POWER LOCK KIT - Harley
Contents
1. Figure 13 Service Parts Tour Pak Power Lock Kit Table 2 Service Parts Table Item Description Quantity Part Number Kit 76510 08 1 Tour Pak actuator Not Sold Separately 2 Tape double sided Not Sold Separately J04427 6 of 7 Table 2 Service Parts Table Item Description Quantity Part Number 3 Cable bracket 79135 08 4 Lock stop Not Sold Separately 5 Retaining pin Not Sold Separately 6 Lock hook Not Sold Separately 7 E clip Not Sold Separately 8 Lock driver Not Sold Separately 9 Tour Pak power lock cover 79171 08 10 Cap screw 2478 11 Catch 79182 08 12 Adhesive backed clip 10102 13 Tour Pak wire harness 76481 08 A Tour Pak wire harness connector Not Sold Separately J04427 70f72. 1 Clip fastener 2 Shock absorber Figure 10 Install Clip Fastener Left Side Shown Install Power Lock in Tour Pak 1 See Figure 11 Remove lock set from Tour Pak lid Save washer 1 lock guide 2 and locknut 3 for re installation J04427 2 See Figure 13 Install Tour Pak actuator assembly 1 into lid of Tour Pak Remove backing from double sided tape 2 on bottom of actuator before positioning 3 Assemble lock components using washer nut and lock guide from Step 1 4 Remove Tour Pak liner 5 Route wires from actuator across the inside top of lid to hinge area Hold in place with clips 12 6 Route wires down into the Tour Pak bottom 7 See Figure 12 Connect F to Tour Pak harness see Figure 13 Item 13 8 Connect the 2 way connector to the Tour Pak harness after the harness is routed inside the Tour Pak Connect the Tour Pak harness to the actuator is05179 1 Washer 2 Lock guide 3 Locknut Figure 11 Tour Pak Lock Set Final Assembly 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 1 Connect the battery cables positive battery cable first following the instructions in the appropriate Service Manual 2 Install Tour Pak liner 3 Install seat following
3. Bolt 2 Spacer Figure 5 Remove Bolt and Spacer is04998 Spacer for models without ABS Receiver module bracket Bolt Receiver module Rubber washer Washer Nut NOP en gt Figure 6 Install Receiver Module J04427 is05198 1 Foot of receiver bracket 2 Battery caddy Figure 7 Install Receiver Bracket onto the Battery Caddy is05190 1 B connector 160B Figure 8 Upper Frame Crossmember Under Seat 11 See Figure 10 Push clip fastener 1 into frame hole located in front of shock absorber mounting 2 12 See Figure 12 Route wires F and G over the rear fender 13 Connect the two pin connector G to the frame on the left side in front of the shock absorber Figure 10 Item 2 14 See Figure 12 If not installing the Tour Pak lock kit Install the three pin connector F with weather plug 18 15 Connect the actuator wire connectors exiting the sad dlebag before locking the saddlebag 16 Install saddlebags following the instructions in the appro priate Service Manual 3 of 7 is04996 1 Box and actuator assembly right side Box and actuator assembly left side not shown Screw 2 Power lock spacer E clip Spring Cord grip strain relief bushing Inner cam Outer cam 10 Face plate 11 Cover right side 12 Cover left side not shown N OO NO UT R Figure 9 Saddlebag Assembly
4. instructions in the appropriate Service Manual 4 Test the power locks with key fob Press the lock and unlock buttons to test 4 of 7 SERVICE PARTS is04989 Figure 12 Service Parts Power Lock Kit Table 1 Service Parts Table Item Description Quantity Part Number Kit 76463 08 1 Lock assembly 2 53986 07 2 Actuator assembly right side 79163 07 3 Actuator assembly left side not shown 79156 07 4 Harness saddlebag actuator 76458 08 5 Receiver module 76524 08 6 Bracket receiver module 76528 08 7 Washer rubber 6035A 8 Washer 6036 9 Nut 7499 10 Key fob 2 76543 08 J04427 5 of 7 Table 1 Service Parts Table Item Description Quantity Part Number 11 Drill template 94093 08 12 Spacer for models without ABS only 90175 00 13 Screw 3277 14 Clip adhesive backed not shown 10102 15 Secondary lock included with items 1 and 2 74152 98 16 Housing 2 way socket included with items 1 and 2 74112 98BK 17 Power lock wire harness 76458 08 18 Weather plug installed in F 72163 94 19 Clip 73198 96 20 Power lock hardware kit 88283 07 Wire Harness Designations A To right saddlebag module To receiver module To ground Fuse holder To battery To Tour Pak 0l Tn m oO w To left saddlebag module is04999 2i lt p A
5. cMOTOR HARLEY DAVIDSON WY J04427 INSTRUCTIONS REV 2007 12 04 POWER LOCK KIT GENERAL Kit Number 76463 08 76510 08 Models For model fitment information please see the P amp A Retail Cat alog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required 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 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 12 and Table 1 and Figure 13 and Table 2 INSTALLATION WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a 1 Disconnect the battery negative battery cable first following the instructi
6. nstall new lock 1 on saddlebag hinge Tighten to 30 40 in Ibs 41 54 Nm J04427 NOTE See Figure 9 There are two actuator assemblies a left side 2 and a right side 1 If the actuator cable does not lay against the hinge wall of the saddlebag use the other actuator 2 Install actuator 1 into bottom back corner of saddlebag Peel off the backing from the double sided tape on bottom of actuator before positioning into saddlebag The cable from the actuator should be tight against the hinge side wall of the saddlebag 3 Align the cam plate with the 0 344 hole previously drilled Install two inner screws to face plate 10 of the lid hinge Tighten finger tight 4 Push the outer cam 9 through the hole in the saddlebag and cam plate Align the inner cam 8 to the square stock of the outer cam 5 Slide the small end of the spring 6 over the square stock of the outer cam 9 Press the spring in place with the spacer 4 6 Secure the assembly with the E clip 5 7 Attach the cable barrel to the cam arm and tighten the locknut on the cable end 8 Tighten the two inner screws to 25 in lbs 2 8 Nm 9 Install cover 11 over the cam assembly Install the lid tether on the back of the cover 11 Install screws 3 Tighten the screws only to the point where the tether fabric just begins to wrinkle 10 Install strain relief bushing 7 into the 0 50 hole previously drilled Install the actuator cable int
7. o the strain relief bushing 11 Install the self adhesive clips to hold wire against side of the saddlebag 12 Install the 2 way housing 16 onto the ends of the actuator wires and secure with the secondary lock 13 Repeat Steps 1 12 for the other saddlebag NOTE Saddlebag liners 88235 07 right and 88236 07 left are available from your Harley Davidson dealer Install Receiver Module and Wire Harness 1 Remove right side cover 2 See Figure 5 Remove bolt 1 and spacer 2 holding arm of battery caddy 3 See Figure 6 For Models without ABS Install receiver bracket 2 and spacer 1 to the caddy with bolt 3 For Models with ABS Install receiver bracket 2 to the caddy with bolt 3 Spacer 1 can be discarded 4 Tighten screw to 72 96 in lbs 8 11 Nm NOTE See Figure 7 Ensure the foot 1 of the receiver bracket hook onto the arm of the battery caddy 2 5 See Figure 6 Install receiver module 4 onto receiver module bracket 2 with rubber washer 5 washer 6 and nut 7 Tighten nut to 20 40 in Ibs 2 3 4 5 Nm 2of7 6 See Figure 12 Plug connector B into receiver module 7 Route connector wires C and E up the front of the battery 8 Install ground wire C onto ground stud on the motorcycle frame 9 See Figure 8 Plug connector E into the B connector 160B 10 See Figure 12 Route wire A between frame and rear fender on right side of motorcycle is04997 1
8. ons in the appropriate Service Manual N Remove seat following the instructions in the appropriate Service Manual Preparing the Saddlebags for Power Locks 1 Remove saddlebags following the instructions in the appropriate Service Manual J04427 See Figure 1 Remove lid 1 and hinge 2 from sad dlebag Remove lock 3 from saddlebag See Figure 2 Set drill template on hinge surface of the saddlebag aligning the template 5 with hinge mounting holes 7 See Figure 3 Drill 0 344 11 32 inch diameter hole 1 Place the template on the back of the saddlebag 4 aligning front mounting grommet 2 and forward latch bracket 1 See Figure 4 Drill 0 500 0 515 inch diameter hole 1 Repeat on the other saddlebag is04988 1 Saddlebag lid 2 Saddlebag hinge 3 Saddlebag lock Figure 1 Remove Lid Hinge and Lock from Saddlebag 1 of 7 is04985 Forward latch bracket position Mounting grommet position Drill 0 5 0 515 inch diameter hole in saddlebag back Saddlebag back Saddlebag hinge side Drill 0 344 inch diameter hole in hinge area Rear hinge mounting hole NS NONA Figure 2 Drilling Template is05189 1 0 344 inch diameter hole Figure 3 Drill Hole in Saddlebag Front is05188 1 0 500 0 515 inch diameter hole 2 Grommet Figure 4 Drill Hole in Saddlebag Back Installing Power Lock in Saddlebags 1 See Figure 12 I
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