INSTALLATION
RUN-TURN-BRAKE CONTROLLER KIT FOR TOUR PAK™
THANK YOU FOR CHOOSING KϋRYAKYN!
PROTECT YOURSELF AND OTHERS FROM POSSIBLE INJURY AND PROPERTY DAMAGE OR LOSS. PAY CLOSE ATTENTION TO ALL INSTRUCTIONS, WARNINGS, CAUTIONS, AND NOTICES REGARDING THE INSTALLATION, USE, AND CARE OF THIS
PRODUCT.
THIS INDICATION ALERTS YOU TO THE FACT THAT
IGNORING THE CONTENTS DESCRIBED HEREIN CAN
RESULT IN POTENTIAL DEATH OR SERIOUS INJURY.
This indication alerts you to the fact that ignoring
the contents described herein can result in minor or
moderate potential injury.
This indication alerts you to the fact that ignoring the
contents described herein may negatively affect product
performance and functionality or damage the product itself
or the product to which it is being attached.
MAKE SURE THE FOLLOWING PARTS HAVE BEEN INCLUDED IN THE KIT:
1
1
1
1
1
Run-Turn-Brake Harness — long wires
Run-Turn-Brake Controller — yellow casing
8-Pin Adapter — short wires
Hardware Kit containing:
1
T. S. M. Load Equalizer
1
Run-Turn-Brake NO FLASH tab
1
Dielectric Grease pack
4
4” Cable Ties
2
8” Cable Ties
Installation Instructions
TOOLS SUGGESTED:
Set of wrenches, screwdriver, small pick tool
These installation instructions contain important information.
Ensure that the end user receives this copy and is aware of its
importance for future reference.
STEP 1
Read and understand all steps in the instructions before starting the installation.
Park the motorcycle on a hard, level surface and turn off the ignition.
Kuryakyn P/N 5490, Run-Turn-Brake Controller for Tour Pak™
enables the turn signal system to function as Run-Turn-Brake.
In order to comply with Federal and State regulations, rear
turn signals must be equipped with RED lenses or RED L. E. D.
conversions (sold separately from Kuryakyn).
5490-22HD-0514
-cont.-
Other than Kuryakyn Panacea Controllers, all other modules
and controllers MUST BE REMOVED before installing Kuryakyn
p/n 5490 (Run-Turn-Brake Controller for Tour Pak™). Motorcycles equipped with Kuryakyn Panacea Controllers require
Kuryakyn p/n 5488 (Adapter Harness, R-T-B & Panacea Modules, sold separately).
5490
CUSTOMER SERVICE
877.370.3604 (toll free)
INSTALLATION QUESTIONS
[email protected]
or call 715.247.2983
LIMITED WARRANTY
Küryakyn warrants that any Küryakyn products
sold hereunder, shall be free of defects in
materials and workmanship for a period of one
(1) year from the date of purchase by the
consumer excepting the following provisions:
● Küryakyn shall have no obligation in the event
the customer is unable to provide a receipt
showing the date the customer purchased the
product(s).
●The product must be properly installed,
maintained and operated under
normal conditions.
●Küryakyn makes no warranty, expressed or
implied, with respect to any gold plated
products.
●Küryakyn shall not be liable for any
consequential and incidental damages, including
labor and paint, resulting from failure of a
Küryakyn product, failure to deliver, delay in
delivery, delivery in nonconforming condition, or
for any breech of contract or duty between
Küryakyn and a customer.
●Küryakyn products are often intended for use in
specific applications. Küryakyn makes no
warranty if a Küryakyn product is used in
applications other than intended.
●Küryakyn electrical products are warranted for
one (1) year from the date of purchase by the
consumer. L.E.D.’S contained in components of
Küryakyn products will be warranted for defects
in materials and workmanship for 3 years from
the date of purchase where as all other
components shall be warranted for one(1) year.
This includes, but is not limited to; control
modules, wiring, chrome & other components.
●Küryakyn makes no warranty of any kind in
regard to other manufacturer¹s products
distributed by Küryakyn. Küryakyn will pass on
all warranties made by the manufacturer and
where possible, will expedite the claim on behalf
of the customer, but ultimately, responsibility for
disposition of the warranty claim lies
with the manufacturer.
ABOUT OUR CATALOG
For purchasing Küryakyn® products, you
can receive a complete catalog free of charge.
Send the Proof-of-Purchase below with your
address to: Küryakyn
454 County Road V V
Somerset, WI 54025-9031
Please indicate either Accessories Catalog for
Harley-Davidson® or GL & Metric Cruisers.
Be sure to ask your local dealer about other
Küryakyn® products, the motorcycle parts and
accessories designed for riders by riders.
©2005 Küryakyn USA® All Rights
reserved.
BIKE PREP:
STEP 2
Open the Tour Pak ™ lid; locate and remove the
two acorn nuts and washers securing the document pouch to the Tour Pak™. Set the pouch,
acorn nuts, and washers aside for now.
PIC 1
Gently lift up on the Tour Pak™ lining to remove
it. Set it aside for now.
BRAKE LIGHT
HOUSINGS
STEP 3
Refer to PIC 1. Locate and disconnect the 3-pin
Tour Pak™ lighting connector; it will not be reused.
Locate and disconnect the 2-pin side-marker
connectors (if equipped).
STEP 4
Refer to PIC 2. Remove the two bulb sockets by
pressing the tab down, twisting the sockets
counterclockwise and pulling them straight out
of the brake light housings.
STEP 5
Refer to PIC 3. Push the bulbs in and twist
counterclockwise, then pull straight out to remove them from the sockets; set the bulbs
aside for now, they will be reused.
2-PIN SIDE MARKER
CONNECTORS (IF
EQUIPPED)
GROMMET
AND HOLE
FRONT OF BIKE
3-PIN TOUR PAK™
LIGHTING CONNECTOR
CLUTCH-SIDE (LEFT)
BRAKE-SIDE (RIGHT)
PIC 3
PIC 2
TWIST COUNTERCLOCKWISE
PRESS TAB
PULL STRAIGHT OUT
PUSH BULB IN
PULL STRAIGHT OUT
BRAKE LIGHT HOUSING
TWIST COUNTERCLOCKWISE
INSTALL THE HARNESS, CONTROLLER, AND ADAPTER:
STEP 6
Locate the included Run-Turn-Brake Harness (it has the long wires).
Remove the metal plate to fully remove the OEM wiring harness. Get help to secure
PIC 4
the Tour Pak™ while the fasteners are being removed. Reinstall the metal plate and
route the new Run-Turn-Brake Harness around the edges of the Tour Pak™. Ensure no
wires are pinched during reinstallation of the metal plate.
Dielectric grease inhibits moisture and prevents corrosion.
Kuryakyn recommends the use of the included dielectric grease
on ALL electrical connections. Apply dielectric grease directly to
mating surfaces.
Apply some of the included dielectric grease to the metal bases of the existing bulbs
(from STEP 5); install them in the new sockets in the reverse order they were removed. Ensure that the metal socket flanges are flat against the rubber plugs. Carefully bend the metal terminal down 90 degrees as shown in PIC 4.
NOTE:
The new bulb sockets are SIDE-SPECIFIC. The right-side bulb
socket has the BROWN wire; the left side bulb socket has the
VIOLET wire.
-cont.-
RUN-TURN-BRAKE CONTROLLER KIT FOR TOUR PAK™
BEND TERMINAL
90 DEGREES
PAGE
2
INSTALLATION
STEP 7
Connect the 2-pin connectors from the R-T-B Harness to the 2-pin side-marker connectors (if
equipped).
NOTE:
The new side-marker light-connectors (if equipped) are SIDE-SPECIFIC. The
right-side connector has the BROWN wire; the left side connector has the
VIOLET wire.
STEP 8
Refer to PIC 1 on PAGE 2. Temporarily remove the rubber grommet in the lower front side. Route
the white 3-pin connector (on the long wire) through the hole; reinstall the rubber grommet after
routing the wiring.
STEP 9
Remove the seat; set it aside for now. Refer to FIG 1. Underneath the seat, locate and separate the
OEM rear-lighting harness (black 8-pin connector). The rear-lighting side of the harness will be coming out of a hole in the rear fender.
Dielectric grease inhibits moisture and prevents corrosion. Kuryakyn recommends the use of the included dielectric grease on ALL electrical connections.
Apply dielectric grease directly to mating surfaces.
FIG 1
FLASH TAB
3
8-PIN ADAPTER
2
TO REAR
LIGHTS
REARLIGHTING
HARNESS
(MALE)
OUTPUT
INPUT
1
4
3-PIN CONNECTOR FROM TOUR PAK™
RUN-TURN-BRAKE
CONTROLLER
MAIN
WIRING
HARNESS
(FEMALE)
TO MAIN
HARNESS
3-PIN LOAD EQUALIZER ADAPTERS
STEP 10
Refer to FIG 1. Locate the included Run-Turn-Brake Controller and connect it to the main wiring harness (female connector,
1) on the bike.
Locate the included 8-Pin Adapter and connect it to the rear-lighting harness (male connector,
2).
Connect the Controller to the Adapter (3); the 8-Pin Adapter must be “down stream” from the R-T-B
Controller.
STEP 11
Route the white 3-pin connector (male) from
STEP 8 towards the 8-Pin Adapter; connect it to 3-pin
connector (female) on the Adapter (4). The 3-pin connector (male) MUST be connected to the 3-pin
connector (female) on the Adapter; DO NOT connect it to the 3-pin Load Equalizer connectors
(female) on the Controller.
-cont.-
RUN-TURN-BRAKE CONTROLLER KIT FOR TOUR PAK™
PAGE
3
INSTALLATION
TEST FOR FUNCTION AND FINISH INSTALLATION:
STEP 12
PIC 5
BRAKE LIGHTS
Refer to PIC 5. Turn on the ignition and test for proper Run-Turn-Brake function. The
brake lights (and side marker lights, if equipped) on the Tour Pak™ and the lower turn
signals should now function as Run-Turn-Brake.
NOTE:
Refer to FIG 1 on
SIDE-MARKERS,
IF EQUIPPED
PAGE 3. Remove the FLASH tab from the RTB
NO FLASH tab to disable the
Controller and insert the included
flashing brake function.
If the turn signals flash faster than normal:
TAILLIGHT
TURN SIGNALS
turn the ignition off;
connect the included T. S. M. Load Equalizer to one of the open 3-pin connectors on the R-T-B Controller (refer to FIG 1 on PAGE 2);
turn the ignition on and test for proper function.
STEP 13
Install the bulb sockets in the brake light housings. Push the new sockets into the housings at an
angle to get one side started then push the rest of it into the housing. Refer to PIC 4 on
Ensure that the 90 degree terminal is facing downward so it does not catch on the liner.
STEP 14
PAGE 2.
Secure wiring away from any moving parts, pinch points or extreme heat with the included Cable
Ties.
Secure all wiring away from any moving parts, pinch points or extreme heat.
Kuryakyn WILL NOT provide warranty coverage on any electrical component
that fails due to pinched, crimped, broken, abraded, melted or frayed wires.
STEP 15
Reinstall the lining and document pouch in the reverse order they were removed.
STEP 16
Close lid and ensure it latches correctly.
STEP 17
Reinstall the seat.
STEP 18
Ensure proper operation of ALL light functions BEFORE operating the motorcycle.
VISIBILITY IS A MAJOR CONCERN FOR MOTORCYCLISTS. A
LIGHT MALFUNCTION COULD RESULT IN DEATH OR SERIOUS INJURY. ENSURE PROPER LIGHT OPERATION BEFORE RIDING THE
MOTORCYCLE.
It is the end user’s responsibility to ensure that all of the fasteners
(including pre-assembled) are tightened before operation of the motorcycle. Küryakyn will not provide warranty coverage on products or components lost or damaged due to improper installation or lack of maintenance.
Periodic inspection and maintenance are required on all fasteners.
PAGE
Ride On!
RUN-TURN-BRAKE CONTROLLER KIT FOR TOUR PAK™
4
INSTALLATION
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