TOUR-PAK WRAP-AROUND LED LIGHT KITS - Harley
Contents
1. e With left or right turn signal actuation the end sections will flash 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 3 Refer to the service manual and follow instructions to install the seat 4 Install the rubber mat or molded liner Install the pouch inside the Tour Pak using the two acorn nuts with flat washers previously removed 3of5 SERVICE PARTS Figure 3 Service Parts Tour Pak Wrap Around LED Light Kits 40f5 J05090 SERVICE PARTS Table 1 Service Parts Table Kit Item Description Quantity Part Number Kit 67853 10 1 LED Wrap Around Light assembly includes items 2 through 6 Not sold separately Red Lens 2 Bezel LED Wrap Around Light 67937 11DH 3 LED light assembly red lens right 67862 10 4 LED light assembly red lens center 73402 10 5 e LED light assembly red lens left 69901 10 6 e Backing plate 2 67945 11 Kit 67914 10 1 LED Wrap Around Light assembly includes items 2 through 6 Not sold separately Smoked Lens 2 Bezel LED Wrap Around Light 67937 11 3 LED light assembly smoked lens right 67860 10 4 LED light assembly smoked lens center 69908 10 5 e LED light assembly smoked lens left 69900 10 6 e2. and tighten securely d Install the AM FM antenna mast onto the adapter e Insert the antenna adapter 14 into the cavity C at the top right of the lamp bezel 2 with the small threaded hole forward f Shield the threads of the antenna terminal stud E with strip of light cardboard Insert the stud through the large hole in the Tour Pak and with pliers around the cardboard strip thread it into the hole in the antenna adapter g Install the flat washer F antenna ground ring ter minal and hex nut G onto the stud and tighten securely h Install the CB antenna mast onto the adapter J05090 2 Check the AM FM and CB radio for proper operation Check Lamp Function NOTE Verify that the ignition key switch is in the OFF position before installing the main fuse or attaching the negative battery cable 1 Models with main fuse Refer to the service manual and follow the instructions given to install the main fuse Models with main circuit breaker Refer to the service manual and follow the instructions given to attach the negative battery cable Apply a light coat of Harley Davidson electrical contact lubricant H D Part No 99861 02 petroleum jelly or cor rosion retardant material to the negative battery terminal 2 Check for proper lamp function e With ignition key switch ON All three lamp sections are illuminated e With brake lever or brake pedal actuation the CENTER section will brighten
3. Backing plate 2 67945 11 Parts common 7 Screw pan head TORX 6 4 3597 to BOTH kits 8 Washer 4 6029 9 Pin housing eight way Molex 72478 07BK 10 Seal plug 72473 07 11 Module harness 69911 11 12 Pin housing six way AMP 73106 96BK 13 Y harness 70933 10 14 Antenna adapter AM FM 2 8230 15 Antenna plug assembly 76258 86 16 Hex jam nut 76259 86 17 Plug 2 90493 83 18 Flange nut 7 7878 19 Drilling template Not Sold Separately Items mentioned in text but not included in kit A Threaded studs 7 on back of light assembly AM FM antenna cavity CB antenna cavity Two wire conduits 2 from left or right lamp CB antenna plug assembly saved earlier CB antenna washer saved earlier CB antenna nut saved earlier IO nim 0 0 ow AM FM antenna washer saved earlier J05090 5 of 5
4. MOTOR HARLEY DAVIDSON WY J05090 INSTRUCTIONS REV 2012 07 10 TOUR PAK WRAP AROUND LED LIGHT KITS GENERAL Kit Numbers 67931 11 67932 11 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 Tools and Supplies Required Silicone sealant a drill and various small bits will be needed to install this kit Electrical Contact Lube H D Part No 99861 02 or equivalent is required for the proper installation of this kit This item is available from a Harley Davidson dealer IWIN NIN 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 and 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 electrical current than the vehicle s charging system can produce the electrical consumption can di
5. Retain all seat mounting hardware NOTE When working on the Tour Pak with the lid open brace or tie the lid securely in the open position to prevent head hand or finger injury or scratching of the Tour Pak lid finish 2 Open the Tour Pak lid and if necessary remove all items from inside the Tour Pak Models with molded liner Open the pouch and remove the acorn nuts with flat washers Remove the pouch and liner 3 Remove the mast from the antenna and set aside for later installation Remove all of the antenna components from the rear wall of the Tour Pak and set aside for later discard or installa tion 4 Remove all nuts holding the existing light from the back wall of the Tour Pak 5 Remove the existing Tour Pak light by cutting away the caulking from inside of the Tour Pak After light is removed clean any remaining caulk from opening in Tour Pak 1of5 Please dispose of materials responsibly 7 Remove bulbs from sockets Wrap sockets with tape and secure Installation 1 Position the template 19 from the kit across the rear of the Tour Pak aligning the template around the hinge on the left side and the latch on the right Tape the template securely to the Tour Pak 2 Drill 1 16 inch 1 5 mm diameter pilot holes through the template and Tour Pak at fourteen marked locations 3 Drill holes at each pilot location as indicated on the tem plate e ALL installations One 7 16 in 11 0 mm
6. diameter hole near the center One 5 16 in 7 9 mm diameter hole at the left rear e 0 25 in 6 35 mm holes in the remaining eleven locations 4 Remove the template Smooth off any rough edges around the holes and clean up any drilling debris and tape residue from the Tour Pak 5 See Figure 3 Apply a small amount of silicone sealant around the base of the seven threaded studs A on the back of the LED Wrap Around Light assembly 1 to pre vent water leakage into the Tour Pak NOTE The LED Wrap Around Light assembly mounts to the Tour Pak with the antenna holes B C facing UP 6 Mark the two wire conduits D with their source left or right lamp close to the terminal ends Make sure the conduits are retained in the grooved ribs inside the light assembly Insert the wires from the three lamps through the 0 437 in 11 0 mm diameter hole near the center Pull the wires through the hole while positioning the light assembly to the Tour Pak NOTE If the motorcycle is equipped with an AM FM radio antenna mounted on the Tour Pak Install backing plates inside Tour Pak to cover the large holes in the Tour Pak Secure by posi tioning over stud from light and flange nut 7 Fasten the light assembly with the seven flange nuts 6 but do not fully tighten at this time 8 From the inside of the Tour Pak use the four TORX pan head screws 7 and washers 8 to fasten the light assembly at the sides Tighten secur
7. ely 9 Alternately tighten the flange nuts securely Wiring 1 Get the eight way Molex pin housing 9 from the kit See Figure 1 Follow the instructions in the service manual to J05090 insert the light assembly wires and pin terminals into the correct cavities of the housing a Violet wire from right auxiliary tail lamp to cavity 1 b Violet wire from center auxiliary tail lamp to cavity 2 c Blue wire from center auxiliary stop lamp to cavity 3 d Violet wire from left auxiliary tail lamp to cavity 4 e Black wire from left lamp ground to cavity 5 f Black wire from center lamp ground to cavity 6 g Seal plug 10 to cavity 7 Black wire from right lamp ground to cavity 8 is06401 Figure 1 Molex Eight Way Pin Housing 72478 07BK Wire End View Cavity Identification 2 Get the adapter harness with module 11 from the kit Plug the eight way socket housing from the adapter har ness into the Molex pin housing from the LED Wrap Around Light assembly 3 Route the adapter harness out through the grommet at the lower front corner of the Tour Pak and toward the rear lighting harness connector 7 on the vehicle Position the control module on the floor of the Tour Pak between the steel plate and the back wall Figure 2 AMP Six Way Pin Housing 73106 96BK Wire End View Cavity Identification 4 Get the six way AMP pin housing 12 from t
8. he kit See Figure 2 Follow the instructions in the service manual to insert the adapter harness wires and pin terminals into the correct cavities of the housing 20f5 Amp Six Way Pin Housing Cavity Identification a BNcavity 1 b O W cavity 2 c Vcavity3 d BK cavity 4 e Yellow cavity 5 NOTE For vehicles with Light Conversion Kit 69461 06B installed The Y harness 13 must be installed installed between the main harness and the Light Conversion Kit har ness Disconnect the Light Conversion Kit harness from the main harness connector 7A then connect the Y harness 13 to the main harness 7A and the Light Conversion Kit harness connector 5 Get the Y harness 13 from the kit Unplug the halves of the vehicle rear lighting harness connector 7 and install the Y harness between the main harness connector 7A and rear lighting harness connector 7B 6 Connect the adapter harness to the Y harness Antenna Installation 1 Ifthe motorcycle is equipped with an AM FM radio antenna mounted on the Tour Pak a Insert the antenna adapter 14 into the cavity B at the top left of the lamp bezel 2 with the small threaded hole forward b Shield the threads of the antenna plug assembly 15 with a strip of light cardboard and with pliers around the cardboard strip thread it into the hole in the antenna adapter c Install the washer H and antenna ground ring ter minal and a new hex nut 16 onto the stud
9. scharge 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 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 J05090 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled This Light Kit requires up to 230 mA additional current from the electrical system Kit Contents See Figure 3 and Table 1 INSTALLATION Preparation Models with main fuse WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 1 Refer to the service manual and follow the instructions given to remove the main fuse Models with main circuit breaker WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 Refer to the service manual and follow the instructions given to remove the seat and disconnect the negative black battery cable from the negative battery terminal
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