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2000 Tour Pak Mounting Bracket Removal

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Old Jul 23, 2020 | 10:14 AM
  #1  
Z's Avatar
Z
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Road Warrior
Joined: Nov 2005
Posts: 1,484
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From: Mountain View, California
Default 2000 Tour Pak Mounting Bracket Removal

My bracket broke and needs replacing. The service manual makes no mention of how to remove it.

On either side of the bike, adjacent the upper rear shock mounting point, there is a T40 bolt securing the forward end of this U-shaped bracket (the rear attaches to the license plate frame.

Turning the T40 bolt causes the stud behind it - to which the bracket is attached - to spin such that the bolt will not loosen. I cant see how to hold the back side of that stud so that the T40 can be removed. Anyone have experience with this? I'm hesitant to just reach back there with Vice Grips (if I can even get them in there) for fear of screwing things up.


 
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Old Jul 23, 2020 | 10:36 AM
  #2  
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EVOrider
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Joined: Feb 2007
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From: Russellville, Arkansas
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Same thing happened to me....I had to pry on it the same time I was turning the bolt. You’ll get it....

As for replacing it.....two different top support tubes were available depending on your bike.

53425-98 was used up to mid 2000. It was a three point mount with threaded inserts that the tour pack mounted to.

53801-98 was used mid 2000 to 2008. It was a five point mounted to tour pack. It had no threaded inserts. It used five spacers 53799-99. The bolts go through the tour pack, through the spacer, through the tube, and with a nut on bottom. Much better design and easy to make it work on your bike.

Which one is on your bike?

 
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Old Jul 27, 2020 | 11:29 AM
  #3  
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Z
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Road Warrior
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From: Mountain View, California
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Since the bolts go through the Tour Pak, through the bracket, and into a separate nut, then I suspect I have 53810 in place now.

Thanks for your input! I haven't taken the old one off yet, but I have a plan of attack now. Much appreciated
 
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