SADDLEBAG EXTENSION KIT
J049192009-06-23
GENERAL
Kit Number
90999-09
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
This kit must be installed by an authorized Harley-Davidson Dealer. Proper installation of this kit requires special materials, tools or training only available through an authorized dealer.
Additional Parts Required
Separate purchase of Lord Fusor® Adhesive 152 (10.1 oz) (300 mL) or 153 (1.7 oz) (50 mL). Applied properly, the 1.7 ounce bottle will be enough for both saddlebag extensions.
Loctite® 262, Threadlocker and Sealant (94759-99) is required for proper installation of this kit. See a Harley-Davidson dealer.
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
| 1. | Have extensions primed and painted prior to installation. | |||||||||
| 2. | Refer to the service manual to remove the saddlebags. | |||||||||
| 3. | Wash the saddlebags so that they are clean and free of any dirt, grease, road grime or foreign substances that would prevent the adhesive on the extensions from making a good bond with the saddlebags. | |||||||||
| 4. | See Figure 3. Remove the rear saddlebag support cushion and install cushion (8). | |||||||||
| 5. | See Figure 1. Apply masking tape to the painted surface of the saddlebag at the approximate drilling points on the mounting surface side of the saddlebag. Lay the saddlebag on a clean, soft cloth with the mounting side facing up. Measure carefully and mark the drilling points (1 and 2) with a grease pencil (or similar). | |||||||||
| 6. | Drill two holes into the saddlebag with a 7/32 inch drill bit through the masking tape. Clean excess material from the holes, remove the masking tape and any debris from the inside of the saddlebag. | |||||||||
| 7. | See Figure 3. Install the saddlebag bumper (9) by pulling the two rubber prongs through the drilled holes. Cut off the stem at the top of the crown after installation. | |||||||||
| 8. | Position the extension on the saddlebag and check the fit. If the alignment is acceptable, mark the bottom of the saddlebag at the screw bosses for drilling. | |||||||||
| 9. | Remove the extension and drill the five holes in the bottom of the saddlebag using a 3/8 inch drill bit. | |||||||||
| 10. | Apply the adhesive to the extension as shown in Figure 2 and install the extension to the saddlebag following the adhesive manufacturer's instructions. Clamp or apply pressure for 30 minutes. | |||||||||
| 11. | See Figure 3. When the adhesive has set, place the stud plate assemblies (3) in the drilled holes inside the saddlebag. Install the washers (5) and apply Loctite 262 to the screws (4). Tighten screws to 0.7–0.9 N·m (6–8 in-lbs). | |||||||||
| 12. | Apply the appropriate wear strip (1 or 2) to the bottom of the extension as shown in Figure 3. | |||||||||
| 13. | Repeat Steps 4 through 12 for the opposite saddlebag. | |||||||||
| 14. | Refer to the service manual to install the saddlebags. | 
Figure 1. Drill Hole Locations for Saddlebag Bumper |
| 1 | Apply 0.25 inch (6.4 mm) bead of adhesive as shown |
| 2 | Apply 0.25 inch (6.4 mm) inside bead of adhesive 1.5 inches (38 mm) from top of extension |
Figure 2. Applying Adhesive to Inside of Saddlebag Extension
SERVICE PARTS
Figure 3. Service Parts: Saddlebag Extension Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Saddlebag wear strip, left side | 88335-09 |
2 | Saddlebag wear strip, right side | 88336-09 |
3 | Stud plate assembly (10) | 90866-09 |
4 | Hex socket button head screw (10) | 3007 |
5 | Plain washer, type A (10) | 6716 |
6 | Saddlebag extension, left side | Not Sold Separately |
7 | Saddlebag extension, right side | Not Sold Separately |
8 | Saddlebag support cushion | 88334-09A |
9 | Saddlebag bumper | 88337-09 |
Items shown in
illustration but not included in kit | ||
A | Saddlebag | |