CONTOURED TOUR-PAK LUGGAGE RACK KIT
J038072005-10-11
GENERAL
Kit Number
79148-06A
Models
This Tour-Pak® Contoured Luggage Rack Kit is designed for installation on all King and Chopped Tour-Paks®.
Does not fit with 100th Anniversary Two-Tone Tour-Pak, Air Wing Tour-Pak Lid Trim (53936-03) or Chrome And Simulated Leather Accent Panel (53911-01).
INSTALLATION
NOTE
The location of the Tour-Pak spoiler has a direct relationship to the location of Tour-Pak mounted luggage rack. The spoiler template will locate the Tour-Pak spoiler in the correct position for the luggage rack so that the spoiler may be added in the future. It is recommended that the spoiler be installed first. See Figure 1.
| 1. | Identify if the installation of a Tour-Pak mounted spoiler is desired in the future. Use the template if the spoiler will be installed. Cut the template along the appropriate line. Carefully place template on top of Tour-Pak lid, aligning edges of template with top surface of Tour-Pak. Tape template in desired location. NOTE Position top rack with upright section toward rear of motorcycle. To avoid contact with the passenger backrest pad, do not mount the top rack in too far forward a position. | 
Figure 1. Tour-Pak Rack and Spoiler | ||
| 2. | See Figure 2. Place the four mounting pads (1) onto the four mounting supports on top rack (2). Carefully center the rack on the lid and position the rack rear supports 5/8 inch to 3/4 inch (16 mm to 19 mm) in front of the emblem on the Tour-Pak lid, as shown. | 
Figure 2. Locate Holes From Emblem | ||
| 3. | Use a grease pencil to temporarily mark the positions of the four mounting pads on Tour-Pak cover. NOTE Apply masking tape to the Tour-Pak cover painted surface at the four points where the top rack mounting holes will be drilled. The tape can be marked for hole location, and will help prevent the paint from being chipped during the drilling procedure. | |||
| 4. | Carefully remove top rack/mounting pad assembly. Place a strip of masking tape over each grease pencil mark on the Tour-Pak cover. Once again, position top rack/mounting pad assembly on Tour-Pak cover in the desired mounting location. | |||
| 5. | Using a soft lead pencil on the masking tape strips, trace a circle around each mounting pad. Remove top rack/mounting pad assembly. Use a ruler to mark the exact center of each circle drawn on the tape strips. NOTE Remove all contents from within the Tour-Pak to avoid possible contact with the moving drill bit during the following drilling procedure. | |||
| 6. | Drill starter holes using a 1/16 inch drill bit. Drill the finished holes for the mounting screws using a 9/32 inch drill bit. Remove masking tape strips. | |||
| 7. | Apply a small amount of silicone sealant around each mounting hole on interior surface of Tour-Pak cover, and onto threads of each screw (4) from kit. This will help prevent water leakage at the mounting points. | |||
| 8. | Lift Tour-Pak cover. Position top rack/mounting pad assembly onto exterior of cover, aligning mounting holes of each. Install four screws (3) with four lockwashers (4), flat washers (5), and plastic mounting washers (6), through interior surface of cover, through mounting pads (1), and into threaded holes in top rack supports. Tighten all four screws evenly and securely, but do not over tighten. Plastic mounting pads and washers should deform (bulge) only slightly when bolts are properly secured. |
WARNINGSee ACCESSORIES AND CARGO section within the SAFETY FIRST section in your owner's manual. Improper cargo loading or accessory installation can cause component failure and adversely affect stability, handling and performance, which could result in death or serious injury. (00021c)
NOTE
Maximum luggage rack weight capacity is 10 lbs (4.5 Kg).
WARNINGDo not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a)
NOTE
Combined load of top rack and Tour-Pak must not exceed 25 lbs (11.3 Kg). Overloading the motorcycle will cause unstable handling and reduced braking efficiency, which could result in death or serious injury.
WARNINGDo not exceed Tour-Pak weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00401c)
- Be sure top rack cargo is secure and will not shift while riding. Recheck load periodically.
- An item with a large surface area, such as a duffel bag, that is installed on the top rack can adversely affect vehicle handling.
SERVICE PARTS
Figure 3. Service Parts: Tour-Pak Luggage Rack Kit
Table 1. Service Parts: Tour-Pak Luggage Rack Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Mounting pad (4) | Included in P/N 90869-85A |
2 | Rack | Not Sold Separately |
3 | Screw, 1/4-20 x 3/4 in. (4) | 3787 |
4 | Lockwasher (4) | 7036 |
5 | Flat washer (4) | 6703 |
6 | Plastic mounting washer (4) | Included in P/N 90869-85A |
7 | Template, Tour-Pak, Spoiler (Not shown) | 50001-01 |
A | Mounting Support | |
B | Front of motorcycle | |
C | Apply masking tape to these locations | |