SOFTAIL DEUCE SADDLEBAG KIT
J017702007-05-09
GENERAL
Kit Number
90394-00
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English).
Additional Parts Required
WARNINGRider 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)
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.
Kit Contents
See Service Parts section for kit contents.
WARNINGDo 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
Maximum weight capacity is 10 lbs (4.5 Kg) in each saddlebag.
PREPARE FOR SERVICE
| 1. | Remove seat according to the instructions in the Service Manual. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) WARNINGDisconnect 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) | ||
| 2. | Disconnect battery cables, negative (-) cable first. |
Installation
Install Turn Signal Relocation Kit
| 1. | See Figure 1. Insert phillips head screwdriver into middle hole of license plate light assembly. Push screwdriver in to disengage clip while gently pulling lamp out. | |||||||||
| 2. | See Figure 2. Disconnect tail/stop light wiring (4-place multilock) at stop/tail lamp connector. | 
Figure 1. Remove Tail/Stop Light Assembly 
Figure 2. Disconnect Turn Signal Wires | ||||||||
| 3. | See Figure 1. Disconnect left (white, 2-place multilock) and right (black, 2-place multilock) turn signals by depressing button on socket terminal side of connector and pulling apart pin and socket halves. | |||||||||
| 4. | See Figure 3. Remove two fender support front socket head screws (1). Save hardware for re-installation. | |||||||||
| 5. | See Figure 3. Remove fender support cap screw (2) (under fender) near end of fender support. While supporting the fender support, remove the cap screw at approximate midpoint of the support. | |||||||||
| 6. | See Figure 3. Carefully remove fender support and signal lamp assembly with wiring through holes in fender. Save cap screws and washers for installation. | |||||||||
| 7. | Perform Steps 3 through 5 for the opposite side fender support and signal lamp assembly. |
| 1 | Fender support socket head screws |
| 2 | Fender support cap screws |
| 3 | Oblong hole for signal wiring and connector |
Figure 3. Rear Fender Support and License Plate Bracket Assembly
NOTE
At this point, the turn signal (2-place Multilock) connector must be removed from the turn signal wire in order to remove the signal and signal mount from the fender support. The connector is re-installed after routing wire through relocation mount and installing signal/relocation mount to fender support. Snap-On Pick Tool part number TT600-3 is recommended for this procedure however, the sharp end of a safety pin will work after some practice.
| 8. | To remove wire (with socket terminal) from left connector, refer to Appendix B of the Service Manual. | 
Figure 4. Turn Signal and Signal Mount | ||||||||
| 9. | See Figure 4. Remove turn signal and signal mount from fender support by removing cap screw shown. Gently pull wiring through fender support and mount. Discard mount and cap screw. | 
Figure 5. Route Signal Wiring | ||||||||
| 10. | Repeat Steps 7 and 8 for the opposite side. | |||||||||
| 11. | See Figure 5. Route wiring from left turn signal through mount as shown. | |||||||||
| 12. | See Figure 6. Install turn signal to relocation mount with socket head cap screw from kit. Tighten screw securely. NOTE In the next step, the function of the holes in the fender support are reversed from original installation. The signal wiring is routed through the hole originally used by the cap screw for mounting the signal; the hole originally used for wiring will be used for installing signal relocation cap screw. | 
Figure 6. Install Turn Signal to Relocation Mount 
Figure 7. Route Wiring and Install Signal Relocation Mount | ||||||||
| 13. | See Figure 7. Route wires through left fender support as shown. Install signal relocation mount to fender support with long cap screw and washer provided in the kit. Tighten cap screw securely. | |||||||||
| 14. | Repeat Steps 10 through 12 for the right side. NOTE At this time, the signal wiring is re-installed to the connectors removed in Step 7. NOTE For wire location purposes, when facing the secondary lock side and with button up, the black wire inserts into the left side of the connector; purple wire into the right side of the connector. The left turn signal utilizes the white 2-place connector; the right turn signal uses the black 2-place connector. | 
Figure 8. Install Wire to Connector | ||||||||
| 15. | Install wire (with socket terminal) to connector by performing the following: a. See Figure 8. From the secondary lock side of the connector, insert the terminal into its respective chamber until it snaps in place. For proper fit, the slot on the terminal must face the tang (up) in the chamber. b. Gently tug on wire end to verify that the terminal is locked in place and will not back out of chamber. c. Rotate the hinged secondary lock inward until tabs fully engage latches on both sides of connector. d. Perform Steps a through d for the opposite connector. | |||||||||
| 16. | See Figure 3. While holding left side fender support/signal assembly, route wiring with connector through oblong hole in fender and back to original location near tail/stop lamp assembly. | |||||||||
| 17. | See Figure 3. Reinstall socket head cap screws removed in Step 3 at front of fender support. Tighten finger-tight. | |||||||||
| 18. | Reinstall original cap screws and washers through fender at midpoint and near end of fender support. Make sure fender support does not bind or pinch turn signal wiring. Tighten cap screws to 16.3–20.3 N·m (12–15 ft-lbs). | |||||||||
| 19. | Return to socket head cap screws at front and tighten to 19–21.7 N·m (14–16 ft-lbs). | |||||||||
| 20. | Insert turn signal connector (white, 2-place) into left turn harness connector (white, 2-place) until it snaps. | |||||||||
| 21. | Perform Steps 15 through 19 for the right fender support assembly, however in Step 19, the right turn signal connectors are black. | |||||||||
| 22. | Connect tail/stop lamp connector (white, 4-place) to harness connector (black, 4-place). | |||||||||
| 23. | Align lamp with cutout in fender as shown. Insert upper spring into place and with index finger, push upward slightly on lower spring while firmly pressing assembly toward fender. Assembly is secure when upper and lower springs "click". |
Install Saddlebag Support Kit
| 1 | Rounded section |
| 2 | Mounting bracket cutouts for saddle support bolts |
| 3 | Bracket rails |
| 4 | Front of motorcycle |
Figure 9. Bracket Installed under Fender (Left Side Shown)
NOTE
Figure 9 and 11 are provided for illustration purposes only. It is not necessary to remove fender for the following procedures.
| 1 | Saddlebag support - left side |
| 2 | Slide support up under the fender |
Figure 10. Saddlebag Support Mounting
| 1. | Obtain the left support and loosely install the two (carriage-style) mounting bolts and two nuts with bolt heads facing outer (saddlebag) side of support assembly. Tighten finger-tight. NOTE If possible, lift the motorcycle so the rear wheel drops to the bottom of shock travel. This will help provide clearance between the rear tire and fender and provide room for tools and hands when accessing the mounting bracket. | 
Figure 11. Slide Saddlebag Support Forward (View from Inside Fender) | ||||||||||
| 2. | See Figure 9. Visually locate rounded sections of mounting bracket cutouts (2) (on bracket mounted under fender) which will capture the rounded head of the support bolts when attaching saddlebag supports. | |||||||||||
| 3. | See Figure 10. Slide upper section of left support up under fender as shown. While aligning rails on support with rails on mounting bracket, engage rounded head of mounting bolts with rounded portion of bracket cutouts (See Figure 9 and Figure 11 ). You may have to move the support back and forth while pulling toward fender in order to feel rail alignment and bolt heads engage the bracket. It may also be necessary to push on the nuts to help engage the bolt heads into the bracket cutouts. | |||||||||||
| 4. | See Figure 11. When rails are aligned and both bolts are fully engaged within cutouts, slide the saddlebag support as far forward as possible to lock each of the support bolts into position. | |||||||||||
| 5. | Snug each of the nuts to hold the support in position but do not tighten fully at this time. NOTE The nuts will be tightened after the rear support is installed and all supports are aligned. | |||||||||||
| 6. | Perform Steps 1 through 5 for the right saddlebag support. | 
Figure 12. Install Rear Saddlebag Support and Adjust Supports | ||||||||||
| 7. | See Figure 12. Obtain the rear support and align mounting hole in support with hole in left saddlebag support. Install bolt, washer and nut. Tighten finger-tight. | |||||||||||
| 8. | Align mounting hole in right saddlebag support with hole in rear support and install bolt, washer and nut. Tighten finger-tight. | 
Figure 13. Install Saddlebag Locating Bumpers | ||||||||||
| 9. | Adjust left and right saddlebag supports to run parallel to side of bike. Adjust rear support so that it runs parallel with rear fender and license plate. See Figure 12. Tighten all support fasteners securely. | 
Figure 14. Install Grommets | ||||||||||
| 10. | See Figure 13. Obtain saddlebag locating bumpers and install to lower rail of left and right saddlebag supports as shown. | |||||||||||
| 11. | See Figure 14. Obtain left saddlebag and two rubber grommets from kit. Install grommets with larger side toward the outside and the ribbed side facing inside of the saddlebag. Repeat this step for the opposite saddlebag. | 
Figure 15. Install Saddlebag to Support | ||||||||||
| 12. | See Figure 13 and Figure 15. Align bottom of left saddlebag with locating bumper and install to support using washer and pin latch. Rotate pin latch 1/4 turn clockwise until bag locks into position. Repeat for the front pin latch making sure bag locks securely. | |||||||||||
| 13. | Repeat Step 12 for the opposite saddlebag. | |||||||||||
| 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) | ||||||||||||
| 14. | See Figure 16. Locate area approximately 7 inches from front and near lid lip of lower section of saddlebag. | 
Figure 16. Install Reflectors | ||||||||||
| 15. | Using isopropyl alcohol, thoroughly clean the area in which reflector is to be installed. Let dry completely. Remove adhesive backing and install reflector. Repeat for opposite saddlebag. Let adhesive cure for 24 hours. | |||||||||||
| 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) | ||||||||||||
| 16. | Connect battery cables, positive cable first. | |||||||||||
| 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) | ||||||||||||
| 17. | Install seat. |
SERVICE PARTS
Figure 17. Service Parts: Softail Deuce Saddlebag Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Receptacle stud (4) | 70909-95 |
2 | Label, saddlebag support (2) (not shown) | 90249-00 |
3 | Saddlebag support (left side) | 90253-00 |
4 | Saddlebag support (right side) | 90252-00 |
5 | Saddlebag support (rear) | 90254-00 |
Items 6-10 are part of the Directional Relocation Kit | 90395-00 | |
6 | Directional signal mount (left side) | Not Sold Separately |
7 | Directional signal mount (right side) | Not Sold Separately |
8 | Screw, socket head cap (2) | 3531A |
9 | Screw, hex cap (2) | 3929 |
10 | Washer (4) | 6702 |
11 | Stud, ball head (4) | 90834-95 |
12 | Washer (4) | 6229W |
13 | Grommet (4) | 11545 |
14 | Screw, hex cap (33/8-16 x 0.875) (2) | 2851 |
15 | Locknut, flange (3/8-16) (6) | 7601 |
16 | Bolt, carriage (3/8-16 x 0.75) (4) | 5418 |
17 | Reflector, red (2) | 59173-00 |
Figure 18. Service Parts: FXST Softail Saddlebag Kit, Saddlebag Assembly
Table 2. Service Parts Table
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Retaining ring | 11015 | 14 | Loop latch | 90231-00 | |
2 | Screw, M6-6H (2) | 1394 | 15 | Bracket, latch | 90232-00 | |
3 | Screw, 10-24 x 3/8 inch (6) | 3018 | 16 | Lockset, saddlebag | 90235-00 | |
4 | Machine screw, panhead (2) | 3595 | 17 | Cover latch assembly | 90237-00 | |
5 | Screw, hi-lo (8) | 3596 | 18 | Label, saddlebag (not shown) | Not sold separately | |
6 | Tether | 53633-00 | 19 | Lid, saddlebag (left) | 90261-00 | |
7 | Washer, spring curved (2) | 6970 | 20 | Lid, saddlebag (right) | 90260-00 | |
8 | Nut, flanged (2) | 7878 | 21 | Body, saddlebag (left) | 90264-00 | |
9 | Assembly, latch | 90166-00 | 22 | Body, saddlebag (right) | 90262-00 | |
10 | Catch, hinge | 90172-00 | 23 | Bracket, upper tether | 90417-00 | |
11 | Pin | 90173-00 | 24 | Bracket, lower tether | 90418-00 | |
12 | Hinge, hook bracket | 90176-00 | 25 | Key set (specify code) | 90235-00A | |
13 | Gasket | 90230-00 | 26 | Gasket, lock (2) | 90290-02 | |
27 | Screw, lockset | 1395 |