. Press the antenna, with the cable downward, into the center of the cleaned surface of the Hands Free Module. Hold for about 60 seconds to set the adhesive. | |
12. | Obtain the four Dual-LockTM mounts (5) from the kit. Assemble squarely into two sets of fasteners. NOTE For King Tour-Pak: Center the fasteners equally between the top and bottom of the module. For Chopped Tour-Pak: Align the bottom edge of the fasteners with the bottom edge of the module. | |
13. | Peel the liner from the adhesive backing on one side of each assembled fastener, and press the fasteners onto the cleaned surface of the Hands Free module, centering each fastener between the antenna and the edge of the module. | |
14. | Unless already assembled to the module, obtain the Hands Free harness (6) and place it into the Tour-Pak. | |
15. | Connect the harness connector to the module in the Tour-Pak. Connect the beige antenna connector to the module. NOTE For Tour-Paks without liner: With the connector at the bottom, center the module on the left side wall of the Tour-Pak between the two hinges. Make sure the mounting area has been thoroughly cleaned with the alcohol wipe. For King Tour-Pak: The top of the module should be below the top edge, and the connector should not contact the floor of the Tour-Pak base. For Chopped Tour-Pak: The top of the module may rise above the top edge of the Tour-Pak base, but the connector should not make contact with the floor of the Tour-Pak base. | |
16. | Peel the liner from the adhesive backing on the remaining side of each fastener. Press the Hands Free module squarely and firmly into place in the cleaned area on the side of the Tour-Pak base, and hold for about 60 seconds to set the adhesive. After releasing pressure, allow about 20 minutes before exerting force on the module. | |
17. | Thread the loose end of the Hands Free harness through the hole at the left front and out of the Tour-Pak, leaving only enough harness to easily rest on the floor of the Tour-Pak. NOTE If a grommet is already installed in the Tour-Pak hole, remove it and replace with the grommet from this kit, which has a larger opening for the additional wires. | |
18. | Obtain the grommet (7) from the kit. Install the grommet onto the harness near the hole in the Tour-Pak. Carefully work the grommet into the hole to seal the opening around the harness. | |
19. | Close and latch the Tour-Pak lid. | |
20. | Route the harness forward on the vehicle: a. along the left-side Tour-Pack support. Use a tie strap from the kit to fasten the harness to the support. b. Continue forward, tucking the harness inboard of the frame tube and avoiding the forward saddlebag guard mounting screw head so the harness does not get pinched by the seat. Use four tie straps from the kit to fasten the harness to the frame tube. c. Route the harness along the left side of the battery cavity and harness tray to the rear of the fuel tank. NOTE If not already installed, the Fairing Speaker Switch and Left-Hand Control Switch Assembly (purchased separately, individually or as part of the Communication Switch Kit) must be installed at this time according to the instructions that follow. | |
21. | On the fairing cap, remove the inner left side hole plug. See Figure 8 and the FAIRING CAP SWITCHES (FLHTC/U) section in the Service Manual. Install the fairing speaker switch in the opening as follows: If a cruise control switch IS present:See FAIRING CAP SWITCHES (FLHTC/U) in the Service Manual. Install the Fairing Speaker Switch (purchased separately or as part of the Communication Switch Kit) in the opening and connect the wiring already there. If a cruise control switch IS NOT present: a. Obtain the speaker switch adapter wire (purchased separately or as part of the Communication Switch Kit) and the butt splice connector included with the speaker switch. b. Refer to SEALED BUTT SPLICE CONNECTORS in the Service Manual. Splice the adapter wire to the black/ green speaker switch lead. c. Insert the terminated end of the adapter wire into cavity 12 of the fairing cap switch connector [105B] | |
22. | Remove the original equipment left-hand control switch assembly per the HANDLEBAR SWITCHES, REMOVAL, LEFT HANDLEBAR CONTROLS instructions in the Service Manual. | |
23. | Install the new left-hand control switch assembly (purchased separately or as part of the Communication Switch Kit). | |
24. | Remove the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD REMOVAL in the Service Manual. | |
WARNING When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) | ||
25. | ALL models: Install the Console Pod Assembly. a. Note the routing of the main harness, fuel level sender/ fuel pump conduit, and fuel vapor vent tube as they travel beneath the console. b. Carefully cut the anchored cable strap securing the main harness, fuel level sender/ fuel pump conduit, and fuel vapor vent tube to the left side of the frame backbone. c. Open the fuel door on the console. Remove the two Allen head screws inboard of the rubber bumpers. These screws secure the console to the clip nuts on the canopy bracket. All models EXCEPT FLHX: Remove the Allen head screw to detach the flange at the rear of the console from the clip nut on the fuel tank weldment. FLHX models: Remove the bolt (with flat washer) at the rear of the fuel tank to release the console bracket. This also frees the rear of the tank from the frame backbone. Remove the two screws that fasten the fuel door to the console, and remove the door. Remove the hinge mounting clip, and the hinge pin. Save these parts for re-installation. d. Lay a clean shop towel on the forward part of the rear fender. Remove the filler cap from the neck of the fuel tank. All models EXCEPT FLHX: Remove the console and lay it upside down on the shop towel. Re-install the filler cap. FLHX models: Remove the console and discard it. Re-install the filler cap. Obtain the new fuel tank console (Part Number 61270-98A, sold separately). Install the fuel door to the new console, and tighten securely. Lay the console upside down on the shop towel. Re-install the bolt (with flat washer) to secure the rear of the fuel tank to the frame backbone. Tighten the bolt to 15-20 ft-lbs (20-27 Nm). e. Feed the pin housing and console pod conduit through the top of the console, seating the Console Pod Assembly (Part Number 77136-03, sold separately) in the recess. Install three Phillips screws (Part Number 2462, also sold separately) from the underside to secure the pod to the console. Alternately tighten the screws to 6-11 in-lbs (0.7-1.2 Nm). Route the pod harness toward the front of the console. |
1 | 8-place pin housing |
2 | 8-place socket housing [187], labelled "Hands Free Module" |
3 | 35-place socket housing [28] to radio |
4 | 12-place pin housing [53], labelled "Intercom" to console pod |
5 | 6-place pin housing [6A], labelled "Interconect" |
1 | 8-place pin housing |
2 | 8-place socket housing [187], labelled "Hands Free Module" |
3 | 35-place socket housing [28] to radio is part of vehicle audio harness. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Hands free phone interface module | 76222-06A |
2 | Hands free interface antenna | 76311-06A |
3 | Adhesive tape (two-sided) | Not Sold Separately |
4 | Template | 94458-06 |
5 | Alcohol wipe | 74678-00Y |
6 | Dual Lock mount (4) | 76434-06 |
7 | Harness, hands free interface | 76467-06 |
8 | Grommet | 11507 |
9 | Tie wrap (10) | 10006 |
10 | Owner's Manual (not shown) | 76409-06 |
Items mentioned in text, but not included in kit: | ||
A | Tour-Pak liner | |
B | Ultra overlay harness | |
C | Non-Ultra overlay harness | |
D | 35-way connector [28] | |
E | 8-way connector [187] |