VRSCR SPORT SADDLEBAG KIT

J038732005-06-16

GENERAL

Kit Number

91200-06A

Models

This kit is designed to fit 2006 and later VRSCR model motorcycles.

Additional Parts Required

Installation of this kit will require Loctite^® 243 (blue) (Harley- Davidson part number 99642-97), which is available from any Harley-Davidson dealership.

Kit Contents

See Figure 5 and Table 1.

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

Maximum saddlebag weight capacity is 4.5 Kg (10 lbs).

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)

INSTALLING THE RELEASE/ATTACH WELDMENT

NOTE

If possible, lift the rear of the motorcycle up so the rear wheel drops to the bottom of shock travel. This will help provide clearance between the rear tire and fender when installing the mounting brackets.

Open the seat.

1	Nut and washer
2	Pillion

Figure 1. Remove Pillion Mount Nut and Washer

See Figure 1. Note how TSSM (Turn Signal/Security Module) wiring routes under pillion base and remove and save the pillion mounting nut (1) for re-installation.

Pull the grabstrap forward off of the pillion.

See Figure 1. Push the pillion (2) forward to release the slot on the bottom of the pillion from the tongue on the fender. Lift the pillion back and away from the motorcycle and set aside.

Figure 2. Remove Fender Support Screws and Washers (4)

See Figure 2. Remove four fender support screws and washers (1) near the center of the fender.

Lift fender enough to allow access to the saddle bag mounting holes along the side of the frame.

NOTE

Apply Loctite^® 243 (blue) to last 4 threads of leave-on screws.

1	Fender holes
2	Leave-on mount
3	Relese/attach weldment
4	Screw (4)
5	Washer (4)
6	Nut (2)

Figure 3. Saddlebag Mounting Hardware

See Figure 3. Install the saddlebag leave-on (2) to the inside of the fender using two screws (4), washers (5) and nuts (6) from the kit. Repeat for the opposite side. Tighten screws to 48 N·m (35 ft-lbs).

See Figure 3. Install the release/attach weldment (3) to the saddle bag leave-ons (2) using four screws (4) and washers (5) from the kit. Tighten screws to 25 Nm (18 ft-lbs).

See Figure 2. Install the fender and four screws with washers (1), saved in Step 4. Tighten screws to 4.5–7.5 N·m (40–60 in-lbs).

10.

Insert the pillion into position under the grabstrap.

11.

Push the pillion toward the front of the vehicle until the mounting hole in the base is approximately 25 mm (1 inch) in front of the mounting hole in the frame.

12.

Route the TSSM harness through the recessed channel on the base of the pillion.

13.

While applying downward pressure on the middle of the pillion, slide the pillion rearward to fully engage the slot on the bottom with the tongue on top of the fender. Push rearward until the mounting hole on the pillion base is aligned with the mounting stud on the frame.

14.

Obtain hex nut and washer saved in Step 2 and install to secure base to frame. Tighten screw to 11–17 N·m (97–150 in-lbs).

15.

Close the seat.

WARNING

16.

Thoroughly clean the area in which reflector is to be installed. Remove adhesive backing from reflector and apply to the saddlebag. Position the reflector to the rear-most portion of the saddlebag at the lowest height, ensuring that the reflector is parallel to the ground. While pressing back from the inside of the saddle bag, apply pressure to entire reflector to promote adhesion. Repeat Step for the opposite side of saddlebag.

ATTACHING AND RELEASING SADDLEBAGS

1	Hook
2	Locking pin
3	Isolator pad
4	Release mechanism
5	Release pin

Figure 4. Saddlebag Mounting Hardware

1.	See Figure 4. To attach saddlebags: a. Prior to attaching saddlebags, ensure that the locking pin (2) is tightened to 5.6 N·m (50 in-lbs). b. To attach saddlebag, hang hooks (1) on saddlebag over the release/attach assembly ensuring that the isolator pad (3) locates between the hooks. c. Ensure that the locking pin (2) locates in the hole of the release mechanism (4). Push in on the bottom of the saddle bag until it locks into place with an audible click. If it will not lock, remove saddlebag. Loosen the locking pin nut, back out pin one turn, and retighten. Repeat Steps a-c, as necessary, until saddlebag locks properly into place. d. Repeat procedure for opposite saddlebag.
	WARNING Do not operate motorcycle without saddlebags attached unless the saddlebag support bracket is also removed. The support bracket obscures stock reflectors. Low visibility of rider can result in death or serious injury. (00425e)
2.	See Figure 4. To release the saddlebag, press in on the release pin (5), tilt the bottom of the saddlebag outward, and lift it up and away. Repeat for opposite saddlebag.

SADDLEBAG OPERATION AND CARE

Opening Saddlebag

To open saddlebag, first disengage the snap at the rear of the saddlebag, then pull the tabs of the two zippers to the front of the saddlebag and lift the lid.

Closing Saddlebag

To close the saddlebag, pull the tabs of the two zippers towards the rear of the saddlebag, and engage the snap at the rear.

Care of Cloth

Avoid exposure to transmission fluid.

Care of Snaps

The snaps on the front and rear of the saddlebags will periodically need to be oiled.

Smear a drop of motor oil into the female side of the snap, being careful not to get any oil on the cloth.

Repeat the snap oiling procedure every 30 to 60 days, or whenever the snaps become noticeably more difficult to engage or disengage.

SERVICE PARTS

Figure 5. Service Parts: VRSCR Sport Saddlebag Kit

Table 1. Service Parts: VRSCR Sport Saddlebag Kit

Item	Description (Quantity)	Part Number	Item	Description (Quantity)	Part Number
1	Saddlebag attach/release assembly	90819-01	8	Washer (8)	6812
2	Screw, button head, M5 x 0.8 x 6 mm (4)	4489M	9	Hex nut, M10 x 1.5 (4)	7440M
3	Saddlebag, attach/release weldment	91204-06	10	Screw, socket head, M10 x 1.5 x 20 mm (8)	3852M
4	Saddlebag, right	91206-06A	11	Reflector, right	59288-92
5	Saddlebag, left	91205-06A	12	Reflector, left	59287-92
6	Leave-on, saddlebag, right	91217-06	13	Rubber isolator pads	91214-06
7	Leave-on, saddlebag, left	91279-06