TOUR-PAK RACK LIGHT KIT
J046692010-12-16
GENERAL
Kit Number
68250-08A, 68271-08A
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 and installation of additional parts or accessories may be required for proper installation of this kit on your model motorcycle. See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
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
| 1. | Remove all contents from Tour-Pak®. | |||||
| 2. | For easier installation, remove Tour-Pak rack, if installed, by removing cap screw, washers and mounting pads. | |||||
| 3. | See Figure 1. Remove rubber plug from bottom rear rail on left side of rack. | |||||
| 4. | See Figure 2. Use line wire feeder in kit to thread through left rear rack foot and out through the back opening of rail. | |||||
| 5. | Attach light harness wires to line wire feeder loop. | |||||
| 6. | Carefully pull line wire feeder and light harness wires through rack mounting foot. | |||||
| 7. | See Figure 5 and Table 1. Apply foam pads (5) to top surface of light. | |||||
| 8. | Secure light (1) to rack with socket head screws (4) and washers (6). | 
Figure 1. Left Side Rack Plug 
Figure 2. Thread Wires Through Rack | ||||
| 9. | Position rack/light assembly to Tour-Pak lid and route wires through lid, washer and hollow mounting bolt. | |||||
| 10. | Attach rack/light assembly to Tour-Pak using instructions and hardware provided with rack except for use of hollow bolt from Step 9. | |||||
| 11. | Remove Tour-Pak liner. | |||||
| 12. | Thread wires through black vinyl conduit. | |||||
| 13. | Ultra Classic models: Follow Steps 14 through 21. | |||||
| 14. | Locate and disconnect three pin AMP connector for Tour-Pak lights. | |||||
| 15. | See Figure 3. Attach the Y-harness (item 2, Figure 5) to the three pin male connector (1) of Tour-Pak harness. | |||||
| 16. | Route light wires from back of Tour-Pak along left side to front. Secure conduit with adhesive clips provided in kit. | |||||
| 17. | Trim length of light wires and conduit to reach Y-harness. | |||||
| 18. | See Figure 5. Refer to the Service Manual electrical appendix to install terminal pins (8) to rack light wires and install terminals to three pin housing (7) as follows: a. #1 cavity = blue lead b. #2 cavity = red with yellow lead c. #3 cavity = black lead | |||||
| 19. | Connect rack light to remaining Y-harness connector. | |||||
| 20. | Replace Tour-Pak liner. | |||||
| 21. | Check operation of Tour-Pak tail and stop light functions before operating motorcycle. | |||||
| 22. | Classic models: See Figure 4. If necessary, drill hole in lower left bottom of Tour-Pak and install grommet. Route rack light wires through grommet. | |||||
| 23. | Refer to the Service Manual electrical appendix to install terminal receptacle (8) to rack light wires and install terminals to three pin receptacle housing (7) as follows: a. #1 cavity = blue lead b. #2 cavity = red with yellow lead c. #3 cavity = black lead NOTE To prevent corrosion, fill the cavities of the connectors with dielectric grease (included in kit) prior to making connections. As an additional precaution against moisture seepage into the Tour-Pak, apply silicone sealant (not included in kit) to the entrance of the light harness wire tunnel. See figure 2 for location reference. | |||||
| 24. | Connect rack light to male connector of two connector wire harness (12) and connect to accessory connector under seat. | |||||
| 25. | Replace Tour-Pak liner. | |||||
| 26. | Check operation of Tour-Pak tail and stop light functions before operating motorcycle. |
| 1 | Tour-Pak lights connector |
Figure 3. Tour-Pak Harness Connector
| 1 | Accessory connector |
Figure 4. Under Seat Accessory Connector
SERVICE PARTS
Figure 5. Service Parts: LED Rack Light
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | LED light assembly | Not Sold Separately |
2 | Auxiliary wiring harness | Not Sold Separately |
3 | Dielectric grease (not shown) | Not Sold Separately |
4 | Socket head screw, 8-32, stainless steel (2) | Not Sold Separately |
5 | Pad (2) | Not Sold Separately |
6 | Flat washer, 0.172 x 0.375 x 0.035, stainless steel (2) | Not Sold Separately |
7 | Pin housing, 3 place | 73103-96BK |
8 | Pin terminal, 16-20 AWG (3) | 73190-96 |
9 | Grommet | 11507 |
10 | Cable strap (4) | 10006 |
11 | Clip, adhesive backed (4) | 10102 |
12 | Wiring harness, auxiliary light | Not Sold Separately |
13 | Conduit, 42 inches long (not shown) | Not Sold Separately |
14 | Wire guide, nylon monofilament (not shown) | Not Sold Separately |