FLHRS SADDLEBAG LOCK SET KIT

J030792006-01-27

GENERAL

Kit Number

46287-04

Models

This kit fits all 2004 and later FLHRS (Road King^® Custom) model motorcycles with stock leather saddlebags 91316-04 (left) and 91400-04 (right).

The lock can be keyed to match your motorcycle's ignition key. Please specify the key code when ordering.

Kit Contents

See Figure 2 and Table 1.

INSTALLATION

1.	Lay a clean pad or blanket on the work surface to protect the saddlebag leather surfaces.
2.	Open the saddlebag lid. Remove the saddlebag from the motorcycle, leaving the lid open. See SADDLEBAG REMOVAL in the Service Manual. Lay the saddlebag flat on the pad or blanket with the inboard side facing up and the lid furthest from you.
3.	See Figure 1. Obtain the templates (10) from the kit. Lay the correct (left or right) template in the upper rear corner of the hard plastic inboard face of the saddlebag. Fit the template around the rear of the lid hinge and against the curve of the raised surface in the middle of the saddlebag, and tape it into place.	Figure 1. Template Placement (Left Side Shown)
4.	Drill four 3/16 (0.19)-inch holes in the saddlebag inboard face where indicated on the template.
5.	Drill four 5/32 (0.15)-inch holes in the saddlebag inboard face as indicated on the template.
6.	Remove the template. Cut out the area in between the four smaller holes to create a rectangular opening for the lock arm. Stand the saddlebag upright, with the cover open.
7.	See the Figure 2. Obtain one lockset (1) and two screws (5) from the kit. Position the lockset to the saddlebag as shown, with the actuator rod protruding through the rectangular opening cut in step 6. Insert the screws through the lockset mounting holes and into the saddlebag.
8.	Position a backing plate (3) over the screw threads inside the saddlebag. Fasten the lockset and backing plate to the saddlebag with two lockwashers (6) and hex nuts (7) from the kit.
9.	Using a 3/16-in. hex wrench, remove the two screws holding the inside cover over the existing pushbutton lid release. Remove the cover. NOTE Make sure you are using the correct retaining-ring pliers. Verify that tips of pliers are not excessively worn or damaged.
	WARNING Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a)
10.	Remove the retaining ring fastening the lid release cable to the pushbutton. Unhook the cable from the pushbutton lever, and pull the cable sheath out of the retaining channel on the inboard wall of the saddlebag. Remove the flat washer from the cable end. Do not discard the retaining ring and washer.
11.	Trim about one inch (25 mm) from the rearmost part of the retaining channel, and re-insert the cable into the channel so the free end is at the rear of the saddlebag.
12.	Insert the cable end through the hole in the backing plate, and slip the washer over the end of the cable fitting. Insert the cable into the slot in the lockset actuator rod so the ball on the end of the cable fits into the depression. NOTE Make sure you are using the correct retaining-ring pliers. Verify that tips of pliers are not excessively worn or damaged.
	WARNING Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a)
13.	Install the retaining ring into the cable fitting groove.
14.	Install the cover (4) over the lockset actuating rod and the cable end, and fasten with the two hex washer head Hi-Lo self-tapping screws (9).
15.	To avoid rattles, use a tie strap (8) to tie the pushbutton lever to the cable retaining hole. Re-install the cover over the pushbutton.
16.	Insert the key into the lockset, and turn to unlock if necessary. Press the key inward and check the latch for proper operation. Close the lid and re-install the saddlebag onto the motorcycle. Repeat all steps for the remaining saddlebag.

SERVICE PARTS

Figure 2. Service Parts, FLHRS Saddlebag Lock Set

Table 1. Service Parts Table

Item	Description (Quantity)	Part Number
1	Lockset, saddlebag (2)	Not sold separately
2	Key (specify key code)	71452-91A/xxxx
3	Backing plate (2)	Not sold separately
4	Cover (2)	Not sold separately
5	Machine screw, pan head cross-recess (Phillips), #8-32 x 3/4 in. (4)	2646
6	Lock washer, split, #8 (4)	7015
7	Hex nut, #8-32, brass (4)	7517
8	Tie strap, black (2)	10065
9	Screw, hex washer head, #6-19 Hi-Lo x 0.50 in. (2)	Not sold separately
10	Drilling template	Not sold separately
Items mentioned in text, but not included in kit:
A	Original equipment cable, washer and retaining ring