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TOUR-PAK REPLACEMENT LATCH KIT
J004912006-10-03
GENERAL
Kit Number
90681-95A
Models
This Tour-Pak® Replacement Latch Kit fits:
  • all 1985 through 2006 FLT model Tour-Paks,
  • 1985-1992 FLT saddlebags, and
  • all FXRT/D model Tour-Paks.
Additional Tools and Materials Required
A rivet tool (Part Number HD-39787) is required for proper installation of this kit.
Loctite® 243 (Blue) Threadlocker and Sealant (H-D Part Number 99642-97) is required for the proper installation of this kit.
NOTE
If this procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in damage to vehicle components.
Kit Contents
See Figure 1 and Table 1.
INSTALLATION
NOTE
This kit contains an improved design latch, spacer and catch. The applicable components of this kit MUST all be installed with each other. DO NOT attempt to use old parts with the new items from the kit, except where noted. Mixing old and new parts WILL cause the latch to malfunction and damage parts.
Be careful not to damage the gasket and Tour-Pak lid or saddlebag cover when drilling the rivet heads.
If a new Tour-Pak lid or saddlebag cover is being installed that already has a pre-installed new-style catch, discard the catch in this kit and perform only Steps 3 and 4 of the procedure.
  1. See Figure 1. Use a 5/32 in. (4 mm) bit to drill the flared, inside ends off the rivets securing the catch (2) and backing plate (5). Remove and discard the catch, backing plate and rivets.
  2. Place the new catch and backing plate from the kit in position, and install the correct rivets (item 3 or 4, depending on model) using the HD-39787 rivet tool.
  3. Remove the screws (A) and washers (B) holding the spacer (6) and latch assembly (1). Retain the screws and washers, but discard the latch and spacer.
  4. Place a washer onto the threads of each screw removed in Step 3. Apply a few drops of Loctite 243 (Blue) to the screws threads. Place the new latch assembly and spacer from the kit in position, and install using the original screws and washers. Tighten securely.
SERVICE PARTS
Figure 1. Service Parts, Latch Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Latch assembly
90649-07
2
Catch (rivet hasp)
90705-97
3
Rivet, 5/16 in. (8 mm) long (2)
(for FLT models)
90965-63
4
Rivet, 3/8 in. (9.5 mm) long (2)
(for FXRT/D models)
90967-63
5
Backing plate
90688-85
6
Spacer
53615-85A
Items not included in kit.
A
Original equipment screw (2)
B
Original equipment flat washer (2)