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. |
Figure 1. Mount Light to Tour-Pak Lid Latch | ||||||||||||
3. | Remove the large lock nut (4) and the lock guide (with tab, as on 5). | |||||||||||||
4. | Slide the light 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. |
1. | Using the alcohol wipe from the kit, prepare the interior surface of the Tour-Pak lid and base for adhesive backed wire retainers at equally spaced locations around the front of the Tour-Pak lid (see Figure 2 ) and several locations on the interior surface of the Tour-Pak baseFigure 3 ). | |||||||
2. | Peel the backing from three wire retainers (1) and press them into position on the inside of the Tour-Pak lid, as shown in Figure 2 ). | |||||||
3. | Run the wire harness (2) from the light (3) around the inside face of the front edge of the Tour-Pak lid. | |||||||
4. | Install cable straps 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. |
Figure 2. Suggested Wire Retainer Locations on Lid | ||||||
5. | See Figure 3. Peel the backing from the wire retainers and press them into position on the inside of the Tour-Pak base. | |||||||
6. | Loop the long side of the light harness forward of the front hinge and down the side of the Tour-Pak base. | |||||||
7. | Fold the light conduit back on itself, and loosely install cable straps through the wire retainers and around the wire conduit. | |||||||
8. | Lay the harness connector over toward the opposite corner along the front face of the Tour-Pak. | |||||||
9. | Install cable straps through the remaining wire retainers and around the harness conduit. |
1 | Retainer locations |
10. | See Figure 4. Remove the large split grommet (1) from the corner of the Tour-Pak. | Figure 4. Split Grommet |
11. | See Figure 5. Obtain the harness extension (2) with the in-line fuse (3) 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. | |
12. | Mate the harness extension two-way socket housing to the two-way pin housing on the Tour-Pak light harness (2). | |
13. | Fit the grommet over the harness extension conduit, and press the grommet groove into the grommet hole in the Tour-Pak. | |
14. | 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. 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) | ||
15. | Coat the ring terminal on the red lead with dielectric grease (6) from the kit. Thread the battery bolt through the ring terminal and through the red positive (+) cable into the battery positive (+) terminal. | |
16. | 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. | |
17. | Tighten the terminal bolts to 6.8–10.9 N·m (60–96 in-lbs). | |
18. | With the red and black leads routed to avoid chafing or heat points, use cable straps (5) to attach the wire leads to the vehicle wire harness in at least two locations. | |
19. | Verify that the Tour-Pak lid opens and closes without pinching the harness, then tighten the cable straps and cut off the ends. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Tour-Pak light, lens and wire harness assembly | Not sold separately |
2 | Harness extension | 90103-06A |
3 | Fuse, glass, 5 Amp | 70333-06 |
4 | Wire retainer (6) | 11769 |
5 | Cable strap (10) | 10126 |
6 | Dielectric grease packet, 5 gram | Not sold separately |
7 | Alcohol wipe | 94678-00Y |