Between July 13, 2007, and July 14, 2007, I finally got around to installing a Harley Davidson King Tour Pak with all the goodies, on my Electra Glide. The following is a review of the installation, some pictures, and my review.
First off, I wanted to add a King Tour Pak to my Electra Glide for added luggage space for long trips which I take quite often, and I wanted the Tour Pak to be detachable so that I can use my standard Harley Davidson detachable backrest and luggage rack for local rides. I also wanted to make the ride more comfortable for my old lady and me, and move her back a bit.
Since I already have the mounting kit for my detachable passenger backrest and luggage rack, I did not have to order the mounting kit for the detachable Tour Pak. I had heard that the plastic bushings do wear out on the docking points after a while so I will probable order some spares in the future as needed.
The Harley Davidson King Tour Pak is a custom order product from Harley Davidson because it is manufactured and painted at the factory depending upon your motorcycle and color. My Electra Glide is Vivid Black so that is what I ordered. When you order the King Tour Pak you are told that it can take between 6 to 8 weeks for delivery because it is a custom part. I got lucky and got mine within 3 weeks because Harley Davidson already had a vivid black Tour Pak in stock at the factory.
When you order the Harley Davidson King Tour Pak, you also need to order other parts with it so that it can be locked, installed, etc. All that comes with the Tour Pak is the actual Tour Pak in the box, some holes pre-drilled in the bottom, a hole for a key set, a rubber mat for the bottom, and a leather pouch. That is about it. Secondly, when I opened the box there were no reflectors, or anything on the outside, except the Harley Davidson inscription painted on the top. Of course it was vivid black!
Along with the Tour Pak I had to order, a lock, and a bunch of separate parts for the lock assembly so that the Tour Pak can be locked. This was not mandatory, but in my opinion it would be stupid to put on a Tour Pak without a lock, and that leaves a big hole on the side!
Luckily the place I ordered my parts from; Chicago Harley Davidson online, found that I was missing a 25 cent washer from my order and added it for me! Along with the drum lock comes two additional keys for the lock which are cut for your specific motorcycle. I needed my VIN number so that Harley Davidson could cut the keys for my motorcycle. Now I have 3 spare keys for my motorcycle. That is a good thing I guess!
Here is a list of the parts I ordered for this installation:
King Tour Pak Vivid Black – Harley Davidson Part No. 53116-97DH
Suggested Retail- 675.00
King Tour Pak Pillow like passenger backrest – Harley Davidson Part No. 53116-97DH 52201-97A
Suggested Retail- 209.95
Removable Rack for Tour Pak – Harley Davidson Part No. 53116-97DH 53276-04
Suggested Retail- 169.95
Lock for Removable Rack – Harley Davidson Part No. 53116-97DH 46063-98
Suggested Retail- 32.95
Set of Two Locks for Removable items – Harley Davidson Part No. 53116-97DH 46106-00
Suggested Retail- 59.95
Antenna Relocation Kit – Harley Davidson Part No. 53116-97DH 76326-00A
Suggested Retail- 99.95
Lock for Tour Pak (this can be keyed for your bike, you need VIN or Key Code – Harley Davidson Part No. 53116-97DH 53848-00
Suggested Retail- 20.00
Nut for Tour Pak Lock – Harley Davidson Part No. 53116-97DH 84850-92
Suggested Retail- 1.50
Custom License Lay Down License Plate Bracket
Crutchfield Amplified Antenna for Inside Fairing
Installation of the Tour Pak
As you can see from the pictures, the installation of the Tour Pak was not bad for a non mechanic like me, but it did require some drilling on a brand new and freshly painted fiberglass Tour Pak which cost me a chunk of money. I was not happy about having to drill holes to mount the premium luggage rack, the passenger backrest, and removable Tour Pak rack, but it was a hell of a lot cheaper than letting the dealer do it!
The first thing I installed was the lock assembly for the Tour Pak. Since it came with no instructions, I relied on my trusty shop manual to do the installation. By the way, a shop manual for a Harley Davidson is a must! Once I got the lock assembly on and made sure it worked ok, I proceeded to install the premium luggage rack.
The premium luggage rack came with a template that you tape onto the top of the luggage rack to find your drill points. First I cut out the template for my Tour Pak type and rack and placed it on the top of the Tour Pak. Even with the template on, you have to eyeball the placement to ensure that it is straight, and there is enough room for the passenger back rest pad and a future spoiler if you are going to install one on the Tour Pak. I eyeballed it to ensure it was where I wanted it. I then placed painter’s grade masking tape in the area where the post were on the premium luggage rack, and then traced a circle around each post to find the center. I then made an X in the circle to find the center. Once this was done, used a punch tap to make a small indentation for the drill bit, I did not use a hammer for obvious reasons; instead I worked the tap in so that it would make the indentation for the drill bit. I then placed a very small diameter wood drill bit into my drill and set the drill to a slow setting so that the drill would not go too fast and heat up the fiberglass or crack it. Then I started drilling. No big deal. Once I got the small bit through, I worked my way up through two larger drill bits before I got to the right size. I did not start with the proper diameter bit first for fear of cracking the area where I was drilling or causing paint damage. It is real important to drill on the masking tape and not the paint itself for obvious reasons. If you drill is set to a high revolution setting or you do not have a proper tap it can walk across the new paint and cause paint damage or worse. The painter’s grade masking tape is important as well, because it comes off easy and does not damage the new paint.
Once I got all 4 holes drilled for the luggage rack to the proper diameter, I cleaned the holes of any debris that was left. I then checked the rack for proper fit and wholla, it fit perfectly! I used a waterproof silicon glue on the screws that screw into the rack from the inside of the Tour Pak lid, and go through the lid into the premium luggage rack mounting post, so that it would be waterproof; the job was done, the rack was on straight, and now it was time to add the removable Tour Pak mounting bracket!
The Removable Tour Pak mounting bracket allows you to remove your Tour Pak from the motorcycle so that you can set the motorcycle up for solo operation, or use the Harley Davidson removable passenger backrest and/or luggage rack. I opted to go with this option so that I could take the Tour Pak off whenever I wanted.
The first thing I did with the rack was to install the removable accessory lock on the mounting bracket. With a combined part the cost around $1,500.00, there is no way that I would not use a lock on this setup. The lock prevents someone from just coming along and stealing your Tour Pak setup with the easy detach kit on the removable rack. The installation of the lock was no big deal and simply involved removing the regular circular mounting accessory from the rack, and installing the locked version. I installed mine on the right hand side.
Next I proceeded to put the Tour Pak on its side to align the holes for mounting the Tour Pak to the detachable Tour pak rack. I would recommend two people for this part of the install but I managed to get it done by myself.
Low and behold the pre-drilled holes on the bottom of the Tour Pak did not line up with the detachable Tour Pak Rack. They are apparently drilled out for the permanent Tour Pak rack. This was a real bummer; more drilling. As discussed above I put painter’s masking tape where I needed to drill. Used a tap to make a notch for the small drill bit, and then proceed to drill with a very small drill bit at minimal revolutions, working my way up to the proper size. Once the holes were drilled I mounted the Tour Pak to the detachable rack. It went on perfectly.
The next order of business was to install the passenger pillion cushion onto the Tour Pak; again more drilling. The passenger pillion came with a paper template, to tape on to figure out where to drill the front of the Tour Pak out for the male studs that are a part of the passenger pillion setup and go through to the inside of the Tour Pak. I took a little more time doing this step because of the curves in the Tour Pak where the passenger pillion attaches. I repeated the same drilling process mentioned above after I was sure everything was lined up. Let me tell anybody contemplating doing an install like this; take your time. One screw up and you will have either multiple holes or a crooked setup. Luckily for me, the passenger pillion lined up perfectly with the holes that I drilled, and it bolted on perfectly.
I do have a pet peeve with Harley Davidson; why would they sell a model specific Tour Pak without holes for the passenger pillion and mounting bracket pre-drilled? I can understand not putting holes in for a luggage rack because some people may not want it, but the other holes; come on! Anyway………………
After getting everything ready to mount on the motorcycle, I vacuumed the bits of fiberglass and dust that accumulated inside the Tour Pak during the drilling process. I took a few pictures of the completed product before mounting. Unfortunately I did not take pictures of the entire installation process; I just wanted to get the job finished if you know what I mean.
Now for the fun part; I carried the King Tour Pak out to my Electra Glide to attach it to the motorcycle, and low and behold, it would not seat all the way down on the mounting docks for the detachable Tour Pak because the stock license plate was in the way.
All of the Harley Davidson documentation states that the Stock License plate bracket should work with the detachable Tour Pak rack but it did not!
I called multiple Harley Davidson dealers. Most of them told me that it was supposed to work and that I should bring the motorcycle in for them to look at! How can I ride the motorcycle to the dealership with a Tour Pak that is not fully on! At the time I was doing the installation, I did not have someone who could carry the Tour Pak in their car while I rode the motorcycle, and besides, I was really pissed off at this point. One dealer about 100 miles away indicated to me that he had an aftermarket lay down license plate bracket that may work, but after reading the documentation on the license plate bracket he wanted to sell me, it turns out that it specifically will not work with a detachable Tour Pak. Harley Davidson’s lay down license plate bracket also will not work with the detachable Tour Pak. I was at a loss. Harley had a solution that would have required using a license plate bracket down near the brake lamp that required drilling out the fender. There was no way I was going to be drilling on my pristine fender just for a license plate bracket. Hell I am a motorcycle lawyer, not a fabricator or mechanic.
I figured that I could take the stock license plate bracket to a machine shop and have them shave the top around ¼ inches and that would do the trick.
Luckily, I found a guy on eBay selling a custom license plate bracket made exactly for my application. So rather than trucking the motorcycle to the dealer, drilling out the fender, or finding a machine shop, I bought the custom lay down license plate bracket from the guy on eBay. Unfortunately, I had to wait for the part to come. However, once it came it fit perfectly!! I am glad I went with this solution rather then gerry rigging something else. The guy on eBay was fully aware of the “non-fitting” stock license plate bracket with the detachable Tour Pak kit, and he custom makes a solution that is very well made. I am sure you can find him on eBay if you need him, if not contact me and I will put you in contact with him.
What to do with the Stock Whip Antenna?
First off, I ordered the Harley Davidson Antenna relocation kit with the intent of using it on my Tour Pak setup, and then reusing the same antenna when the Tour Pak is not installed. This is exactly what the relocation kit is supposed to do. You simple screw the Antenna onto the Tour Pak when it is being used, and then screw a connecting cable between the Tour Pak and the motorcycle. When the Tour Pak is not in use, you simply screw the whip antenna onto the bracket mounted on the motorcycle. Sounds easy enough! Right!
Before I actually went to mount the Tour Pak on the Electra Glide and discovered that the license plate would not let it seat down all the way on the docking points, I prepared the Antenna Relocation Kit for installation as well. On my motorcycle the whip antenna was on the right side of the motorcycle, but the antenna relocation kit is designed to be mounted on left side of the motorcycle. Damm; I would have to re-route the antenna cable.
First, I proceeded to remove the seat, and the stock whip antenna bracket and assembly on the right side of the motorcycle. I then traced the antenna cable from where it was routed along the frame, and cut the tie wraps holding to the brake and turn signal cable, to free it up to route along the left side of the motorcycle. I then re-tie wrapped the brake and turn signal cables in their original position. I then re-routed the antenna cable across the left side of the motorcycle near the battery, and to the back of the motorcycle. Luckily there was enough antenna cable to reach the left side where it needed to be.
I then mounted the Antenna Relocation kit on the left side of the motorcycle on the back of the bike, and screwed the antenna cable onto the bottom of the connection where indicated in the directions. I then tie wrapped the antenna cable so it would be secure on the left side of the motorcycle. It was ready to roll!
Then the bummer…….. I tried to remove the whip antenna from the stock stud using pliers, wrenches, you name it. It kept turning and turning but would not come off of the stock stud. After thoroughly ruining the bottom of the stock whip antenna I realized that there was a very small allen screw that held it on. Stupid me. After removing the allen screw, the antenna would still not come off. I had stripped it. Oh well, I called Harley Davidson and it would be no big deal to get a replacement whip antenna. I then looked at the instructions for mounting the Antenna Relocation Kit onto the actual Tour Pak, and to be frank I was disgusted. The instructions called for all sorts or measurements to be made so that the mount would be perfectly placed on the Tour Pak, but what really bothered me was the fact that the instructions called for drilling out a ¾ inch hole on the back of the Tour Pak, and on the front bottom of the Tour Pak for the cable. To top it off, the kit did not come with a rubber grommet to waterproof the hole for the cable the goes out of the bottom to the connection on the motorcycle. I called Harley Davidson and they were no help with respect to getting a rubber grommet to ensure that the hole was water proofed. To top it off, I realized that the protruding portion of the Antenna mount inside of the Tour Pak would take up valuable room, as well as the cable to the back bottom of the Tour Pak. Furthermore, an antenna mounting on the back of the Tour Pak where it is supposed to be mounted would interfere with each access to the inside of the Tour Pak from the back. It would be in the way!
It was at this point that I remembered some guys using hidden fairing antennas that do away with the whip antenna in the back, and give you a cleaner look on the back. I did some research on the internet and discovered that there were indeed different types of antennas that could be used to replace the whip antenna that would mount and be hidden inside of the fairing. Some hidden antenna set ups cost as much as 80 bucks! I decided to try out a 20 dollar amplified antenna from Crutchfield. There were also some solutions available on eBay. I used Crutchfield because I knew they would ship quickly and that there would be no hassles.
I then proceeded to remove the Harley Davidson Antenna Relocation Kit from the motorcycle. I coiled up the Antenna cable and stuffed it in the battery compartment area just in case I decide to use it in the future.
Once the Crutchfield amplified antenna came, I removed the front fairing from the Electra Glide, taped the flat antenna on top of the Harley Davidson Advanced Sound System, spliced into the cigarette lighter for my 12 volts, grounded the antenna, and wholla it worked! Obviously I tested it before I put the front fairing back on.
Now I will be frank, the hidden antenna is flat out not as good as the stock whip antenna. FM and Weather band work perfectly, but my AM traffic and talk show channels do not come in like with the whip antenna. Most of the time I ride, I have my MP3 player plugged into the auxiliary jack of the Harley Davidson Advanced Sound System anyway so it is no big deal. FM works, and some AM works. I may later decide to go back with the whip antenna setup, or I may sell the motorcycle and do another setup, you never know. At least for now, I have a hidden inner fairing antenna that works well enough, and a spare Harley Davidson Antenna Relocation Kit never used complete with instructions that I may stick on eBay since it is taking up room. If you are interested in buying it, shoot me an email to firstname.lastname@example.org .
Review of the Tour Pak Set Up Finally!
I do not know how I ever lived without a Tour Pak before. That is my frank and to the point assessment of the Tour Pak. I have in the past ridden Japanese Cruisers, Harley Davidson Hardtails, Harley Davidson Softails, and everything in between. My Electra Glide has very spacious hard saddlebags, however nothing comes close to having a Tour Pak that you can open up and put all of your stuff in without any hassles! The Tour Pak fits two full size helmets and a whole bunch more. I do not use my saddlebags anymore in most cases! I am presently selling my Kuryakyn Full Dresser Motorcycle Luggage, (If you are interested in buying it shoot me an email) and am looking for a big Tour Pak bag to mount on top of the Premium Luggage Rack for long trips. I will tell you what; I am no longer worried about having room for storage on long trips! I have not taken the Tour Pak off since I installed it even though I have the removable kit! There is just no need at this point. The motorcycle rides just as well with the Tour Pak on as it does off.
Relocation of the Passenger Backwards on the Electra Glide!
One of the other reasons I got a Tour Pak was to move my passenger back a couple of inches to give me more room. With the stock passenger backrest, we felt cramped. I like to spread out on the bike and have lots of room.
There are a couple of kits on the market to relocate the Tour Pak back anywhere from 2.5 inches to 4.75 inches to give you and your passenger more room to stretch out. I purchased a 4.75 inch Tour Pak relocation kit that will move the Tour Pak back 4.75 inches. I have not installed the kit yet so I cannot review it.
All in all, this was the best approximately $1,500.00 upgrade I have done on my Harley Davidson Electra Glide. I guess you would call me a Bagger now! I do not mind. I am 44 years old; I have ridden all over the country with no windshield, and minimal storage. I have eaten bugs, been hit by rocks, dirt, and debris, holding on at 80mph as the wind pushed against me. I kind of like luxury now. For me and the kind of riding I do, I can never see going back to riding a bar hopper!
The Harley Davison Tour Pak is a must for anyone with a FLH model.
If you have any comments I would like to hear them!
By Norman Gregory Fernandez, Esq., © 2007