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chrome tour-pak lid trim kit - HARLEY

1. areas to be sure distances are equal Figure 1 Center of Template NOTE Apply masking tape to the Tour Pak cover at the five points where you will be drilling the trim mounting holes The tape will serve as a marker for drilling as well as to keep the fiberglass surface from chipping or splintering during the drilling process NOTE Remove all belongings from within the Tour Pak to avoid pos sible contact with the moving drill bit during the following drilling procedures 5 _ Drill starter holes using a 1 16 inch drill bit Using a 3 8 375 inch drill bit drill the finished holes Remove the masking tape pieces 6 See Figure 4 Obtain the Tour Pak lid trim piece 4 and five of the rubber washers 3 from kit At each of the mounting studs on the trim piece carefully fit a rubber washer onto the stud end NOTE The rubber washers are sized specifically to surround the stud with a seal tight fit Make sure washers are placed correctly at each of the mounting studs 7 Open and lift up the lid of the Tour Pak Place the chrome lid trim piece onto the lid carefully aligning each of the mounting studs with washers with each of the drilled holes 1 of 2 is01542 Figure 2 Trim Piece Mounting Studs 8 See Figure 3 Obtain a rubber washer 3 10 metal washer 2 and self tapping mounting screw 1 from kit Install the metal washer followed by the rubber washer onto the self tapping screw 9 While h
2. cMOTOR HARLEY DAVIDSON NU J02622 INSTRUCTIONS REV 2005 05 12 CHROME TOUR PAK LID TRIM KIT GENERAL Kit Number 53936 03 Models This kit fits 1993 2005 Touring models equipped with a King or Chopped Tour Pak except 100th Anniversary Two tone versions This kit does not fit with Mini Tour Pak Lid Rack part number 53100 96 or previously installed Tour Pak Lid Orga nizer part number 53249 01A NOTE A Service Manual for your model motorcycle is available from a Harley Davidson Dealer Kit Contents See Figure 4 and Table 1 INSTALLATION 1 Obtain template from this kit and carefully cut around the outer line Measure the 1 inch reference line to be sure of correct scale 2 See Figure 1 Carefully place template in recessed area of Tour Pak and align the template with the 3 surrounding ridges forming the recess Center template by measuring equal distances from side of template to left and right ridges and at top corners Tape the template to the Tour Pak in the centered location 3 Use a scribe or similar tool to carefully mark the exact center of each of the five trim mounting holes on the tem plate Press hard enough that marking will penetrate paper and will also mark the Tour Pak surface 4 Place apiece of masking tape at each of the marked holes and copy the scribe marks made in the last step to the masking tape J02622 is01541 Ep aew aar 1 Template 2 Measure these
3. olding the lid trim with one hand hold screwdriver as straight and as parallel to the mounting stud as possible and tighten the self tapping screw until the lid trim piece begins to draw up tight then stop Repeat Steps 8 and 9 for the remaining screws and washers 10 Return to all five screws and tighten evenly and securely but do NOT overtighten is01544 Self tapping screw 10 metal washer Rubber washer PeNa Rubber washer Figure 3 Lid Trim Kit Drill and Hardware Locations J02622 SERVICE PARTS See Figure 4 and Table 1 is01543 Figure 4 Service Parts Chrome Tour Pak Lid Trim Kit Table 1 Service Parts Item Description Quantity Part Number Screw panhead Torx 10 24 5 4194 2 Washer 10 wide 5 6831 3 Washer EPDM 10 57964 97 4 Lid Tour Pak chrome trim Not Sold Separately 5 Template not shown 53937 03 2 of 2

chrome tour-pak lid trim kit - HARLEY

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