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[Kisscorky]

Okay, I have the Tour Pak 54114-10 and the Two Up Tour Pak Luggage Rack 54051-08 to mount it on. I also have the required Docking Hardware Kit 54245-10. Now here is my problem, I do not know how to get the existing Docking Hardware off. Tried a Torx T40, but it is to small. Tried a Torx T45, but it is to big. HELP?

 Once I get them off, how does the New Docking Hardware get installed? The directions that came with them is confusing?

Kisscorky

[porkypig]

Cork, using my unreliable memory, I installed the tour pak/mounting bracket/docking kit last November when I got the bike.  I have forgotten the torx number that is required to remove the 2 bolts on each side.  There is nothing magical about the process.  It is just a long bolt you remove, then add the 2 wider spacers to each side and put in the longer bolt that should have come with the kit.  the reason you need the docking kit of course is because without the wider spacers you can not install the saddlebags afterwards.  That is the only reason.  When I get home this evening, I will investigate it just a little more and try to get you some more detailed info.  But it is one of those torx sizes you mentioned, I believe.  Now, if you need to remove the rear footpegs because you want to add rear footboards, you will need to purchase longer torx drivers that are available at a Shuck's store for about $16 for a set of 4 larges sizes because the bolt is in there too deeply.  But that is another issue. 

[ice6900]

I dont believe there is an inbetween size T40 to T45, so it must be one or other

http://www.wihatools.com/Marketing/torxspec.htm

[REHAB]

Mine takes a T-45.
Hope this helps.
MrGPD

[tjstreetglide]

The torx fastener are the worst fasteners ever manufactured, In my opinion. The wrenches do no fit correctly. They all seem to be  a little to small. I stripped three of the bolts on my primary the first time I changed the fluid. I am slowly changing all my fasteners to polished stainless, rolled thread, twelve sided bolts. Not only do they look good, They can actually be used more than once. allen bolts seem to be the place to buy them. Google them.

[RCFlyer]

Mine is the same way.  All of the bolts on the support arm are a sloppy fit with a T45. They're probably made in China.  Or maybe Harley purchased them at Lowes!!

[ice6900]

Mine is the same way.  All of the bolts on the support arm are a sloppy fit with a T45. They're probably made in China.  Or maybe Harley purchased them at Lowes!!

Its all to do with the fact that the Torx bolts were precision forged to a very high spec then some bozo decided they could save a few yen by plating a thinner layer a chrome onto the bolts, this thin layer also accounts for the fact that the chrome just peels off!

[kb]

The guy who invented the Torx system should be shot. It is nothing but a pain in the azz.

[Kisscorky]

Porkypig,

If you could take a picture of your your docking setup it would help me see how all four should look.

Thanks,

Francis

[Kisscorky]

You know what I like about Torx bolts......nothin'

[Wanna ride]

Not that it's much help, but I just installed my tour pak a few weeks ago too. And I was disappointed with the instructions on the hardware and detach kit. They did a pretty sloppy, over-complicated job of writing those instructions. WTF? The other aggravating thing I noticed, is how many different size fasteners are in such a small area. You spend more time switching tool sizes, than actually removing/installing fasteners. WTF?

I was definitely not impressed with that entire project.

[Kisscorky]

I'm still working on it. Started last week and then had to go out of town. I should finish tomorrow nite. Will post pics. I agree with you on the three different instruction sheets. Whoever does these must have an evil sense of humor.

[porkypig]

Well, I just looked and my bolts are definitely a T-45.  However, I threw the chrome ones that came with the docking kit (crap if I ever saw crap.......and they were hex heads rather than the torx which is what the bike came with) and purchased new chrome ones from a local bolt shop.  They gleam even though you never see them except when the bags are off and the docking kits are exposed (which is why I bought them) they were about $5 per but I like the bolts myself.  Why Harley has 7 different type bolts is beyond me.  Why don't they stick with a pattern and just give you larger or smaller ones of the same design.  Especcccccially on these bikes?  Anixter Fasteners is the company Harley contracts with to make all the bolts for our bikes.
Anyway, my bike is covered with sand and dirt from our local dirt storm on Monday so hopefully will get the bike washed and take some pictures.   Pork

[Kisscorky]

Pork,

I agree with you. Going to hardware store tomorrow to replace those bolts.

[Wanna ride]

I hear ya' Porky. When mine came in, I honestly(and naively) thought that I would buzz home, throw it all on and be riding in an hour or so. HAH! About three hours, a bucket of cusswords, and two thrown wrenches later...