1. Open Tour-Pak. Open map pocket and remove acorn nuts (with flat washers). Remove map pocket and molded liner from Tour-Pak.
2. Depress external latch and rotate housing to release bulb socket from left side of Tour-Pak.
3. Rotate knurled lock ring in a counterclockwise direction to separate pin and socket halves of radio antenna cable connector [51]. Release cable from two adhesive clips at bottom of Tour-Pak.
4. Disconnect Tour-Pak lights connector [12], 3-place Multi-lock. See Figure 2-115.
5. Pull grommet into Tour-Pak and remove from main har-ness conduit.
6. Feed main harness conduit and connectors through hole in Tour-Pak. See Figure 2-116.
7. Release rear headset receptacle from bracket at bottom of left side speaker box.
8. Remove trim ring and gently pull on wire harness to draw rear speaker/passenger controls connector [42], 6-place Deutsch, out of left side speaker box. Depress external latch and use a rocking motion to separate pin and socket halves.
9. Moving to right side of motorcycle, disconnect CB antenna cable connector [50]. Release cable from two adhesive clips at bottom of Tour-Pak. See Figure 2-118.
10. Pull right side grommet into Tour-Pak and remove from CB antenna cable. Feed CB antenna cable through hole in Tour-Pak.
11. Remove trim ring and gently pull on wire harness to draw rear speaker/passenger controls connector [41], 6-place Deutsch, out of right side speaker box. Depress external latch and use a rocking motion to separate pin and socket halves.
12. Holding nylon cap locknuts at bottom of luggage rack rail, remove four hex head bolts (with flat washers) from inside Tour-Pak. Luggage rack spacers will become free as locknuts are removed.
13. Holding button head bolt at rear center hole, remove locknut (and flat washer) from inside Tour-Pak to release Tour-Pak from luggage rack. Be sure to have a firm grasp on the Tour-Pak as the bolt is removed. See Figure 2-117.
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1. CB antenna cable connector [50]
2. Adhesive clip 3. Grommet
Figure 2-118. Disconnect CB Antenna Cable Connector
Installation
1. Place Tour-Pak on luggage rack and open lid.
2. Align rear center hole in Tour-Pak with same hole in lug-gage rack. Slide button head bolt through spacer (concave side up), luggage rack and Tour-Pak holes. From inside Tour-Pak, install flat washer, radio antenna ground ring terminal and locknut on bolt. With concavity on spacer inline with the rail, hold locknut and tighten bolt until snug.
NOTE
Always install hex head bolts from inside Tour-Pak. If hex head bolts are installed upside down, then loss of a nylon cap could cause the end of a bolt to tear the molded liner and scratch objects, such as helmets, stored inside the Tour-Pak.
3. From inside Tour-Pak, install two hex head bolts (with flat washers) in two front Tour-Pak and luggage rack holes (one each side). At bottom of luggage rack, install spacer (concave side up) and nylon cap locknut on each bolt.
With concavity on spacer inline with the rail, hold locknut and tighten each bolt until snug.
4. Position two spacers between bottom of luggage rack and tabs of license plate bracket. Slide two hex head bolts (with flat washers) through two center holes in Tour-Pak and luggage rack, and then through spacers and tabs of license plate bracket. If necessary, loosen two hex head bolts at back of license plate bracket to align holes in tabs with bolts. Install flat washers and nylon cap locknuts on bolts and tighten until snug. See inset of Figure 2-117.
5. In a crosswise pattern, alternately tighten five bolts to 96-108 in-lbs (10.8-12.2 Nm). Be sure that concavity on each spacer is inline with the rail and has not rotated out of position.
6. Connect rear speaker/passenger controls connector [41], 6-place Deutsch. Feed connector back up into right side speaker box pressing trim ring into hole.
8. Connect CB antenna cable connector [50]. Capture cable in two adhesive clips at bottom of Tour-Pak. See Figure 2-118.
9. Moving to opposite side of motorcycle, connect rear speaker/passenger controls connector [42], 6-place Deutsch. Feed connector back up into left side speaker box pressing trim ring into hole.
10. Capture rear headset receptacle in bracket at bottom of left side speaker box.
11. Feed socket connectors and main harness conduit through hole in Tour-pak. Capture conduit in grommet. Install grommet in hole with the larger OD facing inside.
12. Connect Tour-pak lights connector [12], 3-place Multilock.
See Figure 2-115.
13. Rotate knurled lock ring in a clockwise direction to mate pin and socket halves of radio antenna cable connector [51]. Capture cable in two adhesive clips at bottom of Tour-Pak.
14. Install bulb socket on left side of Tour-pak.
15. Install molded liner in Tour-Pak. Install map pocket and secure using acorn nuts (with flat washers). Close Tour-Pak.
ADJUSTMENT
NOTE
The Tour-Pak can be moved forward/rearward approximately one inch for best passenger comfort.
1. Proceed as follows:
a. FLHTC: Open Tour-Pak. Remove rubber mat.
b. FLHTCU: Open Tour-Pak. Open map pocket and remove acorn nuts (with flat washers). Remove map pocket and molded liner from Tour-Pak.
2. From inside Tour-Pak, remove plastic plug from unused rear center hole.
3. Holding nylon cap locknuts at bottom of luggage rack rail, remove four hex head bolts (with flat washers) from inside Tour-Pak. Luggage rack spacers will become free as locknuts are removed.
4. Holding button head bolt at rear center hole, remove locknut (and flat washer) from inside Tour-Pak to release Tour-Pak from luggage rack. Be sure to have a firm grasp on the Tour-Pak as the bolt is removed. See Figure 2-117.
5. Move Tour-Pak to the forward/rearward position. See Figure 2-119.
6. Align rear center hole in Tour-Pak with same hole in lug-gage rack. Slide button head bolt through spacer (concave side up), luggage rack and Tour-Pak holes. From inside Tour-Pak, install flat washer, radio antenna ground ring terminal and locknut on bolt. With concavity on spacer in-line with the rail, hold locknut and tighten bolt until snug.
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1. Forward 2. Rearward
Figure 2-119. Adjust Position of Tour-Pak for Passenger Comfort
7. From inside Tour-Pak, install two hex head bolts (with flat washers) in two front Tour-Pak and luggage rack holes (one each side). At bottom of luggage rack, install spacer (concave side up) and nylon cap locknut on each bolt and tighten until snug.
8. Verify that two spacers are in position between bottom of luggage rack and tabs of license plate bracket. Slide two hex head bolts (with flat washers) through two center holes in Tour-Pak and luggage rack, and then through spacers and tabs of license plate bracket. Install flat washers and nylon cap locknuts on bolts and tighten until snug. See inset of Figure 2-117.
9. In a crosswise pattern, alternately tighten five bolts to 96-108 in-lbs (10.8-12.2 Nm).
10. Verify that wire harness to Tour-pak is not bunched or stretched at any point. Rearrange wire harness slightly if necessary. Install new cable straps capturing wire harness and luggage rack rails if rearrangement required cutting of existing cable straps. See Figure 2-120.
11. From inside Tour-Pak, install plastic plug in unused rear center hole. See Figure 2-119.
12. Proceed as follows:
a. FLHTC: Install rubber mat. Close Tour-Pak.
b. FLHTCU: Install molded liner in Tour-Pak. Install map pocket and secure using acorn nuts (with flat washers). Close Tour-Pak.
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Figure 2-120. Right Side Luggage Rack Rail (FLHTCU)