1. | Open the lid and, if necessary, remove all items from inside the Tour-Pak luggage. Remove the rubber mat from the luggage floor. | |||||||
2. | If holes ARE NOT pre-drilled in the floor of the
luggage, see Figure 1. To prevent damage to the leather while drilling, place blocks of wood underneath the Tour-Pak luggage at the drilling sites. Use the four inboard holes (3) in the metal base of the luggage (2) as a guide. Carefully drill four 9 mm (11/32 in) holes through the floor of the luggage. NOTE See Figure 3. When installing the luggage to the rack note the holes in the luggage rack (2). The forward (A) and rearward (B) positions for mounting the luggage. |
Figure 1. Drill Attachment Hole Locations in Tour-Pak | ||||||
3. | Place the luggage on the luggage rack. Align the holes in the luggage mounting plate with the forward or rearward holes in the rack. | |||||||
4. | ALL applications: Obtain the hex head cap screws (9), locknuts (11) and plain washers (10) from the kit. Place a washer over the threads of each screw. Insert the screw threads, from the inside, through the Tour-Pak luggage mounting plate and floor, and into the holes in the rack. NOTE Always install the mounting screws from inside the luggage. If the screws are installed from the bottom, the screw ends can tear the rubber mat. The screw ends scratch objects, such as helmets, stored inside the luggage. | |||||||
5. | From the underside of the rack, install a washer and locknut onto the threads of each screw. In a crosswise pattern, incrementally tighten each screw to 25 N·m (19 ft-lbs). | |||||||
6. | Install the rubber mat into the luggage. Close saddlebag. | |||||||
7. | Install the Detachable Docking Hardware Kit to the vehicle per the instructions in that kit. |
1 | Pull front hook into front docking point (2) |
2 | Rotate rear of rack downward |
3 | Close rack rotary latch onto rear docking point (right side latch, viewed from left and rear) |
4 | Tour-Pak rack front hook (2) |
5 | Front docking point (2) |
6 | Rear docking point (2) |
7 | Tour-Pak rack sideplate (2) |
8 | Rotary latch (2) |
9 | Rotary latch release button (2) |
10 | Rear docking point neck |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Detachable two-up Tour-Pak luggage rack assembly (includes items 2, 3, 4R, 4L) | Not sold separately |
2 |
| Not sold separately |
3 |
| Not sold separately |
4 |
| 50300108 |
5 |
| Not sold separately |
6 |
| 6828 |
7 |
| 6827 |
8 |
| Not sold separately |
9 | Hex head cap screw, 5/16-18 x 25.4 mm (1 in) long (4) | 4017 |
10 | Flat washer (8) | 6016 |
11 | Hex lock nut, 5/16-18 (4) | 7739 |
Items mentioned in text, but not included in kit: | ||
A | Forward Tour-Pak luggage mounting location (4) | |
B | Rearward Tour-Pak luggage mounting location (4) | |
C | Front Tour-Pak luggage rack hook (2) | |
D | Rear Tour-Pak luggage rack notch (2) | |
E | Rotary latch release button (2) |