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DYNA RIGID MOUNT SADDLEBAG HARDWARE
J048032008-06-12
GENERAL
Kit Number
92025-09
Models
Fits 2002-2005 Dyna models equipped with Dyna Rigid Mount Saddlebags.
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.
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 2 and Table 1.
INSTALLATION
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
Refer to the labels in the saddlebags for maximum weight capacity.
To simplify installation, raise the motorcycle on a motorcycle lift and remove the lower bolt from both rear shock absorbers, (to allow rear wheel to drop and allow access to the fender strut and turn signal hardware).
Complete the following procedure on one side of the motor-cycle before working on the other side.
NOTE
Refer to Figure 2 for the following procedure.
  1. Refer to the service manual for instructions to remove the screws fastening the stock turn signals to the rear-fender side cover. Route the wires to accommodate the turn-signal relocation kit for your model motorcycle.
  2. Remove the forward screw holding the fender sidecover in place. Discard the screw.
  3. Install the chrome plug (5) into the rear-fender side-cover hole as shown.
  4. Insert the 3-inch long bolts (7) with the thin washers (6) through the inside of the fender.
  5. Install the spacers (4) onto the bolts (7) as they protrude through the side cover.
    6. NOTE
    On vehicles equipped with detachable side plates, replace the spacers (4) in this kit with the detachable mounting points from the detachable side plate kits.
  6. Install the saddlebags onto the bolts as follows:
NOTE
Washer (3) is included in the hardware kit that came with the saddlebag kit.
Use one thick washer (3) per bolt (7) if:
  • Rigid-mount side plates are installed on the vehicle.
  • The vehicle comes equipped with a spacer (see Figure 2 ).
  • The vehicle has the spacer (see Figure 2 ) and detachable side plates are installed.
Use two thick washers (3) per bolt (7) if:
  • No rigid mount side plates are installed on the vehicle.
  • The vehicle does not come equipped with a spacer (see Figure 2 ).
  • The vehicle has no spacer (see Figure 2 ) and detachable side plates are installed.
1. Fasten an acorn nut (2) onto the bolts (7) from the inside of the saddlebag. Tighten the nuts to 34 N·m (25 ft-lbs).
2. See Install Reflectors onto Saddlebags and install saddlebag reflectors.
NOTE
If you removed the lower bolt from the rear shock absorbers for saddlebag installation, install the hardware in reverse order of removal to fasten the shock absorbers to the vehicle. Apply Loctite® 243 (blue) to the bolt threads. Torque the fasteners to 34–54 N·m (25–40 ft-lbs).
Install Reflectors onto 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)
1. Place a small amount of paint on studs on back of reflector mount.
2. See Figure 1. Measure approximately 1-1/2 in. (38 mm) from the bottom edge of the saddlebag. Orient the reflector horizontally and carefully center the reflector mount between the straps of bags with straps or locate it at the rearward portion of bags without straps. Gently press reflector mount to saddle bag so paint marks transfer and punch or drill small holes through saddlebag where paint marks transferred to saddlebag.
3. Remove adhesive backing from reflector and firmly press reflector into reflector mount.
4. Install reflector assembly to saddlebag and secure with push nuts.
5. Repeat for the other saddlebag.
Figure 1. Install Reflector
CARE & MAINTENANCE
  • To open the saddlebag, first disengage the snaps, then unbuckle the quick connect buckles.
  • For saddlebags with lid snaps, it will be necessary to periodically oil the snaps. Smear a drop of motor oil into the female side of the snap, being careful not to get any of the oil on the leather. Re-oil the snaps every two-three weeks.
  • Apply the Genuine Leather Dressing included with your saddlebag according to the directions included with the leather care kit.
SERVICE PARTS
Figure 2. Service Parts Table
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Saddlebag, right side (generic saddlebag shown)
2
Acorn nut (4)
7862
3
Washer, thick (8)
Part of saddlebag kit
4
Medium spacer, 0.9 inch (4)
40950-98A
5
Chrome plug (2)
56239-93
6
Washer, thin (4)
6701
7
Hex head bolt, 3/8-16 x 3 inch (4)
3526
Items mentioned in text, but not included in kit:
A
Fender cover
B
Spacer
NOTE: In Item 4, two spacers are provided in the hardware kit and two are provided in the saddlebag kit.