BIG BIKE PARTS 52-969 Tour Pack Rack Instruction Manual

BIG BIKE PARTS 52-969 Tour Pack Rack

Product Information

The product is a Tour Trunk Rack designed to fit Honda GL1800 2021-newer models. The part number for this product is 52-969/52-969BK.

Product Usage Instructions

1. Before starting the installation process, read through and understand all the instructions provided in the user manual.
2. Make sure you have all the necessary tools required for the installation, including a Phillips screwdriver, 5mm and 4mm Allen wrenches, razor knife, drill, 11/16 step drill bit, and a pencil/fine marker.
3. Begin the installation process by positioning the rack on the trunk lid and marking the location of the mounting holes using a pencil or marker.
4. Using a razor knife, cut the carpet on the marked area to expose the mounting holes.
5. Using the 11/16 step drill bit, drill holes on the marked spots on the trunk lid.
6. Attach the mounting brackets to the rack using screws and nuts provided in the kit.
7. Place the rack on the trunk lid and align it with the drilled holes.
8. Insert bolts through the drilled holes and secure them with nuts provided in the kit.
9. Adjust the rack to ensure it is level and centered on the trunk lid.
10. Tighten all nuts and bolts to secure the rack in place.
11. Reinstall the trunk liner and ensure that it fits properly.
12. Test the rack for stability and ensure that it can support the weight of your luggage.
13. If you notice any issues with the rack, recheck the installation process and make necessary adjustments.
14. After completing the installation, make sure to clean the rack and remove any debris or dust.
15. Regularly inspect the rack for any signs of wear or damage and replace any worn-out parts immediately.
16. The estimated installation time is 60 to 90 minutes.

PLEASE READ THROUGH AND UNDERSTAND THESE INSTRUCTIONS BEFORE BEGINNING.
ESTIMATED INSTALLATION TIME: 60 TO 90 MIN.

INSTALLATION

1. OPEN THE TRUNK LID AND REMOVE THE 6 PHILLIPS SCREWS SHOWN IN FIG. 1 AND ONE PHILLIPS SCREW ON EACH SIDE LOCATED BY THE ARROWS IN FIG. 1.
2. WITH THE TRUNK LID LOWERED, CAREFULLY LIFT THE PASSENGER BACKREST PAD AND DISCONNECT THE WIRE HARNESS ON TOP OF THE TRUNK LID TO REMOVE THE BACKREST PAD (FIG. 2). DO NOT STRESS THE WIRE HARNESS WHEN LIFTING THE BACKREST PAD.
3. REMOVE THE WIRE HARNESS AND CONNECTOR FROM THE TABS IN THE TRUNK LID (FIG. 3).
4. REMOVE THE SIX SCREWS IN FIG. 3 AND REMOVE THE TRUNK LID. (BE SURE TO SUPPORT THE TRUNK LID WHEN REMOVING THESE SCREWS)
5. PLACE TRUNK LID WITH THE INSIDE FACING UP ON A CLEAN SOFT SURFACE TO AVOID SCRATCHING.
6. REMOVE ALL THE SCREWS AND LATCHES IN FIG. 4 AS WELL AS THE 6 RUBBER HOLE PLUGS.
7. STARTING AT THE FRONT OF THE TRUNK LID, CAREFULLY REMOVE THE LID LINER FROM THE LID BY PULLING THEM APART AT EACH SCREW LOCATION UNTIL THE LID LINER POPS OUT. SET THE LID LINER ASIDE FOR NOW.
8. FROM INSIDE THE TRUNK LID, USE A RAZOR KNIFE TO REMOVE THE RIB SHOWN IN FIG. 5 FROM THE TRUNK LID LEFT INSERT PANEL. (FIG. 5) NOTE: IF YOU REMOVE THE INSERT PANEL FROM THE TRUNK LID, IT MAY NOT SEAL AS WELL WHEN REINSTALLED.
9. REPEAT STEP 8 ON THE RIGHT LID RIGHT INSERT PANEL.
10. CAREFULLY CUT OUT THE LEFT SIDE TEMPLATE PROVIDED IN THE KIT AND TAPE IT TO THE TOP OF THE TRUNK LEFT INSERT PANEL. (FIG. 6)
11. REPEAT STEP 10 ON THE RIGHT SIDE.
12. REMOVE THE RUBBER CAPS FROM THE FOUR LEGS OF THE NEW TRUNK RACK AND CAREFULLY SET THE TRUNK RACK IN PLACE ON TOP OF THE TRUNK LID (FIG. 7) LINING EACH LEG UP WITH THE CENTER MARKS ON THE TEMPLATES. (IF ALL THE LEGS DO NOT LINE UP, LINE THEM UP AS CLOSE AS YOU CAN)
13. WHILE HOLDING THE RACK IN PLACE, TRACE A CIRCLE AROUND EACH LEG ON THE TEMPLATES (DO NOT MOVE RACK UNTIL ALL 4 LEGS ARE TRACED). REMOVE THE RACK ONCE ALL FOUR LEGS ARE TRACED.
14. MARK THE CENTER OF EACH CIRCLE FROM STEP 13. (FIG. 8)
15. USE A STEP DRILL BIT TO CAREFULLY DRILL AN 11/16” HOLE AT EACH CENTER MARK FROM STEP 14. (BE SURE TO SUPPORT THE INSERT PANEL WHILE DRILLING)
16. INSTALL THE FOUR RUBBER GROMMETS SUPPLIED IN THE KIT INTO THE 4 DRILLED 11/16” HOLES FROM THE TOP SIDE OF THE TRUNK LID. (FIG. 9)
17. INSTALL THE TRUNK RACK ON THE TRUNK LID BY SLIDING THE FOUR LEGS THROUGH THE FOUR RUBBER GROMMETS. (USE A SOAPY WATER SOLUTION ON THE LEGS OF THE RACK TO SLIDE THROUGH THE RUBBER GROMMETS)
18. ON THE TRUNK LID LINER, STARTING ON THE RIGHT SIDE, INSTALL ONE OF THE SUPPORT BRACKETS AS SHOWN IN FIG. 10. REPEAT ON LEFT SIDE.
19. REINSTALL THE TRUNK LID LINER TO THE TRUNK LID WITH THE RACK INSTALLED. (THE RACK LEGS WILL HOLD THE LID LINER OUT FROM THE TRUNK LID UNTIL FUTURE STEPS)
20. INSTALL THE FOUR M6-1.0X25MM LONG BUTTON HEAD SCREWS INTO THE TRUNK RACK LEGS WITH AN M6 FLAT WASHER ON EACH. (FIG. 11) DO NOT TIGHTEN.
21. STARTING AT THE FRONT OF THE TRUNK LID, PRESS THE TRUNK LID AND TRUNK LID LINER TOGETHER ENOUGH TO START THE SCREWS REMOVED IN STEP 6. INSTALL THE LATCHES LAST AFTER THE OTHER SCREWS ARE TIGHTENED.
22. TIGHTEN THE FOUR M6-1.0X25MM SCREWS TO SECURE THE RACK.
23. REPEAT STEPS 1 THROUGH 3 IN REVERSE ORDER TO REINSTALL THE TRUNK LID.

WARNING
THREADLOCK CAUSES PLASTICS TO CRACK, BREAK OR BECOME BRITTLE. WHEN USING THREADLOCK TO INSTALL HARDWARE WITH PLASTIC COMPONENTS, ONLY APPLY TO METAL COMPONENTS. IT IS CRITICAL THAT ANY EXCESS THREADLOCKER OR SPILLAGE IS CLEANED COMPLETELY FROM PLASTIC COMPONENTS IMMEDIATELY BEFORE DRYING. A DAMP TOWEL OR RAG IS THE BES1 WAY TO ACHIEVE THIS. IF EXCESS THREADLOCKER IS NOT CLEANED UP RIGHT AWAY, IT COULD LEAD TO DAMAGED PRODUCTS AND VOID WARRANTY.

NOTICE
DO NOT EXCEED THE LOAD CAPACITY THAT IS SPECIFIED BY THE VEHICLE MANUFACTURER. EXCESSIVE LOADING ON THE TRUNK LUGGAGE RACK MAY CAUSE LOSS, DAMAGE TO THE MOTORCYCLE OR INJURY. BIG BIKE PARTS IS NOT RESPONSIBLE FOR LOSS, DAMAGE OR INJURY CAUSED DUE TO EXCESSIVE LOADS OVER THE VEHICLE MANUFACTURER’S LOAD SPECIFICATIONS ON THE LUGGAGE RACK.

Copyright© 2022 by Big Bike Parts, Inc. No part of this instruction sheet may be reproduced without the written permission of Big Bike Parts, Inc.

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