INSTRUCTIONS - Harley
Contents
1. 1 in openings and press in tightly around both corners Check to be sure there is clear ance between each opening and lamp housing around entire perimeter If there is interference the housing will not fit cor rectly Enlarge any interference area with a file 9 See Figure 3 Measure downward from lip at top of tour pak a distance of 2 3 4 in at centerline Mark a reference point Measure down 1 1 2 in from lip and make a horizontal line at three places one at center one 6 in left of center and one 6 in right of center 10 Mount lamp housing on tour pak and align top center hole over the 2 3 4 in mark at centerline Align the top edge of lamp housing with the three horizontal lines 1 1 2 in down from top edge of tour pak Using the lamp housing as a tem plate mark the six hole locations Prick punch the center of each hole and drill a 1 4 in hole at each location NOTE If there is to be an antenna mounted to the tour pak a 1 2 in hole is drilled 9 3 4 in to the left of centerline downward 1 1 4 in from lip If existing antenna hole does not align with antenna hole in lamp housing drill new hole as described and seal any portion of existing hole that extends beyond lamp housing with silicone 11 See Figure 4 Lay lamp housing down with back side facing upward Cut off lip of silicone applicator and thread onto it the top for the silicone tube furnished in kit Lay a bead of silicone sealant into grooves at top and bott2. 70585 93 Butt splice blue 2 70586 93 Adapter harness 1 70307 99 Template 50002 01 NOTE A Service Manual for your vehicle is available from your Harley Davidson Dealer WARNING To avoid accidental start up of motorcycle and possible per sonal injury disconnect the battery cables negative cable first before performing any of the following procedures If the battery should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in death or serious injury Acaution When working on tour pak with top open be sure to brace or tie top securely in open position If this is not done the top could fall which may result in minor or moderate injury Installation 1 Locate two sided templates printed on 11 x 17 in sheet of poster board Cut out template N If vehicle is radio equipped separate antenna cable from terminal at antenna base Remove the nut lockwasher and ground ring terminal from antenna terminal Remove phillips head screw threaded into antenna base Remove mast and antenna base Detach mast from antenna base by turning counterclockwise with adjustable wrench across flats w See Figure 11 Shield threads of antenna terminal stud with strip of light cardboard Remove terminal with pliers across cardboard strip Save terminal and mast for later installation the tour pak mount template 2 left side out at left side with top edge against
3. lip of tour pak and large square end flush with centerline Tape top of template to tour pak with last tab bent around corner Remember all tabs are against top lip of tour pak While holding template tightly around corner of tour pak trace outline of cut out area portion with diagonal lines with felt tip pen or grease pencil 6 Remove hole template and mount at right side of tour pak right side out in same manner described in Step 4 Trace outline of cut out area CAUTION Use only a hand saw equipped with a fine tooth hacksaw blade for marking opening Do not use power tools as a high speed reciprocating blade can set up stress cracks File or sand smooth any irregular or rough edges where a crack may originate and result in property damage 7 Carefully drill a 1 2 in hole in each corner of both designated cut out areas With a hacksaw blade mounted in handle or keyhole saw with fine hacksaw blade cut out the marked openings i00248a tif 1 Tour pak 2 Hole template 4 Center template Figure 1 Mounting Templates 1of4 8 If pockets are glued to backside of tour pak carefully pull the pocket piece free of tour pak wall and discard See Figure 2 Remove left lamp socket 2 from lamp housing 1 by depressing locking tab and rotating downward in direction of wire leads Remove right lamp socket 2 from lamp housing 1 by depressing locking tab and rotating upward in direction of lead wires Place lamp housing
4. 2 Strip paper backing from Harley Davidson name plate 6 and press into place over screw heads at lamp hous ing 1 17 See Figure 7 Obtain wiring harness from kit Lay harness in the bottom of tour pak with the two lights aiming towards the rear corners of tour pak and the end with the black connector located towards the left front corner of tour pak See Figure 9 Align three tabs on left light socket with slots in lamp hous ing Gently push light socket inward and turn clockwise until it clicks Wires should end up facing toward center of tour pak Repeat for right side i00251 3 Seal rubber short 1 Seal rubber long 2 Lamp housing Figure 4 Mounting Sponge Rubber Seal 2of4 i00252 i00253a tif Fill with silicone sealant Trim strip Figure 5 Applying Trim Strip 18 If tour pak has side marker lights with a wiring end connector connect side marker lights to tour pak wiring harness If side marker lights do not have a connector remove the tour pak side light lenses Unhook the tour pak wiring harness from rearmost bulb making note of posts to which black wires are connected See Figure 9 Pull wires back into tour pak and cut them off as close to metal plate in bottom of tour pak as possible 19 Feed a blue and black wire through tour pak and attach wire Figure 6 Clip Installation and Sealing Housing ring terminal to bulb socket post Make sure black wire is attached on the post where the orig
5. MOTOR WV HARLEY DAVIDSON INSTRUCTIONS J01631 REV 12 06 2001 Kit Number 68012 88D KING TOUR PAK WRAP AROUND LIGHT KIT See Figure 1 Open tour pak top and remove all loose contents Remove tour pak Place center line template 4 along rear top edge of tour pak 1 with curved end against one corner Mark centerline at top edge of tour pak Reverse center line template and mark center with curved end against opposite corner If centerlines overlap mark center one half the distance between the two lines Place a square against lip at top of tour pak and draw a 3 in line downward from the center mark Attach four pieces of masking tape to top edge of hole template 2 The hole template is reversible with one side marked left and one side marked right Looking at the rear of General 4 This kit is designed for installation on 1980 and later FLHTC and FLTC model vehicles with King Tour Pak Kit contents Description Qty Part Wires blue 2 Not sold Wires black 2 Not sold Socket housings 2 73152 96BK 5 Plug 2 743 i Screw hex 6 3541 Washer flat 6 6716 Cable strap 6 10006 Trim solid black 1 Not sold Clip 2 58380 89 Nameplate 1 58381 89 Lamp housing assembly 1 Not sold Seal rubber long 1 58382 89 Seal rubber short 1 Not sold Cable assembly 1 70648 00 Adapter antenna 1 76260 89 Nut acorn 6 90844 80 Silicone sealant 1 99710 88 Butt splice red 3
6. e Wires should be locked in place Insert orange cap back into plug until it snaps into place Continue to Step 28 24 1980 to 1993 models only Cut three metal sockets off adapter harness as close to metal ends as possible Strip 1 4 inch of insulation off of each of the three wires leaving bare wire ends Continue to Step 25 or 26 depending on your model year 25 1991 to 1993 models only Strip 1 4 in of insulation off of wire ends of plug that was cut from in Step 20 Connect to other end of wire that passed through hole drilled in Step 21 using red butt splices included with kit by inserting wires into red shrink wrap butt splice See Figure 10 for butt splice procedures Continue to Step 28 lt _ Rear of motorcycle Figure 8 Tour Pak Side Lights J01631 3 of 4 Rear of Tour pak Figure 9 Inside Tour Pak Metal Plate Use extreme caution when operating the UltraTorch UT 100 or any other radiant heating device Read the manu facturer s instructions carefully before using the tool Improper tool handling can result in death or serious injury Always keep hands away from tool tip area and heat shrink attachment Avoid directing the heat toward any fuel system compo nent Extreme heat can cause fuel ignition explosion resulting in death or serious injury Avoid directing heat toward any electrical system compo nent other than the connectors on which heat shrink work is being performed Be s
7. inal black wire in step 18 47 was removed Inside tour pak install socket housing onto blue and black wire and connect side marker lights to the tour pak gt harness AT A 20 1997 and later models only Attach connector on new wrap around light harness to mating connector in tour pak Discard Light adapter harness Continue to Step 28 A g 21 1980 to 1996 models only Attach adapter harness to wrap around light harness by snapping together mating connectors See Figure 7 Cut off plug end of existing wiring harness located in front of tour pak as close to metal plate in bottom of tour pak as possible See Figure 9 Retain end Black Blue 22 1980 to 1996 models only See Figure 9 Drill a 1 2 in hole N 1 inch above location where existing wiring harness exited front left corner of tour pak Pass three wire ends on adapter a Adapter harness through this hole J harness 1996 and 23 1994 to 1996 models only Remove plug from wire harness earlier end that was cut in Step 21 by gently prying away orange cap bp with a thin flat blade screwdriver Pull back retaining tabs Attaches inside plug using small flat blade screwdriver and pull out at front of wires Discard three cut wire stubs Insert wires from adapter tour pak harness back into plug in the following manner Blue wire Cavity A Red Yellow wire Cavity B Black wire Cavity C Make sure all wires have clicked into place by gently tugging on each wir
8. om of lamp housing at areas shown Seat long piece of sponge rubber seal 1 in sili cone at top groove in housing 2 Seat short piece of sponge rubber seal 3 in silicone at bottom groove in housing 2 i00249 Lamp housing Wiring harness and socket right side Screw hex l Nut acorn 0 Clip Washer flat Nameplate Seal rubber long Seal rubber short Tour pak Figure 2 Wrap Around Light Assembly J01631 i00250a tif Figure 3 Centering and Squaring Lamp Housing 12 Mount housing with holes aligned in tour pak See Figure 5 If tour pak has Harley Davidson decal at backside which partly shows outside of lamp housing remove paper from back of solid black trim strip Mount trim strip on tour pak under lamp housing flush with the two lower edges of housing 13 See Figure 2 Insert the six hexagon screws 3 through holes in lamp housing 1 and tour pak 9 From inside tour pak place a flat washer 5 on each screw and thread on an acorn nut 4 Tighten each nut 4 snugly but do not tighten to where heads of screws turn inside square seat in lamp hous ing 14 See Figure 6 At inside of tour pak insert clip into slot in lamp housing with curved portion against side of tour pak Push clip or tap with rubber hammer until shoulder of lip is flush with lamp housing 15 Fill area between lamp housing and opening in tour pak with silicone sealant around entire perimeter 16 See Figure
9. read terminal removed from antenna base into tapped hole in antenna adapter Place ground wire ring terminal followed by lockwasher onto threaded terminal and thread on nut Tighten nut Thread mast onto threaded end of J01631 Steps For Using Butt Splice Connectors Insert wires to be connected into red or blue butt splice connector from kit Crimp butt splice to wires with wire crimper Tug gently on wires to ensure they are properly crimped Using heat gun heat middle portion of butt splice shrink wrap until liquid flows into each end of cavity on butt splice Heat ends until plastic shrinks to wires Let cool for 1 2 minutes before handling to allow liquid to properly set Figure 10 Using Butt Splice Connectors adapter Tighten mast with adjustable wrench across flats Push antenna cable socket onto antenna terminal If the vehicle is not radio equipped the adapter hole is sealed with plastic plug furnished in kit 29 Secure tour pak and complete electrical connections into wiring harness to vehicle Awarnine Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in death or serious injury 30 Reconnect battery positive cable first 31 Reinstall seat using original hardware Awarnine After installing seat pull upward on front of seat to be sure it is locked in po
10. sition If seat is loose it could result in shifting during vehicle operation loss of control of vehicle death or serious injury i00257ba tif Antenna adapter Antenna terminal Ground wire Figure 11 Antenna Adapter and Hole Plug 4of4
11. ure to turn the ON OFF switch to the OFF posi tion after use 26 1986 to 1990 models only Strip 1 4 in of insulation off of wire ends of plug that was cut in Step 20 With red butt splice from kit connect black wires together and connect blue wires together Cut a piece of 18 gauge wire long enough to reach from tour pak to motorcycle wiring harness brake light wire located under seat Connect one end of wire to red yellow wire using a red butt splice from kit Splice remaining end of wire to brake light wiring harness located under seat using a blue butt splice from kit by cutting brake light wire inserting one end of wire into end of butt splice connector inserting remaining end of wire and new wire into remaining end of splice Crimp wires Continue to Step 28 27 1980 to 1985 models only For ground wire cut a length of wire long enough to reach from tour pak to a suitable fastener threaded into a metal frame member under seat Splice one end to black wire on tour pak using butt splice from kit Crimp ring terminal on other end and secure it to fastener on frame member Cut two more wires long enough to reach from tour pak to brake light and running light wires under seat and splice them to wires as described in Step 24 28 See Figure 11 If the vehicle is radio equipped the antenna terminal is connected to the antenna adapter furnished with the kit Insert adapter so tapped hole aligns with hole in housing th
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