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PREMIUM TOUR-PAK LUGGAGE RACK KIT
J006272010-06-04
GENERAL
Kit Number
53665-87, 91793-85
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Kit Contents
See Figure 1 and Table 1.
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 (7) included in this kit will locate the luggage rack in the correct position for the current or future installation of a Tour-Pak Spoiler.
NOTE
A template is not required if installing rack without spoiler.
  1. If a spoiler is already installed, or if the installation of a Tour-Pak-mounted spoiler may be desired in the future, cut the template along the appropriate line.
  2. Carefully place the trimmed template on top of the Tour-Pak, aligning the edges of the template with the top surface of the Tour-Pak lid. Tape the template to the lid in the desired location. The template will help to properly locate the rack so that a spoiler may be added in the future.
Rack Installation on Tour-Pak
1. ALL installations: Open the lid, and remove all loose contents from the Tour-Pak.
2. See Figure 1. Slip the mounting pads (2) onto each of the mounting bosses (B) of the luggage rack (1).
NOTE
Kit 53665-87: Position rack with wide upright toward rear of vehicle.
Kit 91793-85: Position rack with upright toward rear of vehicle.
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. Position the rack on the Tour-Pak lid in the desired location.
4. Carefully raise the rack, and place masking tape (A) on the Tour-Pak lid where the four mounting bosses contact the cover.
5. Lower the rack onto the tape in the location chosen in Step 3. Using a soft lead pencil on the masking tape strips, trace a circle around each mounting boss. Remove the rack, and use a ruler to mark the exact center position of each mounting boss on the tape.
6. Drill four 1/16 inch (1.5 mm) diameter pilot holes through the masking tape and Tour-Pak lid at each mounting boss center position. Use a 7 mm (9/32 in) diameter bit to drill the finish holes.
7. Remove the masking tape.
NOTE
Clean off any drilling debris, tape residue and pencil marks.
Brace or tie the Tour-Pak lid securely in the open position during rack installation to prevent hand or finger injury, or scratching of the Tour-Pak lid finish.
8. Obtain the three hex head cap screws (4), lockwashers (5), flat washers (6) and rubber washers (3) from the kit. Place first a lockwasher, then a flat washer, then a rubber washer over the threads of each screw. Apply a small amount of silicone sealant between the underside of the Tour-Pak lid and the rubber washers, and around the screw threads to prevent water leakage.
9. Lift the Tour-Pak lid and secure in the full open position. Position the rack over the holes in the lid. Install the screw and washer assemblies (with the silicone sealant) through the holes in the Tour-Pak lid and into the rack mounting bosses, but do not fully tighten at this time.
10. Tighten all four luggage rack screws evenly and securely to 6.8–9.5 N·m (60–84 in-lbs).
IN USE
WARNING
See 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)
WARNING
Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a)
NOTE
Maximum Tour-Pak luggage rack weight capacity is 4.5 kg (10 lb).
  • Be sure luggage rack cargo is secure and will not shift while riding. Check load periodically.
  • An item with a large surface area, such as a duffel bag, that is installed on the luggage rack can adversely affect vehicle handling.
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)
NOTE
Combined load of luggage rack and Tour-Pak must not exceed 11.3 kg (25 lb). Overloading the motorcycle will cause unstable handling and reduced braking efficiency, which could result in death or serious injury.
SERVICE PARTS
Figure 1. Service Parts, Premium Tour-Pak Luggage Rack Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Rack assembly, Tour-Pak
Not sold separately
Mounting pad and washer set (includes items 2 and 3)
90869-85A
2
  • Mounting pad (4)
Not sold separately
3
  • Rubber washer (4)
Not sold separately
4
Hex head cap screw,
1/4-20 x 19 mm (¾ in) long (4)
3787
5
Lockwasher (4)
7036
6
Flat washer (4)
6703
7
Template, rack/spoiler mounting
(not shown)
50001-01
Items mentioned in text, but not included in kit.
A
Apply masking tape at these locations
B
Mounting boss (4)