SOFTAIL® DETACHABLE SADDLEBAG KITS
J031452005-05-20
GENERAL
Kit Number
90384-06 and 90388-04
Models
These kits do not fit with Wide Tire kits, Rear Axle Covers or Flat Lens Turn Signal kit 68431-95 or 68432-95.
Kit 90384-06 fits 2000 and later Softail (except FLSTF, FXSTD, FLSTN and models equipped with Shotgun-style exhaust systems).
2006 FL Softail and 2000-2005 Softail models require separate purchase of Saddlebag Support kit 90979-06.
2000-2001 models require separate purchase of Bullet-style Turn Signal kit 68005-99.
Kit 90388-04 fits 2000 and later FLSTF and Softail models (except FXSTD and FLSTN) equipped with Shotgun-style exhaust systems.
2000-2001 models require separate purchase of Bullet-style Turn Signal kit 68005-99.
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 saddlebag weight capacity is 7 pounds (3.2 Kg.)
Do not exceed 7 lbs. (3.2 Kg) maximum load in each saddlebag. Evenly distribute weight between each saddlebag. Improper loading can cause vehicle handling problems leading to death or serious injury.
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)
INSTALLATION
Saddlebag Bar Installation-All Models
- See Figure 1. Remove and discard the two stock fender attaching screws as shown. Models with docking points; remove and save the docking points for use with the new saddlebag bar.
- See Figure 6. Obtain the following items from the kit:
- a saddlebag mounting bar (15),
- two screws (17),
- EITHER 3-1/4in (82 mm) long (2002 or earlier models)
- OR 2-3/4 in (70 mm) long (2003 or later models),
- AND two spacers (16) (models not using docking points).
Figure 1. Remove and Discard Stock Screws
| 1 | Mounting bar, saddlebag (position with slot upward) |
| 2 | Spacer (Used on models without docking points only) |
| 3 | Button-head socket cap screw: 3-1/4 in (82 mm) long (2002 or earlier models) OR 2-3/4 in (70 mm) long (2003 or later models) |
| 4 | Docking point saved from Step 1 (used on models with docking points) |
Figure 2. Install Mounting Bar
- See Figure 2. Fasten the mounting bar to the fender support as follows:
- If docking points were removed in Step 1, position a docking point against the back side of the mounting bar with the countersunk side away from the bar. Skip to Step 3c.
- If a docking point was not removed in Step 1, position a spacer (2) from the kit against the back side of the mounting bar.
- Line up the hole in the docking point or spacer with one of the end holes in the bar.
- Insert the proper screw (3) for your year motorcycle through the hole in the mounting bar, and the spacer or docking point. Apply a few drops of Loctite® 243 (blue) to the screw threads.
- Position the mounting bar with the rectangular slot facing upward, and attach the bar to the rear fender, but do not fully tighten at this time.
NOTE
If the saddlebag mounting bar contacts the rear turn signal, it will be necessary to loosen the turn signal and adjust to allow clearance with the bar. Loosen the turn signal mount screw two to three turns. Adjust rearward to allow approximately 1/32" (1 mm) of clearance between the turn signal and the mounting bar. Tighten the turn signal mount screws.
| 1. | Position the second spacer or docking point at the other end of the mounting bar. Swing the mounting bar into place, lining up the holes. Insert a screw through the hole in the mounting bar and the spacer or docking point. Apply a few drops of Loctite 243 (blue) to the screw threads. Attach the bar to the rear fender. | |
| 2. | If using the spacers, rotate the spacers so the outer edges align with the rounded ends of the mounting bar. | |
| 3. | Tighten both screws to 28.5–36.6 N·m (21–27 ft-lbs). | |
| 4. | Repeat Steps 1 through 6 for the opposite side, then proceed to Left and Right Side Installation for your model. |
Mounting Hardware Installation: Left Side-All Models, Right Side-Kit 90384-06 only
| 1 | Footpeg support |
| 2 | Torx screw |
| 3 | Hex bolt |
| 4 | Spring washer |
| 5 | Locknut |
| 6 | Passenger footpeg |
| 7 | Hex socket screw |
| 8 | Split lockwasher |
| 9 | Docking point |
| 10 | Lower front support |
| 11 | Star washer |
Figure 3. Lower Front Saddlebag Support (Left Side All, Right Side Without Shotgun Exhaust)
- See Figure 3. Remove the bolt (3) and locknut (5) retaining the passenger footpeg (6) and spring washer (4) to the footpeg support (1). Use an extended T-50 Torx® drive head to remove the screw (2) fastening the footpeg support to the motorcycle frame.
- Obtain the following items from the kit:
- one lower front support (10),
- one docking point (9),
- one external-toothed (star) washer (11),
- one 5/16-18 x 1-1/2 in. long button head screw (7),
- one 5/16 in. split lockwasher (8).
- Insert the Torx® screw (2) through the footpeg support (1) and the large hole in the lower front support (10). Place the star washer (11) over the screw threads, and apply a few drops of Loctite 243 (blue) to the threads.
- Thread the screw into the mounting hole in the motorcycle frame, but do not fully tighten at this time.
- Proceed to instructions under Saddlebag Installation OR Right Side hardware installation for your model motorcycle.
Mounting Hardware Installation: Right Side on Kit 90388-04 (Fat Boy or Models with Shotgun Exhaust)
WARNINGPerform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311b)
| 1 | Screw |
| 2 | Washer |
| 3 | Original rear muffler bracket |
| 4 | New rear muffler bracket/lower front support |
| 5 | Acorn nut (chrome) |
| 6 | Docking point |
| 7 | Flat head screw |
| 8 | Flanged hex head screw (4) |
| 9 | Muffler support |
Figure 4. Lower Front Saddlebag Support (Right Side With Shotgun Exhaust)
- See Figure 4. Remove the four flanged-head hex screws (8) holding the rear muffler bracket (3) to the front and rear mufflers.
- Remove the screw (1) and washer (2) holding the rear muffler bracket (3) to the muffler support (9).
- Obtain the following items from the kit:
- the muffler bracket/ lower front support (4),
- one docking point (6),
- a flat head screw (7),
- a chrome acorn nut (5).
| 5. | Position the new muffler bracket/ lower front saddlebag support (4) as shown, and install in place of the stock rear bracket (3) with the same screws (8) removed earlier. Do not fully tighten at this time. | |
| 6. | Loosely install the screw (1) and washer (2) to attach the new muffler bracket to the muffler support. Tighten screw (1) to 20.3–25.8 N·m (15–19 ft-lbs). Tighten the four screws (8) securely. Proceed to instructions under "Saddlebag Installation". |
Saddlebag Installation - All Models
| 1 | Quick release bail head studs |
| 2 | Isolator rings |
| 3 | Hanger bracket |
| 4 | Rectangular hole |
| 5 | Saddlebag mounting bar |
| 6 | Rubber pad (under hanger bracket) |
| 7 | Locknuts |
| 8 | Lower support bracket |
| 9 | Wire form stud retainer |
| 10 | Screw, pan head (2) |
| 11 | Lockwasher (2) |
| 12 | Flat washer (4) (items 9-12 are pre-installed in the saddlebag mounting bar) |
| 13 | Split lockwasher |
Figure 5. Rear View of Saddlebag and Saddlebag Mounting Bar
| 1. | For 2006 and later FL Softail and 2000-2005 Softail models, unbolt lower support arm from both saddlebags. Replace arms with arms from Saddlebag Support Kit 90455-04. Re-install as shown in Figure 5. Tighten locknuts (7) to 7–11 N·m (60–96 in-lbs). | |
| 2. | The saddlebags are side-specific. Obtain the correct saddlebag from the kit. Insert the lower support bracket on the saddlebag into the docking point on the lower front support. | |
| 3. | See Figure 5. With the two quick-release bail-head studs (1) fully retracted into the isolator rings (2), rotate the saddlebag down until the hanger bracket (3) fits into the rectangular hole in the top of the saddlebag mounting bar. Check to make sure the molded rubber isolator pad (6) on the underside of the hanger bracket sits squarely on the top of the bar. |
NOTE
The molded rubber isolator pad on the underside of the saddlebag hanger bracket must sit squarely on the top surface of the saddlebag mounting bar. If saddlebag is not fully seated, loosen the locknuts (7) securing the lower support bracket (8) to the saddlebag frame, and adjust the support rod forward or back as needed. Alternately tighten the nuts to 7–11 N·m (60–96 in-lbs) after seating the saddlebag.
| 4. | For all except HDI models: Grasp the "D"-ring on one of the two quick-release studs (1) inside the saddlebag. For HDI models: Regulations require that the "D"-ring be removed from the quick-release studs in all HDI applications. Without the "D"-ring, a coin or flat-bladed tool will be needed to install or remove the saddlebags. For all models: With the groove at the end of the stud held in a horizontal position, insert the stud through the hole in the saddlebag mounting bar (5). When the groove engages the wire form (9) inside the bar, turn the stud clockwise a full 1/4 turn until it snaps in place. Install the second quick-release stud in the same manner. | |
| 5. | See Figure 3. Rotate the footpeg support (1) so the footpeg slot angles up toward the rear at a 45 degree angle. Using an extended T-50 Torx® drive head, torque the screw (2) to 61–68 N·m (45–50 ft-lbs). | |
| 6. | See Figure 5. Make sure the lower support bracket (8) is fully inserted into the groove in the docking point. If if is not fully inserted, loosen the locknuts (7) securing the lower support bracket to the saddlebag frame, and adjust the support rod forward or back as needed. Alternately tighten the nuts to 7–11 N·m (60–96 in-lbs) after fully inserting the lower support bracket. | |
| 7. | See Figure 3. Install the passenger footpeg on the footpeg support as shown using the bolt (3), spring washer (4), and locknut (5) removed earlier. NOTE The spring washer (4) goes between the jaws of the footpeg support (1) along with the mounting end of the footpeg (6). NOTE Footpeg must be installed in the bracket with the rounded side of the mounting end inboard. When footpegs are properly installed, footpegs will fold upward at a 45 degree angle toward the rear of the motorcycle. | |
| WARNING Footrests must fold up and toward rear of motorcycle if struck. Failure to set footrests to fold up and back could result in death or serious injury. (00366a) | ||
| 8. | Repeat Steps 1 through 6 under "Saddlebag Installation All Models" on the opposite side of the vehicle. | |
| 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) | ||
| 9. | See Figure 6. Install the reflectors from the kit on the outboard side of the saddlebag lid, centered between the strap rivets. The reflectors are side-specific. Obtain the correct reflector from the kit. Remove the adhesive backing and press the reflector firmly into place on each saddlebag to activate the adhesive. |
Maintenance
Saddlebag Support Brackets
WARNINGThe lower saddlebag support bracket is not a footrest or step. Using the support bracket as either a footrest or step can cause the supports to separate from the docking points and fall to the road, which could cause loss of control and death or serious injury. (00405e)
Saddlebag Mounting Bolts
NOTE
After 500 miles (800 km) of on-road use with the saddlebags installed, it is necessary to check the torque on the saddlebag mounting bolts. Check to make sure the torque is still 28.5–36.6 N·m (21–27 ft-lbs). Re-tighten bolts if necessary. See the Caution below.
NOTICE
Failure to tighten saddlebag mounting bolts to specified torque could result in damage to saddlebags. (00406c)
Saddlebag Quick-Release Studs
NOTE
After 15,000 to 20,000 miles (24,000 to 32,000 km) of on-road use with the saddlebags installed, it is necessary to replace the wire form stud retainers shown in Figure 5. Two Stud Retainer Kits (Part Number 70923-04) will be needed, and are available for purchase at any Harley-Davidson Dealer.
NOTICE
Failure to replace stud retainers after each 15,000 to 20,000 miles (24,000 to 32,000 km) of road use could result in saddlebag damage. (00407c)
Saddlebag Docking Points
NOTE
In time, the docking points may wear, causing the lower front support brackets to become loose. The fit may be tightened using the following procedure:
- Loosen the docking hardware.
- Rotate the docking points clockwise approximately 45 degrees.
- Tighten the docking hardware to the appropriate torque values as indicated in the installation procedures.
This procedure can be repeated up to 3 times before replacement of the docking points is recommended.
Saddlebag Care
Apply the Leather Dressing included with the saddlebag kit according to the supplied directions.
NOTE
Genuine Harley-Davidson Leather Dressing (part number 98261-91V) is available for purchase from any Harley-Davidson Dealer.
SERVICE PARTS
Figure 6. Service Parts: Softail Detachable Saddlebag Kits
Table 1. Service Parts: Softail Detachable Saddlebag Kits
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Saddlebag assembly, (includes items 2 - 9) | 17 | Saddlebag mounting bolts, button-head socket cap screw (4) | |||
Right side saddlebag, Kit 90384-06 | 90441-06 | 3/8-16 x 3-1/4 in (2002 & earlier) | 4229 | |||
Right side saddlebag, Kit 90388-04 | 90442-04 | 3/8-16 x 2-3/4 in (2003 & later) | Not Sold | |||
Left side saddlebag (not shown), Kit 90384-06 | 90623-06 | 18 | Docking point (2) | 53683-96 | ||
Left side saddlebag (not shown), Kit 90388-04 | 90452-04 | 19 | Reflector (red) right side | 59287-92 | ||
Items 2 through 9 are pre-installed on the saddlebag | Reflector (red) left side | 59288-92 | ||||
2 | Bracket, support (lower) | See Service Kits | Items 20-22 in Kit 90388-04 only (For models with shotgun exhaust) | |||
3 | Lock nut (2) | 7686 | 20 | Acorn nut (chrome) | 94008-90T | |
4 | Split lockwasher (2) | 94080-90T | 21 | Saddlebag support and muffler bracket, lower front | Not Sold | |
5 | Isolator ring (2) | 11464 | 22 | Flat head cap screw | 1605 | |
6 | Stud, quick release (2) | Not Sold | The following Service Kits are available for these kits: | |||
7 | Retaining ring (2) | Not Sold | Bracket Kit for 90384-06, Right Hand | 90525-06 | ||
8 | Ornament, saddlebag lid (right) | See Service Kits | Bracket Kit for 90384-06, Left Hand | 90957-06 | ||
9 | Push nut (3) | 8126A | Bracket Kit for 90384-06 with saddlebag support Kit 90979-06, Right Hand | 90455-04 | ||
10 | Leather dressing, (not shown) | Not Sold | Bracket Kit for 90384-06 with saddlebag support Kit 90979-06, Left Hand | 90457-04 | ||
11 | Saddlebag support, lower front | 90346-00 | Bracket Kit for 90388-04, Left Hand | 90457-04 | ||
12 | Button head cap screw 5/16-18 x 1-1/2 in (2) | Not Sold | Bracket Kit for 90388-04, Right Hand | 90456-04 | ||
13 | Lockwasher, 5/16 in (2) | 94081-90T | Ornament kit (right hand) (includes items 8 and 9) | 90458-04 | ||
14 | Lockwasher, external tooth (2) | 7145W | Ornament kit (left hand) (includes items 8 and 9) | 90459-04 | ||
15 | Mounting bar, saddlebag | See Service Kits | Fender mounting kit (Includes item 15 and two of item 16) | 91797-04 | ||
16 | Spacer (2) | See Service Kits | Stud retainer kit (includes items 9-12 shown in Figure 5) | 70923-04 | ||