AIR WING TOUR-PAK LID RACK KIT
J039322014-03-12
GENERAL
Kit Number
79179-08, 53000063
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
This kit is not compatible with a previously installed Tour-Pak Lid Organizer (Part Number 53249-01A or 53249-01B).
Tools and Supplies Required
Silicone sealant, a drill, various small bits, masking tape, grease pencil in a contrasting color and soft lead pencil for proper kit installation.
INSTALLATION
Template Positioning (Rack Installation WITH SPOILER only)
The location of the luggage rack has a direct relationship to the location of the Tour-Pak® Spoiler. The template (11) included in this kit will locate the luggage rack in the correct position for the current and future installation of a Tour-Pak Spoiler.
NOTE
A template is not required when installing rack without spoiler.
- If a spoiler is already installed, or for future spoiler installation, cut the template along the appropriate line.
- Carefully place the trimmed template on top of the lid. Align the edges of the template with the top surface of the lid. Tape the template to the lid in the desired location. The template locates the rack so a spoiler can be installed.
Rack Installation on Tour-Pak
| 1. | ALL installations: Open the lid. Remove all loose contents from the Tour-Pak. | |
| 2. | See Figure 1. Slip the larger diameter mounting pad (8) onto the left-rear leg. Slip the three smaller diameter mounting pads (10) onto each of the remaining mounting legs (A). With the Harley-Davidson name to the rear, position the rack on the Tour-Pak lid in the desired location. NOTE Carefully center the rack from left to right, and position the rack squarely on the lid for best appearance. Do not mount the rack too far forward to avoid contact with the backrest pad. | |
| 3. | Use a grease pencil to mark the positions of the four mounting pads on the lid. Remove the rack. | |
| 4. | Apply masking tape (E) to the Tour-Pak lid where the four mounting pads (A) contact the lid. Position the rack on the lid in the same location as in the previous step. Using a soft lead pencil on the masking tape strips, trace a circle around each mounting pad. Remove the rack. Use a ruler to mark the exact center position of the mounting pads on the tape. | |
| 5. | Drill four 1/16 in (1.5 mm) diameter pilot holes through the masking tape and Tour-Pak lid at the locations marked (C) and (D). Use a 9/32 in (7 mm) diameter bit to drill three holes through the tape and lid at the locations marked (C). Use a 3/8 in (9.5 mm) diameter bit to drill a hole through the tape and lid at location (D). | |
| 6. | Remove the masking tape. NOTE Clean off any drilling debris, tape residue and grease-pencil marks. Apply a small amount of silicone sealant between the underside of lid, plastic washers, screw threads to reduce water leakage. Brace or tie the lid securely in the open position. | |
| 7. | Obtain the 3 hex head cap screws (4), smaller diameter flat washers (5) and plastic washers (9) from the kit. Place first a metal washer, next a plastic washer over the threads of each screw. | |
| 8. | Secure the Tour-Pak lid in the full open position. Position the rack over the holes in the lid . Install the three screw and washer assemblies (with the silicone sealant) through the three smaller diameter holes in the lid and into the three smaller rack mounting pads, finger tighten. | |
| 9. | Obtain the hollow hex head screw (2), larger diameter flat washer (3) and plastic washer (7) from the kit. Place the metal washer, next the plastic washer over the screw threads. Install the screw and washer assembly (with silicone sealant) through the remaining hole in the lid and into the rack mounting pad, finger tighten. | |
| 10. | Tighten all four luggage rack screws evenly and securely to 6.8–9.5 N·m (60–84 in-lbs). |
In Use
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 Tour-Pak lid rack weight capacity is ten pounds (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 lid 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)
- Verify that lid rack cargo is secure. Recheck load periodically.
- Items with a large surface area mounted on the lid rack can adversely affect vehicle handling.
SERVICE PARTS
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Rack assembly, Tour-Pak®, lighted | Not sold separately |
2 | Screw, hollow, hex head, 5/16-18 | 4860 |
3 | Flat washer, 0.74 inch (19 mm) O.D. | 6235 |
4 | Cap screw, hex head, 1/4-20 x 3/4 (3) | 4702 |
5 | Flat washer, 0.63 inch (16 mm) O.D. (3) | 6703 |
6 | Mounting pad and washer set (includes items 7 through 10) | 90875-08 |
7 |
| Not sold separately |
8 |
| Not sold separately |
9 |
| Not sold separately |
10 |
| Not sold separately |
11 | Template, Tour-Pak rack/spoiler mounting (not shown) | 50001-01 |
Items mentioned in text, but not included in kit: | ||
A | Rack mounting support (4) | |
B | Tour-Pak lid | |
C | Drill 9/32 inch (7 mm) diameter hole (3) at these locations | |
D | Drill 3/8 inch (9.5 mm) diameter hole at this location | |
E | Masking tape, (4) places | |
SERVICE PARTS
Figure 1. Service Parts, Air Wing Tour-Pak Lid Rack