Touratech Topcase Carrier Mounting Instructions
Harley-Davidson Pan America 1250
Model Numbers: 01-440-5455/5456-0
Date: October 2021
General Recommendations and Safety
Recommendation: We recommend having the accessory parts fitted by a specialist workshop.
Liability: Touratech accepts no liability for incorrectly fitted parts and resulting material damage or personal injury. These instructions are written based on our current state of knowledge. Information is provided without any guarantee as to its accuracy. Subject to technical modifications.
Regulations: Please observe applicable road vehicle regulations as well as EC/ECE Directives and applicable laws in your country. If parts are fitted which require inspection and/or approval after fitting, take your vehicle to a testing station immediately and have the vehicle papers updated.
Bolt Checks: Check and if necessary tighten all bolted connections after 50 km.
Lean Angle: Please take into account that fitting panniers, crash bars, foot peg lowering kits (rider and pillion), Kickstand enlargmentplate, front spoilers and engine guards may restrict the bike's lean angle!
Modifications: If modifications are made to the fairing, stem, handlebar, etc., ensure that electrical wiring, brake lines, accelerator and clutch cables are refitted correctly. Check clearance with full steering lock. Check clearance of all functional parts.
Electrical Work: Always disconnect the battery when working on the electrics!
Stone Chip Protection: We recommend cutting protective film to size and applying it to impact areas that are likely to be chipped by stones.
Brake & Suspension: Work on the brake system and suspension should always be carried out by a specialist workshop.
Luggage Load: Maximum load on luggage racks is 5 kg! Luggage racks ZegaPro TC is 10 kg!
Accessory Compatibility: If other original accessories or aftermarket accessories are used, ensure clearance, fitment and do not come into contact with other parts!
Lubrication: Apply conventional lubricant to stainless steel bolts prior to assembly.
Instructions Download: PDF fitting instructions can also be downloaded from the Touratech webshop.
Torque Specifications
Standard tightening torques in Nm for bolted connections with strength class 8.8. For special tightening torques refer to your specialist workshop!
| Bolt Size | Steel 8.8 (Nm) | Inox A2 (Nm) |
|---|---|---|
| M 4 | 2.7 | 0.8 |
| M 5 | 5.5 | 1.7 |
| M 6 | 9.7 | 3.0 |
| M 8 | 23.0 | 7.9 |
| M10 | 47.0 | 14.0 |
| M12 | 80.0 | 24.0 |
| M14 | 130.0 | -,- |
| M16 | 196.0 | 59.0 |
| M18 | 270.0 | -,- |
| M20 | 385.0 | 114.0 |
Mounting Steps
The order of assembly steps must be followed.
Note: Dismantling of left and right side is identical.
Note: Fitting of left and right side is identical.
Step 1: Prepare Mounting Points
Identify the mounting points on the motorcycle frame, typically near the rear subframe or tail section. Ensure all necessary original parts are present.
Step 2: Attach Main Carrier Structure
Position the main carrier structure onto the designated mounting points. Ensure any provided cellular rubber protection is correctly placed between the carrier and the motorcycle frame to prevent damage and vibration.
Instruction: Insert screws loosely at this stage. Do not tighten them fully yet.
Step 3: Install Rear Support (if applicable)
For certain configurations, or if the original pannier rack is not fitted, a rear support bracket may be attached. This may involve using spacers (e.g., 4 mm or 8 mm) depending on the specific fitment.
Step 4: Final Tightening
Once all components are correctly positioned and the carrier is aligned, proceed to tighten all screws securely.
Instruction: Tighten all screws. Refer to the torque specifications table for correct values, especially for critical connections.
Step 5: Final Checks
Verify that all connections are secure and that the carrier is firmly attached. Check for any interference with the rear light or other components.
Note: After 50 km of riding, re-check and tighten all bolted connections.
Diagram Description 1 (Page 3): Diagram showing the rear section of a motorcycle. Numbered indicators point to different areas: '1' points to the frame near the rear wheel axle. '2' points to the main structure of the top case carrier. '3', '4', and '5' point towards the rear light assembly area, suggesting potential interaction or clearance checks needed there. A text box states: 'Dismantling of left and right side is identical'.
Diagram Description 2 (Page 4, Top): Diagram illustrating the initial assembly of the top case carrier. Part '1' shows the carrier being aligned with mounting points on the motorcycle frame. Screws are shown being inserted but with a note indicating 'insert screws do not tighten'. The diagram contrasts the Touratech part with the 'original' motorcycle parts. Part '2' shows the carrier structure, highlighting the placement of 'cellular rubber protection' between the carrier and the frame. A text box states: 'Fitting of left and right side is identical'.
Diagram Description 3 (Page 4, Middle): Diagram showing an alternative or additional mounting point, possibly for specific configurations or when the original pannier rack is removed. It illustrates a bolt passing through the carrier, a spacer (with options for 4 mm or 8 mm thickness), and into the motorcycle's mounting bracket. A label indicates: 'only without pannier rack'.
Diagram Description 4 (Page 4, Bottom): Diagram depicting the final tightening of all screws. A torque wrench symbol is shown, indicating the need to tighten to specified torque values (Nm). A large exclamation mark symbol (⚠️) emphasizes the importance of this step. A text box states: 'tighten all screws'.
