SPORTSTER SADDLEBAG KIT
J027912007-05-01
GENERAL
Kit Number
91412-04XX
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Proper installation of this kit requires the separate purchase of Saddlebag Hardware Kit which is available from a Harley-Davidson dealer.
- For 1994 to 2003 Models: Hardware kit 91385-00
- For 2004 and later Models: Hardware kit 91405-04
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
This saddlebag kit includes the following kits and assemblies:
Table 1. Kit Contents
Kit/Assembly | Figure/Table |
|---|---|
Saddlebag Bracket Kit (91383-00) | Figure 16, Table 2 |
Saddlebag Bracket Hardware Kit (91457-00B) | Figure 17, Table 3 |
Saddlebag Assembly, R.H. (90035-00) | Figure 18, Table 4 |
Saddlebag Assembly, L.H. (90036-XX) | Figure 18, Table 4 |
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)
Maximum weight capacity is 7 lbs (3.18 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. |
REMOVAL
Remove Turn Signals
| 1. | Locate and separate tail lamp connector (4-place multilock) under seat. Then remove wires from connector. Refer to AMP MULTILOCK ELECTRICAL CONNECTORS in Service Manual. | |||||||||||||||||
| 2. | 1994-1998 Models: Pull turn signal wires through clips (if present) and rear fender. 1999 and Later Models: a. See Figure 1. Remove two screws and tail lamp lens (1) from base (2). b. See Figure 2. Using a Terminal Pick Tool (HD-41475-100) (1), depress locking tabs and remove turn signal connectors (2-place) (2, 3). Save connectors for kit installation. Refer to AMP MULTILOCK ELECTRICAL CONNECTORS in Service Manual. c. Remove wires from turn signal connectors. Note location of terminal for proper reassembly. d. Remove turn signal wiring from clips under rear of fender and pull wires out. | |||||||||||||||||
| 3. | See Figure 3. Remove screw (1) from inside the rear fender. Then remove turn signal (2) from mount (3). | 
Figure 1. Remove Tail Lamp Lens 
Figure 2. Remove Turn Signal Connectors 
Figure 3. Rear Turn Signal and Hardware | ||||||||||||||||
| 4. | Carefully pull turn signal wiring out through turn signal mount. Discard mount. | |||||||||||||||||
| 5. | Repeat steps for opposite turn signal. |
ASSEMBLY
NOTE
Proper installation of this kit requires that the tasks be completed for one side of the motorcycle first before continuing to the opposite side.
Assemble Relocation Bracket and Turn Signals
| 1. | For 3-Inch Signal Lamp (1994-2001 Models):For 2-3/8 Inch Signal Lamp (2002-Later Models): a. See Figure 4. Remove conduit from turn signal housing and cut wiring 12 inches (305 mm) from entrance to lamp housing. Cut a 1 inch (25 mm) section off conduit and slide it over wiring. b. Moisten wires with wet shop towel and insert through relocation bar ( Figure 16 , Item 3, 4) until wires exit from opposite end of tube. Slide conduit down to protect wiring at entrance of relocation bracket. c. See Figure 17. Apply LOCTITE® 243 Threadlocker and Sealant - Blue to threads of screw (1). d. See Figure 5. Install turn signal to relocation bracket (1) using screw (2) and lockwasher (3). Tighten securely. e. Install rubber plug (4) to cover opening of tube on relocation bar. f. See Figure 4. Moisten wires with wet shop towel and insert wires through relocation bracket ( Figure 16 , Item 3 and 4) until wires exit from opposite end of tube. g. See Figure 17. Apply Loctite 243 (blue) to threads of screw (1). h. See Figure 6. Install turn signal to relocation bracket (1) using screw (2), lockwasher (3), and spacer (4). Spacer should be installed between turn signal and relocation bracket. Tighten securely. i. Install rubber plug (5) to cover opening of tube on relocation bar. | 
Figure 4. Install Wiring into Relocation Bracket 
Figure 5. Install 3 Inch Turn Signals 
Figure 6. Install 2-3/8 Inch Turn Signals |
| 2. | See Figure 17. Pull two wires out of conduit from wiring harness (15). Terminals are attached to both ends of the wires to support all models. NOTE Before removing terminals that are not needed, temporarily attach the correct terminals to the turn signal connector (under seat for 1994-1998 models; at tail lamp for 1999 and later models). | |||||
| 3. | Identify the yellow tape on the wires and remove terminals as follows: a. 1994-1996 Models: Remove terminals farthest away from the yellow tape. b. 1997 and Later Models: Remove terminals closest to the yellow tape. | |||||
| 4. | See Figure 7. Stagger cut wire lengths to approximately 21 inches (533 mm). | |||||
| 5. | Cut black conduit to 25 inches (635 mm). NOTE Cutting one of the wires slightly shorter before installing connectors staggers the location of the butt splices and makes sliding conduit over wiring much easier. | |||||
| 6. | See Figure 17. Match wire colors and splice wiring from turn signal to harness using connector (16). Refer to SEALED BUTT SPLICE CONNECTORS in Service Manual. | |||||
| 7. | Slide conduit from harness over butt splices and approximately 2 inches (51 mm) into relocation bracket tube. | |||||
| 8. | See Figure 8. Remove adhesive and install retaining clip ( Figure 17 , Item 11) under fender cover at locations shown. a. 1994-1998 Models: Use 3 clips. b. 1999 and Later Models: Use one clip and install on fender cover near wire entrance hole. | 
Figure 7. Install Wiring Harness  Figure 8. Retaining Clip Locations |
Assemble Support Hanger and Relocation Bracket on Saddlebag
| 1. | See Figure 9. Install large grommets (1) in upper holes in saddlebag and small grommets (2) in remaining holes. | 
Figure 9. Install Grommets and Spacers (Left Saddlebag Shown) | ||||||||||||||||||||||||
| 2. | Install large spacer (3) into upper grommet and small spacers (4) into small grommets. NOTE Models equipped with detachable docking points requires an additional hardware kit as follows:
| |||||||||||||||||||||||||
| 3. | See Figure 10. Insert one screw (1) and two washers (2) from inside saddlebag. | |||||||||||||||||||||||||
| 4. | Put support hanger (3) on saddlebag and push screw and washers through channel. | |||||||||||||||||||||||||
| 5. | Fasten bottom of support hanger to saddlebag with screw (4), washer (2), and flange nut (5). NOTE The hex spacer that holds the top of the support hanger to the saddlebag is removed when the saddlebag assembly is installed on the motorcycle. | |||||||||||||||||||||||||
| 6. | Insert screw (6) and washer (7) from inside saddlebag. Hold in place with hex spacer (8). | 
Figure 10. Assemble Support Hanger on Saddlebag 
Figure 11. Assemble Relocation Bracket on Support Hanger and Saddlebag | ||||||||||||||||||||||||
| 7. | See Figure 11. Assemble turn signal and relocation bracket (1) on support hanger and saddlebag using two screws (2), washers (3), and flange nuts (4). |
INSTALLATION
NOTE
Proper installation of this kit requires that the tasks be completed for one side of the motorcycle first before continuing to the opposite side.
| 1. | Raise rear wheel off the ground and support the vehicle securely. | |||||||||||
| 2. | See Figure 12. Remove left and right lower shock screws (1) so there is adequate clearance to install the saddlebag mounting hardware. | |||||||||||
| 3. | Remove remaining screws (2) from inside the fender that secure fender cover (3) to rear fender. a. For 1994-1999 Models: Remove nut holding upper shock mount. b. For 2000 and Later Models: Remove screw and stud cover from top of of shock. Remove and save fender cover. | 
Figure 12. Shock and Fender Cover Hardware | ||||||||||
| 4. | Install spacer on inside of fender cover in the second hole from rear. Then attach fender cover to rear fender. | |||||||||||
| 5. | Install shock mount screw as follows: For 1994 to 1999 Models:For 2000 and Later Models: a. Apply Loctite 243 (blue) to threads of shock mount screw. b. Remove hex spacer temporarily attached to saddlebag and thread it onto the stud. c. Tighten stud to 28–47 N·m (21–35 ft-lbs). e. Apply Loctite 243 (blue) to threads of stud. f. Remove hex spacer temporarily attached to saddlebag and thread it onto stud. g. Tighten stud to 28–47 N·m (21–35 ft-lbs). | 
Figure 13. Shock Mount Cover and Stud | ||||||||||
| 6. | See Figure 17. Remove screw (4) temporarily attached to saddlebag. | |||||||||||
| 7. | See Figure 12. Insert screw from inside fender through the second hole from rear (5) in fender cover. | |||||||||||
| 8. | Apply Loctite 243 (blue) to threads of screw inserted through front mounting location. | |||||||||||
| 9. | See Figure 14. Place saddlebag assembly on motorcycle and attach to fender cover with two screws. | |||||||||||
| 10. | Tighten screws to 36.6–39.3 N·m (27–29 ft-lbs) to secure saddlebag to motorcycle. | |||||||||||
| 11. | See Figure 17. Hold nut (24) inside saddlebag to attach screw. | |||||||||||
| 12. | Snap vinyl cap (23) onto exposed threads. |  Figure 14. Saddlebag Mounting Hardware |
ROUTE TURN SIGNAL WIRING
For 1994 to 1998 Models:
- Route wiring harness from turn signal along bottom of fender cover and insert into retaining clips. Adjust harness if necessary, then bend clip tabs to secure wiring in place.
- Continue routing under front of fender cover and through middle boxed area of the frame to connectors.
- Match wire color to numbered connector cavity. Install pin terminals to cavities in turn signal connector. Refer to AMP MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
For 1999 and Later Models:
| 1. | Route wiring harness along fender cover and through hole in cover. Then route through retaining clips on inside of fender to tail light. | |
| 2. | Continue routing through hole in fender into tail light. | |
| 3. | Match wire color to numbered connector cavity. Install pin terminals to cavities in turn signal connectors. Refer to AMP MULTILOCK ELECTRICAL CONNECTORS in Service Manual. | |
| 4. | See Figure 1. Attach tail lamp lens (1) to base (2) with two screws. | |
| 5. | Tighten screws to 2.3–2.7 N·m (20–24 in-lbs). |
RETURN TO SERVICE
Install Reflectors and Medallions
NOTE
Red reflectors are included in this kit and must be installed to meet domestic and international requirements.
WARNINGFederal 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)
| 1. | Using a 50/50 isopropyl alcohol solution, thoroughly clean the surface where the reflector will be installed. | |||||
| 2. | Allow the surface to dry completely before continuing. | |||||
| 3. | See Figure 15. Remove adhesive backing and install Harley-Davidson medallion (1) in recessed area of saddlebag lid. | |||||
| 4. | Remove adhesive backing and install red reflector (2) in recessed area of saddlebag bottom. | 
Figure 15. Install Medallion and Reflector | ||||
| 5. | Let adhesive cure for 24 hours at no less than 60° F (16° C). | |||||
| 6. | Repeat steps for opposite saddlebag. |
Final Assembly
WARNINGConnect 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. | Connect battery cables, negative (-) cable first. | |
| 2. | Install seat according to the instructions in the Service Manual. | |
| 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) WARNINGBe sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) | ||
| 3. | Check turn signals for proper operation. | |
| 4. | Check tail light for proper operation. |
SERVICE PARTS
Figure 16. Service Parts: Saddlebag Bracket Kit (91383-00)
Table 2. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Hanger, saddlebag support R.H. | 91376-00 |
2 | Hanger, saddlebag support L.H. | 91377-00 |
3 | Relocation bracket, turn signal R.H. | 90138-00 |
4 | Relocation bracket, turn signal L.H. | 90139-00 |
SERVICE PARTS
Figure 17. Service Parts: Saddlebag Bracket Hardware Kit (91457-00B)
Table 3. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Screw, hex socket button (2) (3 inch turn signal) | 3538 |
2 | Screw, button socket head (2) | 4118 |
3 | Screw, button head 5/16-18 x 1-1/4 in. (6) | 4219 |
4 | Screw, hex head 4 in. (2) | 4288 |
5 | Spacer (2) | 5792 |
6 | Washer, plain (10) | 6254 |
7 | Washer, plain (2) | 6416 |
8 | Lockwasher (2) (2-3/8 and 3 inch turn signals) | 7042 |
9 | Nut, flange locking 3/8-18 (6) | 7531 |
10 | Strap, cable (4) | 10065 |
11 | Clip, adhesive (6) | 10102 |
12 | Grommet, large (2) | 11447 |
13 | Stud, shock mount (2) | 47237-00 |
14 | Plug, hole (2) | 53644-00 |
15 | Wiring harness, turn signal (2) | 70468-00 |
16 | Connector, sealed butt (4) | 70585-93 |
17 | Grommet, small (8) | 90148-00 |
18 | Spacer, large (2) | 90149-00A |
19 | Spacer, small (8) | 90186-00A |
20 | Spacer, hex | 91394-00 |
21 | Screw, 5/16-18 x 1 in. (2) (2-3/8 inch turn signal) | 4092 |
22 | Spacer, 0.150 in. (2) (2-3/8 inch turn signal) | 65849-01 |
23 | Vinyl cap, thread cover (2) (Not Shown) | 70573-94 |
24 | Nut, hex (2) (Not Shown) | 8093 |
25 | LOCTITE® 243 Threadlocker and Sealant - Blue, 0.5 ml packet (Not Shown) | Not Sold Separately |
NOTE: Loctite (Item 25) is only available in 6 ml tube, part number 99642-97. | ||
SERVICE PARTS
Figure 18. Service Parts: Saddlebag Assemblies (R.H. 90035-XX and L.H. 90036-XX)
Table 4. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Saddlebag bottom, right side | 91371-00 |
Saddlebag bottom, left side | 91372-00 | |
2 | Saddlebag lid, right side | 91373-00 |
Saddlebag lid, left side | 91374-00 | |
3 | Reflector, red, right side | 59287-92 |
Reflector, red, left side | 59288-92 | |
4 | Plate, cam lock | 91454-00 |
5 | Keeper latch | 91392-00 |
6 | Medallion, H-D | 90167-00 |
7 | Plate, lid hinge mount | 90158-00 |
8 | Plate, base hinge mount | 90188-00 |
9 | Plate, latch backing | 90159-00 |
10 | Cam, latch lever | 91390-00 |
11 | Latch assembly | 90166-00 |
12 | Hinge assembly | 90151-00 |
13 | Cover, latch | 91391-00 |
14 | Lever, latch | 91386-00 |
15 | Lock assembly (set of 2) | 91455-00 |
16 | Cam block | 91389-00 |
17 | Screw, self-tapping #10-16 x 1/2 in. (9) | 5233 |
18 | Washer, nonmetallic | 91387-00 |
19 | Nut, keps #10-32 (3) | 7629 |
20 | Screw, M6-6h x 25 (2) | 1369 |
21 | Screw, #8-32 x 3/8 in. | 4241 |
22 | Washer, flat #8 | 6182W |
23 | Screw, button head, 1/4-20 x 1/2 in. (2) | 936 |
24 | Gasket | 90174-00 |
25 | Label, saddlebag | 90248-00 |
26 | Plate, hinge cover | 91375-00 |
27 | Screw, 1/4-20 X 1/4 in. | 1397 |
28 | Gasket, lock | Included with Item 15 |