TOUR-PAKS FOR FLHP, FLHTP POLICE MODELS
J050892010-03-12
GENERAL
Kit Number
54177-10, 54178-10, 54179-10, 54180-10
Models
This Police Tour-Pak® Kit is designed for installation on 2000 and later FLHP and FLHTP (Police) model motorcycles.
NOTE
This accessory must be removed when vehicle is sold for non-police use. Follow all applicable federal, state and local regulations when changing to a civilian vehicle.
Additional Parts Required
2009 and later models will require separate purchase and installation of a Police Tour-Pak Adapter Plate Kit (H-D Part No. 53196-09) to complete the installation. See Figure 14 and Table 2.
2008 and earlier models will require separate purchase of the following items:
Table 1. Additional Items, 2008 and Earlier Models
Description (Quantity) | Part Number |
|---|---|
Support tube mounting block | 53906-01 |
Air reservoir mounting block | 53905-01 |
Flange nut, 1/4-20, with lock (2) | 7716 |
Cap screw, hex head, 1/4-20 x 63.5 mm (2.5 in) long (5) | 3768 |
Plain washer, 1/4 in. (10) | 6235 |
Machine screw, pan head Phillips, #10-24 x 41.3 mm (1⅝ in) long, special (2) | 2581 |
Plain washer, #10 (2) | 6716 |
LED emergency lights are sold separately in a variety of colors. Installation of LED lights requires separate purchase of an auxiliary battery (H-D Part No. 65989-97C).
Tools and Supplies Required
Electrical Contact Lube (H-D Part No. 99861-02) or equivalent is required for the proper installation of this kit. This item is available from a Harley-Davidson dealer.
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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
PREPARATION
NOTE
See Figure 1. 2008 and earlier models use five screws (Item 1). 2009 and later models use four screws.
| 1 | Police tray screw (4 for 2009+; 5 for 2008-) |
| 2 | Air reservoir mounting screw (2) |
| 3 | Police equipment mounting tray |
| 4 | License plate spacer (2) |
| 5 | Spacer (3) |
| 6 | 2008 and earlier models |
| 7 | 2009 and later models |
Figure 1. Remove Police Tray and Hardware
| 1. | Remove the two Phillips-head air reservoir mounting screws (2) and lockwashers, and the five hex head cap screws (1), washers and nuts securing the original equipment (OE) police mounting tray (3) to the support rails. For 2008 and earlier models, leave the two rectangular license plate spacers (4) in place, and set aside the three remaining spacers (5) for later installation. Discard the screws and washers, but save the nuts for later installation. Discard the tray. NOTE Wrap the reservoir with a clean shop towel so it doesn't scratch the paint. | |||||||||||||||||||||||||||||||
| 2. | See Figure 2. Carefully remove the Tour-Pak assembly and hardware from the shipping container. Open the Tour-Pak lid, and remove the four hex head screws (2) and washers (3) securing the upper mounting plate (1). Remove the four hex standoffs (5) and the flange nut (6) securing the lower mounting plate or power supply mounting plate (4) to the isolator studs (8). For 2009 and later models only: Remove the five flange nuts (9) on the outside of the Tour-Pak securing the isolator studs. Remove the isolator studs. | 
Figure 2. Remove Upper and Lower Plate Hardware 
Figure 3. Access Tour-Pak Mounting Locations (2008 and Earlier Shown) 
Figure 4. Remove Trim Panel (2007 and Earlier Models) | ||||||||||||||||||||||||||||||
| 3. | For ALL models: See Figure 3. Raise the rear edge of the lower mounting plate/power supply mounting plate (1), and lean the plate up against the front of the Tour-Pak to provide access to the isolator studs (2), and the Tour-Pak mounting hole (3) locations for 2008 and earlier models. If necessary, use a cable strap (not supplied) to hold the mounting plate in place. Temporarily set the Tour-Pak assembly aside. | |||||||||||||||||||||||||||||||
| 4. | For 2007 and earlier models: See Figure 4. Remove the quick release clip from the seat pin (1), and pivot the seat forward as far as possible. It may be necessary to tie or brace the seat in the full forward position. For 2008 and later models: Remove the pin and pivot bolt at the front of the seat. | |||||||||||||||||||||||||||||||
| 5. | Remove the two nuts (2) and washers securing the seat trim panel assembly to the fender, and remove the panel. Save the panel and hardware for later installation. | |||||||||||||||||||||||||||||||
| 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) | ||||||||||||||||||||||||||||||||
| 6. | Refer to the service manual and follow the instructions to disconnect the battery cables, negative (-) cable first. | |||||||||||||||||||||||||||||||
| 7. | Cut the two cable straps (3) securing the pole lamp connector [59B] harness leg (with black and red/green wires) to the support rail. Discard the cable straps. Route the pole lamp wires away from the Tour-Pak mounting area. Proceed to INSTALLATION for the correct year vehicle. |
INSTALLATION
2008 and Earlier Models
| 1. | See Figure 3. Measure to locate the centers of the semi-circular bosses molded in the bottom of the Tour-Pak. Mark the center position of each boss. Support the Tour-Pak with wood blocks and drill a 1/16 inch (1.5 mm) diameter pilot hole through the Tour-Pak at each location. Drill a 5/32 inch (4 mm) diameter hole at each pilot hole. | |||||||||||||||
| 2. | See the upper section of Figure 5. Install four 1/4-20 x 63.5 mm (2.5 in) long hex head screws (1) with 1/4 in washers (H-D Part Nos. 3768 and 6235, both purchased separately) from inside the bottom shell of the Tour-Pak through the four mounting holes drilled in Step 1. | |||||||||||||||
| 3. | Lift the Tour-Pak and position it onto the support rails, aligning the four mounting bolts with the four holes in the rails (two on each side). See the lower section of Figure 5. Make sure the two license plate bracket spacers (3) remain in position and the bolts can pass through them. Get the two rectangular luggage rack spacers (2) and four nuts saved earlier. Get four 1/4 in washers (H-D Part No. 6235, purchased separately), and loosely install the washers and nuts to secure the Tour-Pak to the support rails. | |||||||||||||||
| 4. | See Figure 6. Get the support tube mounting block (with one hole, H-D Part No. 53906-01), a 1/4-20 x 63.5 mm (2½ in) long hex head bolt (H-D Part No. 3768) and two 1/4 inch flat washers (H-D Part No. 6235), all purchased separately. Also get the rectangular spacer and nut removed earlier. | |||||||||||||||
| 5. | Install one washer to the bolt, and position the bolt above the hole at the rear center of the Tour-Pak above the support tube block mounting position. | |||||||||||||||
| 6. | Orient the rear mounting block with the hole running vertical, and position it between the recessed area of the Tour-Pak (near the center) and the support rail. Install the bolt through the Tour-Pak, mounting block and rail, then loosely Install the spacer followed by the washer and nut. | 
Figure 5. Install Tour-Pak Mounting Hardware (2008 and Earlier Shown) 
Figure 6. Tour-Pak Rear Mounting (2008 and Earlier) | ||||||||||||||
| 7. | Get the air reservoir mounting block (with two holes, H-D Part No. 53905-01, purchased separately), and two #10-24 x 41.3 mm (1⅝ in) long pan head Phillips screws (H-D Part No. 2581) and #10 flat washers (H-D Part No. 6716) from the kit. | |||||||||||||||
| 8. | See Figure 7. Install a flat washer to each Phillips screw, and position the screws above the two holes near the front center of the Tour-Pak, above the air reservoir mounting block position. | 
Figure 7. Install Tour-Pak Front Mounting Bracket - '08 & earlier | ||||||||||||||
| 9. | Position the air reservoir block (2), with holes running vertical, between the Tour-Pak and air reservoir mounting bracket (1). Install the screws through the Tour-Pak and mounting block, and thread into the air reservoir mounting bracket. Tighten the screws to 2.5 N·m (22 in-lbs). | |||||||||||||||
| 10. | Return to the Tour-Pak mounting hardware previously installed, and alternately tighten to 6.8–9.5 N·m (5–7 ft-lbs). | |||||||||||||||
| 11. | Reposition the lower mounting plate/power supply mounting plate onto the isolator studs, and install a 1/4-20 hex flange nut onto the forward center stud. Install the four hex standoffs previously removed onto the remaining studs. Tighten the flange nut and standoffs to 9 N·m (80 in-lbs). | |||||||||||||||
| 12. | If installing LED Emergency Light Kits, proceed to that section. If NOT installing LED Emergency Light Kits, proceed to Tour-Pak Electrical Connection to Vehicle. |
2009 and Later Models
| 1. | See Figure 8. Remove the two screws (2) from the air reservoir mounting bracket. Get the adapter plate kit (H-D Part No. 53196-09, purchased separately). Align the adapter plate and install the reservoir bracket screws through the holes in the adapter plate into the reservoir mounting bracket. Install the adapter plate to the support rails with the four hex socket head screws (1) and washers from the adapter plate kit. Tighten the screws to 2.5 N·m (22 in-lbs). | |||||||||||
| 2. | Lift the Tour-Pak and position it onto the adapter plate, aligning the holes in the bottom of the Tour-Pak with the five holes in the adapter plate. | |||||||||||
| 3. | See Figure 9. Insert the five rubber isolators (1) into the holes with the longer studs down, thread them through the Tour-Pak into the adapter plate, and tighten securely. Install a 1/4-20 x 12.7 mm (½ in) screw (2) and washer (3) from the adapter kit (see Figure 14 ) through the rear center hole in the Tour-Pak and into the adapter plate. Tighten the screw to 9 N·m (80 in-lbs). | |||||||||||
| 4. | Reposition the lower mounting plate/power supply mounting plate onto the isolator studs and install a 1/4-20 hex flange nut onto the forward center stud. Install the four hex standoffs previously removed onto the remaining studs. Tighten the flange nut and standoffs to 9 N·m (80 in-lbs). | 
Figure 8. Installing Adapter Plate 
Figure 9. Install Tour-Pak Mounting Hardware | ||||||||||
| 5. | If installing LED Emergency Light Kits, proceed to the next section If NOT installing LED Emergency Light Kits, proceed to Tour-Pak Electrical Connection to Vehicle. |
Installing LED Emergency Light Kits
| 1. | Place an electrical receptacle anchor clip from this kit to the inside surface of the Tour-Pak at one LED mounting hole. Install the clip and LED light using the screws, nuts, and washers from the light kit. Tighten to 1.02 N·m (9 in-lbs) Repeat for the remaining light kits. | |
| 2. | Connect the Deutsch connectors on the LED lights with the mating connectors from the Tour-Pak wiring harness. Secure the connectors to the Tour-Pak walls by sliding them into the mounting clips. |
Installing the Auxiliary Battery
| 1. | See Figure 10. Loosely assemble the battery mounting bracket (1) to the semi-circular boss molded in the bottom of the Tour-Pak with the 3/8-16 x 25.4 mm (1 in) long hex head screw (2), two washers (3) and a flange nut (7) from the kit. | 
Figure 10. Install Auxiliary Battery | ||||||||||||||
| 2. | Orient and position the auxiliary battery (purchased separately) behind the mounting bracket as shown, placing it on the rubber battery cushion. Loosely install the battery strap (4) using two 3/8-16 x 44.4 mm (1¾ in) long hex head screws (5), four washers (6) and two flange nuts (7) from the kit. | |||||||||||||||
| 3. | Make sure the battery is centered, and the mounting bracket is positioned properly. While pushing the mounting bracket forward, tighten the bracket hardware to 13.6–16.3 N·m (10–12 ft-lbs). Return to the battery strap hardware and tighten to 13.6–16.3 N·m (10–12 ft-lbs). NOTE DO NOT CONNECT the battery terminals to the auxiliary battery at this time. | |||||||||||||||
| 4. | Locate the red (positive) and black (negative) battery cables inside the Tour-Pak. Make sure the cables are not touching each other or anything metal in the Tour-Pak. |
Tour-Pak Electrical Connection to Vehicle
| 1. | Refer to the service manual, and remove the ECM and tray for access to the main motorcycle battery. | |||||
| 2. | Locate the rear lighting wiring harness on the vehicle. Disconnect the rear lighting harness from the main vehicle harness. See Figure 17. Connect the Police Tour-Pak harness (71) to the main wire harness and rear lighting wire harness. Route the Police Tour-Pak harness from the Tour-Pak along the left upper frame tube to the rear lighting harness connector. | |||||
| 3. | Place the upper mounting plate (41) onto the four hex stand-offs (36) and secure using four 1/4-20 x 12.7 mm (½ in) hex screws (37) and washers (38). Tighten to 9 N·m (80 in-lbs). NOTE Verify that the ignition key switch is in the OFF position before attaching the battery cables. | |||||
| 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) | ||||||
| 4. | See Figure 11. Route the Tour-Pak positive battery cable with the 40 Amp in-line fuse (1) as shown, and loosely install the terminal over the currently installed positive terminal on the motorcycle battery positive post. Tuck the fuse holder into the space between the battery and the left upper frame tube as shown. Tighten the terminal to 3.4 N·m (30 in-lbs). NOTE DO NOT connect the negative battery cable at this time. | 
Figure 11. Connect Tour-Pak Battery Cables to Motorcycle Battery | ||||
| 5. | See Figure 12. Install a cable strap (1, not provided) to secure the Tour-Pak Harness to the mounting rail. | |||||
| 6. | Return to the Tour-Pak and locate the positive (black with red collar) and negative (black) battery cables inside the Tour-Pak. | 
Figure 12. Secure Tour-Pak Harness to Mounting Rail | ||||
| 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) | ||||||
| 7. | Route the positive battery cable terminal to the auxiliary battery and install the terminal to the positive battery post. Tighten the terminal screw to 3.4 N·m (30 in-lbs). | |||||
| 8. | Route the negative battery cable terminal to the auxiliary battery and install the terminal to the negative battery post. Tighten the terminal screw to 3.4 N·m (30 in-lbs). Apply a light coat of Harley-Davidson electrical contact lubricant (H-D Part No. 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. | |||||
| 9. | If not installing an auxiliary battery, remove the 40 Amp fuse from the in-line holder. Failure to do so could cause arcing from the positive cable, leading to electrical or equipment damage. | |||||
| 10. | Locate the two-way Deutsch pole lamp socket housing [59B] (with black and green/red wires) at the left rear of the vehicle under the luggage rack, and connect it to the two-way pin housing coming from the Tour-Pak. | |||||
| 11. | See Figure 11. Return to the area under the seat. Route the Tour-Pak negative battery cable (2) around the front of the motorcycle battery, and install the terminal over the currently installed negative terminal on the negative battery post. Tighten the terminal to 3.4 N·m (30 in-lbs). Apply a light coat of Harley-Davidson electrical contact lubricant (H-D Part No. 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. | |||||
| 12. | For 2007 and earlier models: See Figure 13. Install the trim panel (1) to the fender using the nuts and washers saved earlier. Install the trim panel cover to protect the battery and wiring. For 2008 and later models: Install the ECM caddy and ECM to the underseat location. | 
Figure 13. Install Trim Panel | ||||
| 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) | ||||||
| 13. | Refer to the service manual, and follow instructions to install the seat. | |||||
| 14. | Close the Tour-Pak and test the auxiliary stop/tail/turn signal (STT) light for proper operation. This light has a built-in momentary flash feature. Federal Motor Vehicle Safety Standard #108 does not allow flashing red rear lights. Approved law enforcement agencies must obtain a waiver deviating from this standard. To disable this feature and change to a standard tail
light/brake light operation: Short across the two prongs again to enable the flash pattern. a. Turn the ignition key switch to IGNITION, but do not start the motorcycle. b. With the ignition key switch ON, The CENTER section is illuminated, along with the vehicle tail lamp. c. With brake lever or brake pedal actuation, the CENTER section will brighten, along with the vehicle tail lamp. d. With left or right turn signal actuation, the end sections FLASH, along with the vehicle turn signal lamps. e. Loosen the lens by partially undoing the two mounting screws. f. Pull the lens away from the light base, exposing the two prongs on the LED board, above the right-hand screw g. Momentarily short across the two prongs with a flat blade screwdriver or similar metallic tool. | |||||
| 15. | Check the operation of the LED lights, if installed. a. Select AUX on the right-side handlebar pursuit switch to activate the Tour-Pak LED lights. b. Multiple flasher patterns are available with these lights. To change the flasher pattern, press and release the push button on the right side of the Tour-Pak. Continue pressing and releasing the button to cycle through the available flasher patterns until the desired pattern displays. |
POLICE TOUR-PAK ADAPTER PLATE KIT
Figure 14. Police Tour-Pak Adapter Plate Kit 53196-09
Table 2. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Adapter plate, Police Tour-Pak | Not sold separately |
2 | Hex head cap screw, 1/4-20 x 12.7 mm (½ in) (install from inside Tour-Pak) | 3728 |
3 | Plain washer, 1/4 inch (install from inside Tour-Pak) | 6235 |
4 | Hex socket button head screw, 1/4-20 x 12.7 mm (½ in) (4) | 4365 |
WIRING DIAGRAM
Figure 15. Wiring Diagram; Police Tour-Pak 54177-10 or 54178-10
WIRING DIAGRAM
Figure 16. Wiring Diagram; Police Tour-Pak 54179-10 or 54180-10
SERVICE PARTS
Figure 17. Service Parts, Tour-Paks for FLHP, FLHTP Police Models
Table 3. Service Parts, Tour-Paks for FLHP, FLHTP Police Models
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Parts common to ALL kits | 1 | Bottom shell, Police Tour-Pak (white or black) | Not sold separately |
2 | Cover, Police Tour-Pak (white or black) | Not sold separately | |
3 | Gasket, cover | 53907-01 | |
4 | Hinge, lower (2) | 53427-80 | |
5 | Hinge, upper (2) | 90902-93 | |
6 | Backing plate (8) | 90964-63 | |
7 | Rivet (12), 3.12 mm (0.123 in) dia x 12.7 mm (0.500 in) long | Not sold separately | |
8 | Rivet (4), 3.12 mm (0.123 in) dia x 7.92 mm (0.312 in) long | 90965-63 | |
9 | Rivet (2), 3.12 mm (0.123 in) dia x 26.92 mm (1.06 in) long | 8502 | |
10 | Latch body (2) | 90649-07 | |
11 | Spacer, latch (2) | 53620-01 | |
12 | Hasp, rivet (2) | 90705-97 | |
13 | Backing plate | 90688-85 | |
14 | Rivet (4), 3.12 mm (0.123 in) dia x 9.52 mm (0.375 in) long | Not sold separately | |
15 | Screw, pan head TORX, #6 x 157 mm (0.62 in) long (4) | 3597 | |
16 | Plain washer, #6 (4) | 6717 | |
17 | Tour-Pak Lock Kit (includes items 18-23) (See dealer for key code) | 53194-07 | |
18 |
| 53584-92 | |
19 |
| 53641-02 | |
20 |
| 53617-85 | |
21 |
| 84850-92 | |
22 |
| 90686-92 | |
23 |
| Not sold separately | |
24 | Catch, Tour-Pak latch | 79182-08A | |
25 | Rivet (2), 3.12 mm (0.123 in) dia x 12.7 mm (0.500 in) long | Not sold separately | |
26 | Stay, Tour-Pak lid (2) | Not sold separately | |
27 | Rivet, semi tubular (8), 3.12 mm (0.123 in) dia x 9.52 mm (0.375 in) long | 90967-64 | |
28 | Plain washer, #4 (4) | 6335 | |
29 | Washer, nylon (4) | 6759 | |
30 | Auxiliary stop/tail/turn signal (STT) bar | 69705-10 | |
31 | Screw, pan head, #6-32 x 41.3 mm (1⅝ in) long (2) | Not sold separately | |
32 | Hex nut, #6-32, with external-tooth lockwasher (2) | 7889 | |
33 | Fitting, straight through (2) | Not sold separately | |
34 | Rubber mount (5) | 63960-01 | |
35 | Flange nut, 1/4-20, with lock (6) | 7716 | |
36 | Hex standoff (4) | 12400001 | |
37 | Cap screw, hex head, 1/4-20 x 12.7 mm (0.5 in) long (5) | 3728 | |
38 | Plain washer, 1/4 in. (5) | 6235 | |
39 | Label, Tour-Pak capacity | 90921-09 | |
40 | Label, Harley-Davidson logo with wings | 53908-01 | |
Kit 54177-10 (Birch White) Kit 54178-10 (Vivid Black) Police Tour-Pak (Plain) | 41 | Mounting plate (2) | 72659-10 |
71 | Harness, Police Tour-Pak (for auxiliary stop/tail/turn signal only) | 72640-10 | |
Kit 54179-10 (Birch White) Kit 54180-10 (Vivid Black) Police Tour-Pak (For LED Lighting) | 41 | Mounting plate, upper | 72659-10 |
42 | Mounting plate, lower | Not sold separately | |
43 | Fuse/terminal block | Not sold separately | |
44 | Screw, pan head, #10-24 x 25.4 mm (1.0 in) long (2) | Not sold separately | |
45 | Flange nut, #10-24, with lock (4) | 7878 | |
46 | Fuse, automotive (blade type), 15A (3) | 72347-94 | |
47 | Battery charger | 99863-01B | |
48 | Bracket, battery tender | Not sold separately | |
49 | Screw, pan head, #8-32 x 9.5 mm (⅜ in) long (4) | Not sold separately | |
50 | Hex nut, #8-32, with external-tooth lockwasher (4) | 7830 | |
51 | Relay, Tour-Pak power, 70A | 31533-01 | |
52 | Screw, pan head, #10-24 x 12.7 mm (½ in) long (2) | Not sold separately | |
53 | Power outlet | 91889-97 | |
54 | Cover, power outlet | 91844-97 | |
55 | Power inlet, 120 Volt, with cap | Not sold separately | |
56 | Machine screw, pan head Phillips, #6-32 x 16 mm (⅝ in) special (3) | 3225 | |
57 | Plain washer, #6 (3) | 6717 | |
58 | Hex nut, #6-32, with external-tooth lockwasher (3) | 7889 | |
59 | Boot, reset switch | 67880-94 | |
60 | Cushion, battery | Not sold separately | |
61 | Bracket, battery | Not sold separately | |
62 | Strap, battery | 29525-01 | |
63 | Hex head cap screw, 3/8-16 x 25.4 mm (1 in) long | 2879W | |
64 | Hex head cap screw, 3/8-16 x 44.4 mm (1¾ in) long (2) | 4720W | |
65 | Plain washer, 3/8 in. (6) | 6416 | |
66 | Flange nut, 3/8-16, with lock (3) | 7601 | |
67 | Cushion, battery strap and bracket (8) | 66352-65 | |
68 | Anchor, electrical receptacle (attachment clip, used with LED kits) | 72199-94 | |
69 | Power cord, 110V AC | Not sold separately | |
70 | Harness, power outlet | Not sold separately | |
71 | Harness, Police Tour-Pak (for auxiliary stop/tail/turn and side/rear flashers) (includes Items 72 and 73) | 70697-10 | |
72 |
| 31511-01B | |
73 |
| 72314-01 | |
74 | Harness, battery/power (includes Item 75) | Not sold separately | |
75 |
| 72314-01 |