TOUR-PAK LUGGAGE
941007142026-01-14
GENERAL INFORMATION
Table 1. General Information
Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
53001268xxx, 53001269xxx, 53001289xxx, 53001290xxx, 53001291xxx, 53001296xxx, 53001297xxx, 53001298xxx, 53001300xxx, 53001304xxx, 53001305, 53001308xxx, 53001310xxx, 53001314xxx, 53001315xxx, 53001316xxx | Safety glasses, Torque wrench |  |
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Tour-Pak Luggage
Table 2. Kit Contents: Tour-Pak Luggage Kit
 | Verify that all contents are present in the kit before installing or removing items from vehicle. | ||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
 | 1 | 4 | Locknut, hex | 7686 | |
| 2 | 16 | Screw, TORX, 8-32 x ½ | 10200061 | |
| 3 | 10 | Screw, lid, TORX, 8-32 x 3/8 | 10200062 | |
| 4 | 2 | Screw, TORX | 10201228 | |
| 5 | 4 | Screw, TORX | 10200147 | |
| 6 | 5 | Screw, TORX, 8-16 | 10200154 | |
| 7 | 1 | Warning label, load limit | 14004460 | |
| 8 | 1 | Lid latch, strike | 53001065 | |
| 9 | 1 | Hinge, Tour-Pak, front, chrome | 53001066 | Kits: 53001268xxx, 53001289xxx, 53001304xxx, 53001305xxx |
| Hinge, Tour-Pak, front, black/color | 53001067xxx | Kits: 53001269xxx, 53001290xxx, 53001291xxx, 53001296xxx, 5300197xxx, 53001298xxx, 53001300xxx, 53001308xxx,53001310xxx, 53001314xxx, 53001315xxx, 53001316xxx | ||
| 10 | 1 | Hinge, Tour-Pak, rear, chrome | 53001068 | Kits: 53001268xxx, 53001289xxx, 53001304xxx, 53001305xxx |
| Hinge, Tour-Pak, rear, black/color | 53001069xxx | Kits: 53001269xxx, 53001290xxx, 53001291xxx, 53001296xxx, 5300197xxx, 53001298xxx, 53001300xxx, 53001308xxx,53001310xxx, 53001314xxx, 53001315xxx, 53001316xxx | ||
| 11 | 1 | Latch case, chrome | 53001070 | Kits: 53001268xxx, 53001289xxx, 53001304xxx, 53001305xxx |
| Latch case, black/color | 53001071xxx | Kits: 53001269xxx, 53001290xxx, 53001291xxx, 53001296xxx, 5300197xxx, 53001298xxx, 53001300xxx, 53001308xxx,53001310xxx, 53001314xxx, 53001315xxx, 53001316xxx | ||
| 12 | 1 | Plate, Tour-Pak | 53001089 | |
| 13 | 1 | Gasket, lid | 53001097 | |
| 14 | 1 | Panel, rear, lightless, black/color | 53001101xxx | ALL painted kits |
| Panel, rear, lightless, molded | 53001100 | Kit: 53001305 | ||
| 15* | 1 | Lid, base, solid | 53001282xxx | Kits: 53001268xxx, 53001269xxx, 53001308xxx |
| Lid, molded | 53001384 | Kit: 53001305 | ||
| Lid, solid w/graphic | 53001385xxx | Kit: 53001300xxx | ||
| 53001386xxx | Kit: 53001291xxx | |||
| 53001387xxx | Kit: 53001296xxx | |||
| 53001388xxx | Kit: 53001304xxx | |||
| Lid, pinstripe | 53001389xxx | Kits: 53001289xxx, 53001290xxx | ||
| Lid, design w/ graphic | 53001390xxx | Kit: 53001297xxx | ||
| 53001391xxx | Kit: 53001310xxx | |||
| Lid, design | 53001392xxx | Kits: 53001298xxx, 53001314xxx | ||
| Lid, pinstripe w/graphic | 53001393xxx | Kit: 53001316xxx | ||
| 53001394xxx | Kit: 53001315xxx | |||
| *LID SERVICE KITS INCLUDE LABEL ITEM 7 AND GASKET ITEM 13 | ||||
| 16 | 1 | Liner, bottom base, Tour-Pak | 53001143 | |
| 17 | 1 | Tub, base, solid | 53001182xxx | Kits: 53001268xxx, 53001269xxx, 53001289xxx, 53001290xxx, 53001291xxx, 53001300xxx, 53001304xxx, 15001314xxx,15001315xxx, 53001316xxx |
| Tub, base, routed | 53001181 | Kit: 53001305 | ||
| Tub, base, design | 53001295xxx | Kits: 53001296xxx, 53001297xxx, 53001298xxx, 53001308xxx, 53001310xxx | ||
| 18 | 4 | Clip, fairing, front | 57000779 | |
| 19 | 1 | Tether, retractable | 53000141B | |
| 20 | 4 | Washer, plain | 6703 | |
Items mentioned in text, but not included in kit | |||||
| A | 1 | Tour-Pak rack (stock accessory) | Various | |
| B | 1 | Lock, Tour-Pak & saddlebags | 90300030 | |
| C | 1 | Backrest pad (not shown) | Various | |
GENERAL
Instruction sheet is also available electronically. To verify you are using the most current version available, do one of the following:
- Go to h-d.com/isheets
- Scan QR code in upper left corner of the instruction sheet
NOTE
This instruction sheet may have a Supplemental Video to assist installer in clarifying a certain part of the assembly. A linked video would be located at the end of this instruction sheet.
Models
For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.
Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.
Installation Requirements
WARNINGRider 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 references service manual information. A service manual for the year and model motorcycle is required for this installation and is available from:
- A Harley-Davidson dealer.
- H-D Service Information Portal, a subscription-based access available for most 2001 and newer models.
These items are available at your local Harley-Davidson dealership.
- Separate purchase of a Tour-Pak is required for this installation.
- Separate purchase of a key-matched lock (Part No. 90300030) is required for this installation.
- Separate purchase of a King Backrest Pad is required for this installation.
ASSEMBLY
Assembly Tub
NOTE
- Protect painted items from damage. Place on clean, soft surfaces and cover as needed to prevent tools, hardware and assembly processes from damaging painted surfaces.
- If the Grand Tour-Pak is already painted and assembled, proceed to INSTALLATION.
| 1. | See Figure 1. Obtain the painted tub (17), latch assembly (11), lock-set (B) purchased separately, four 1/2-inch pan-head screws (2) and two 3/8-inch pan-head screws (3), ground plate (12) and two ½-inch large washer pan-head screws (4). | |
| 2. | Orient lock (B) with key notches toward the top. Install the lock to the latch assembly using two 3/8-inch long pan-head screws (3). Tighten. Torque: 2.8–4 N·m (25–35 in-lbs) Lock | |
| 3. | Install latch assembly to Tour-Pak tub using four 1/2-inch pan-head screws (2). Tighten. Torque: 2.8–4 N·m (25–35 in-lbs) Latch | |
| 4. | Install ground plate using two 1/2-inch pan-head screws (4). Tighten. Torque: 3.4–4.7 N·m (30–42 in-lbs) Ground plate | |
| 5. | Obtain rear panel (14), four panel clips (18) and four button head screws (5). | |
| 6. | Install four panel clips (18) on to rear panel (14). | |
| 7. | See Figure 1. Install rear panel onto painted tub (17) using four button head screws (5). Tighten. Torque: 3.8–4.5 N·m (34–40 in-lbs) Rear panel |
Assemble Lid
NOTE
- Hinges and latch strike must be installed prior to gasket installation to avoid damaging gasket surfaces.
- The hinges are identified by having the letter "F"ront or "R"ear cast into them.
- The two screws nearest the edge of the lid are washer-less and shorter than the remaining six. Install the shorter screws first.
| 1. | Install the hinge assemblies to Tour-Pak lid using two 1/2-inch (2) and two 3/8-inch (3) pan-head screws. Tighten. Torque: 2.8–4 N·m (25–35 in-lbs) Hinges | |
| 2. | Install latch strike (8) to Tour-Pak lid using four 3/8-inch pan-head screws (3). Tighten. Torque: 2.8–4 N·m (25–35 in-lbs) Latch strike | |
| 3. | Install tether reel assembly (19) to Tour-Pak lid using three 3/4-inch pan-head plastite screws (6). Tighten. Torque: 2.6–3.2 N·m (23–28 in-lbs) Tether reel NOTE To prevent the possibility of water intrusion, be careful the seal does not bunch or kink at the corners. | |
| 4. | Install gasket (13) to Tour-Pak lid. NOTE Do not cut seal long. Doing so may cause seal to bunch allowing a path of water intrusion. a. Peel back a few inches of backing material. Beginning at scribe line at front middle (behind passenger backrest area), adhere the end of the seal. Work only a few inches at a time. b. Continue around opening until seal returns to the point of beginning. Use care at the corners to prevent bunching or kinking of the seal. c. Cut the seal squarely so ends mate tightly together. A gap of up to Distance: 1.588 mm (0.0625 in) is allowed. | |
| 5. | Install load-limit label (7) to inside surface of lid. Align lower left corner of label with scribe lines molded into the lid. |
Final Assembly
NOTE
The installation of the lid assembly to the tub assembly is a two-person procedure to best protect the painted surfaces from damage.
| 1. | Hold lid approximately perpendicular to tub. Align holes in hinges and secure with eight 1/2-inch pan-head screws (2). Tighten. Torque: 2.8–4 N·m (25–35 in-lbs) Hinges | |
| 2. | Install liner (16) into Tour-Pak prior to installing tether anchor. | |
| 3. | Extend tether. Install tether anchor to tub with two 3/4-inch pan-head plastite screws (6). Tighten. Torque: 2.6–3.2 N·m (23–28 in-lbs) Tether anchor NOTE Do not allow the lid to slam shut. Cosmetic damage will result. | |
| 4. | Close and latch lid to check alignment. Adjust alignment as needed. |
INSTALL
NOTE
An open Tour-Pak is unstable before it is secured. Use two persons to install the Tour-Pak.
| 1. | Set Tour-Pak in place on support. | |
| 2. | Secure Tour-Pak: a. See Figure 2. Install four washers (4) and flange nuts (3) from underside of Tour-Pak rack (2). b. Adjust Tour-Pak to desired location. Tighten. Torque: 10–12 N·m (89–106 in-lbs) | |
| 3. | Install Tour-Pak rack per instructions provided with rack kit. | |
| 4. | Install passenger backrest per instructions provided with backrest kit. |
WARNINGDo not exceed Tour-Pak weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00401c)
| 1 | Screw (4) |
| 2 | Tour-Pak rack |
| 3 | Washer (4) |
| 4 | Flange nut (4) |
Figure 2. King Classic Tour-Pak Mounting