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TOUR-PAK® LUGGAGE AND SADDLEBAG INTERIOR LIGHT KITS
J033562011-01-13
GENERAL
Kit Number
54331-04A, 54332-04B, 54333-04A
NOTE
Kit number 54331-04A includes the Tour-Pak® and Saddlebag lights.
Kit number 54332-04B includes ONLY the Tour-Pak lights.
Kit number 54333-04A is a Saddlebag Light Expansion Kit for vehicles already equipped with a Tour-Pak light.
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Kit Contents
See Figure 7 and Table 1.
INSTALLATION
For Kit 54333-04A: Begin at Step 9.
For ALL other kits:
Preparation for Service
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
  1. Refer to the Owner's Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware.
Tour-Pak Interior Light/Controller Installation
  1. Open the Tour-Pak® lid.
  2. See Figure 1. Remove the retaining nut (1) and lockwasher (2) from the latch arm (cam hook) (3) on the lid latch. Remove the cam lock.
  3. Remove the large lock nut (4) and the lock guide (with tab, as on 5).
  4. Slide the light/controller and bracket (6) with the long tab (5) oriented into the Tour-Pak over the flats on the lock.
  5. Thread on the large lock nut (4) and tighten.
  6. Orient and slide the cam hook (3) over the flats on the lock.
  7. Install the lockwasher (2) and retaining nut (1) and tighten securely. For Kit 54331-04A: Continue at Step 9. For Kit 54332-04B: Proceed to Step 13.
1Retaining nut
2Lockwasher
3Cam hook
4Large lock nut
5Long tab on light/controller bracket
6Light/controller and bracket
Figure 1. Mount Light/Controller to Tour-Pak Lid Latch
Saddlebag Light Element Installation
1. Models equipped with mat: Fold back the mat at the bottom of the Tour-Pak. Models equipped with liner: Remove the fasteners inside the Owner's Manual pouch on the back wall of the Tour-Pak and lift out the liner.
2. Remove the rubber bumpers under the front corners of the Tour-Pak.
NOTE
The flared end of the rubber housing around the saddlebag light element LED and lens will match the edge curve of the Tour-Pak (see Figure 2 ).
3. Run the three leads from each saddlebag light element through the correct bumper hole, and press the threaded studs on the light elements into the bumper holes.
4. Capture the studs of each light element with two nylon nuts from the kit, and tighten all four nuts to 0.68–1.22 N·m (6–10 in-lbs).
Figure 2. Saddlebag Light Element on Tour-Pak
For Kit 54333-04A: Proceed to Step 23.
For ALL other kits: Continue at Step 13.
Wire Harness Routing
5. For ALL Kits: Using alcohol wipes from the kit, prepare the interior surface of the Tour-Pak lid for adhesive backed wire retainers at several equally spaced locations around the front of the Tour-Pak lid (see Figure 3 ).
1Wire retainers
2Wire harness
3Light/controller
Figure 3. Suggested Wire Retainer Locations on Lid
6. Peel the backing from three wire retainers (1) and press them into position on the inside of the lid.
7. Run the wire harness (2) from the light/controller (3) around the inside face of the front edge of the Tour-Pak lid.
8. Install cable ties from the kit through the wire retainers and around the harness conduit.
NOTE
Allow sufficient slack so that the Tour-Pak lid will open and close without pinching the harness at either the front or along the hinge line of the Tour-Pak.
9. Using alcohol wipes from the kit, prepare the interior surface of the Tour-Pak base at several locations for adhesive backed wire retainers (see Figure 4 ).
10. Peel the backing from several wire retainers and press them into position on the inside of the Tour-Pak base.
11. Loop the long side of the controller harness forward of the front hinge and down the side of the Tour-Pak base.
12. Fold the controller conduit back on itself, and loosely install cable ties through the wire retainers and around the wire conduit.
13. Lay the harness connector over toward the opposite corner along the front face of the Tour-Pak.
1Retainer locations
Figure 4. Suggested Wire Retainer Locations in Base
14. Install cable ties through the remaining wire retainers and around the harness conduit. For Kit 54331-04A: Continue at Step 23. For Kit 54332-04B: Proceed to Step 26.
Saddlebag Light Element Connection to Harness
15. See Figure 5. Match the wire colors of the saddlebag light leads (2) to the wire colors in the left- and right-side three-way pin housings in the Tour-Pak light/controller harness (white to white, red to red, black to black).
NOTE
The tangs on the saddlebag light lead-wire socket terminals must be installed in the cavities of the three-way socket housings on the side opposite the external latch.
1Connector half
2White, red and black wire leads
Figure 5. Saddlebag Light Element
16. One at a time, position each saddlebag light lead to the correct cavity of a three-way socket housing. Snap the socket terminals into the cavities.
17. Mate the socket housings to the three-way pin housings in the Tour-Pak light/controller harness.
For Kit 54333-04A: Proceed to Step 36.
For ALL other kits: Continue at Step 26.
Connection to Vehicle Harness
18. For ALL Kits: See Figure 6. Remove the large split grommet (1) from the corner of the Tour-Pak.
Figure 6. Split Grommet
19. See Figure 7. Obtain the harness extension (3) with the in-line fuse (4) from the kit. Fit the connector end through the grommet hole in the Tour-Pak. The conduit end with the in-line fuse, black and red wires and ring terminals will be routed to the battery.
20. Mate the harness extension two-way socket housing to the two-way pin housing on the Tour-Pak light/controller harness (2).
21. Fit the grommet over the harness extension conduit, and press the grommet groove into the grommet hole in the Tour-Pak.
22. Route the ring terminated wire leads along the inside of the frame rails so that the red power lead fits to the positive (+) battery terminal and the black ground lead fits to the negative (-) battery terminal.
23. Coat the ring terminal on the red lead with dielectric grease (7) from the kit. Thread the battery bolt through the ring terminal and through the red positive (+) cable into the battery positive (+) terminal.
24. Coat the ring terminal on the black lead with dielectric grease. Thread the battery bolt through the ring terminal and through the black negative (-) cable into the battery negative (-) terminal.
25. Tighten the terminal bolts to 6.8–10.9 N·m (60–96 in-lbs).
26. With the red and black leads routed to avoid chafing or heat points, use cable straps (6) to attach the wire leads to the vehicle wire harness in at least two locations.
27. Verify that the Tour-Pak lid opens and closes without pinching the harness, then tighten the cable straps and cut off the ends.
Return to Service
28. Models equipped with mat: Straighten the mat at the bottom of the Tour-Pak. Models equipped with liner: Install the liner, and secure the Owner's Manual pouch to the back wall of the liner with the fasteners removed earlier.
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)
29. Check each light for proper operation. Press in firmly on the center of the lens to activate the switch and turn the light on. Press again to turn the light off.
NOTE
The Tour-Pak light has a feature that disables the light after five minutes if the Tour-Pak contents press against the light and activate the switch.
If the light has been disabled in this manner, it can be re-enabled by disconnecting the two-way pin housing on the Tour-Pak light/controller harness from the harness extension socket housing, and then re-connecting the harnesses.
SERVICE PARTS
Figure 7. Service Parts, Tour-Pak Luggage and Saddlebag Interior Light Kits
Table 1. Service Parts Table
Kit
Item
Description (Quantity)
Part Number
Kit 54331-04A
3-Light Tour-Pak®
and Saddlebag
Lights
1
1-Light Tour-Pak Light Kit (includes Items 2 through 8)
54332-04B
2
  • Tour-Pak light, lens and wire harness assembly
Not sold separately
3
  • Harness extension
90103-06A
4
  • Fuse, 5 Amp
70333-06
5
  • Wire retainer (10)
11769
6
  • Cable strap (14)
10126
7
  • Dielectric grease pack
Not sold separately
8
  • Alcohol wipe
94678-00Y
9
Saddlebag Light Expansion Kit (includes Items 10 through 12)
54333-04A
10
  • Saddlebag light assembly (2)
Not sold separately
11
  • Nylon nut, 1/4-28 (4)
Not sold separately
12
  • Socket housing, three-way (2)
Not sold separately