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BUELL LIGHTNING XB REMOVABLE SADDLEBAGS
J035632004-11-12
GENERAL
Kit Number
91458-05Y
Models
This kit fits 2003 and later Buell® XB9S, XB9SX, XB12S and XB12Scg model motorcycles.
The Buell® Lightning® XB Removable Trunk Bag (Kit Number 91456-05Y) fits the plastic latches mounted to the top of the saddlebags. The trunk bag is available separately from any Buell dealer.
Additional Parts Required
NOTE
A Service Manual for your motorcycle is available at your Buell dealer.
Kit Contents
See Figure 3 and Table 1.
INSTALLATION
Prepare the Motorcycle
Follow Owner's Manual instructions to remove the seat.
Install the Reflector Relocation Brackets
1. Use a thin flat blade, like an X-Acto® knife, and carefully pry the reflectors off of the turn signal mounting brackets.
2. Remove the adhesive residue from the brackets and the back of the reflector.
NOTE
When removing adhesive residue, take care to keep from scratching or damaging the reflector, mounting bracket or surrounding parts. New reflectors (Part No. 59256-84A) are available from your Buell dealer.
WARNING
Federal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b)
3. Mount the new reflector relocation brackets (4) to the stock reflector mounting brackets.
4. Loosely attach each relocation bracket through the slots in the stock bracket with two screws, flat washers and lock nuts.
5. Slide the relocation bracket to the rearmost position and tighten securely.
6. Remove the backing from the foam tape on the relocation bracket.
7. Press the stock reflector squarely onto the foam tape.
Install the Saddlebags
1. Hold the left and right saddlebags against the sides of the tail section.
Figure 1. Velcro Straps thorough Buckles
2. See Figure 1. Over the top of the tail section, pull an upper strap from the right saddlebag through the plastic buckle from the left saddlebag. Double back the Velcro® hook strip to engage the loop strip.
3. Repeat for the second strap.
4. Under the tail section, pull the lower strap from the right hand saddlebag through the plastic buckle from the strap on the left hand bag. Double back the Velcro® hook strip to engage the loop strip.
5. Wrap the rear Velcro® hook straps on each saddlebag around the reflector brackets to engage the loop strips on the bottom of the saddlebags.
6. At the front of both bags, wrap the Velcro® hook straps around the passenger footrest support and engage the hooks with the loops on the front of the saddlebags.
7. To prevent damaging the finish, cut and fit lengths of the clear protective tape to those points where the saddlebags and straps contact the tail section.
8. To remove any slack, press the saddlebags backward so the molded-in notches fit around the turn signals. Adjust the straps and securely engage all Velcro® hook and loop strips.
Return the Motorcycle to Service
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
Follow Owner's Manual instructions to install the seat.
Open and Close the Saddlebags
WARNING
Do not open storage compartments while riding. Distractions while riding can lead to loss of control, which could result in death or serious injury. (00082a)
To open the saddlebags, run the 2 outside zipper pulls in opposite directions.
To close, run the 2 outside zipper pulls together.
WARNING
Improper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00099a)
  • Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize change in the center of gravity.
  • Distribute weight evenly on both sides of the vehicle.
  • Do not load bulky items too far behind the rider or add weight to the handlebars or front forks.
  • Maximum recommended load is 3 lbs (1.3 Kg) for each saddlebag.
Expand the Saddlebags
See Figure 2. To expand the saddlebags, unzip the single pull on the inside of the bag.
Remove the Saddlebags
The saddlebags can be removed by removing the seat and releasing the Velcro® straps.
Figure 2. Saddlebag Expanded
SERVICE PARTS
Figure 3. Service Parts: Buell Lightning XB Removable Saddlebags
Table 1. Service Parts: Buell Lightning XB Removable Saddlebags
Item
Description (Quantity)
Part Number
1
Saddlebag, right
92160-05Y
2
Saddlebag, left
92161-05Y
3
Bracket, reflector relocation (2)
92163-05Y
4
Hardware kit, reflector relocation
92164-05Y
Screw, 1/4-20 x 3/4" (4)
Not Sold Separately
Plain washer, 1/4" (4)
Not Sold Separately
Lock nut, 1/4"-20 (4)
Not Sold Separately
Protective tape (clear), 8" x 1" (2)
Not Sold Separately