TOUR-PAK SPOILER AND AUXILIARY REAR - Harley
Contents
1. flashing Turn ignition switch ON but do not start the motorcycle a Spoiler lamp and tail lamps are illuminated b Actuate front brake lever or rear brake pedal Spoiler lamp and tail lamps noticeably brighten c Actuate turn signal The correct turn signal lamp flashes d Actuate hazard warning emergency four way flasher Both turn signal lamps flash e Turn ignition OFF Both turn signals continue to flash f Turn ignition switch to ON or ACCY position Turn OFF hazard warning flasher Turn signal lamps stop flashing 3 Install the passenger backrest flap if previously removed Tighten screws to 21 24 in lbs 2 4 2 7 N m 4 Install Tour Pak liner 5 Install the Tour Pak tether anchor Tighten screws to 25 35 in Ibs 2 8 4 0 N m 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 6 See the service manual Install seat 3of4 IN USE Care and Cleaning benzene paint thinner gasoline or any other type of harsh cleaner SERVICE PARTS e The spoiler is constructed of polycarbonate DO NOT use is08384 Figure 3 Service Parts Tour Pak Spoiler and Auxiliary Rear Light Kit Table 1 Service Parts Kit ltem Description Quantity Part Number Kit 53000238 1 Auxiliary light assem2. newly drilled wiring hole 2 of 4 4 See Figure 2 Get the six remaining adhesive backed wire clips from the kit Use the clips to route the spoiler wiring a Along the underside of the lid to the left side wall b Drop straight down to the floor of the Tour Pak c Route the wiring forward to the grommet location is08392 Figure 2 Spoiler Light Wire Routing Inside Tour Pak Chopped Tour Pak Shown NOTE e Apply a light coat of liquid soap to the wiring and grommet as necessary to ease installation e Make sure that there is sufficient slack in the wiring to open and close the Tour Pak lid easily 5 Insert the spoiler wiring through the grommet 6 See Figure 3 Get the three way Molex pin housing 10 See the service manual appendix Insert the spoiler wires into the pin housing e Red Yellow wire to cavity 1 e Blue Red wire to cavity 2 e Black wire to cavity 3 7 Get the spoiler auxiliary lighting wire harness 11 Models WITH OE Tour Pak a Unplug the six way vehicle harness connector C12 behind the seat Plug the six way spoiler harness connectors into connector halves C12A and C12B b Plug the three way connector on the spoiler harness into the spoiler connector Models WITHOUT OE Tour Pak a Unplug the six way vehicle harness connector C7 under the seat FLHX FLHXS FLHXSE FLTRX FLTRXS models Next to the Electronic Control Module ECM FLHR FLHRSE models Top fron
3. bly with red lens 68000057 Red Lens Kit 53000239 1 Auxiliary light assembly with smoke lens 68000059 Smoke Lens Parts common 2 Base Tour Pak spoiler Not sold separately to BOTH kits 3 Button head socket cap screw 1 4 20 x 1 0 in 25 4 mm long 2 Not sold separately 4 Washer nylon special beveled 2 Not sold separately 5 Button head socket cap screw 8 32 x 0 50 in 12 7 mm long 2 Not sold separately 6 Button head socket cap screw 8 32 x 0 375 in 9 5 mm long 4 Not sold separately 7 Gasket set of 2 closed cell neoprene Not sold separately 8 Grommet Not sold separately 9 Clip metal adhesive back 0 25 in 6 4 mm 7 10102 10 Pin housing three way Molex black 72511 07BK 11 Wire harness Tour Pak auxiliary lighting 69200573 12 Cable strap 2 10006 Item mentioned in text but not included in this kit A Spoiler cover J05625 4 of 4
4. cMOTOR HARLEY DAVIDSON WY J05625 INSTRUCTIONS REV 2014 06 20 TOUR PAK SPOILER AND AUXILIARY REAR LIGHT KIT GENERAL Kit Numbers 53000238 53000239 Models For model fitment information see the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only Installation Requirements Purchase a color matched Tour Pak Lid Spoiler Cover Part No 57200086xxx to complete this installation This item is available separately from a Harley Davidson dealer Models NOT shipped from the factory with an original equipment OE color matched Tour Pak require separate purchase of an extension harness Part No 69201157 WARNING The rider s safety depends 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 00333a NOTE This instruction sheet refers to service manual information A service manual for this year model motorcycle is required for this installation One is available from a Harley Davidson dealer ELECTRICAL OVERLOAD NOTICE It is possible to overload your vehicle s charging system by adding too many electrical accessories If the combined electrical accessories operating at any one time consume more elec
5. ight assembly 1 and an adhesive backed wire clip 9 from the kit Feed the light wiring through the base wiring hole on the left side Position the light assembly with the bottom lip against the front edge of the base Align the mounting ears with the base screw holes Route the wires through the notch and out the wiring hole Apply the clip to the spoiler base to hold the wiring in place Get the spoiler cover A purchased separately Install the cover over the spoiler base and light assembly Make sure that the wires are not pinched a Assemble the base and light to the cover with two longer socket head cap screws 5 as shown DO NOT fully tighten b Install the four shorter screws 6 in the remaining holes but DO NOT fully tighten c Tighten the six screws incrementally to 6 8 in lbs 0 7 0 9 N m Get the gasket pair sheet 7 from the kit Cut along the dashed line to separate the pair DO NOT remove the protective tape from the adhesive backing now NOTE The gaskets are side specific The left gasket has three holes The right gasket has two holes J05625 Get the three hole left gasket a Feed the wiring through the outboard hole in the gasket b While holding the gasket in position against the base peel the protective tape from the corner nearest the wire Apply that corner to the base c Remove the rest of the protective tape Adhere the rest of the gasket to the spoiler base d Repeat w
6. ith the remaining gasket on the opposite end of the spoiler base NOTE The beveled washers install with the angled face against the cover DO NOT apply liquid threadlocker to the screws Feed the spoiler wiring through the Tour Pak cover Install the spoiler to the cover using the beveled washers 4 and screws 3 from the kit Allow the washers to rotate into alignment with the underside of the cover Tighten the screws to 20 25 in lbs 2 3 2 8 N m Wire Routing 1 See Figure 1 Lay strips of masking tape on the outside of the Tour Pak front wall in the approximate area of the required wiring hole Carefully measure and mark the hole location as shown is08391 r Z ar King Tour Pak bottom Measure 7 25 in 184 mm down Chopped Tour Pak bottom Measure 4 25 in 108 mm down Tour Pak cover tether mounting hole 2 Measure 11 312 in 287 mm from inboard hole Drill 1 8 in 3 mm diameter pilot hole Enlarge pilot hole to 7 16 in 11 mm diameter ON oo eo Ns Figure 1 Drill Hole in Front Left Lower Tour Pak Wall Drill a 1 8 in 8 mm diameter pilot hole at the marked location Enlarge the hole to 7 16 in 11 mm diameter Remove the masking tape Lightly sand the hole to remove burrs and sharp edges Clean the Tour Pak with a 50 50 mixture of isopropyl alcohol and distilled water Allow to dry completely See Figure 3 Install a grommet 8 from the kit into the
7. ront wall of the Tour Pak b Remove the Tour Pak inner liner c Remove the passenger backrest flap if present from the exterior front wall of the Tour Pak 1 of 4 Please dispose of materials responsibly INSTALLATION Drill Spoiler Mounting Holes 1 Lay masking tape on the Tour Pak cover outer surface in the spoiler installation area Locate two drill points molded into the inner surface of the spoiler installation area Drill 1 8 in 8 mm diameter holes through the center of each drill point From outside enlarge holes to 5 16 in 8 mm diameter NOTE The beveled washers install with the angled face against the cover DO NOT apply liquid threadlocker to the screws See Figure 3 Temporarily mount the spoiler base 2 to the Tour Pak cover with the beveled washers 4 and larger screws 3 Allow washers to rotate into alignment on the underside of the lid DO NOT fully tighten screws Locate the wiring hole on the spoiler base Mark the loca tion of the wiring hole on the masking tape Remove the spoiler base from the Tour Pak cover Drill a 1 8 in 8 mm diameter hole at the marked location Enlarge the hole to 3 8 in 9 5 mm diameter Remove the masking tape Lightly sand the holes to remove burrs and sharp edges Clean the Tour Pak cover with a 50 50 mixture of isopropyl alcohol and distilled water Allow to dry completely Install Spoiler 1 See Figure 3 Get the spoiler base auxiliary l
8. t of rear fender b Plug the six way spoiler harness connectors into connector halves C7A and C7B c Insert the extension harness Part No 69201157 purchased separately into the spoiler auxiliary lighting wire harness 11 d Route the extension harness along the left frame tube Plug the spoiler connector into the extension harness 8 Secure wiring with cable straps 12 as needed J05625 COMPLETION NOTE Verify that the ignition is OFF before installing the main fuse 1 See the service manual Install the main fuse WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 2 Check for proper function of rear lighting With ignition OFF Spoiler lamp and tail lamps are off a Actuate brake or turn signal Rear lamps remain off b Actuate hazard warning emergency four way flasher NO lamps flash Turn ignition switch to ACCY position a Spoiler lamp and tail lamps are illuminated b Actuate front brake lever or rear brake pedal Spoiler lamp and tail lamps noticeably brighten c Actuate left and right turn signal Signal lamp DOES NOT flash d Actuate hazard warning emergency four way flasher Both turn signal lamps flash e Turn ignition OFF Both turn signals continue to flash f Turn ignition switch to ON or ACCY position Turn OFF hazard warning flasher Turn signal lamps stop
9. trical current than the vehicle s charging system can produce the electrical consumption can discharge the battery and cause damage to the vehicle s electrical system See an authorized Harley Davidson dealer for advice about the amount of current consumed by addi tional electrical accessories or for necessary wiring changes 00211c J05625 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled WARNING When installing any electrical accessory be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modi fied Exceeding the maximum amperage can lead to elec trical failures which could result in death or serious injury 00310a This kit requires up to 215 mA more current from the electrical system Kit Contents See Figure 3 and Table 1 PREPARATION WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b NOTE WITH security siren With security fob present turn ignition switch ON See the service manual After system is disarmed turn ignition OFF IMMEDIATELY remove the main fuse WITHOUT security siren See the service manual Remove main fuse e ALL models See the service manual Remove seat N Open and support the Tour Pak lid See the service manual to a Remove the tether anchor from the interior f
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