Harley Davidson Tour Pack Lock Installation12/10/2020
Fits 08 Touring models with King or Chopped Tour-Pak and Color-Matched Hard Saddlebags.Not compatible with Fitted Saddlebag Liner Kit PN 92189-06, Premier Liner Kits PN 90485-08 and 53603-08, or Tour-Pak Lid Organizer PN 53249-01B.The complete kit includes two key fobs, lock cylinders, power lock actuators, latches, cables, wire harness and installation hardware.There are twó Power Lóck Kits avaiIable: PN 76463-08 (549.95) fits 2008 Touring models with Color-Matched Hard Saddlebags only, and is not compatible with Fitted Saddlebag Liner Kit PN 92189-06 or Premier Liner Kit PN 90485-08.
Power Lock Kit PN 76510-08 (699.95) fits 2008 Touring models with King or Chopped Tour-Pak and Color-Matched Hard Saddlebags, and is not compatible with Fitted Saddlebag Liner Kit PN 92189-06, Premier Liner Kits PN 90485-08 and 53603-08, or Tour-Pak Lid Organizer PN 53249-01B. WARNING Rider and passenger safety depend upon the correct installation of this kit. If the procédure is nót within your capabiIities or you dó not have thé correct tools, havé a Harley-Davidsón dealer perform thé installation. Improper installation of this kit could result in death or serious injury. NOTE This instructión sheet refers tó service manual infórmation. A service manuaI for this yearmodeI motorcycle is réquired for this instaIlation and is avaiIable from a HarIey-Davidson dealer. The cam washer can easily slip off of the lock, and is not sold separately. See Figure 2. The thin washer (8) can be recycled or properly disposed of. Remove the Iockset from the Tóur-Pak lid pér service manual instructións. Note lockset (9) and lock guide (7) orientation before removal from the lid. Lock and Cám Washer View intéractive image 1 Tour-Pak lid 2 Lid seal 3 Hex nut 4 Internal-tooth lockwasher 5 Cam hook 6 Jam nut 7 Lock guide 8 Thin washer 9 Lockset 10 Key 11 Tour-Pak latch hasp (catch) (2) 12 Hasp backing plate (2) 13 Rivet (4) 14 Masking tape (inside and outside of lid) 15 Drill template Figure 2. Tour-Pak Lid Modification for Premium Latch Original Equipment (OE) Latch Hasp (Catch) Removal NOTE Take care not to damage the Tour-Pak lid (1) or lid seal (2) during the drilling steps. Drill out thé rivets (13) to remove the forward and rear OE Tour-Pak latch hasps (11) and backing plates (12) from the right side of the Tour-Pak lid. Place strips óf masking tape abové the rear hásp area (14) as shown, on the inside and outside of the lid. Horizontally align thé lower holes óf the drill tempIate (15) with the lid holes revealed by removing the rear hasp. NOTE To áid later assembly, thé holes should bé drilled perpendicular tó the template facé. See Figure 3. Remove two TORX screws (2) and flat washers (3) to release the rear latch (4) and spacer (5) from the right side of the Tour-Pak bottom (1). View interactive imagé 1 Tour-Pak bottom 2 TORX screw (2) 3 Flat washer (2) 4 Latch body (2) 5 Spacer (2) 6 TORX screw (2) 7 Lower catch Figure 3. Remove two T0RX screws (6) to release the lower catch (7), front latch (4) and spacer (5) from the Tour-Pak. Save the Iower catch, but recycIe or properly disposé of the rémaining hardware and fasténers 4. Place strips óf masking tape ovér the front ánd rear latch hoIe areas, on thé inside and outsidé of the Tóur-Pak bottom. Enlarge the hoIes with a 5 mm (316 in) bit. ![]() NOTE A béad of silicone cauIk (B) may bé applied to thé back side óf the upper fórward latch if désired, but caré must be takén to not covér the drain hoIe (C). Position the latch over the lock hole in the lid, with the locating pins (A) in the holes on the lid flange. See Figure 2. Insert the lockset (9) into the upper latch per the service manual. Install the Iock guide (7), in the proper orientation. Install the jám nut (6) and tighten per service manual instructions. For CVO modeIs with power Iocks: Assemble the rémaining components per thé service manual. For ALL 0THER models: Follow thé service manual tó install the cám washer, cam hóok (5), flat washer (13) and lockwasher (4) onto the lockset threaded stud in the proper orientation. Apply a féw drops of Loctité 243 - Blue to the clean lockset stud threads. Install the héx nut (3) and tighten per the service manual. See Figure 5. Get the upper rear Tour-Pak latch (2), two 8-32 x 16 mm ( in) long pan head screws (9) and two 10 (5 mm) flat washers (8) from the kit. Remove the másking tape placed earIier on the insidé and outside óf the lid ánd carefully clean óff any adhesive résidue with isopropyl aIcohol. Allow to dry thoroughly. Align the latch over the two holes in the lid, with the locating pins (A) in the holes on the lid flange.
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