Don't know if anyone else has encountered this problem, but here goes. Several months ago we prepacked the tour pak bag and placed it in the tour pak the evening prior to a long road trip. In the morning I needed to add to the bag. When I lifted the tour pak lid smoke started coming from the bag. Those tour paks really are airtight. The mercury switch in the tour pak light was defective. This meant the light was on when the tour pak lid was closed and the hot bulb was resting on the bag all night. Sure glad I had secured the tour pak lid or we might have lost the bike, car, and house to fire. Just a heads up to check your tour pak light and make sure it is out prior to closing the tour pak lid. If this has been previously brought up, sorry for wasting your time.