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12 Volt Tour-Pak Power Supply
J050382015-07-15
GENERAL
Kit Number
91671-10
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
WARNING
Rider 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. One is available from a Harley-Davidson Dealer.
Kit Contents
See Figure 5 and Table 1.
INSTALLATION
Vehicle Preparation
1. See the service manual. Remove seat.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
2. See the service manual. Disconnect battery or remove main fuse.
Install Kit on Vehicles with Rear Speaker Pods
1. Remove bottom Tour-Pak® liner or mat, if equipped.
2. See Figure 1. Remove the two lower mounting screws (1) and washers (2) for the right speaker pod.
1Screw (2)
2Washer (2)
312 V Power Outlet
Figure 1. Installation with Speaker Pod
3. Install the 12 V outlet (3) inside the Tour-Pak and secure with previously removed screws and washers. Tighten screws to 2.8–4 N·m (25–35 in-lbs).
Install Kit on Vehicles without Rear Speaker Pods
1. See Figure 5. Install 12 V outlet (1) onto the outlet bracket (4) and secure with acorn nuts (5) and washers (7). Tighten acorn nuts to 2.8–4 N·m (25–35 in-lbs).
2. Remove the Tour-Pak liner or mat, if equipped.
3. See Figure 2. Remove two nuts (1) from under the Tour-Pak. Save hardware.
4. Clean the inside surface of the Tour-Pak where the adhesive tape mounts with a mixture of 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry completely.
5. See Figure 5. Install the adhesive pad (6) to the outlet bracket (4).
a. Cut the adhesive pad (6) in half.
b. Remove protective film from one piece and fold the pad in half.
c. Remove the protective film from the other side of the pad.
d. See Figure 2. Install the pad (5) to the back of the outlet bracket over the stud location.
e. Repeat steps b-d for the remaining piece of adhesive tape.
6. See Figure 2. Lift reinforcing plate (2). Install the outlet bracket (4) over the large boss under the front right corner of the plate. The large hole in the bracket locates over the boss. The small hole locates over the rubber bumper (3) tab.
7. Press the outlet bracket and adhesive pads against the Tour-Pak wall. Maintain the pressure for one minute before releasing.
8. Install nuts to reinforcing plate studs. Tighten to 7.3–7.9 N·m (65–70 in-lbs).
1Flange nut (2)
2Reinforcement plate
3Rubber bumper
412 Volt power outlet and bracket
5Adhesive pad
6Hole
Figure 2. Installation without Speaker Pod
12.0 in (50.8 mm)
21.0 in (25.4 mm)
Figure 3. Drill Hole in Lower-Front of Tour-Pak
Final Installation
  1. See Figure 5. Connect the two-way connector of the Tour-Pak harness (2) to the outlet.
  2. See Figure 2. If no hole (6) exists, drill a 13 mm (0.50 in) diameter hole in location shown in Figure 3. Install grommet (57978-63) (not included).
  3. Route the harness along the front corner of the Tour-Pak and out the opening on the left side with the other harnesses, then down the left side fender support and forward to the area of the ECM.
    4. NOTE
    If the accessory connector [4A] is already in use, obtain Y-harness (70264-94A) from an authorized dealer.
  4. Locate and connect the harness to the four-way accessory connector [4A].
  5. Secure the harness with cable straps.
  6. Install the 10 Amp fuse (3) into the inline fuse holder of the Tour-Pak harness.
  7. See Figure 4. Modify Tour-Pak liner:
    1. Mark the liner as shown.
    2. Use a sharp knife to cut opening for the outlet.
  8. Install the Tour-Pak liner or mat, if equipped.
  9. See the service manual. Install the main fuse or connect the battery negative cable.
  10. See the service manual. Install seat.
11.13 in (28.7 mm)
21.50 in (38.1 mm)
31.0 in (25.4 mm)
Figure 4. Cut Liner
OPERATION
The power port is connected to the accessory switch and operates when the switch is ON.
SERVICE PARTS
Figure 5. Service Parts: 12 Volt Power Outlet
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Tour-Pak outlet, 12 V
91823-10
2
Harness, Tour-Pak, 12 V outlet
Not Sold Separately
3
Fuse, 10 A, mini
72462-00
4
Bracket, outlet
Not Sold Separately
5
Nut, acorn (2)
7737W
6
Pad, adhesive
Not Sold Separately
7
Washer (2)
6036