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FLSTN HARD SADDLEBAG KIT
J045172007-10-02
GENERAL
Kit Number
90725-YYxxx
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).
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 7 pounds (3.2 Kg.) in each bag.
Additional Parts Required
Separate purchase and installation of additional parts or accessories may be required for proper installation of this kit on your model motorcycle. Please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
Tools and Supplies Required
Loctite® 243 (Blue) Threadlocker and Sealant (H-D Part Number 99642-97) is required for the proper installation of this kit.
WARNING
Rider 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
See Figure 10 and Table 1.
INSTALLATION
Preparation
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse.
  2. Remove the debris deflector from the vehicle. Refer to BELT GUARD/DEBRIS DEFLECTOR; REMOVAL in the Service Manual.
Install Saddlebag Supports
WARNING
Do not use the 2-1/4 inch fasteners if docking hardware is not installed. Fastener contact with tire can lead to premature tire failure, which could result in death or serious injury. (00574c)
  • When installing these saddlebags without detachables, use the 3/8-16 x 1-3/8 inch socket head screws (Part Number 1002) provided in the Hard Saddlebag Kit.
  • When installing these saddlebags with detachables, use the 3/8-16 x 2-1/4 inch screws provided in the Detachable Hardware Kit.
  • See Figure 1. If docking hardware is installed, install the docking points (1) between the fender support (2) and the saddlebag support (3).
1Docking point (2)
2Rear fender support
3Saddlebag support
4Socket head screw (2)
Figure 1. Saddlebag Support With Detachables
1. Install the saddlebag support (3) to the fender support and fender as shown using the correct length socket head screws (4), and tighten the fasteners to 37 N·m (27 ft-lbs) Repeat for the opposite side.
Loosen Exhaust System
NOTE
Splash guard removal will provide easier access to fasteners when removing the exhaust mounting bracket hardware and left side footrest mounting hardware.
2. Remove the hex flange head screw from the bottom of the splash guard at the forward end of the rear fork. Lift up on the lower tabs and pull the lower end of the splash guard rearward. Remove the splash guard from the rear fork.
3. Loosen all four exhaust header flange nuts at the cylinder heads. See Figure 2. Loosen the carriage bolt (4) and locknut (5) retaining the exhaust clamp (3) to the exhaust system support bracket (2) at the transmission case. Slip the clamp out of the slot in the support bracket.
4. Remove the TORX® button head screw (8) and two locknuts (7) that hold the muffler support (6) to the vehicle frame. On models so equipped, remove the screws (10) retaining the exhaust actuator (9) to the muffler support.
NOTE
The passenger footpeg can remain assembled to the support.
5. Swing the exhaust system and muffler support out of the way as needed to access the hex socket head screw (8).
6. See Figure 11. Obtain the right-side lower saddlebag support bracket (32), one 3/8-16 x 1-1/4 inch hex head screw (35), one flanged locknut (38) and one shoulder washer (37) from the kit.
1Exhaust system
2Exhaust system support bracket
3Exhaust clamp
4Carriage bolt
5Clamp locknut
6Muffler support
7Support locknut (2)
8TORX screw
9Exhaust actuator (ECE, AUS, ENG)
10Hex head screw with washer (2)
11Plug
Figure 2. Exhaust System Support Bracket
7. Remove the plug ( Figure 2 , Item 11) from the threaded hole in the motorcycle frame. Thread the new screw all the way through the hole. Tighten the screw to 34–41 N·m (25–30 ft-lbs). Install the saddlebag support bracket over the screw threads, then install the shoulder washer (shoulder first) onto the threads. Fit the shoulder into the hole in the saddlebag support bracket. Thread the flanged locknut onto the screw, but do not fully tighten at this time.
8. Obtain the left-side lower saddlebag support bracket (31), one 3/8-16 x 1-5/8 inch hex socket screw (34), one flanged locknut (38) and the remaining shoulder washer (37) from the kit. Remove and discard the TORX screw retaining the left-side passenger footpeg support to the vehicle frame.
NOTE
The passenger footpeg can remain assembled to the support.
9. Insert the screw threads through the hole in the footpeg support bracket, and thread all the way through the hole in the frame. Tighten the screw to 34–41 N·m (25–30 ft-lbs). Install the shoulder washer onto the screw threads. Install the saddlebag support bracket over the screw threads, and thread the flanged locknut onto the screw. Do not fully tighten.
Install Brackets to Saddlebag Supports
NOTE
See Figure 3. If docking hardware is installed, use the inner two holes (3) to mount the support bracket (2) to the saddlebag support (1). If docking hardware has not been installed, use the outer two holes. (4)
1Saddlebag support
2Saddlebag support bracket
3Inner two holes
4Outer two holes
5Rubber isolator
Figure 3. Install Support Bracket to Saddlebag Support
10. Obtain four 5/16-18 x 5/8 inch screws (39) and four locknuts (43) from the kit. On the right side of the vehicle, install two screws through the saddlebag support and into the support bracket as shown. Install the nuts and tighten to 13.1 N·m (10 ft-lbs). Repeat on the left side of the vehicle.
11. Tighten the left- and right-side lower support bracket mounting locknuts to 34–41 N·m (25–30 ft-lbs).
12. Re-install the splash guard to the front of the rear fork.
13. Re-install and tighten all exhaust mounting brackets and hardware. Refer to EXHAUST SYSTEM; INSTALLATION in the Service Manual.
Prepare Saddlebags for Installation
14. See Figure 3. Install the rubber isolators (5) from the kit over each saddlebag support bracket with the "flat" side facing down.
Figure 4. Install Grommets and Sleeves
15. See Figure 4 and Figure 11. Install rubber grommets (45) from the kit into the holes in the side of each saddlebag as shown. Install a steel spacer sleeve (44) into each of the grommets as shown.
Install Saddlebags To Supports
16. See Figure 11. Obtain four button head screws (40), flat washers (41), aluminum spacers (42) and lock nuts (43) from the kit. See Figure 5. Hold the saddlebag (1) up to the saddlebag support (2), and position a spacer (3) between the saddlebag and support. See Figure 6. Install a screw (1) and flat washer (2) from inside the saddlebag, through the spacer (3), then install a nut (4) onto the screw threads and finger tighten. Repeat for the second spacer.
1Saddlebag
2Saddlebag support
3Spacer
Figure 5. Install Spacer
1Screw
2Flat washer
3Spacer
4Nut
Figure 6. Secure Saddlebag to Support
17. Ensure that the saddlebag is aligned properly, then tighten the screws and nuts securely.
18. Repeat Steps 18 and 19 for the remaining saddlebag.
Install Reflectors to Saddlebags
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)
NOTE
Red reflectors are provided in this Kit, and must be installed to meet US and Canadian requirements.
Ambient temperature should be at least 60° F (16° C) for proper adhesion of the reflectors to the saddlebags.
19. See Figure 7. Locate an area approximately 7 inches (178 mm) from the front (1) and 1/4 inch (6 mm) from the lid lip (2) of the lower section of each saddlebag.
1Measure 7 inches (178 mm) from front
2Measure 1/4 inch (6 mm) from lip
Figure 7. Install Reflectors to Saddlebags
20. Clean the reflector areas with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. Peel the liner from the adhesive backing of one reflector. Carefully position the reflector to the saddlebag, and press firmly into place. Hold the reflector in position with steady pressure for a few seconds to ensure proper adhesion. Repeat for the remaining saddlebag.
NOTE
Allow AT LEAST 24 hours after applying the reflectors before exposing the saddlebags to vigorous washing, strong water spray or extreme weather.
The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature.
Return to Service
  1. Re-install the debris deflector to the vehicle. Refer to BELT GUARD/DEBRIS DEFLECTOR; INSTALLATION in the Service Manual.
  2. Verify that the Ignition/Light Key Switch is turned to the OFF position. Refer to the Service Manual and follow the instructions given to re-install the Maxi® Fuse.
HINGE REPLACEMENT (OPTIONAL)
NOTE
The saddlebags are shipped with a hinge and tether for raising and lowering the lid. However, due to various styles of seat or accessories installed, it may be preferable to replace the existing hinges with the optional hinges provided in the kit, which allow complete removal of the lid.
If hinge replacement is desired, perform the following:
1Upper tether attaching screw (2)
2Lower tether attaching screw (2)
Figure 8. Remove Tether
1. See Figure 8. Remove the screws (1) securing the upper portion of the tether to the saddlebag lid, and (2) the lower portion of the tether to the saddlebag body. Remove the tether.
2. See Figure 9. Remove the C-clip (1) securing the hinge pin, and remove the pin from the hinge (2). Separate the lid from the saddlebag base.
1C-clip
2Hinge
3Hinge screw (2)
Figure 9. Remove Hinge
3. Remove the two screws (3) securing the hinge to the saddlebag lid and carefully slide the hinge out from under the rubber seal.
4. Obtain the replacement hinge half for the saddlebag lid. Carefully slide the hinge under the rubber seal, and fasten the hinge half to the lid using the screws removed in Step 3. Tighten the screws securely.
5. Install the original pin to the hinge and secure with the C-clip removed in Step 2.
6. Install the lid to the saddlebag base by aligning the hinge halves and close the lid. Pull up on the front of the lid to make sure the lid is fastened securely.
SERVICE PARTS
Table 1. Service Parts Table, Saddlebags
Item
Description (Quantity)
Part Number
1
Saddlebag assembly, left (shown)
Saddlebag assembly, right (not shown)
(includes items 2 through 27)
90026-YYxxx
90027-YYxxx
2
  • Base, saddlebag (left) Base, saddlebag (right)
90264-00
90262-00
3
  • Latch assembly
90166-00
4
  • Bracket, latch
90232-00
5
  • Cover assembly, latch
90237-00
6
  • Screw, pan head TORX®, #10-24 x 3/8 inch (4)
3018
7
  • Screw, TORX head, #12-16 x 5/8, high-low, self-tapping (2)
3596
8
  • Screw, TORX head, M6-6H, with lock patch (2)
1394
9
  • Screw, TORX
1395
10
  • Lock set, saddlebag (includes items 10 and 11)
90235-00A
11
  • Key set (specify code)
90234-00
12
  • Gasket, lock (2)
90290-02
13
  • Lid, saddlebag (left) Lid, saddlebag (right)
90261-00
90260-00
14
  • Catch, hinge
90172-00
15
  • Hinge, hook bracket
90176-00
16
  • Hinge pin
90173-00
17
  • Retaining ring
11015
18
  • Loop, latch
90231-00
19
  • Screw, TORX head, #12-16 x 5/8, high-low, self-tapping (6)
3596
20
  • Gasket
90230-00
21
  • Tether
53633-00
22
  • Bracket, tether (upper)
90417-00
23
  • Bracket, tether (lower)
90418-00
24
  • Pan head machine screw, #6-32 x 1/4 inch, with lock patch (2)
3595
25
  • Spring washer, 1/4 inch, curved (2)
6970
26
  • Screw, pan head TORX, #10-24 x 3/8 inch (2)
3018
27
  • Lock nut, flanged, #10-24 (2)
7878
Figure 10. Service Parts, Saddlebags
Figure 11. Service Parts, Support Bars and Hardware
SERVICE PARTS
Table 2. Service Parts Table, Support Bars and Hardware
Item
Description (Quantity)
Part Number
28
Saddlebag support bar kit (includes items 29 through 32)
90805-08
29
  • Support, saddlebag (left)
90859-08
30
  • Support, saddlebag (right)
90855-08
31
  • Bracket, saddlebag support (left)
90852-08
32
  • Bracket, saddlebag support (right)
90848-08
33
Saddlebag hardware kit (includes items 34 through 47)
90749-05A
34
  • Screw, hex socket head, 3/8-16 x 1-5/8 inch (3)
4371WA
35
  • Screw, hex head, 3/8-16 x 1-1/4 inch
3536
36
  • Screw, hex socket head, 3/8-16 x 1-3/8 inch (4)
1002
37
  • Shoulder washer (2)
5816
38
  • Lock nut, flanged, 3/8-16 (6)
7601
39
  • Screw, hex socket button head, 5/16-18 x 5/8 inch (4)
3540
40
  • Screw, hex socket button head, 5/16-18 x 1-3/8 inch (4)
4214
41
  • Flat washer (4)
6213
42
  • Spacer. aluminum (4)
90175-00
43
  • Hex lock nut, 5/16-18, with nylon insert (8)
7739
44
  • Spacer sleeve, steel (4)
90186-00A
45
  • Rubber grommet (4)
90148-00
46
  • Isolator, rubber (2)
90267-00
47
  • Reflector, red (2)
59173-00
48
  • Hinge, open (2)
90229-00