XR1200 SADDLEBAGS
J043142010-03-12
GENERAL
Kit Number
90328-08A
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
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.
INSTALLATION
WARNINGImproper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00121a)
Use the following guidelines when equipping a motorcycle or carrying passengers and cargo.
- Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize the change in the motorcycle's center of gravity. Distribute weight evenly on both sides of the vehicle and do not load bulky items too far behind the rider or add weight to the handlebars or front forks.
- Be sure cargo is secure and will not shift while riding. Periodically recheck load.
- Verify that the saddlebag strap buckles are secure.
- Secure straps, keep away from rear wheel.
- Do not put more than 7 pounds (3.2 kg) in each saddlebag.
| 1 | Seat |
| 2 | Pillion |
| 3 | Bolts (short) and washers |
| 4 | Bolts (long) and washers |
| 5 | Retainers |
| 6 | Seat base |
Figure 1. Remove Seat, Pillion and Seat Base
| 1. | See Figure 1. Remove rider's seat (2) and passenger pillion (1). | |||||||
| 2. | Remove short screws and washers (3) and long screws (4) and retainers (5) and lift seat base (6) from frame. | |||||||
| 3. | See Figure 5 and Table 1. Remove two screws and washers from the muffler support (B) on the right side frame rail. Save screws in case saddlebags and brackets need to be removed. Washers will be used in next step. | |||||||
| 4. | Overlay the bungee bar (3) and saddlebag support (1) over the muffler support using two previously removed washers behind the left side of bungee bar as shown in illustration and fasten with 1.75 inch screw (6) on the rear and 2.00 inch screw (5) on the front. Tighten screws to 20.3–27.1 N·m (15–20 ft-lbs). Loosen screws and then retighten to 31.2–33.9 N·m (23–25 ft-lbs). | |||||||
| 5. | Remove the corresponding hardware from the left side frame rail (D). Stack the bungee bar (4) first and then the saddlebag support (2) to the rail and install with screws from hardware kit using a 1.75 inch screw (6) on the front and a 1.50 inch screw (7) on the rear. No washers are used on this side. Tighten screws to 20.3–27.1 N·m (15–20 ft-lbs). Loosen screws and then retighten to 31.2–33.9 N·m (23–25 ft-lbs). Save the original hardware should the saddlebags need to be removed. | 
Figure 2. Attaching Saddlebag | ||||||
| 6. | See Figure 2. Place back flap of saddlebag over bungee bar (1) and bring lower bag straps over bag support (2) and connect the strap buckles (3). Repeat for other side. NOTE Because the saddlebags obstruct the original rear side reflectors they must be removed and replaced with the brackets included in the kit. | |||||||
| 7. | Remove existing rear side reflectors. | |||||||
| 8. | See Figure 3. Loosely Install reflector brackets and license plate to bracket. | |||||||
| 9. | See Figure 4. Extend the bracket out on each side out to 1.625 inches (41.3 mm) and tighten fasteners securely. | |||||||
| 10. | See Figure 1. Install seat base to frame and tighten all screws to 8.1–13.6 N·m (72–120 in-lbs). | |||||||
| 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) | ||||||||
| 11. | Install passenger pillion and riders seat. | 
Figure 3. Reflector Installation  Figure 4. Reflector Relocation |
SERVICE PARTS
Figure 5. Service Parts: XR1200 Saddlebags
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Saddlebag support, right | 90341-08A |
2 | Saddlebag support, left | 90335-08A |
3 | Bungee bar, right | Not Sold Separately |
4 | Bungee bar, left | Not Sold Separately |
5 | Screw, hex drive, 2.00 inch | Not Sold Separately |
6 | Screw, hex drive 1.75 inch (2) | Not Sold Separately |
7 | Screw, hex drive 1.50 inch | Not Sold Separately |
8 | Saddlebag, right | 90333-08A |
9 | Saddlebag, left | 90332-08A |
10 | Reflector bracket, right | 90437-08 |
11 | Reflector bracket, left | 90436-08 |
12 | Reflectors, (2) | 59259-90 |
Items mentioned in text, but not included in kit: | ||
A | Right frame rail | |
B | Muffler support | |
C | Washers (2) | |
D | Left frame rail | |