FLHTCUSE TOUR-PAK INSTALLATION KIT
J035402006-05-22
GENERAL
Kit Number
90067-06
Models
This kit fits 1997 and later Road King, FLHT, FLHX, and FLTR models equipped with a Tour-Pak® rack and appropriate docking kits.
Additional Parts Required
All models require separate purchase of FLHTCUSE Tour-Pak (79189-06), Keyed-to-match Tour-Pak Lock (53865-06), lock clip (53868-06) and Fitted Tour-Pak Liner's (91814-06 and 53230-06). International models require separate purchase of License Plate Relocation kit (60095-00A).
Proper installation of this kit also requires prior installation of one of the following rack kits: Detachable Two-Up Tour-Pak Rack (53276-04), Tour-Pak Mounting Kit (53118-98A), or Detachable Solo Tour-Pak Rack (53260-02).
FLHX and FLTR models require separate purchase of antenna relocation kit 76326-00A
WARNINGRider and passenger safety depend upon the correct installation of this kit. 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. (00308b)
Kit Contents
See the Service Parts section of this Instruction Sheet for a list of kit contents.
INSTALLATION
Prepare Motorcycle for Service
| 1. | See the Owner's Manual and remove the seat. | |||||||||||||||
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) | ||||||||||||||||
| 2. | Remove the bolt and negative (-) battery cable from the battery. | 
Figure 1. Antenna Loading Coil and Tour-Pak Lock Installation | ||||||||||||||
| 3. | Remove the bolt and positive (+) battery cable from the battery. | |||||||||||||||
| 4. | Install a Tour-Pak Rack kit (53276-04, 53118-98A or 53260-02) according to the Instruction Sheet contained in the kit. | |||||||||||||||
| 5. | For FLHX and FLTR models: Install Antenna Relocation kit according to the instruction sheet in that kit. NOTE Discard antenna mounts from antenna relocation kit and use mounts supplied with this kit. To open the Tour-Pak prior to installing the Tour-Pak lock, insert a flat head screwdriver into the lock location and turn clockwise while pulling up on the lid. | |||||||||||||||
| 6. | Install the Tour-Pak onto the Tour-Pak Rack using the hardware included in the Tour-Pak Rack kit according to Instruction Sheet included with that kit. |
Install Tour-Pak Components
NOTE
See Figure 1 for Steps 1-3.
| 1. | Install Keyed-to-Match Tour-Pak Lock (7) into the Tour-Pak lock location, as shown. Secure with clip (4). | |||||||||||||||||||||||||||||||||
| 2. | Install lock shroud (3) over lock assembly and secure with nut (5) and screw (6). | |||||||||||||||||||||||||||||||||
| 3. | Install loading coil assembly (1) onto the mounting stud on the bottom of the Tour-Pak. Position the coil as shown and secure with nut (2). Tighten the nut to 11.3 N·m (100 in-lbs). | 
Figure 2. Antenna Base Installation | ||||||||||||||||||||||||||||||||
| 4. | Secure the loading coil pin terminated wire lead under the two clips on the inner right side of the Tour-Pak. NOTE See Figure 2 for Steps 5-11. To determine which antenna base is the left side antenna base and which is the right side antenna base, match each antenna base to the antenna base off-set (2 or 10) with which it fits. Each off-set has a "L" or "R" on it which indicates whether it is the right side or left side off-set. The base that fits the right side off-set will be the right side base, and the base that fits the left side off-set will be the left side base. | |||||||||||||||||||||||||||||||||
| 5. | Obtain the right side antenna base (1), one antenna adapter (3) and cup point screw (7). Insert the adapter into the base, as shown. Rotate the adapter until the threaded hole of the adapter is aligned with the hole in the base, then thread the stud into the threaded hole. Turn until the stud is finger tight. | |||||||||||||||||||||||||||||||||
| 6. | Place right side antenna base off-set (2) over cup point screw, then install assembled right side antenna base to the Tour-Pak. Install reinforcement plate (5), oriented as shown, over the stud, then secure antenna base with screw (6). Tighten screw to 1.7 N·m (15 in-lbs). | |||||||||||||||||||||||||||||||||
| 7. | Install the loading coil ring terminated wire lead (13) over the cup point screw (7) and secure with nut (8). Tighten nut to 0.7 N·m (6 in-lbs). | |||||||||||||||||||||||||||||||||
| 8. | Obtain the left side antenna base (9), one antenna adapter (3) and coaxial antenna jack (12). Insert the adapter into the base, as shown. Rotate the adapter until the threaded hole of the adapter is aligned with the hole in the base, then thread the coaxial jack into the threaded hole. Turn until the coaxial jack is finger tight. | |||||||||||||||||||||||||||||||||
| 9. | Place left side antenna base off-set (10) over the coaxial jack, then install assembled left side antenna base to the Tour-Pak. Install reinforcement plate (11), oriented as shown, over the coaxial jack, then secure antenna base with screw (6). Tighten screw to 1.7 N·m (15 in-lbs). | |||||||||||||||||||||||||||||||||
| 10. | Install the large ring of the ground strap (14) over the coaxial jack and secure with internal tooth lockwasher (15) and nut (16). Tighten nut to 1.1 N·m (10 in-lbs). | |||||||||||||||||||||||||||||||||
| 11. | Install one thread protector (4) over each of the two antenna adapters (3). If relocating an antenna to Tour-pak leave thread protector off right side adapter. NOTE When installing retaining plate, ensure that the cupped or concave side of the retaining plate faces the underside of the Tour-Pak lid. | |||||||||||||||||||||||||||||||||
| 12. | See Figure 3. Install medallion (1) to the Tour-Pak lid mounting location (2) and secure with retaining plate (3). Hold the medallion firmly in place against the Tour-Pak lid, install the retaining plate over the medallion's prongs. Press the retaining plate firmly against the Tour-Pak lid to hold the medallion tightly in place. | |||||||||||||||||||||||||||||||||
| 13. | See Figure 6. Install six hole plugs (20) into the six holes on the forward side of Tour-Pak as shown, then install six retaining washers (22) over the ends of the hole plugs. |
| 1 | Medallion |
| 2 | Tour-Pak lid medallion mounting location |
| 3 | Retaining plate |
Figure 3. Medallion Installation
| 1 | Isolator (3) |
| 2 | Screw, 1/4-20 X 1-1/4 in. (2) |
| 3 | Washer, 1/4 X 27/64 in. (2) |
| 4 | Washer 9/32 X 1/2 in. (2) |
| 5 | Spacer (2) |
| 6 | Lanyard |
| 7 | Lanyard spacer |
| 8 | Screw, 1/4-20 X 2 in. |
Figure 4. Backrest Installation
Install Backrest
NOTE
See Figure 4 for Steps 1-4.
| 1. | Cut the cable strap holding the lanyard to the right side backrest mounting hole. Cut the cable strap holding the two washers, two plastic spacers and lanyard spacer to the backrest mounting hole. Be careful not lose any of the attached parts. | |
| 2. | Insert three isolators (1) into the three backrest mounting holes in the Tour-Pak lid. | |
| 3. | Install the Tour-Pak backrest to the Tour-Pak lid with two screws (2) and washers (3). Tighten screws to 2.8 N·m (25 in-lbs). | |
| 4. | Install screw (8) into the backrest through the lanyard spacer (7), lanyard (6), two plastic spacers (5) and two washers (4) in the order shown in Figure 4. Tighten screw to 2.8 N·m (25 in-lbs). |
Install Tour-Pak Light Power Harness
| 1. | Obtain the Tour-Pak light power harness from the kit. | |
| 2. | Mate the 2-pin power harness connector to the 2-pin connector on the Tour-Pak light harness. | |
| 3. | Route the ring terminated wire leads out of the Tour-Pak through the hole in the bottom, forward, left side corner of the Tour-Pak. Continue to route the leads along the inside of the frame rails so that ring terminated end of the power (red) lead fits to the positive (+) battery terminal and the ground (black) lead fits to the negative (-) battery terminal. | |
| 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. | Coat ring terminal on red lead with dielectric grease and thread the bolt through the ring terminal and through the positive (+) cable (red) into battery positive (+) terminal. | |
| 5. | Coat ring terminal on black lead with dielectric grease and thread the bolt through the ring terminal and through the negative (-) cable (black) into battery negative (-) terminal. | |
| 6. | Tighten terminal bolts to 6.8–10.9 N·m (60–96 in-lbs). | |
| 7. | With the red and black leads routed to avoid chafe or heat points, cable strap the wire leads to the existing wire harness in at least 2 locations. | |
| 8. | Verify that the lid opens and closes without pinching the harness and tighten the cable ties and cut off the ends. | |
| 9. | Open the lid and verify light operation. |
Return Motorcycle to Operation
- Install the Fitted Tour-Pak Liners (91814-06 and 53230-06) by pressing them into place inside the Tour-Pak.
- See the Owner's Manual and install the seat.
SERVICE PARTS
Figure 5. Service Parts for Tour-Pak Installation Kit (Top)
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Concho | Not Sold Separately |
2 | Retaining plate, concho | Not Sold Separately |
3 | Screw, 1/4-20 X 1-1/4 in. (2) | 1327 |
4 | Washer, 1/4 X 27/64 in. (2) | 6235 |
5 | Isolator (3) | 79133-06 |
6 | Backrest, Tour-Pak, FLHTCUSE | 79124-06 |
7 | Screw, 1/4-20 X 2 in. | 4761 |
8 | Service Kit, concho (Not Shown; contains Items 1 & 2) | 53160-06 |
NOTE: See the FLHTCUSE Model Parts Catalog (99428-06) for a complete list of FLHTCUSE Tour-Pak service parts. | ||
Figure 6. Service Parts for Tour-Pak Installation Kit (Bottom)
Table 2. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Antenna adapter (2) | 76445-06 |
2 | Antenna base, right side | 76443-06 |
3 | Antenna base, left side | 76442-06 |
4 | Off-set, adapter base, right side | 76488-06 |
5 | Off-set, adapter base, left side | 76489-06 |
6 | Reinforcement plate (2) | 76480-06 |
7 | Screw, button head, #10-32 X 1 in. (2) | 2495 |
8 | Screw, cup point, hex drive | 11771 |
9 | Nut | 7492 |
10 | Coaxial antenna jack | 76444-06 |
11 | Cable assembly, AM/FM, antenna ground | 70465-86A |
12 | Lockwasher, internal tooth, 9/32 in. | 7129 |
13 | Nut | 76353-00 |
14 | Cable ties (4) (Not Shown) | 10006 |
15 | Lock shroud | 76446-06 |
16 | Nut, hex, flange, lock #10-32 X 7/32 in. | 7626W |
17 | Screw, pan head, flat head, #10-24 X 3/8 in. | 4091 |
18 | Loading coil assembly | 76294-98 |
19 | Locknut, flange, 1/4-20 X 7/16 in. | 7716 |
20 | Plug, hole (6) | 90102-06 |
21 | Thread protector (2) | 90100-06 |
22 | Washer, retaining (6) | Not Sold Separately |
23 | Harness, Tour-Pak light (Not Shown) | 90103-06 |
NOTE: See the FLHTCUSE Model Parts Catalog (99428-06) for a complete list of FLHTCUSE Tour-Pak service parts. | ||
Items Mentioned In Text But Not Included In Kit | ||
A | Clip, locking | 53868-06 |