How to Install a Brake Light kit in a Tour Pac
Thread Starter
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Seasoned HDF Member
Joined: Jun 2006
Posts: 30,860
Likes: 32,761
From: King George, VA
How to Install a Brake Light kit in a Tour Pac
I will have to do this in a few posts because there are a few pictures.
As I posted a few days ago, my Tour Pac Brake Light kit finally arrived and I thought I would do an installation procedure with pictures. I’ve always wanted to do one of these and thought, “Heck, a H-D kit with instructions. Piece of cake. I should be able to do this in a couple hours.”
[IMG]local://upfiles/14260/2A205E020D6D4C1D8547AB87351149F5.jpg[/IMG]
The instructions tell ya to empty the Tour Pac of all items.
[IMG]local://upfiles/14260/5C9B3CAA79DD4B1CA4F5FC3C751B7958.jpg[/IMG]
This took me a while but I did find the horse shoes I had been looking for. Next step is to use the paper template H-D provides to mark the Tour Pac where ya will have to cut out for the lights to set into the box.
[IMG]local://upfiles/14260/08C3C756EDE84D94863712619A88095D.jpg[/IMG]
If you’re careful, the paper won’t tear and you can mark some straight lines. Next step is to use a sharp tool and carefully cut out the corners where ya marked them.
[IMG]local://upfiles/14260/20851D736F764295BBD34A1664A4A461.jpg[/IMG]
Discard the chunks of plastic, oh and don’t forget your eye protection. Next step is to install the brake light frame in the Tour Pac then use an awl to mark the places where six screws will hold the frame in the Tour Pac.
[IMG]local://upfiles/14260/243E623CFD974E828B2904D3C3253931.jpg[/IMG]
As I posted a few days ago, my Tour Pac Brake Light kit finally arrived and I thought I would do an installation procedure with pictures. I’ve always wanted to do one of these and thought, “Heck, a H-D kit with instructions. Piece of cake. I should be able to do this in a couple hours.”
[IMG]local://upfiles/14260/2A205E020D6D4C1D8547AB87351149F5.jpg[/IMG]
The instructions tell ya to empty the Tour Pac of all items.
[IMG]local://upfiles/14260/5C9B3CAA79DD4B1CA4F5FC3C751B7958.jpg[/IMG]
This took me a while but I did find the horse shoes I had been looking for. Next step is to use the paper template H-D provides to mark the Tour Pac where ya will have to cut out for the lights to set into the box.
[IMG]local://upfiles/14260/08C3C756EDE84D94863712619A88095D.jpg[/IMG]
If you’re careful, the paper won’t tear and you can mark some straight lines. Next step is to use a sharp tool and carefully cut out the corners where ya marked them.
[IMG]local://upfiles/14260/20851D736F764295BBD34A1664A4A461.jpg[/IMG]
Discard the chunks of plastic, oh and don’t forget your eye protection. Next step is to install the brake light frame in the Tour Pac then use an awl to mark the places where six screws will hold the frame in the Tour Pac.
[IMG]local://upfiles/14260/243E623CFD974E828B2904D3C3253931.jpg[/IMG]
Thread Starter
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Seasoned HDF Member
Joined: Jun 2006
Posts: 30,860
Likes: 32,761
From: King George, VA
RE: Installing a Brake Light kit in a Tour Pac
Pull the awl out, if ya can, then use a ¼” drill bit to drill where ya just marked the Tour Pac.
[IMG]local://upfiles/14260/CB3C28D45F3D4BEEA347AD2BADC71C44.jpg[/IMG]
Install the bolts through the Brake Light frame and put the cap bolts on and tighten them just enough so the bolt isn’t turning in the plastic on the outside.
[IMG]local://upfiles/14260/DB458D14B51E49959A006CC8423EDFFC.jpg[/IMG]
Install the curved clips in the ends of the Brake Light frame then tap them gently until they seat in the slot.
[IMG]local://upfiles/14260/D35B59D6C96B4435909E8C0595954EBE.jpg[/IMG]
Install the Harley Davidson name plate on the outside of the Brake Light Frame.
[IMG]local://upfiles/14260/57E111656F0848F2A8C62A82155ED674.jpg[/IMG]
Ok, here’s where the instructions get vague. Find the plug for the Brake Light kit. Do ya see it. Right there. Hiding behind the shock. Yeah that’s it.
[IMG]local://upfiles/14260/F87C70E6D13F4D569F76687F12AE635F.jpg[/IMG]
[IMG]local://upfiles/14260/CB3C28D45F3D4BEEA347AD2BADC71C44.jpg[/IMG]
Install the bolts through the Brake Light frame and put the cap bolts on and tighten them just enough so the bolt isn’t turning in the plastic on the outside.
[IMG]local://upfiles/14260/DB458D14B51E49959A006CC8423EDFFC.jpg[/IMG]
Install the curved clips in the ends of the Brake Light frame then tap them gently until they seat in the slot.
[IMG]local://upfiles/14260/D35B59D6C96B4435909E8C0595954EBE.jpg[/IMG]
Install the Harley Davidson name plate on the outside of the Brake Light Frame.
[IMG]local://upfiles/14260/57E111656F0848F2A8C62A82155ED674.jpg[/IMG]
Ok, here’s where the instructions get vague. Find the plug for the Brake Light kit. Do ya see it. Right there. Hiding behind the shock. Yeah that’s it.
[IMG]local://upfiles/14260/F87C70E6D13F4D569F76687F12AE635F.jpg[/IMG]
Thread Starter
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Seasoned HDF Member
Joined: Jun 2006
Posts: 30,860
Likes: 32,761
From: King George, VA
RE: Installing a Brake Light kit in a Tour Pac
I wanted to be sure the lighting system worked before doing a permanent install, so I pulled the harness out of the Brake Light frame and plugged it into the bike wiring harness and checked things out.
[IMG]local://upfiles/14260/40E8F99846D64931964BC4AC8E14ACFD.jpg[/IMG]
The wiring harness provide with the Brake Light kit provide a connector that would plug into the bike wiring harness, but it was about 15” to short. It cut it off and added the extra wire to go the distance, wrapped in shrink wrap, and heated it up.
[IMG]local://upfiles/14260/4B9456C673994A2BAEF6668FD8CBDDD1.jpg[/IMG]
Next thing, find a good working surface and use a sharp tool to trim the grommet big enough so both the radio antenna cable and the new Brake Light wiring harness can pass through the Tour Pac.
[IMG]local://upfiles/14260/FBC9423DA48546E6AA085C296C5A3479.jpg[/IMG]
Install the Tour Pac on the bike, install the antenna and make the RF cable connection. And the finished product is a scooter that can be seen better from the rear.
[IMG]local://upfiles/14260/9C8F18464D864B28863A964CEC3487C8.jpg[/IMG]
Enjoy your April 1st day.
[IMG]local://upfiles/14260/40E8F99846D64931964BC4AC8E14ACFD.jpg[/IMG]
The wiring harness provide with the Brake Light kit provide a connector that would plug into the bike wiring harness, but it was about 15” to short. It cut it off and added the extra wire to go the distance, wrapped in shrink wrap, and heated it up.
[IMG]local://upfiles/14260/4B9456C673994A2BAEF6668FD8CBDDD1.jpg[/IMG]
Next thing, find a good working surface and use a sharp tool to trim the grommet big enough so both the radio antenna cable and the new Brake Light wiring harness can pass through the Tour Pac.
[IMG]local://upfiles/14260/FBC9423DA48546E6AA085C296C5A3479.jpg[/IMG]
Install the Tour Pac on the bike, install the antenna and make the RF cable connection. And the finished product is a scooter that can be seen better from the rear.
[IMG]local://upfiles/14260/9C8F18464D864B28863A964CEC3487C8.jpg[/IMG]
Enjoy your April 1st day.
Ultimate HDF Member
Joined: Dec 2006
Posts: 8,294
Likes: 33
From: Po-Dunk Looziana
RE: Installing a Brake Light kit in a Tour Pac
Can I borrow your 20" pipe wrench, acetyline torch, machetti, 50lb maul, 1852(date) drill, Davy Crocketthatchet, and lawnchair? I'm gonna do mine next.
RE: Installing a Brake Light kit in a Tour Pac
i might need to use your tools
i might do it wrong with my tools
i might do it wrong with my tools
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Extreme HDF Member
Joined: Apr 2006
Posts: 10,449
Likes: 46
From: Roswell, GA
RE: Installing a Brake Light kit in a Tour Pac
That's exactly the way they do it at my dealer--what's so funny?
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