tour-pak for flhp/e/i, flhtp/i police models - Harley
Contents
1. Nm 3 Reposition power supply mounting plate on to isolator studs and install the five nuts previously removed Tighten nuts to 80 in lbs 9 0 Nm All Models 1 Make the emergency light connections by matching up wire colors of male and female connectors 3 of 7 is05744b 7 oTt Or N SPN f f Battery bracket Screw 3 8 16 x 1 inch Washer 3 8 inch Battery strap Screw 3 8 16 x 1 3 4 inch Washer 3 8 inch Lock nut 3 8 16 not shown NON RNa Figure 10 Install Battery 1 Battery ground stud 2 Accessory connector 3 Battery positive connector Figure 11 Under Seat Connectors NOTE When performing the next few steps install battery mounting bracket battery strap and battery only Do NOT connect battery terminals at this time 2 See Figure 10 Loosely assemble battery mounting bracket 1 with screw 2 washers 3 and nut 7 3 Orient and position battery behind mounting bracket as shown Loosely install battery strap 4 using two screws 5 four Washers 6 and two nuts 7 4 Make sure battery is centered and mounting bracket is positioned properly While pushing mounting bracket for ward tighten bracket hardware to 10 12 ft lbs 13 6 16 3 Nm Return to battery strap hardware and tighten to 10 12 ft lbs 13 6 16 3 Nm 5 Locate red positive and black negative battery cables in Tour Pak Make sure cables are not touching each other or anything met2. them Obtain the two rectangular luggage rack spacers and four nuts saved from previous step Obtain four new 1 4 inch washers and loosely install washers and nuts to secure Tour Pak to support rail 3 See Figure 6 Obtain Rear Mounting Block w 1 hole 1 4 20 x 2 1 2 hex head bolt and two 1 4 inch flat washers from kit Also obtain rectangular spacer and nut removed earlier J02151 4 Install washer to bolt and position bolt above hole at rear center Tour Pak above rear block mounting position 5 Orient rear mounting block with hole running vertical and position between recessed area of Tour Pak near center and rail support Install bolt through Tour Pak rear block and rail then loosely Install spacer followed by washer and nut we re 1 Seat pin 2 Trim panel nuts 3 Cable straps Figure 4 Remove Trim Panel 08 amp earlier is05739 TA Mounting bolts and washers Luggage rack spacer License plate bracket spacer Washers and nuts 1 2 3 4 Figure 5 Install Tour Pak Mounting Hardware 08 amp earlier 2 of 7 is05740 1 Mounting block 2 Spacer 3 Washer and nut Figure 6 Install Tour Pak Rear Mounting Bracket 08 amp earlier 6 Obtain the remaining Mounting Block with two holes two long Phillips pan head screws and two 10 flat washers from kit 7 See Figure 7 Install flat washers to Phillips screws and position screws
3. above two holes near front center of Tour Pak above front mounting block position cd 1 Tank mounting bracket 2 Front mounting block Figure 7 Install Tour Pak Front Mounting Bracket 08 amp earlier 8 Position block 2 with holes running vertical between Tour Pak and air tank mounting bracket 1 Install screws through Tour Pak and mounting block and thread into air tank mounting bracket Tighten screws to 22 in lbs 2 5 Nm 9 Return to mounting hardware previously installed and alternately tighten to 5 7 ft lbs 6 8 9 5 Nm J02151 1 Hex head cap screws and washers 2 TORX head screws Figure 8 Installing Adapter Plate 1 Isolator studs 2 Screw and washer Figure 9 Install Tour Pak Mounting Hardware 2009 and Later Models 1 See Figure 8 Locate air tank reservoir Remove TORX screws 2 from air tank bracket Align adapter plate and install screws into air tank mounting bracket Install four hex head screws 1 and washers in the adapter plate to the support rails Tighten screws to 22 in lbs 2 5 Nm 2 See Figure 9 Raise the Tour Pak up and position onto adapter plate with five rubber isolators 1 aligned with five holes in support rail two on each side and forward center hole Rubber isolators need to be installed with the longer stud down Install 1 2 inch screw and washer 2 in rear center hole Tighten rear screw to 80 in lbs 9 0
4. al in the Tour Pak J02151 6 Refer to service manual and remove ECM and tray for access to main battery 7 See Figure 11 Route control harness from Tour Pak along left upper frame tube to PNA accessory connector in space immediately in front of motorcycle battery 8 Connect control harness to PNA accessory connector WARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 9 Locate the two pin connector originally routed to rear emergency lamp and connect to the two pin connecter coming from Tour Pak NOTE Prior to installing positive battery terminal to battery post locate insulated end of positive battery cable directly after main fuse and bend a 90 degree radius into the cable as shown This will keep the terminal from kinking when installing terminal to bat tery post WARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 10 See Figure 12 Route the positive battery cable with main fuse 1 as shown and loosely install positive battery ter minal over existing terminal to battery positive post Tuck the main fuse along with the rear emergenc
5. cMOTOR HARLEY DAVIDSON WY J02151 INSTRUCTIONS REV 2008 08 26 TOUR PAK FOR FLHP E I FLHTP I POLICE MODELS GENERAL Kit Number 53631 04 53632 04 53634 04 53637 04 Models This Police Tour Pak Kit is designed for installation on 2000 and later FLHP E and FLHTP I Police Model Motorcycles Additional Parts Required 2009 and later models will require separate purchase and installation of adapter plate kit 53196 09 to complete installa tion IWIN IN 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 references service manual information A service manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 16 Figure 17 Table 1 and Table 2 INSTALLATION 1 See Figure 1 Remove the hex head cap screws five screws for 08 and earlier and four screws for 09 and later and two smaller Phillips screws with washers securing existing radio tray to mounting rail For 08 and earlier models leave the two rectangular license plate spacers and set aside three remaining spacers Discard screws and washers but
6. r Pak latch key 2 Not Sold Separately 8 Air tank mounting block 53905 01 J02151 6 of 7 is05776 Figure 17 Service Parts FLHP E Il and FLHTP I Police Tour Pak Adapter Kit Table 2 Service Parts Table ltem Description Quantity Part Number Isolator studs 5 11856 2 Hex screw 1 4 20 x 1 2 inch 3728 3 Washer 1 4 inch 6235 4365 Socket head screws 1 4 24 x 1 3 4 inch 4 A J02151 70f7
7. ry post Tighten terminal to 30 in Ibs 3 4 Nm 18 Route negative battery terminal to negative battery post and install terminal Tighten terminal to 30 in lbs 3 4 Nm 19 If not using auxiliary battery remove red connecting cable from fuse bar Failure to do so could cause arc from lead 1 Warning label Figure 15 Check for Warning Label 20 See Figure 15 Check for load limit warning label 1 on underside of Tour Pak lid If this is not pre affixed install label as shown in figure 15 Insert figure of label on bottom of Tour Pak cover in the center of the cover and squared so that it is legible when lid is opened 21 Close Tour Pak and test rear emergency lights for proper operation 5 of 7 SERVICE PARTS is05765 Figure 16 Service Parts FLHP E Il and FLHTP I Tour Pak Table 1 Service Parts FLHP E I and FLHTP I Police Tour Pak Item Description Quantity Part Number Item Description Quantity Part Number 1 Cable strap 2 10006 9 Support tube mounting block 53906 01 2 Phillips pan head screw 2 2581 10 Flat washer 1 4 inch 10 6235 3 Hex screw 3 8 16 x 1 inch 2879W 11 Flat washer 3 8 inch 6 6416 4 Battery bracket 29523 01 12 Flat washer 10 2 6716 5 Battery strap 29525 01 13 Hex lock nut 3 8 16 3 7601 6 Hex screw 1 4 20 x 2 1 2 inch 5 3768 14 Hex lock nut 1 4 20 2 7716 7 Hex screw 3 8 16 x 1 3 4 inch 2 4720W 15 Tou
8. save nuts for installation later Discard radio tray 2 2009 and later models See Figure 2 Carefully remove Tour Pak assembly and hardware from shipping container Open Tour Pak Remove the five rubber isolator studs securing the power supply mounting plate to the bottom of the Tour Pak 2008 and earlier models Remove five rubber isolator studs and set aside You will use these again later For 09 later models these studs will not be used Rather use the five longer rubber isolator studs in the adapter plate kit J02151 All Models Disconnect the emergency light connectors to allow the power supply mounting plate to be reposi tioned 1 Hex head cap screws 2 Phillips screws with washers Figure 1 Remove Radio Tray and Hardware 08 amp earlier shown re is05774 1 Disconnect emergency light connectors 2 Remove power supply plate fasteners amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Figure 2 Remove Power Supply Plate Hardware 3 See Figure 3 Raise and position lean the mounting plate 1 up against the front side of Tour Pak to provide access to the Tour Pak permanent mounting holes If necessary use a cable strap to hold plate in place Temporarily set Tour Pak assembly aside 1 of 7 Please dispose of materials responsibly E is05737 1 Power supply mounting plate Fig
9. ure 3 Move Power Mounting Plate to Install Tour Pak 08 amp earlier shown 4 2007 and earlier models See Figure 4 Remove the quick release seat pin clip from the seat pin 1 and pivot the seat forward as far as possible It may be necessary to tie or brace seat in the full forward position 2008 and later models Remove the pin and pivot bolt in front of seat 5 Remove the two trim panel nuts 2 and washers securing the trim panel assembly to the fender and remove panel Save hardware and panel for re installation AWARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 6 Disconnect battery cables negative battery cable first 7 Cut the two cable straps 3 securing the rear emergency lamp harness to the support rail Discard cable straps Route rear emergency lamp harness away from Tour Pak mounting area 2008 and Earlier Models 1 See upper half of Figure 5 and Service Parts Illustration Return to the Tour Pak and install four long 1 4 20 x 2 1 2 inch hex head screws 1 with 1 4 inch washers from inside bottom of Tour Pak at four permanent mounting holes 2 Raise the Tour Pak up and position onto rack with four mounting bolts aligned with four holes in support rail two on each side See lower half of Figure 5 Make sure the two license plate bracket spacers remain in position and bolts can pass through
10. y lamp harness 2 down into the space between the battery and the left upper frame tube as shown Tighten terminal to 30 in lbs 3 4 Nm is05760 1 Positive cable with main fuse 2 Rear emergency lamp harness connector se Figure 12 Connect Tour Pak Battery Cables to Motorcycle Battery 4 of 7 is05761 1 Cable strap Figure 13 Secure Tour Pak Harness to Mounting Rail lt 3 1 Trim panel fe Figure 14 Install Trim Panel 11 Route the negative battery cable around the front of the battery and install terminal over existing terminal to neg ative battery post Tighten terminal to 30 in lbs 3 4 Nm 12 See Figure 13 Install cable strap 1 to secure Tour Pak Harness to mounting rail 13 See Figure 14 Re install trim panel 1 to fender using nuts and washers previously saved 2007 and earlier 14 Install trim panel cover to protect battery and wiring 2007 and earlier 15 Install ECM caddy and ECM to underseat location 2008 and later 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 J02151 16 Refer to service manual to install seat 17 Return to Tour Pak and locate positive and negative bat tery cables Route positive battery terminal to battery and install terminal to batte
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