KING CLASSIC AND CHOPPED TOUR-PAK KITS

J053912026-01-13

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
53000375xxx, 53000377xxx, 53000399xxx, 53000402xxx, 53000404xxx, 53000405xxx, 53000521xxx, 53000527xxx, 53000550xxx, 53000574xxx, 53000577xxx, 53000650xxx, 53000651xxx, 53000653xxx, 53000662xxx, 53000663xxx, 53000775xxx, 53000776xxx, 53000777xxx, 53000778xxx, 53000779xxx, 53000780xxx, 53000830xxx, 53000833xxx, 53000835xxx, 53000836xxx, 53000837xxx, 53000866xxx, 53000867xxx, 53000886xxx, 53000889xxx, 53000900xxx, 53000901xxx, 53000944xxx, 53000946xxx, 53000949xxx, 53000950xxx, 53000952xxx, 53000955xxx, 53000960xxx, 53000963xxx, 53000983xxx, 53000985xxx, 53000999xxx, 53001002xxx, 53001015xxx, 53001016xxx, 53001043xxx, 53001044xxx, 53001046xxx, 53001048xxx, 53001050xxx, 53001053xxx, 53001056xxx, 53001059xxx, 53001186xxx, 53001187xxx, 53001188xxx, 53001189xxx, 53001191xxx, 53001192xxx, 53001194xxx, 53001218xxx, 53001221xxx, 53001224xxx, 53001227xxx, 53001230xxx, 53001284xxx, 53001285xxx, 53001287xxx, 53001301xxx, 53001306xxx, 53001307xxx, 92200073xxx, 92200074xxx	Safety glasses, Torque wrench

(1) Tightening to torque value or other moderate tools and techniques required

KIT CONTENTS

Figure 1. Kit Contents: King Classic Tour-Pak Kit

Figure 2. Kit Contents: Chopped Tour-Pak Kit

Table 2. Kit Contents: King Classic and Chopped Tour-Pak Kits

	Verify that all contents are present in the kit before installing or removing items from vehicle.
	Item	Qty	Description	Part No.	Notes
	1	1	Bottom (tub), King Tour-Pak, painted solid color	53000368xxx	Kits: 53000399xxx, 53000377xxx, 53000955xxx
			Bottom (tub), King Tou-Pak, limited paint	53000393xxx	Kit: 92200074xxx
			Bottom (tub), King Tour-Pak, molded & drilled	53000083	Kit: 53000404xxx
			Bottom (tub), King Tour-Pak, pin stripe	53000877xxx	Kits: 53000866xxx, 53000901xxx
			Bottom (tub), King Tour-Pak, design	53000962xxx	Kit: 53000960xxx
			Bottom (tub), Chopped Tour-Pak, painted solid color	53000397xxx	Kits: 53000375xxx, 53000397xxx, 53000402xxx, 53000650xxx, 53000946xxx, 53001287xxx
			Bottom (tub), Chopped Tour-Pak, molded, drilled & primed	53000160	Kit: 53000405xxx
			Bottom (tub), Chopped Tour-Pak, pin stripe	53000878xxx	Kits: 53000867xxx, 53000900xxx
			Bottom (tub), Chopped Tour-Pak, design	53000961xxx	Kit: 53000963xxx
			Bottom (tub), Chopped Tour-Pak, solid	53000374	Kits: 53001284xxx, 53001301xxx, 92200073xxx
			Bottom (tub), Chopped Tour-Pak, design w/graphic	53000656	Kits: 53001306xxx, 53001307xxx
	2	1	Lid, King Tour-Pak, painted w/pin stripe	53000371xxx	Kits: 53000377xxx
			Lid, King Tour-Pak, painted solid color	53000423xxx	Kits: 53000399xxx, 92200074xxx
			Lid, King Tour-Pak, molded & drilled	53000427	Kit: 53000404xxx
			Lid, King Tour-Pak w/waterslide	53000579xxx	Kit: 53000574xxx
			Lid, King Tour-Pak, design	53000683xxx	Kit: 53000653xxx
			Lid, King Tour-Pak w/graphic	53000890xxx	Kit: 53000889xxx
			Lid, King Tour-Pak, solid w/graphic	53000953xxx	Kits: 53000955xxx, 53000960xxx
			Lid, Chopped Tour-Pak, molded drilled	53000424	Kit: 53000405xxx
			Lid, Chopped Tour-Pak, Painted w/pin stripe	53000425xxx	Kit: 53000375xxx
			Lid, Chopped Tour-Pak, painted solid color	53000426xxx	Kits: 53000402xxx, 53001306xxx
			Lid, Chopped Tour-Pak, design	53000468xxx	Kits: 53000650xxx, 92200073xxx
			Lid, Chopped Tour-Pak, w/waterslide, cushion	53000578xxx	Kit: 53000577xxx
			Lid, Chopped Tour-Pak, w/graphic	53000887xxx	Kit: 53000886xxx
			Lid, Chopped Tour-Pak, solid w/graphic	53000947xxx	Kits: 53000946xxx, 53000963xxx
			Lid, Chopped Tour-Pak, design w/graphic	53001222	Kit: 53001307xxx
			Lid, Chopped Tour-Pak, pin striped	53001285	Kits: 53001284xxx, 53001287xxx
			Lid, Chopped Tour-Pak, pin striped	53001286	Kit: 53001285xxx
			Lid, Chopped Tour-Pak, solid w/graphic	53001302	Kit: 53001301xxx
			* Lid service kits include label item 10 and gasket item 20
	3	10	Screw, pan hd, #8-32 x 3/8, TORX drive	10200062
	4	16	Screw, pan hd, #8-32 x 1/2, TORX drive w/washer	10200061
	4	12	Screw, pan hd, #8-32 x 1/2, TORX drive w/washer	10200061	Kit: 53001284xxx, 53001301xxx
	5	5	Screw, pan hd hi/low, #8-16 x 1/2, TORX drive w/washer	10200154
	6	1	Tether assembly	53000141
	6	1	Tether assembly	53000141A	Kits: 53001284xxx, 53001287xxx, 53001301xxx, 53001306xxx, 53001307xxx
	7	1	Hasp, lid latch	53000137
	8	1	Hinge assembly, rear	53000139 (Chrome)
				53000344 (Black)
				53000635xxx (Colormatch)
	9	1	Hinge assembly, front	53000140 (Chrome)
				53000345 (Black)
				53000634xxx (Colormatch)
	10	1	Label, Tour-Pak, capacity	90821-74C
	11	4	Washer, flat, ¼ nom.	6703	Chopped kits: 53000402xxx, 53000375xxx, 53000405xxx, 53000650xxx, 53001284xxx, 53001287xxx, 53001301xxx, 53001306xx, 53001307xxx, 92200073xxx only
	12	4	Nut, hex flange, ¼-20	7716
	13	1	Trim, left	53734-06 (Chrome)
	13	1	Trim, left	61400549 (Black)
	14	1	Trim, right	53735-06 (Chrome)
	14	1	Trim, right	61400550 (Black)
	15	1	Latch assembly	53000138 (Chrome)
				53000342 (Black)
				53000633xxx (Colormatch)
	16	4	Washer, fender, ¼ nom.	6235	Chopped kits: 53000402xxx, 53000375xxx, 53000405xxx, 53000650xxx, 53001284xxx, 53001287xxx, 53001301xxx, 53001306xx, 53001307xxx, 92200073xxx only
	17	4	Screw, hex hd cap, ¼-20 x 1.0	2551W	Chopped kits: 53000402xxx, 53000375xxx, 53000405xxx, 53000650xxx, 53001284xxx, 53001287xxx, 53001301xxx, 53001306xx, 53001307xxx, 92200073xxx only
	18	1	Ground plate, King Tour-Pak mount	53000091	King kits: 53000399xxx, 53000377xxx, 53000404, 92200074xxx only
	19	4	Screw, pan hi/low, #8-16 x ¾, TORX drive	2968	Chopped kits: 53000402xxx, 53000375xxx, 53000405xxx, 53001284xxx, 53001287xxx, 53001301xxx, 53001306xx, 53001307xxx, 92200073xxx only
	20	1	Gasket, lid	53000090
	21	1	Mat, King Tour-Pak, bottom	53000326	King kits: 53000399xxx, 53000377xxx, 53000404, 92200074xxx only
	21	1	Mat, Chopped Tour-Pak, bottom	53000163	Chopped kits: 53000402xxx, 53000375xxx, 53000405xxx, 53001284xxx, 53001287xxx, 53001301xxx, 53001306xx, 53001307xxx, 92200073xxx only
Items mentioned in text, but not included in kit
	A	1	Tour-Pak rack (stock or 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

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 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. For more information see Frequently ask questions about subscriptions.

These items are available at your local Harley-Davidson dealership.

Separate purchase of a King or Chopped Backrest Pad is required for this installation.
Separate purchase of a Tour-Pak Rack and Docking Hardware is required for this installation.
Separate purchase of a Key-Matched Lock (Part No. 90300030) is required for this installation.
Separate purchase of Detachable Conversion Hardware or Reservoir Bracket Kit is required for installation of this kit, with remote reservoir shocks.
Center-Cooled Vehicles: Separate purchase of Spacer Kit For Chopped Tour-Pak (Part No. 53001105A) is required.

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 King Classic or Chopped Tour-Pak is already painted and assembled, proceed to INSTALLATION.

1.	See Figure 1 and Figure 2. Obtain the painted tub (1), latch assembly (15), lock-set (B) purchased separately, four 1/2-inch pan-head screws (4) and two 3/8-inch pan-head screws (3). If assembling a King Classic Tour-Pak, additionally obtain the ground plate (18), chrome trim strips (13, 14) and four 3/4-inch pan-head hi/low screws (19).
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: 2.8–3.9 N·m (25–35 in-lbs) Lock
3.	Install latch assembly to Tour-Pak tub using four 1/2-inch pan-head screws (4). Tighten. Torque: 2.8–3.9 N·m (25–35 in-lbs) Latch NOTE Identify and locate the right and left trims strips.
4.	King Classic Tour-Paks: Install ground plate and chrome trim strips to Tour-Pak using four 3/4-inch pan-head screws (19). Tighten. Torque: 1.5–1.8 N·m (13–16 in-lbs) Trim strips

Assemble Lid

NOTE

Hinges and latch hasp 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 (4) and two 3/8-inch (3) pan-head screws. Tighten. Torque: 2.8–3.9 N·m (25–35 in-lbs) Hinges
2.	Install latch hasp (7) to Tour-Pak lid using four 3/8-inch pan-head screws (3). Tighten. Torque: 2.8–3.9 N·m (25–35 in-lbs) Hasp
3.	Install tether reel assembly (6) to Tour-Pak lid using three 1/2-inch pan-head hi/low screws (5). Tighten. Torque: 2.8–3.9 N·m (25–35 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 (20) 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 the 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 the opening until the 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 the ends mate tightly together. A gap of up to Distance: 1.588 mm (0.0625 in) is allowed.
5.	Install load-limit label (10) to the inside surface of the lid. Align the upper left corner of the label with the 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 the lid approximately perpendicular to the tub. Align the holes in the hinges and secure with 1/2-inch pan-head screws (4). Tighten. Torque: 2.8–3.9 N·m (25–35 in-lbs) Hinges
2.	Extend the tether. Install the tether anchor to the tub with two 1/2-inch pan-head hi/low screws (5). Tighten. Torque: 2.8–3.9 N·m (25–35 in-lbs) Tether anchor NOTE Do not allow the lid to slam shut. Cosmetic damage will result.
3.	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. King Classic: See Figure 3. Install four hex flange nuts (2) from underside of Tour-Pak rack. b. Chopped: See Figure 4. Insert four hex screws (1) and fender washers (2) from inside the Tour-Pak through Tour-Pak rack. c. Install flat washers (3) and hex flange nuts (4) from the underside of the Tour-Pak rack. d. Adjust Tour-Pak to the desired location. Tighten. Torque: 6.8–8.1 N·m (60–72 in-lbs)
3.	Install the Tour-Pak rack per instructions provided with the rack kit.
4.	Install passenger backrest per instructions provided with the backrest kit.

WARNING

Do not exceed Tour-Pak weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00401c)

Install mat (21) in Tour-Pak with ribs up.

1	Stud
2	Flange nut (4)

Figure 3. King Classic Tour-Pak Mounting

1	Hex screw (4)
2	Fender washer (4)
3	Flat washer (8)
4	Flange nut (4)

Figure 4. Chopped Tour-Pak Mounting