1. | Remove saddlebags. See service manual. | |
2. | Figure 6 Install support board (7) to inner saddlebag lid (A). | |
3. | Figure 1 Place support board against lid seam and trace a marker line on leather. |
1. | Figure 1 Apply an even coat of adhesive to saddlebag lid and non-textured side of support board. | |||||||||||||||||||||||||
2. | Bond together with firm pressure and allow one hour for adhesive to set. |
Figure 1. Inner Saddlebag Lid Support Board | ||||||||||||||||||||||||
3. | Remove center chrome stud from saddlebag lid. | |||||||||||||||||||||||||
4. | Figure 2 Install anti-rotation ring (1) where chrome stud was just removed. a. Install with prongs facing inner saddlebag lid. | |||||||||||||||||||||||||
5. | Draw a circle on inside of anti-rotation ring (1). | |||||||||||||||||||||||||
6. | Cut out marked circle. |
Figure 2. Cut Hole for Lock Assembly | ||||||||||||||||||||||||
7. | See Figure 6 and Table 1 Install lock assembly (8) to saddlebag lid (A). a. Install flat washer (f) to cam lock (g). b. Insert cam lock (g) through hole in saddlebag lid. c. Install anti-rotation ring (e) with prongs facing leather. d. Install nut (d) over anti-rotation ring (e). Tighten. e. Install cam plate (c), T-bar (b) and screw (a). Tighten screw to cam lock. f. Use key (h) to check lock operation. | |||||||||||||||||||||||||
8. | See Figure 3 or Figure 4. Install inner supports (1, 2). a. Use temporary hardware: 5/16 screws (3), nuts (4) and washers (5) (not included in kit). | |||||||||||||||||||||||||
9. | Figure 4 If installing this kit with Quick Detach Saddlebag Conversion Kit (Part No. 90200641): a. Use hardware provided in that kit to install inner supports to saddlebag. b. Large washers from that kit should be discarded when installing inner supports. | |||||||||||||||||||||||||
10. | Figure 5 Install lock plate (1) on outside of saddlebag tub. a. T-bar (not shown, under saddlebag lid) must be in a horizontal position. b. Close saddlebag lid. c. Center lock plate (1) with lock assembly (2). d. Carefully lift saddlebag lid and mark location of lock plate (1). e. Using a wood block inside saddlebag, drill 3/16 inch holes using lock plate as a template. f. Figure 6 Position lock plate (2) and install blind rivets (3). g. Install washers (1) from inside of saddlebag tub and over head of blind rivet (3). Pop rivets into place. |
Figure 3. Temporary Hardware Installation
Figure 4. Temporary Hardware Installation With Detach Saddlebag Kit (90200641)
Figure 5. Positioning lock plate | ||||||||||||||||||||||||
11. | Repeat steps for opposite saddlebag. |
1. | Remove temporary hardware from saddlebag. | |
2. | Install saddlebags. See service manual. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Plain washer, Type A (8) | 6717 |
2 | Lock plate (2) | 90200063 |
3 | Rivet, blind (8) | Not sold separately |
4 | Lock plate (2) | Not sold separately |
5 | Inner support, right side (not shown) | Not sold separately |
6 | Inner support, left side | Not sold separately |
7 | Support board (2) | Not sold separately |
Lock Assembly Components (See Installation Requirements): | ||
8 | Lock Assembly (a-h) | |
a | Screw (2) | Not sold separately |
b | T-Bar (2) | Not sold separately |
c | Cam plate (2) | Not sold separately |
d | Nut (2) | Not sold separately |
e | Anti-rotation ring (2) | Not sold separately |
f | Flat washer (2) | Not sold separately |
g | Cam lock (2) | Not sold separately |
h | Key (2) | 71452-91A |
Items mentioned in text, but not included in kit: | ||
A | Saddlebag lid | |
B | Saddlebag tub | |
C | Detachable Saddlebag Conversion Kit |