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TOUR-PAK SPOILER AND AUXILIARY REAR LIGHT KIT
J056252014-06-20
GENERAL
Kit Numbers
53000238, 53000239
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
Purchase a color-matched Tour-Pak® Lid Spoiler Cover (Part No. 57200086xxx) to complete this installation. This item is available separately from a Harley-Davidson dealer.
Models NOT shipped from the factory with an original equipment (OE) color-matched Tour-Pak require separate purchase of an extension harness (Part No. 69201157).
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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
ELECTRICAL OVERLOAD
NOTICE
It is possible to overload the vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. (00211d)
WARNING
When installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a)
This kit requires up to 215 mA more current from the electrical system.
Kit Contents
See Figure 3 and Table 1.
PREPARATION
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
NOTE
  • WITH security siren: With security fob present, turn ignition switch ON. See the service manual. After system is disarmed, turn ignition OFF. IMMEDIATELY remove the main fuse.
  • WITHOUT security siren: See the service manual. Remove main fuse.
  1. ALL models: See the service manual. Remove seat.
  2. Open and support the Tour-Pak lid. See the service manual to:
    1. Remove the tether anchor from the interior front wall of the Tour-Pak.
    2. Remove the Tour-Pak inner liner.
    3. Remove the passenger backrest flap (if present) from the exterior front wall of the Tour-Pak.
INSTALLATION
Drill Spoiler Mounting Holes
  1. Lay masking tape on the Tour-Pak cover outer surface in the spoiler installation area.
  2. Locate two drill points molded into the inner surface of the spoiler installation area. Drill 3 mm (⅛ in) diameter holes through the center of each drill point.
  3. From outside, enlarge holes to 8 mm (5/16 in) diameter.
    4. NOTE
    • The beveled washers install with the angled face against the cover.
    • DO NOT apply liquid threadlocker to the screws.
  4. See Figure 3. Temporarily mount the spoiler base (2) to the Tour-Pak cover with the beveled washers (4) and larger screws (3). Allow washers to rotate into alignment on the underside of the lid. DO NOT fully tighten screws.
  5. Locate the wiring hole on the spoiler base. Mark the location of the wiring hole on the masking tape.
  6. Remove the spoiler base from the Tour-Pak cover.
  7. Drill a 3 mm (⅛ in) diameter hole at the marked location. Enlarge the hole to 9.5 mm (⅜ in) diameter.
  8. Remove the masking tape. Lightly sand the holes to remove burrs and sharp edges. Clean the Tour-Pak cover with a 50-50 mixture of isopropyl alcohol and distilled water. Allow to dry completely.
Install Spoiler
1. See Figure 3. Get the spoiler base, auxiliary light assembly (1) and an adhesive-backed wire clip (9) from the kit. Feed the light wiring through the base wiring hole on the left side.
2. Position the light assembly with the bottom lip against the front edge of the base. Align the mounting ears with the base screw holes. Route the wires through the notch and out the wiring hole. Apply the clip to the spoiler base to hold the wiring in place.
3. Get the spoiler cover (A, purchased separately). Install the cover over the spoiler base and light assembly. Make sure that the wires are not pinched.
a. Assemble the base and light to the cover with two longer socket head cap screws (5) as shown. DO NOT fully tighten.
b. Install the four shorter screws (6) in the remaining holes, but DO NOT fully tighten.
c. Tighten the six screws incrementally to 0.7–0.9 N·m (6–8 in-lbs).
4. Get the gasket pair sheet (7) from the kit. Cut along the dashed line to separate the pair. DO NOT remove the protective tape from the adhesive backing now.
NOTE
The gaskets are side-specific. The left gasket has three holes. The right gasket has two holes.
5. Get the three-hole left gasket.
a. Feed the wiring through the outboard hole in the gasket.
b. While holding the gasket in position against the base, peel the protective tape from the corner nearest the wire. Apply that corner to the base.
c. Remove the rest of the protective tape. Adhere the rest of the gasket to the spoiler base.
d. Repeat with the remaining gasket on the opposite end of the spoiler base.
NOTE
  • The beveled washers install with the angled face against the cover.
  • DO NOT apply liquid threadlocker to the screws.
6. Feed the spoiler wiring through the Tour-Pak cover. Install the spoiler to the cover using the beveled washers (4) and screws (3) from the kit.
7. Allow the washers to rotate into alignment with the underside of the cover. Tighten the screws to 2.3–2.8 N·m (20–25 in-lbs).
Wire Routing
1. See Figure 1. Lay strips of masking tape on the outside of the Tour-Pak front wall, in the approximate area of the required wiring hole. Carefully measure and mark the hole location as shown.
1King Tour-Pak bottom
2Measure 7.25 in (184 mm) down
3Chopped Tour-Pak bottom
4Measure 4.25 in (108 mm) down
5Tour-Pak cover tether mounting hole (2)
6Measure 11.312 in (287 mm) from inboard hole
7Drill 1/8 in (3 mm) diameter pilot hole
8Enlarge pilot hole to 7/16 in (11 mm) diameter
Figure 1. Drill Hole in Front Left Lower Tour-Pak Wall
2. Drill a 3 mm (⅛ in) diameter pilot hole at the marked location. Enlarge the hole to 11 mm (7/16 in) diameter. Remove the masking tape. Lightly sand the hole to remove burrs and sharp edges. Clean the Tour-Pak with a 50-50 mixture of isopropyl alcohol and distilled water. Allow to dry completely.
3. See Figure 3. Install a grommet (8) from the kit into the newly drilled wiring hole.
4. See Figure 2. Get the six remaining adhesive-backed wire clips from the kit. Use the clips to route the spoiler wiring:
a. Along the underside of the lid to the left side wall.
b. Drop straight down to the floor of the Tour-Pak.
c. Route the wiring forward to the grommet location.
NOTE
  • Apply a light coat of liquid soap to the wiring and grommet as necessary to ease installation.
  • Make sure that there is sufficient slack in the wiring to open and close the Tour-Pak lid easily.
Figure 2. Spoiler Light Wire Routing Inside Tour-Pak (Chopped Tour-Pak Shown)
5. Insert the spoiler wiring through the grommet.
6. See Figure 3. Get the three-way Molex pin housing (10). See the service manual appendix. Insert the spoiler wires into the pin housing:
  • Red/Yellow wire to cavity 1.
  • Blue/Red wire to cavity 2.
  • Black wire to cavity 3.
  1. Get the spoiler auxiliary lighting wire harness (11). Models WITH OE Tour-Pak:Models WITHOUT OE Tour-Pak:
    1. Unplug the six-way vehicle harness connector [C12] behind the seat. Plug the six-way spoiler harness connectors into connector halves [C12A] and [C12B].
    2. Plug the three-way connector on the spoiler harness into the spoiler connector.
    1. Unplug the six-way vehicle harness connector [C7] under the seat: FLHX, FLHXS, FLHXSE, FLTRX, FLTRXS models: Next to the Electronic Control Module (ECM). FLHR, FLHRSE models: Top front of rear fender.
    2. Plug the six-way spoiler harness connectors into connector halves [C7A] and [C7B].
    3. Insert the extension harness (Part No. 69201157, purchased separately) into the spoiler auxiliary lighting wire harness (11).
    4. Route the extension harness along the left frame tube. Plug the spoiler connector into the extension harness.
  2. Secure wiring with cable straps (12) as needed.
COMPLETION
NOTE
Verify that the ignition is OFF before installing the main fuse.
1. See the service manual. Install the main fuse.
WARNING
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)
2. Check for proper function of rear lighting. With ignition OFF: Spoiler lamp and tail lamps are off. Turn ignition switch to ACCY position. Turn ignition switch ON, but do not start the motorcycle.
a. Actuate brake or turn signal. Rear lamps remain off.
b. Actuate hazard warning (emergency four-way flasher). NO lamps flash.
c. Spoiler lamp and tail lamps are illuminated.
d. Actuate front brake lever or rear brake pedal. Spoiler lamp and tail lamps noticeably brighten.
e. Actuate left and right turn signal. Signal lamp DOES NOT flash.
f. Actuate hazard warning (emergency four-way flasher). Both turn signal lamps flash.
g. Turn ignition OFF. Both turn signals continue to flash.
h. Turn ignition switch to ON or ACCY position. Turn OFF hazard warning flasher. Turn signal lamps stop flashing.
i. Spoiler lamp and tail lamps are illuminated.
j. Actuate front brake lever or rear brake pedal. Spoiler lamp and tail lamps noticeably brighten.
k. Actuate turn signal. The correct turn signal lamp flashes.
l. Actuate hazard warning (emergency four-way flasher). Both turn signal lamps flash.
m. Turn ignition OFF. Both turn signals continue to flash.
n. Turn ignition switch to ON or ACCY position. Turn OFF hazard warning flasher. Turn signal lamps stop flashing.
3. Install the passenger backrest flap (if previously removed). Tighten screws to 2.4–2.7 N·m (21–24 in-lbs).
4. Install Tour-Pak liner.
5. Install the Tour-Pak tether anchor. Tighten screws to 2.8–4 N·m (25–35 in-lbs).
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)
6. See the service manual. Install seat.
IN USE
Care and Cleaning
  • The spoiler is constructed of polycarbonate. DO NOT use benzene, paint thinner, gasoline or any other type of harsh cleaner.
SERVICE PARTS
Figure 3. Service Parts, Tour-Pak Spoiler and Auxiliary Rear Light Kit
Table 1. Service Parts
Kit
Item
Description (Quantity)
Part Number
Kit 53000238
(Red Lens)
1
Auxiliary light assembly, with red lens
68000057
Kit 53000239
(Smoke Lens)
1
Auxiliary light assembly, with smoke lens
68000059
Parts common
to BOTH kits
2
Base, Tour-Pak® spoiler
Not sold separately
3
Button head socket cap screw, 1/4-20 x 25.4 mm (1.0 in) long (2)
Not sold separately
4
Washer, nylon, special beveled (2)
Not sold separately
5
Button head socket cap screw, #8-32 x 12.7 mm (0.50 in) long (2)
Not sold separately
6
Button head socket cap screw, #8-32 x 9.5 mm (0.375 in) long (4)
Not sold separately
7
Gasket (set of 2), closed cell neoprene
Not sold separately
8
Grommet
Not sold separately
9
Clip, metal, adhesive back, 6.4 mm (0.25 in) (7)
10102
10
Pin housing, three-way Molex, black
72511-07BK
11
Wire harness, Tour-Pak auxiliary lighting
69200573
12
Cable strap (2)
10006
Item mentioned in text, but not included in this kit:
A
Spoiler cover