Tour-Pak and Saddlebag Interior Light Kits
J059002013-11-07
GENERAL
Kit Number
68000151, 68000152, 68000153
NOTE
Kit number 68000151 includes the Tour-Pak® and Saddlebag lights.
Kit number 68000152 includes ONLY the Tour-Pak lights.
Kit number 68000153 is a Saddlebag Light Expansion Kit for vehicles already equipped with a Tour-Pak light.
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
Separate purchase and installation of additional parts or accessories may be required for proper installation of this kit on your model motorcycle. See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
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 your model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Kit Contents
See Figure 7 and Table 1.
INSTALLATION
Preparation for Service
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
  1. See the service manual. Disconnect the battery.
For Kit 68000153: Go to Saddlebag Light Element Installation.
For ALL other kits: Go to Tour-Pak Interior Light/Controller Installation.
Tour-Pak Interior Light/Controller Installation
  1. Open the Tour-Pak lid.
  2. See Figure 1. Test-fit the Tour-Pak light to the inside of the Tour-Pak lid. Do not remove protective tape from adhesive strips now.
  3. Clean the mounting area with an alcohol wipe. Allow to dry completely.
  4. Fold the extra length of the protective tape (on adhesive pads) so it can be pulled when the light is in the mounting location.
  5. Place the light in the mounting location. Orient light to find the best fit.
  6. While holding the light in place, pull the protective tape from the adhesive strips.
  7. Apply sliding pressure to the adhesive strips. For Kit 68000153: Go to Saddlebag Light Element Installation. For Kit 68000152: Go to Wire Harness Routing.
Figure 1. Tour-Pak Interior Light
Saddlebag Light Element Installation
1.
See the service manual. Remove Tour-Pak. Place the Tour-Pak on a towel or other soft work surface to prevent scratching.
2.
See the service manual. Remove Tour-Pak liner.
3.
See the service manual. Remove the ground plate from the Tour-Pak to expose the bottom of the Tour-Pak.
4.
See Figure 2. Place template in the Tour-Pak. Mark drill points. Flip the template over and repeat for opposite side.
5.
Outside of the Tour-Pak, apply masking tape to the drill point locations.
6.
With a 1/8 inch drill bit, drill a pilot hole through each marked drill point.
7.
Turn the Tour-Pak over.
8.
With a 9/32 inch drill bit, enlarge the pilot holes. Drill from the outside to the inside.
9.
Install the light to the Tour-Pak.
a.
Route the wiring of the light through the forward hole of the drilled holes.
b.
Mount the light to the Tour-Pak. Secure with nuts. Tighten nuts to 0.7–1.1 N·m (6–10 in-lbs).
c.
Repeat steps for the opposite side.
10.
See the service manual. Install the ground plate.
11.
See the service manual. Install Tour-Pak.
Figure 2. Template Location
Figure 3. Saddlebag Light Element on Tour-Pak
For Kit 68000153: Go to Saddlebag Light Element Connection to Harness.
For ALL other kits: Go to Wire Harness Routing.
Wire Harness Routing
  1. Using alcohol wipes from the kit, prepare the interior surface of the Tour-Pak lid for adhesive backed wire retainers (Item 7, Figure 7 ) at several equally spaced locations around the front of the Tour-Pak lid .
  2. Remove the protective tape from the adhesive strip on three wire retainers. Press them into position on the inside of the lid.
  3. See Figure 4. Route the wire harness (1) from the light/controller around the inside face of the front edge of the Tour-Pak lid.
  4. Install cable straps from the kit through the wire retainers and around the harness conduit.
  5. NOTE
    Make sure there is sufficient slack that the Tour-Pak lid opens and closes without pinching the harness.
  6. Using alcohol wipes from the kit, prepare the interior surface of the Tour-Pak base at several locations for adhesive backed wire retainers.
  7. Remove the protective tape from the adhesive strip on three wire retainers. Press them into position on the inside of the Tour-Pak base.
  8. Loop the long side of the controller harness forward of the front hinge and down the side of the Tour-Pak base.
  9. Fold the controller conduit back on itself, and loosely install cable straps through the wire retainers and around the wire conduit.
  10. Lay the harness connector over toward the opposite corner along the front face of the Tour-Pak.
  11. Install cable straps through the remaining wire retainers and around the harness conduit. For Kit 68000151: Go to Saddlebag Light Element Connection to Harness. For Kit 68000152: Go to Connection to Vehicle Harness.
1Light harness
2Grommet location
3Tour-Pak lid
4Tour-Pak base
Figure 4. Tour-Pak Interior Light Harness Routing
Saddlebag Light Element Connection to Harness
12.
See Figure 5. Match the wire colors of the saddlebag light leads (2) to the wire colors in the left and right side three-way pin housings in the Tour-Pak light/controller harness (white to white, red to red, black to black).
NOTE
The tangs on the saddlebag light lead-wire socket terminals must be installed in the cavities of the three-way socket housings on the side opposite the external latch.
1Connector half
2White, red and black wire leads
Figure 5. Saddlebag Light Element
13.
One at a time, position each saddlebag light lead to the correct cavity of a three-way socket housing. Snap the socket terminals into the cavities.
14.
Apply dielectric grease from the kit to the terminals in the connector housings.
15.
Connect the socket housings to the three-way pin housings in the Tour-Pak light/controller harness.
For Kit 68000153: Go to Return to Service.
For ALL other kits: Go to Connection to Vehicle Harness.
Connection to Vehicle Harness
16.
See Figure 6. Remove the large split grommet (1) from the corner of the Tour-Pak.
Figure 6. Split Grommet
17.
See Figure 7. Obtain the harness extension (3) with the in-line fuse (4) from the kit. Fit the connector end through the grommet hole in the Tour-Pak. The conduit end with the in-line fuse, black and red wires and ring terminals route to the battery.
18.
Mate the harness extension two-way socket housing to the two-way pin housing on the Tour-Pak light/controller harness (2).
19.
Fit the grommet over the harness extension conduit. Press the grommet groove into the grommet hole in the Tour-Pak.
20.
Route the ring terminated wire leads along the inside of the right frame rail so that the red power lead fits to the positive battery terminal and the black ground lead fits to the negative battery terminal.
21.
Coat the ring terminal on the red lead with dielectric grease (7) from the kit. Thread the battery bolt through the ring terminal and through the red positive cable into the battery positive terminal.
22.
Coat the ring terminal on the black lead with dielectric grease. Thread the battery bolt through the ring terminal and through the black negative cable into the battery negative terminal.
23.
Tighten the terminal bolts to 6.8–10.9 N·m (60–96 in-lbs).
24.
With the red and black leads routed to avoid chafing or heat points, use cable straps (6) to attach the wire leads to the vehicle wire harness in at least two locations.
25.
Verify that the Tour-Pak lid opens and closes without pinching the harness. Tighten the cable straps. Trim cable strap ends.
Return to Service
26.
See the service manual. Install Tour-Pak liner.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
27.
Check each light for proper operation. Press in firmly on the center of the lens to activate the switch and turn the light on. Press again to turn the light off.
NOTE
The Tour-Pak light turns off after five minutes, if the Tour-Pak contents press against the light and activate the switch.
If the light has been disabled in this manner, disconnect and connect the light connector.
SERVICE PARTS
Figure 7. Service Parts, Tour-Pak Luggage and Saddlebag Interior Light Kits
Table 1. Service Parts Table
Kit
Item
Description (Quantity)
Part Number
Kit 68000151
3-Light Tour-Pak
and Saddlebag
Lights
1
1-Light Tour-Pak Light Kit (includes Items 2 through 9)
68000152
2
  • Tour-Pak light, lens and wire harness assembly
Not sold separately
3
  • Harness extension
90103-06A
4
  • Fuse, 5 Amp
70333-06
5
  • Wire retainer (10)
11769
6
  • Cable strap (14)
10126
7
  • Dielectric grease pack
Not sold separately
8
  • Alcohol wipe
94678-00Y
9
  • Grommet
12100055
10
Saddlebag Light Expansion Kit (includes Items 11 through 13)
68000153
11
  • Saddlebag light assembly (2)
Not sold separately
12
  • Nylon nut, 1/4-28 (4)
Not sold separately
13
  • Socket housing, three-way (2)
Not sold separately