0/0
Hardware/Turn Signal Relocation Kit for Sportster Leather Saddlebag Kits
J029822013-11-01
GENERAL
Kit Number
68485-04
Models
This kit is designed for installation of the following leather saddlebags on 1994-2003 XL Model motorcycles (except XL 1200 Sport).
79052-04 Synthetic Leather Saddlebags
79073-04 Leather Teardrop Saddlebags
90342-04 Premium Harness Leather Saddlebags
90598-04 Leather Saddlebag Kit
Refer to page 1 for instructions on installation of 79052-04 and 79073-04.
Refer to page 6 for instructions on installation of 90342-04 and 90598-04.
Installation Instructions for 79052-04 and 79073-04
WARNING
Do not exceed saddlebag weight capacity. Put equal weight in each bag. Too much weight in saddlebags can cause loss of control, which could result in death or serious injury. (00383a)
NOTE
A pick tool (Snap-on TT600-3) will be required for 1996 and later models for removing and reinstalling a multi-lock amp connector.
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
Installation - Hugger Models Only (1994-1997)
WARNING
Be sure rear wheel is supported when removing rear shocks. If wheel is not supported rear fork can drop down, which could result in death or serious injury. (00481b)
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the 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 death or serious injury. (00333b)
1Shock absorber
2Upper nut, acorn
3Washer
4Shock cover
5Upper mounting bolt
6Bolt
7Washer
8Locknut
Figure 1. Shock Absorber Removal - Hugger Models Only
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
WARNING
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
  1. Remove seat, sissy bar and sideplate, if applicable. Retain hardware for reinstallation. Disconnect battery, negative cable first.
  2. Properly support motorcycle under frame to prepare for removal of right and left shocks.
  3. Remove rear buttonhead screw on each side of fender.
  4. See Figure 1. With rear fender and frame securely supported, remove left and right shocks by removing upper nut (2), washer(s) (3) and shock cover (4). Remove bolt (6), washer (7) and locknut (8) at lower shock mount. Remove shock.
  5. See Figure 5. Install long 4-1/2 inch bolt (11) from kit, from inside of fender out through rear holes where buttonhead screws were removed in Step 3.
  6. See Figure 1. Install shocks using original hardware. Torque acorn nut (2) to 21-35 ft-lbs (28.5-47.5 Nm). Torque locknut (8) to 30-50 ft-lbs (40.7-67.8 Nm).
Rear Turn Signal Relocation
NOTE
Rear turn signals must be relocated before saddlebags can be installed.
1. Remove seat and disconnect battery cables, negative cable first. Remove sissy bar and sideplates, if installed. Retain all parts and hardware.
NOTE
See Figure 2. 1994-1995 models have a Deutsch connector located under the seat.
NOTE
Before performing next step, notice location of wire colors in connector so wires can be reinstalled in same positions later.
1Locking wedge
2Seal
3Socket housing
4External latch
5Seal
6Socket Terminal
Figure 2. Rear Turn Signal Electrical Connector
2. See Figure 2. On 1994-1995 models, follow the rear turn signal wires to the two connectors located under the seat. Separate the socket halves of the rear turn signal connectors by pressing the external latch of each connector and rocking the socket half back and forth until free. Leave the pin halves of the connectors attached to the frame. Remove each connector's orange secondary locking wedge by inserting the blade of a small screwdriver in the locking wedge groove. Turn the screwdriver 90 degrees to pop the wedge up. Gently pull the wires from each connector while releasing the small locking tabs on inside of connector, using a small flat blade screwdriver.
NOTE
See Figure 3. 1996-1998 models have an 8-place multi-lock amp connector located under the seat. 1999-2003 models have a 2-place multi-lock amp connector located under the taillight lens.
NOTE
See the Service Manual for more detailed instructions on multi-lock amp electrical connector installation and removal.
NOTE
Perform the following procedures one side at a time until instructed to go to opposite side of vehicle.
3. See Figure 3. On 1999-2003 models, it is necessary to remove the taillight lens to access the multi-lock amp connector. On 1996-1998 models with multi-lock amp connectors. See the Service Manual. Remove the connector from the retaining device.
1Open secondary lock
2Insert pick into cavity on inboard side of connector
3Pivot end of pick to release tang
4Gently tug on wire to remove terminal from housing
5Secondary lock open
6Housing
7Terminal
8View of 1999-2003 connector with secondary lock open
Figure 3. Multi-lock Amp Electrical Connectors
4. See Figure 4. Remove buttonhead screws and locknuts that secure fender support cover to frame. Retain hardware for later reinstallation.
5. Remove the nut on inside of fender securing rear turn signal to fender. Retain nut.
6. On 1994-1999 models, remove the rear shock absorber upper acorn nut, washers and shock stud cover. On 2000- 2003 models, remove 1/2-13 hex head screw, washer and shock cover. This will allow you to pull the fender support cover out far enough to access the stud that holds the rear turn signal in place.
1Button head screws
2Shock stud cover
3Acorn nut
Figure 4. Rear Fender Support
7. With a deep well socket, remove rear turn signal stud from fender support cover, and remove rear turn signal. Discard stud.
8. Take note of how rear turn signal wire is routed (for later rerouting).
9. See Figure 5. Using a small piece of tape, tape washer (2) from kit onto frame over hole from which rear turn signal stud was removed.
NOTE
Use caution not to scratch chrome surface of turn signal when removing bulb assembly.
10. On 2001 and earlier models, remove lens from rear turn signal. Remove bulb from rear turn signal. Retain all parts. On 2002-2003 models, remove lens from rear turn signal. Remove bulb from rear turn signal. Gently pry bulb assembly from turn signal housing using a flat blade screwdriver. Retain all parts. Remove and discard hex capscrew from within turn signal housing.
11. See Figure 5. On 1994-1997 models, except Huggers, insert 4-1/2 inch bolt (11), from inside of fender, out through rearmost hole in fender frame. Leave loosely in place. See Figure 5. On 1998-2001 models, drill out threads in turn signal housing using a 13/32 inch drill bit. Use caution not to scratch chrome surface of turn signal housing. Place washer (2) and bushing (1) on 4-1/4 inch bolt (3) near threads. Install bolt through turn signal housing. Bushing should be level with inside boss in turn signal housing. On 2002-2003 and later models, refer to Step 13.
NOTE
Use caution not to scratch chrome surface of turn signal housing while drilling out threads.
NOTE
Narrow end of relocation pad should point to rear of motorcycle.
12. See Figure 5. On 2001 and earlier models, insert wire from rear turn signal lamp, through center hole in relocation pad, along channel on the inside of the pad and through third hole from rear in fender support cover. Route wire back along inside of fender support cover and retape into place on back of fender support cover.
13. Non-sissy bar models only.
  • See Figure 5. On 1994-1997 models, install rear turn signal with relocation pad and fender support cover onto fender using 4-1/2 inch bolt (11) inserted through rear of fender (Step 11). Tighten bolt until snug using locknut (10) installed onto bolt at inside of turn signal housing.
  • See Figure 5. On 1998-2001 models, place Loctite® #242 (blue) on threads of 4-1/4 inch bolt (3). Install turn signal with relocation pad (9) and fender support cover onto fender with 4-1/4 inch bolt inserted through turn signal housing in Step 11.
  • See Figure 5. On 2002-2003 models, insert exterior-threaded end of 4 inch mounting stud (13) into hole in narrow end of relocation pad (9). Loosely arrange turn signal housing and stalk on mounting stud running the lamp wire through center hole in relocation pad, along channel on the inside of the pad and through third hole from rear in fender support cover.
  • Place Loctite #242 (blue) on exterior threads of mounting stud. Insert mounting stud through fender support cover and into fender support. With a 5/16 inch box-end wrench on mounting stud flat section, tighten stud into fender support to 12 ft-lbs (16.3 Nm). Install hex capscrew (14) inside turn signal housing and tighten to 9 ft-lbs (12 Nm) into mounting stud (13). Firmly pull lamp wire through fender support. Coat the rubber bulb assembly isolator with a suitable lubricant. This will ease installation of the assembly into the turn signal housing. Press light bulb assembly evenly into turn signal housing until seated below lens cover groove.
  • Install original locknut and screw removed from forward most hole in fender support cover. Tighten finger tight.
Models with sissy bars.
  • Place fender support cover over fender support. Install sissy bar sideplate over cover and loosely secure using original hardware.
  • See Figure 5. On 1994-1997 models, install turn signal lamp onto relocation pad with 4-1/2 inch bolt (11) inserted through fender (Step 11). Tighten bolt until snug using locknut (10) installed onto bolt at inside of turn signal housing.
  • See Figure 5. On 1998-2001 models, install turn signal assembly onto relocation pad (9) using 4-1/4 inch bolt (3) inserted through turn signal housing in Step 11. Tighten bolt until snug.
  • See Figure 5. On 2002-2003 models, insert exterior-threaded end of 4 inch mounting stud (13) into hole in narrow end of relocation pad (9). Loosely arrange turn signal housing and stalk on mounting stud running the lamp wire through center hole in relocation pad, along channel on the inside of the pad and through third hole from rear in fender support cover.
  • Place Loctite® #242 (blue) on exterior threads of mounting stud. Insert mounting stud through fender support cover and into fender support. With a 5/16 inch box-end wrench on mounting stud flat section, tighten stud into fender support to 12 ft-lbs (16.3 Nm). Install hex capscrew (14) inside turn signal housing and tighten to 9 ft-lbs (12 Nm) into mounting stud (13). Firmly pull lamp wire through fender support. Press light bulb assembly evenly into turn signal housing until seated below lens cover groove.
14. See Figure 5. On 1994-1997 models, tighten 4-1/2 inch rear turn signal bolt (11) from inside of fender to 12 ft-lbs (16.3 Nm). See Figure 5. On 1998-2001 models, tighten 4-1/4 inch rear turn signal bolt (3) from inside of turn signal housing to 12 ft-lbs (16.3 Nm).
15. Tighten buttonhead screw in forward most hole in fender support cover to 12 ft-lbs (16.3 Nm).
16. Install bulb and rear turn signal lens.
17. Repeat Steps 4 through 15 for opposite side of motorcycle.
NOTE
See the Service Manual for more detailed instructions on installing and removing multi-lock amp electrical connectors.
18. On 1994-1995 models, route rear turn signal wires through frame. Reinsert wires into rubber connector seal. Making sure wire colors match wires in pin half of connector, push wires into connector until wires snap into place. Gently tug on wires to be sure connection is made. Install secondary lock into connector and mate connector halves. On 1996-1998 models: Route rear turn signal wires through frame. On 1999-2003 models: Route rear turn signal wires under fender to taillight. From the secondary lock side of the connector, insert the terminal into its respective numbered chamber until it snaps in place. For proper fit, the slot in the terminal must face the tang in the chamber. Gently tug on wire end to verify that the terminal is locked in place and will not back out of chamber. Rotate the hinged secondary lock inward until tabs fully engage latches on both sides of connector. Insert the socket housing into the pin housing until it snaps into place. Route wires as removed in Step 8.
WARNING
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
19. Reconnect battery (positive cable first), and test rear turn signals for proper operation. Install seat and sissy bar if applicable.
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)
Saddlebag Installation
NOTE
The flat washer (2) must be installed in the location shown in the Service Parts illustration (1 of 3). If the washer is not installed in the correct location, the relocation pad could crack when tightening the 3 inch bolt (7) if sideplates are used, or the saddlebag bracket could be misaligned if sideplates are not used.
1. Align saddlebag bracket front mount hole with hole on fender.
2. See Figure 5. Insert 3-1/2 inch bolt (5) through fender, fender support and saddlebag bracket front. Tighten finger tight with one locknut (4) and washer (6).
3. Insert bolt (7) through rear of saddlebag bracket, fender support and fender. Tighten finger tight with locknut (4) and spacer (8) positioned between fender support and fender.
4. Tighten all hardware to 17 ft-lbs (23 Nm).
5. Repeat Steps 1-4 for opposite side.
NOTE
Two reflectors have been included with this kit to be mounted on saddlebags.
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)
6. Remove adhesive backing from left reflector (15).
7. Center the left reflector (15) in the lower rear corner of the left saddlebag and press firmly to adhere to saddlebag face.
8. Repeat Step 7 to mount right reflector (16) on right saddlebag.
Figure 5. Service Parts (Kit 1 of 3)
Table 1. Service Parts (Kit 1 of 3)
Item
Description (Quantity)
Part Number
*1
Bushing (2)
61778-98
*2
Washer .32 x .69 x .125 (4)
6109
*3
Bolt, hex cap, 5/16-18 x 4.25 inch (2)
4140
*4
Locknut 5/16-18 (4)
7531
*5
Bolt, hex cap, 5/16-18 x 3.5 inch (2)
3427
*6
Washer .32 x .81 x .125 (2)
6116
*7
Bolt, hex cap, 5/16-18 x 3.0 inch (2)
4000
8
Spacer .39 x .88 x .22 (2)
5792
*9
Turn signal relocation pad
68472-94
*10
Locknut 5/16-24 1997 and earlier only (2)
7725
*11
Bolt, hex cap, 5/16-24 x 4.5 inch 1997 and earlier only
4251
*12
Turn Signal Mount Kit
68045-02 (Contains items 13 and 14)
*13
Stud, mounting 4 inch 2002-2003 only (2)
Not sold
*14
Screw, hex cap 2002-2003 only (2)
Not sold
15
Reflector, left (not shown)
59288-92
16
Reflector, right (not shown)
59287-92
17
Saddlebag, left, (not shown)
Not sold
18
Saddlebag, right, (not shown)
Not sold
19
Bracket attached to saddlebag
20
Fender support cover
*These items contained in Hardware/Turn Signal Relocation Kit. All other items included in 79052-04 or 79073-04.
Note: For installation on 1998-2001 models, items 1, 2 and 3 are used. For installation on 1997 and earlier models, Items 10 and 11 are used in place of items 1, 2 and 3. For installation on 2002-2003 models, items 13 and 14 are used in place of items 1, 2 and 3.
Installation Instructions for 90342-04 and 90598-04
NOTE
If this kit is being used along with an XL Docking Hardware Kit, Part No. 90465-98A, be sure to read the Instruction Sheet supplied with the docking hardware kit BEFORE beginning installation.
WARNING
Do not exceed saddlebag weight capacity. Put equal weight in each bag. Too much weight in saddlebags can cause loss of control, which could result in death or serious injury. (00383a)
NOTE
A pick tool (Snap-on TT600-3) will be required for 1996 and later models for removing and reinstalling a multi-lock amp connector.
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
Installation - Hugger Models Only (1994-1997)
WARNING
Be sure rear wheel is supported when removing rear shocks. If wheel is not supported rear fork can drop down, which could result in death or serious injury. (00481b)
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the 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 death or serious injury. (00333b)
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNING
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
1Shock absorber
2Upper nut, acorn
3Washer
4Shock cover
5Upper mounting bolt
6Bolt
7Washer
8Locknut
Figure 6. Shock Absorber Removal - Hugger Models Only
  1. Remove seat, sissy bar and sideplate, if applicable. Retain hardware for reinstallation. Disconnect battery, negative cable first.
  2. Properly support motorcycle under frame to prepare for removal of right and left shocks.
  3. Remove rear buttonhead screw on each side of fender.
  4. See Figure 6. With rear fender and frame securely supported, remove left and right shocks by removing upper nut (2), washer(s) (3) and shock cover (4). Remove bolt (6), washer (7) and locknut (8) at lower shock mount. Remove shock.
  5. See Figure 11. Install long 4-1/2 inch bolt (11) from kit, from inside of fender out through rear holes where buttonhead screws were removed in Step 3.
  6. See Figure 6. Install shocks using original hardware. Torque acorn nut (2) to 21-35 ft-lbs (28.5-47.5 Nm). Torque locknut (8) to 30-50 ft-lbs (40.7-67.8 Nm).
Rear Turn Signal Relocation
NOTE
Rear turn signals must be relocated before saddlebags can be installed.
1. Remove seat and disconnect battery cables, negative cable first. Remove sissy bar and sideplates, if installed. Retain all parts and hardware.
NOTE
See Figure 7. 1994-1995 models have a Deutsch connector located under the seat.
NOTE
Before performing next step, notice location of wire colors in connector so wires can be reinstalled in same positions later.
NOTE
See the Service Manual for more detailed instructions on multi-lock amp electrical connector installation and removal.
1Locking wedge
2Seal
3Socket housing
4External latch
5Seal
6Socket Terminal
Figure 7. Rear Turn Signal Electrical Connector
2. See Figure 7. On 1994-1995 models, follow the rear turn signal wires to the two connectors located under the seat. Separate the socket halves of the rear turn signal connectors by pressing the external latch of each connector and rocking the socket half back and forth until free. Leave the pin halves of the connectors attached to the frame. Remove each connector's orange secondary locking wedge by inserting the blade of a small screwdriver in the locking wedge groove. Turn the screwdriver 90 degrees to pop the wedge up. Gently pull the wires from each connector while releasing the small locking tabs on inside of connector, using a small flat blade screwdriver.
NOTE
See Figure 8. 1996-1998 models have an 8-place multi-lock amp connector located under the seat. 1999-2003 models have a 2-place multi-lock amp connector located under the taillight lens.
3. See Figure 8. On 1999-2003 models, it is necessary to remove the taillight lens to access the multi-lock amp connector. On 1996-1998 models with multi-lock amp connectors, see the service manual to remove the connector from the retaining device.
NOTE
Perform the following procedures one side at a time until instructed to go to opposite side of vehicle.
1Open secondary lock
2Insert pick into cavity on inboard side of connector
3Pivot end of pick to release tang
4Gently tug on wire to remove terminal from housing
5Secondary lock open
6Housing
7Terminal
8View of 1999-2003 connector with secondary lock open
Figure 8. Multi-lock Amp Electrical Connectors
4. See Figure 9. Remove buttonhead screws and locknuts that secure fender support cover to frame. (If you have a Hugger Model with a sissy bar, one of these screws and locknuts may already be removed.) Retain hardware for later reinstallation.
5. Remove the nut on inside of fender securing rear turn signal to fender. Retain nut.
1Button head screws
2Shock stud cover
3Acorn nut
Figure 9. Rear Fender Support
1Relocation pad
2Spacer
34-1/4" hex head bolt
4Bushing
5Washer
6Fender support cover
7Existing hardware
8Mounting location for 2-3/4" rear bracket bolt
Figure 10. Installation on 1998-2001 Models
  1. On 1994-1999 models, remove the rear shock absorber upper acorn nut, washers and shock stud cover. On 2000-2003 models, remove 1/2-13 hex head screw, washer and shock cover. This will allow you to pull the fender support cover out far enough to access the stud that holds the rear turn signal in place.
  2. With a deep well socket, remove rear turn signal stud from fender support cover, and remove rear turn signal. Discard stud.
  3. Take note of how rear turn signal wire is routed (for later rerouting).
  4. See Figure 11. Using a small piece of tape, tape large spacer (14) from kit onto frame over hole from which rear turn signal stud was removed.
    5. NOTE
    Use caution not to scratch chrome surface of turn signal when removing bulb assembly.
  5. On 2001 and earlier models, remove lens from rear turn signal. Remove bulb from rear turn signal. Retain all parts. On 2002 2003 models, remove lens from rear turn signal. Remove bulb from rear turn signal. Gently pry bulb assembly from turn signal housing using a flat blade screwdriver. Retain all parts. Remove and discard hex capscrew from within turn signal housing.
    6. NOTE
    Use caution not to scratch chrome surface of turn signal housing while drilling out threads.
  6. See Figure 11. On 1994-1997 models, except Huggers, insert 4-1/2 inch bolt (15), from inside of fender, out through rearmost hole in fender frame. Leave loosely in place. See Figure 10. On 1998-2001 models, drill out threads in turn signal housing using a 13/32 inch drill bit. Use caution not to scratch chrome surface of turn signal housing. Place washer (5) and bushing (4) on 4-1/4 inch bolt (3) near threads. Install bolt through turn signal housing. Bushing should be level with inside boss in turn signal housing. On 2002-2003 models, refer to Step 13.
    7. NOTE
    Narrow end of relocation pad should point to rear of motorcycle.
  7. See Figure 11. On 2001 and earlier models, insert wire from rear turn signal lamp, through center hole in relocation pad, along channel on the inside of the pad and through third hole from rear in fender support cover. Route wire back along inside of fender support cover and retape into place on back of fender support cover.
  8. Non-sissy bar models only.
  • See Figure 11. On 1994-1997 models, Install rear turn signal with relocation pad and fender support cover onto fender using 4-1/2 inch bolt inserted through rear of fender (Step 11). Tighten bolt until snug using locknut (16) installed onto bolt inside of turn signal housing.
  • See Figure 10. On 1998-2001 models, place Loctite #242 (blue) on threads of 4-1/4 inch bolt (3). Install turn signal with relocation pad (1) and fender support cover onto fender with 4-1/4 inch bolt inserted through turn signal housing in Step 11.
  • See Figure 11. On 2002-2003 models, insert exterior-threaded end of 4 inch mounting stud (19) into hole in narrow end of relocation pad (13). Loosely arrange turn signal housing and stalk on mounting stud running the lamp wire through center hole in relocation pad, along channel on the inside of the pad and through third hole from rear in fender support cover.
  • Place Loctite® #242 (blue) on exterior threads of mounting stud. Insert mounting stud through fender support cover and into fender support. With a 5/16 inch box-end wrench on mounting stud flat section, tighten stud into fender support to 12 ft-lbs (16.3 Nm). Install hex capscrew (20) inside turn signal housing and tighten to 9 ft-lbs (12 Nm) into mounting stud (19). Firmly pull lamp wire through fender support. Coat the rubber bulb assembly isolator with a suitable lubricant. This will ease installation of the assembly into the turn signal housing. Press light bulb assembly evenly into turn signal housing until seated below lens cover groove.
  • Install original locknut and screw removed from forwardmost hole in fender support cover. Tighten finger tight.
Models with sissy bars.
  • Place fender support cover over fender support. Install sissy bar sideplate over cover and loosely secure using original hardware.
  • See Figure 11. On 1994-1997 models, install turn signal lamp onto relocation pad with 4-1/2 inch bolt inserted through fender (Step 11). Tighten bolt until just snug using locknut (16) installed onto bolt inside of turn signal assembly.
  • See Figure 10. On 1998-2001 models, install turn signal assembly onto pad (1) using 4-1/4 inch bolt (3) inserted through turn signal housing in Step 11. Tighten bolt until snug.
  • See Figure 11. On 2002-2003 models, insert exterior-threaded end of 4 inch mounting stud (19) into hole in narrow end of relocation pad (13). Loosely arrange turn signal housing and stalk on mounting stud running the lamp wire through center hole in relocation pad, along channel on the inside of the pad and through third hole from rear in fender support cover.
  • Place Loctite® #242 (blue) on exterior threads of mounting stud. Insert mounting stud through fender support cover and into fender support. With a 5/16 inch box-end wrench on mounting stud flat section, tighten stud into fender support to 12 ft-lbs (16.3 Nm). Install hex capscrew (20) inside turn signal housing and tighten to 9 ft-lbs (12 Nm) into mounting stud (19). Firmly pull lamp wire through fender support. Coat the rubber bulb assembly isolator with a suitable lubricant. This will ease installation of the assembly into the turn signal housing. Press light bulb assembly evenly into turn signal housing until seated below lens cover groove.
  1. See Figure 11. On 1994-1997 models, tighten 4-1/2 inch rear turn signal bolt from inside of fender to 12 ft-lbs (16.3 Nm). See Figure 10. On 1998-2001 models, tighten 4-1/4 inch rear turn signal bolt (3) from inside of turn signal housing to 12 ft-lbs (16.3 Nm).
  2. Tighten buttonhead screw in forwardmost hole in fender support cover to 12 ft-lbs (16.3 Nm).
  3. Install bulb and rear turn signal lens.
  4. Repeat Steps 4-16 for opposite side of motorcycle.
  5. On 1994-1995 models, route rear turn signal wires through frame. Reinsert wires into rubber connector seal. Making sure wire colors match wires in pin half of connector, push wires into connector until wires snap into place. Gently tug on wires to be sure connection is made. Install secondary lock into connector and mate connector halves.
NOTE
See Service Manual for more detailed instructions on installing and removing multi-lock amp electrical connectors.
On 1996-1998 models, route turn signal wires through frame.
On 1999 - 2003 models, route turn signal wires under fender to taillight.
From the secondary lock side of the connector, insert the terminal into its respective numbered chamber until it snaps in place. For proper fit, the slot in the terminal must face the tang in the chamber.
Gently tug on wire end to verify that the terminal is locked in place and will not back out of chamber. Rotate the hinged secondary lock inward until tabs fully engage latches on both sides of connector. Insert the socket housing into the pin housing until it snaps into place. Route wires as removed in Step 8.
WARNING
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
  1. Reconnect battery (positive cable first), and test rear turn signals for proper operation. Install seat and sissy bar if applicable.
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)
Saddlebag Installation
NOTE
The flat washer (17) must be installed in the location shown in the Service Parts illustration (2 of 3). If the washer is not installed in the correct location, the relocation pad could crack when tightening the 2-3/4 inch bolt (10) as shown in Service Parts illustration (3 of 3), if sideplates are used; or the saddlebag bracket could be misaligned, if sideplates are not used.
1. See Figure 12. Place the saddlebag bracket in position with the brackets front attachment hole over the rear shock absorber upper stud (1999 and earlier) or bolt location (2000 - 2003). Secure the brackets rear attachment hole with the 2-3/4 inch bolt (10) and the existing locknut removed in Step 4 of the rear turn signal relocation. Use washer (17) to fill the space between fender support cover and relocation pad if sideplates are installed. If there are no sideplates, place washer on the outside of the relocation pad.
2. On 1994-1999 models, secure the brackets front attachment hole with the barrel nut (11). On 2000 - 2003 models, secure the brackets front attachment hole with 1/2-13 x 3.00 hex head screws (27). Tighten the barrel nut (or screw) to 21-35 ft-lbs (28.5-47.5 Nm). Tighten the rear bracket bolt (10) to 12 ft-lbs (16.3 Nm).
3. See Figure 12. Assemble an isolator washer (7) onto an isolator bushing (6). Place a screw (8) through the bushing.
4. Place the screw and bushing assembly into the top hole inside the saddlebag back.
5. See Figure 12. Push a saddlebag isolator (5) over bushing with cone shape toward saddlebag.
6. Place saddlebag in position on bracket and install the screw into the bracket. Do not tighten screw at this time.
7. Repeat steps above for remaining holes, and after all isolators are in place, tighten screws to 8-10 ft-lbs (10.8-13.6 Nm).
NOTE
Two reflectors have been included with this kit to be mounted on saddlebags.
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)
8. See Figure 12. Center the reflector (21) in the lower rear corner of the saddlebag and mark hole location.
9. See Figure 12. Punch hole in saddlebag and mount reflector in location shown. Use pan head screw (22), washer (23) and locknut (24).
10. Repeat Steps 8 and 9 to mount reflector on other saddlebag.
Figure 11. Service Parts (Kit 2 of 3)
Table 2. Service Parts (Kit 2 of 3)
Item
Description (Quantity)
Part Number
1
Saddlebag, right, for Kit 90598-04
Saddlebag, right, for Kit 90342-04
90605-96A
90304-98A
2
Saddlebag, left, for Kit 90598-04
Saddlebag, left, for Kit 90342-04
90600-96A
90303-98A
3
Saddlebag support, right
90625-96
4
Saddlebag support, left
90608-96
5
Isolator (8)
90677-94
6
Isolator bushing (8)
90676-94
7
Isolator washer (8)
90678-94
8
Screw, buttonhead (8)
90578-94
9
Bumper (4) attached to saddlebag
62123-66
*10
Bolt, hex head, 2-3/4 inch (2)
858A
*11
Nut, barrel 1994-1999 models only (2)
7670
12
Leather care kit (1) (not shown)
98836-92
*13
Relocation pad (2)
68472-94
14
Spacer, .39 inch x .88 inch. x .2 inch (2)
5792
*15
Bolt, hex head, 5/16-24 x 4.5 inch 1994-1997 models only (2)
4251
*16
Locknut, 5/16-24 1994-1997 models only (2)
7725
*17
Washer, .3 inch x .69 inch x .125 inch (4)
6109
*18
Turn Signal Mount Kit (contains items 19 and 20)
68045-02
*19
Stud, mounting 4 inch (2)
Not sold
*20
Screw, hex cap (2)
Not sold
21
Reflector, red (2)
59264-86
22
Screw, pan head, Pozidriv, #10-32 x 5/8(2)
2587
23
Washer #10 x 1/2 x 3/64 (2)
6716
24
Locknut #10-32 (2)
7626W
*25
Bushing (2)
61778-98
*26
Bolt, hex, 5/16-18 x 4-1/4 inch 1998-2003 models only (2)
4140
*27
Screw, hex head, 1/2-13 x 3.00 2000-2003 models only (2)
3871
28
Existing hardware
29
Fender support cover
30
Mounting location for 2-3/4 inch rear bracket bolt item 10
*These items contained in Hardware/Turn Signal Relocation Kit. All other items included in 90342-04 or 90598-04.
Figure 12. Service Parts (Kit 3 of 3)
Table 3. Service Parts (Kit 3 of 3)
Item
Description (Quantity)
Part Number
1
Saddlebag, right, for Kit 90598-04
Saddlebag, right, for Kit 90342-04
90605-96A
90304-98A
2
Saddlebag, left, for Kit 90598-04
Saddlebag, left, for Kit 90342-04
90600-96A
90303-98A
3
Saddlebag support, right
90625-96
4
Saddlebag support, left
90608-96
5
Isolator (8)
90677-94
6
Isolator bushing (8)
90676-94
7
Isolator washer (8)
90678-94
8
Screw, buttonhead (8)
90578-94
9
Bumper (4) attached to saddlebag
62123-66
*10
Bolt, hex head, 2-3/4 inch (2)
858A
*11
Nut, barrel 1994-1999 models only (2)
7670
12
Leather care kit (1) (not shown)
98836-92
*13
Relocation pad (2)
68472-94
14
Spacer, .39 inch x .88 inch. x .2 inch (2)
5792
*15
Bolt, hex head, 5/16-24 x 4.5 inch 1994-1997 models only (2)
4251
*16
Locknut, 5/16-24 1994-1997 models only (2)
7725
*17
Washer, .3 inch x .69 inch x .125 inch (4)
6109
*18
Turn Signal Mount Kit (contains items 19 and 20)
68045-02
*19
Stud, mounting 4 inch (2)
Not sold
*20
Screw, hex cap (2)
Not sold
21
Reflector, red (2)
59264-86
22
Screw, pan head, Pozidriv, #10-32 x 5/8 (2)
2587
23
Washer #10 x 1/2 x 3/64 (2)
6716
24
Locknut #10-32 (2)
7626W
*25
Bushing (2)
61778-98
*26
Bolt, hex, 5/16-18 x 4-1/4 inch 1998-2003 models only (2)
4140
*27
Screw, hex head, 1/2-13 x 3.00 2000-2003 models only (2)
3871
28
Existing hardware
29
Fender support cover
30
Mounting location for 2-3/4 inch rear bracket bolt item 10
*These items contained in Hardware/ Turn Signal Relocation Kit. All other items included in 90342-04 or 90598-04.