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How to Remove and Disassemble the Harley Davidson Tour Pack for Painting

Jan 23, 2024

How to Remove and Disassemble the Harley Davidson Tour Pack for Painting

Harley Davidson is known for manufacturing exceptionally capable cruisers and grand American bagger motorcycles, decked with touring-oriented utilities and components, especially capacious and convenient motorcycle luggage pieces, such as a motorcycle Tour Pack . While some Harley motorcycles are equipped with standard tour packs, other models offer them as optional amenities. The introduction of the stock Tour-Pak® luggage carrier first occurred with the Harley Electra Glide Classic and the Ultra Glide motorcycles, as these bikes were the earliest fully decked members of the company’s bigger movement. Many Harley-Davidson enthusiasts took an instant liking to this additional accessory as it made packing for long-distance trips, camping trips, and cross-country trips a matter of mere minutes. Moreover, the Tour Pack’s classy, color-matched high-gloss finish further complemented the Harley motorcycles’ already refined stylistic elements, further enhancing their touring character and grandiose.

In 2014, Harley introduced the Project Rushmore upgrades for its renowned Electra Glide family of high-achieving touring motorcycles. Under this project, the bikes received many revised and improved parts, with the most prominent touring accessory being the premium Tour-Pak® designed to provide increased storage and act as a comprehensive luggage solution for a wide range of riding purposes and individualistic styles. As the motorcycle touring movement continued to experience exponential growth over the years, several aftermarket motorcycle luggage manufacturing companies also entered the market, offering high-quality Harley Tour Packs to riders at a comparatively lower price than the OEM Harley Davidson Tour Packs. A highly noteworthy example of such Harley luggage manufacturers is Viking Bags , which, in addition to Harley touring motorcycles , also offers stylish and versatile tour packs for Harley Dyna , Softail , Sportster, and street models . Since Harley Davidson motorcycles, such as cruisers, baggers, touring motorcycles, and lavish adventure motorcycles can be used to traverse well-paved roads and roadless regions, the installation of a touring pack on Harley motorcycles has become a necessity in the contemporary motorcycle scene.

Whether aftermarket or factory-made, Harley touring packs are designed to withstand harsh weather, even harsher landscapes, and prolonged rough use, and, if you opt for an aluminum rear motorcycle trunk , they can also provide much-needed crash resistance in the event of a fall, drop, or accidents. However, the painted fiberglass or ABS plastic Harley Davidson tour packs are highly susceptible to scratches due to exposure to debris, dust, gravel, and other damaging elements. Furthermore, when adding or removing items from the Harley tour packs, it is quite easy to damage or scratch the paint. Moreover, storing the motorcycle in the open air without a cover or a shed can also damage the touring pack paint. The fading or peeling paint can significantly diminish the bike’s allure and sophistication. In many cases, the bike’s resale value gets a hit if the original Harley tour packs are not properly maintained.

This article provides you with a comprehensive and easy-to-follow step-by-step guide on how to safely remove and disassemble the tour pack on your Harley Davidson motorcycle to restore its paint job and artistic charm. Though every Harley model is different and the steps may vary depending on your bike’s year and the tour pack you own, this guide will help you get started. Make sure to keep the owner’s manual with you and the installation/removal guide provided with the touring pack (in case it is aftermarket) while reading this article to compare the steps that might be different in your Harley Davidson tour pack’s process of removal and disassembly. However, the general method for painting the tour pack will remain essentially the same.

Also Read: Best Cruiser Motorcycle Luggage Options to Make Your Bike a Bagger
  • Table of Contents

1. What is a Harley Davidson Tour Pack?

2. how to remove harley davidson tour pack, 2.1 tools required to remove the harley touring pack, 2.2 quick steps to remove bolt-on harley davidson touring pack, 2.3 quick steps to remove detachable harley tour pack, 3. how to disassemble a harley davidson tour pack, 3.1 tools required to disassemble the harley davidson tour pack, 3.2 quick steps to disassemble the harley davidson tour pack, 4. how to prep and paint harley davidson touring pack, 4.1 tools required to prep and paint harley touring pack, 4.2 steps to paint harley tour pack, 5. last words.

What is a Harley Davidson Tour Pack?

70 L Premium Extra Large Motorcycle Tour Pack  for Harley Touring Motorcycle

Located at the rear of your Harley motorcycle and securely placed on a metal luggage rack, the Harley Davidson tour pack, or the tour pack is a luggage system designed specifically for long hauls, cross-country trips, and any other riding styles that involve carrying large amounts of travel gear and possessions. From motorcycle tools to jackets, camera gear, and important documents, this large, lockable rear trunk or storage compartment on a Harley Davidson motorcycle is also used for everyday urban action, commutes, and short business trips. Harley touring packs come with either detachable quick-release systems or latches. Either way, removing the touring packs for packing and unpacking is quite easy. In addition to maximizing the bike’s storage capacity, the Harley Davidson tour packs also help with passenger comfort and entertainment as they come equipped with integrated speakers, lighting, and a passenger backrest.

If you own a Harley tour pack that is damaged beyond minor paint repair, it is recommended that you seek professional help for the repair. If you are looking for high-quality and affordable replacements, make sure to explore Viking Bags’ Harley Davidson tour pack collection or the universal fit motorcycle rear trunks collection. On the other hand, if you want to uninstall the touring pack from your Harley motorcycle to restore the damaged paint, follow the general guidelines provided infra .

How to Remove Harley Davidson Tour Pack?

Harley Davidson Touring Road Glide FLTR/I Tour Packs

As mentioned, the process of removing the Harley Davidson touring pack will vary depending on the Harley motorcycle you ride, the bike’s model year, and the type of touring pack you have installed. The functionalities offered by the tour pack, such as lighting and speakers, may require disconnection with the bike’s electrical system. The general instructions provided below will give you the confidence to get started on your DIY Harley Davidson motorcycle tour pack maintenance project.

  • Allen Wrench
  • Screwdriver
  • Torx Wrench
  • Wrench or Socket Set
  • Clean Microfiber Cloth 

For specific wrench sizes, check the instructional manual supplied with the instructional manual.

  • Once you have all the tools with you, start by removing the motorcycle seat and saddlebags to easily access the mounting hardware of the Harley tour pack. Also, removing the seat will make it easier to fully open the tour pack’s lid and fold the internal flaps back to see the wiring properly.
  • Next, if your touring pack has integrated speakers and lighting, such as in Harley Street Glide , Harley Road Glide , and Harley Ultra Limited Tour Paks®, make sure to disconnect all the wiring from the bike’s electrical system. The step is relatively easy, as all you have to do is locate connections and unplug them or simply remove the terminals.
  • Usually, the mounting bolts of the tour pack are located at the bottom, and to remove the trunk, you must first unfasten all the bolts. In case your touring pack does not have the bolts at the bottom, check its sides. Once located, it is best to first loosen all the bolts and then remove them, as this practice reduces the chances of losing any of the mounting hardware. Once you have removed all the bolts and lock nuts, simply lift the tour pak off the luggage rack .
  • Make sure you place all the nuts and bolts safely in a storage box or a drawer so you don’t lose them. Looking for the right hardware can be a huge hassle if the stock bolts get misplaced.
  • Clean the tour pack with a lint-free microfiber cloth before disassembling it for paint prep.
  • If your Harley motorcycle boasts a detachable touring pack setup, start with seat removal first. Usually, Harley Davidson touring motorcycles have a long one-piece seat for both rider and passenger, and it comes right off if you pull gently at the back of the seat.
  • Once the seat is removed, you should be able to see all the wiring and connectors for speakers and lighting. Disconnect the wiring to ensure safe touring pack removal. 
  • To take off detachable Harley Davidson tour packs, there is a release mechanism on the bottom of the tour pack on each side. This release mechanism is secured on the motorcycle thanks to the docking hardware. Luckily, for detachable touring packs, you don’t need to unfasten and remove the docking hardware as the Harley Davidson touring pack will come right off with the quick-release system intact.
  • Carefully lift the tour pack off the bike and set it up on a nearby workstation or table.
  • Clean the detachable touring pak for the Harley motorcycle with a clean cloth after disassembling it.

How to Disassemble a Harley Davidson Tour Pack?

54L - Voyage Extra Large Chopped Tour Pack for Harley Touring Motorcycles

After you remove the tour pack from your Harley Davidson motorcycle, you would have to disassemble some of its components, including the attached backrest, hinges, latches, lid, and inner storage compartments, if any. It is worth mentioning that the disassembling process may vary depending on the internal and external features of the touring pack. Therefore, you must always consult the motorcycle owner’s manual in case of stock Harley tour packs or the instruction manual provided with the OEM or aftermarket Harley Davidson touring packs. 

It is the same as those required to remove the Tour Pack.

  • Allen or Torx Wrenches
  • Ensure you always start with disconnecting any wiring or electrical connections for speakers, lighting, aftermarket USB charging kits, or aftermarket GPS systems.
  • Remove the passenger backrest (if attached) by unfastening its mounting bolts. In addition, remove the quick-release brackets if you own a detachable tour pack, handles, lid strut/lid stay if any, internal organizers, dividers, and internal soft liner (if any). Be sure to spare some time to wash all the internal detachable organizers and liners during the entire DIY project.
  • Some Harley touring packs come with attached luggage racks, so make sure you also locate and remove the mounting bolts of these luggage racks.
  • Remove all the fasteners on the surface of the Harley tour pack, holding the lid in place. Once all the screws, hinges, and latches are removed from the lid section, make sure to store them safely. 
  • Avoid removing the rubber liner or weather seal on the edges of the tour pack. Even if it is easy to remove and put back on, the process might reduce its effectiveness, diminishing your touring pack’s weather resistance and vibration-damping capabilities.
  • It is recommended that you take pictures of every step while disassembling the tour pack as it will help you repeat the process in reverse to assemble it correctly after painting. As for safely storing all the mounting hardware removed, make sure to put the hardware in separate ziplock bags and label them accordingly.
  • Use a lint-free microfiber cloth to thoroughly clean the tour pack and inspect it carefully for any cracks and other similar signs of damage. 

If disassembling the Harley Davidson touring pack for paint seems like a hectic and complicated task, it is best to seek professional help. However, you can also choose not to disassemble the tour pack for repainting, painting, and restoration. The only concern in this regard is that paint can get on the shiny chrome hinges and latches, but you can clean them using steel wool. On the other hand, it might be nearly impossible for you to correctly realign the latches and hinges. Therefore, if you want to save yourself the hassle of ensuring a perfect fit after painting the tour pack, simply avoid disassembling it.

How to Prep and Paint Harley Davidson Touring Pack?

Harley Davidson Touring Street Glide FLHX Tour Pack

Painting a Harley Davidson tour pack seems relatively easy and can be performed easily provided you master the surface prepping skills. To acquire the industry-grade finish and match your bike’s impeccable factory paint job, you must take your time with the sanding process. Also, make sure that the temperature and weather conditions are suitable for the paint adhesion and drying process. Paint in a controlled setting, such as a properly ventilated garage, with moderate temperature, ideally 60°F-75°F, and low humidity levels, about 65%-70% for the best results. It is also advisable to wear a protective mask to avoid inhaling paint droplets. Painting the Harley touring pack is a time-consuming process and you might have to repeat the prepping process several times before achieving just the right finish. However, painting the Harley touring pack yourself has many benefits, including reduced costs, a better understanding of your Harley motorcycle’s systems, and improved painting skills that will allow you to custom paint your bike at home whenever you want a different look. 

Also Read: How Much Does a Custom Motorcycle Paint Job Cost
  • Clean Cloth
  • Soapy Water  
  • Water for Wet Sanding
  • 800 Grit Sandpaper
  • 1000 Grit Sandpaper
  • Spray Paint
  • Clean the Harley tour pack with a clean cloth and soapy water to ensure that there is no grease or grime present on the surface. This step helps preserve the adhesive properties of primer, paint, and clear coat. 
  • Prep the tour pack by wet sanding it using 800 grit sandpaper to remove the existing paint, and high-gloss finish, and smooth out any scratches. While preparing the tour pack with sandpaper, be sure not to rush this step as it determines the quality of the paint finish at the end. It may take you a couple of hours to properly sand either side of the Harley tour pack. Once done, use a fine 1000-grit sandpaper to create a smooth and even surface for primer and paint application. 
  • After sanding, thoroughly wipe down both sides of the tour pack with a dry, clean lint-free microfiber cloth.
  • Next, apply an even coat of primer on the sanded surface to create a smooth finish. Allow the primer to dry completely before dry sanding it with a 1000 grit sandpaper to create a rough texture. This step will help the paint stick to the tour pack ensuring a sophisticated factory-standard finish.
  • Apply the high-gloss lacquer paint using a spray gun or rattle can. Make sure to apply three thin coats of paint and let it dry completely before reassembling the reinstalling the tour pack.
  • If the paint you are using does not come with a clear coat, apply two to three coats of clear separately and let it dry.
  • To closely color-match the tour pack with your Harley’s original paint scheme, you can also apply flake if the factory paint job offers flake.
  • Once the paint is dry, wet sand the surface again with 1000 grit or even finer sandpaper to remove any imperfections or irregularities in your DIY paint job. You can also use a rotary buffer machine to buff out your freshly painted Harley Davidson tour pack.
  • Once the painting is done, reassemble the Harley Davidson tour pack by following the same steps you performed to disassemble it but in reverse order.
  • Reinstall the newly painted blemish-free tour pack on your Harley Davidson motorcycle and embark on another exciting adventure.
Also Read: How to Paint Plastic Motorcycle Parts

Harley Davidson Tour-Paks® has become an essential travel gear or part of the luggage system for many riders, whether they travel on long routes frequently or just use their Harleys to commute to work in style. Purposeful and sturdy, Harley Davidson tour packs offer many benefits when it comes to transporting your possessions on a two-wheeler. From organizers to weather seals, impact-resistant corner guards to key lockable mechanisms, Harley Davidson touring packs elevate your motorcycle touring experiences.

Though low maintenance, tour packs often get paint failures that can spoil the bike’s overall impression and attitude. Luckily, these paint fails can be fixed at home, provided you learn the different functionalities of the touring pack, such as its mounting systems, any electrical connections of the integrated audio and lighting systems, and their overall alignment and structure.

If you familiarize yourself with these operations of the tour pack, you can easily remove, disassemble, and paint your Harley Davidson tour packs anytime a need arises. Furthermore, learning these skills will also increase the aesthetic customization opportunities for you. Make sure to thoroughly read this guide, the Harley motorcycle owner’s manual, and the touring pack instructional guide before performing the removal and disassembly methods.

Also Read: Metal Flake Motorcycle Paint Jobs

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2008 harley tour pack removal

Re: Tour Pack removal Instructions.

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2008 harley tour pack removal

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Hey ... First off thanks for your help. After thinking about it I would like to be able to have the tour pack detachable and be able to keep the 4 speaker set up when it is attached to the bike . So id want to keep the amp I guess.  Install it in the saddlle bag would be ok...its not that big of an amp is it?  It would be great if I could just detach tour pack and unplug a line disconnecting the rear 2 speakers easily...  im afraid to ask  about the cb wires??  Im good with tools and used to be an electrician but im getting nervous....lol...lol...
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Hey ... First off thanks for your help. After thinking about it I would like to be able to have the tour pack detachable and be able to keep the 4 speaker set up when it is attached to the bike. So id want to keep the amp I guess.  Install it in the saddlle bag would be ok...its not that big of an amp is it?  It would be great if I could just detach tour pack and unplug a line disconnecting the rear 2 speakers easily...  im afraid to ask  about the cb wires??  Im good with tools and used to be an electrician but im getting nervous....lol...lol...
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So where is your amp?  What did you do with the cb wires?
What do you think the Harley Dealer would charge for this install??  Would they even know how to do it?  Im afraid to know how much now that I think about it....lol........ 
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Thats not that bad.   Lets see figure 3 hours total...  what do dealers charge these days?  85.00 an hour?  So figure 300.00 in labor.  How much can us CVO web guys get the hawg tunes system for?

2008 harley tour pack removal

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I was going to install the Tour-Pac Extender and it looks like the simple instructions that applied to an Ultra don't apply. It looks like I can't reach the two back nuts holding the Tour-Pac to the Support Frame. It looks like I'll need to remove the six nuts, on the inside of the Trunk, that are holding the Support Frame. Disconnect the wiring plugs. Then I can remove the Tour-pak and add the extender between the Tour-Pak & the Support. Did I miss anything, or is there a surprise that I don't know about? Is there enough playin the wiring harnesses extend the Pac 3"? Thanks in advance for any advice.

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Originally Posted by cmcgahagin I was going to install the Tour-Pac Extender and it looks like the simple instructions that applied to an Ultra don't apply. It looks like I can't reach the two back nuts holding the Tour-Pac to the Support Frame. It looks like I'll need to remove the six nuts, on the inside of the Trunk, that are holding the Support Frame. Disconnect the wiring plugs. Then I can remove the Tour-pak and add the extender between the Tour-Pak & the Support. Did I miss anything, or is there a surprise that I don't know about? Is there enough playin the wiring harnesses extend the Pac 3"? Thanks in advance for any advice. Charles ‘ Welcome to Trike Talk..👍👍
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Originally Posted by cmcgahagin I was going to install the Tour-Pac Extender and it looks like the simple instructions that applied to an Ultra don't apply. It looks like I can't reach the two back nuts holding the Tour-Pac to the Support Frame. It looks like I'll need to remove the six nuts, on the inside of the Trunk, that are holding the Support Frame. Disconnect the wiring plugs. Then I can remove the Tour-pak and add the extender between the Tour-Pak & the Support. Did I miss anything, or is there a surprise that I don't know about? Is there enough playin the wiring harnesses extend the Pac 3"? Thanks in advance for any advice. Yes you must remove the six nuts in the trunk and yes there is enough wire play in the wiring for the extension pf the tour pack.
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Originally Posted by nucseal Yes you must remove the six nuts in the trunk and yes there is enough wire play in the wiring for the extension pf the tour pack. Thanks for the help. I went into the HD online Parts Manual and confirmed what I thought. I was concerned about the wiring harness length though. I was trying to minimize the surprises. Thanks again!
Originally Posted by nucseal Yes you must remove the six nuts in the trunk and yes there is enough wire play in the wiring for the extension pf the tour pack. Thanks again for the input, I installed the extender & pad today. No issues other than changing out the OEM bolts for some shorter ones.

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COMMENTS

  1. Removing Harley Davidson Tour Pac

    Some hints on removing a tour pac from a HD Ultra

  2. tour pack removal

    Removing Harley-Davidson original stock tour pack. Don't forget to leave a thumbs up, and a comment so i can keep improving the quality of the videos depend...

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    Spend the cash, and order the quick removal kit. This way, you can take the tourpak off when you want. You really want a fast and EFFICIENT way to reomve the tourpak, because at over a thousand dollars to replace it, the last thing you want is to be unbolting it and drop/scuff/damage it, or the rear fender of the bike.

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    41 posts · Joined 2010. #9 · Feb 28, 2010. I bought my quik release kit this week of E Bay for $280 , I also bought the hidden antana for $19 of ebay. Harley Detachable Tour-Pak Rack Kit 53303-07 : eBay Motors (item 400102627066 end time Mar-11-10 17:52:37 PST) Like.

  6. How to Remove and Disassemble the Harley Davidson Tour Pack for Painti

    3.2 Quick Steps to Disassemble the Harley Davidson Tour Pack. Ensure you always start with disconnecting any wiring or electrical connections for speakers, lighting, aftermarket USB charging kits, or aftermarket GPS systems. Remove the passenger backrest (if attached) by unfastening its mounting bolts.

  7. Removal of tour pac

    I priced the complete kit with backrest, and luggage rack from the dealer installed and it was $1200.00 cdn. Yeah, I priced the TourPac for a 2010 Street Glide, brackets, paint, etc. Runs about $1,000 USD. (I think the online list is $999.95) Told the dealer we need to rename the product The Harley-Davidson -- THD . . .

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    Detachable Two-wup tour-pack rack. It says requires 53450-97D and 53104-97B docking points. In the docking point diagram on page 418 it showes all docking points and the ones listed are for some other accessory. In the Docking Hardware fitment matrix on page 418, it says to use 53746-97B and 53127-96C.

  9. Tour Pack removal Instructions

    Not including the Hawg-wired install, to remove the HK amp and overlay harness should not tak more than one hour (I can have the amp and harness out in about 30 minutes) To install the detach kit, tour pack rack, anntenna relocation, license plate kit should not be more than 2 hours (if they are really slow) Logged.

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    2325 posts · Joined 2012. #3 · Jan 10, 2013. Yours is like mine, an Ultra Classic, so i will assume you have the rear speakers on your tour pack. I had to remove mine for a few weeks over the summer in order to get a crack repaired (see my entry in the "Dumb things" thread). I was able to unplug the antennas, I had to cut the wires for the ...

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    The Tour-Pak side of the Power Harness provides 6 wire leads for hook up to ground, brake, run, left turn, right turn and auxiliary power and mates with quick disconnect parts CD-TP-QD-HD14 or CD-TP-QD-SS614 depending on your 2013-Earlier model fitment. CD-TP-QD-HD14 can be installed on 1997-2013 Harley-Davidson® Electra Glide, Ultra Classic ...

  16. H-D Detachables Tour-Pak Luggage Conversion Kit

    Find H-D Detachables Tour-Pak Luggage Conversion Kit 53246-09C at Harley-Davidson.com. Free shipping on orders $50+ and free returns. ... Change or remove bike. This part does not fit your . Shop that fit ... Financing Offer available only on new 2019 Harley-Davidson® Touring motorcycle models financed through Eaglemark Savings Bank and is ...

  17. Want to be able to remove tour pack and replace with Backrest

    1517 posts · Joined 2015. #2 · Jan 30, 2018. You need the removable tour-Pack kit, (which is a different baseplate, and the 4-point quick release brackets that go on the bike. Rack #53276-09B, 4-Point Docking Hardware Kit #54205-09A are the Harley part numbers you need. 2020 Road Glide Ultra.

  18. Harley-Davidson Tour Pack Mounting & Relocation Kits

    HogWorkz Two Up Tour Pack Mount For Harley Sport Glide / Low Rider 2018-2024. $159.98. Free Shipping. Open-Box. Vehicle Specific. HogWorkz Rear Docking Hardware Kit For Harley Touring 1997-2008 Chrome [Open Box] $49.48. $54.98.

  19. FAIL Harley Davidson tour pack removal: srkcycles.com

    -SRK Cycles Inventory Click here to see https://www.srkcycles.com/-Want to rent a motorcycle? Check out Riders Share: https://www.riders-share.com/-M1 Moto G...

  20. '21 Tri-Glide Tour-Pac Removal

    I was going to install the Tour-Pac Extender and it looks like the simple instructions that applied to an Ultra don't apply. It looks like I can't reach the two back nuts holding the Tour-Pac to the Support Frame. It looks like I'll need to remove the six nuts, on the inside of the Trunk, that are holding the Support Frame. Disconnect the wiring plugs.