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DETACHABLE SADDLEBAG LATCH SPRING KIT
J054612012-10-18
GENERAL
Kit Number
88257-07B, 90200665
Models
This kit is for replacement of the latch components on select accessory Detachable Saddlebags.
Kit Contents
See Figure 2 and Table 1.
REMOVAL
NOTE
If replacing an older style of detachable latch system as seen in Figure 1 , follow the removal steps for Lobed-Knob Latch Systems. If replacing a newer style of detachable latch system as seen in Figure 2 , follow the removal steps for Position-Indicating Knob Latch Systems.
  1. Remove saddlebag from motorcycle.
Lobed-Knob Latch System
1. See Figure 1. Pull and turn knob (1) (inside saddlebag) toward the front (clockwise for right-side saddlebag, counterclockwise for left-side saddlebag), locking the latch (5) in the closed position.
2. While holding latch screw (6) with a 3/16 in hex wrench, turn/unscrew knob (inside saddlebag) counterclockwise.
NOTE
There should be some resistance when unscrewing knob due to the existing threadlocker on the screw threads. If necessary, use a pliers or similar tool to remove the plastic knob.
3. Remove knob (1) from inside saddlebag.
4. Remove O-ring (2) from inside saddlebag. Note that the O-ring may have already fallen to the bottom of the saddlebag.
5. Remove screw (6) (outside saddlebag) from latch threaded boss using 3/16 in hex wrench.
6. Press latch (5) (outside saddlebag) to unlock the two latch tabs from the square holes in saddlebag rear bracket.
1Knob
2O-ring
3Spacer (red)
4Spring
5Latch
6Screw
7Knob, 7-lobe style
8Knob, 4-lobe style
Figure 1. Lobed-Knob Detachable Latch System
7. Slide latch with spring (4) towards opening in rear bracket and remove latch and spring.
8. Remove existing tube spacer (3) from hole in saddlebag plastic back. Note that the spacer may have already fallen out of the hole.
9. Discard existing knob, latch, spring, spacer, O-ring and screw.
10. Using soapy water or a mixture of 50-70% isopropyl alcohol and 30-50% distilled water, thoroughly clean surfaces inside and on back of saddlebag where new latch assembly and labels will be installed.
11. Allow the surfaces to dry completely before installing kit.
Position-Indicating Knob Latch System
NOTE
See Figure 2. Kit 90200665 does not use the spacer (4) or o-ring (3) and does not include the lock position label (8 and 9).
  1. Verify the knob (1) (inside saddlebag) is in the latch open position (rotated towards the rear - counterclockwise for right-side saddlebag, clockwise for left-side saddlebag). This puts the setscrew (2) in an exposed, vertical position.
  2. Using a 3/32 in hex wrench, loosen or remove the setscrew (2) from the knob (1) (inside saddlebag) until the knob can be removed from the lockpin (7).
  3. Remove knob (1) from inside saddlebag.
  4. Remove O-ring (3) and spacer (4) from inside the saddlebag. Note that the O-ring and/or spacer may have already fallen to the bottom of the saddlebag.
  5. Remove lockpin (7) (outside saddlebag) from the latch (6).
  6. With latch (6) in the unlock position, slide the latch with spring (5) towards opening in rear saddlebag bracket and remove latch and spring.
  7. Discard existing knob, setscrew, latch, spring, spacer, O-ring and lockpin.
  8. Examine the lock position label inside the saddlebag and remove if damaged.
  9. Using soapy water or a mixture of 50-70% isopropyl alcohol and 30-50% distilled water, thoroughly clean surfaces inside and on back of saddlebag where new latch assembly and label will be installed.
  10. Allow the surfaces to dry completely before installing kit.
INSTALLATION
  1. See Figure 2. Install spring (5) over outer diameter of extruded boss of latch (6).
  2. Insert latch with spring into latch opening in saddlebag rear bracket (A) so it is captured between the bracket and saddlebag plastic back (B).
    3. NOTE
    The two square projections on the latch should be facing away from the saddlebag so they will fit into the square holes in the saddlebag rear bracket.
  3. Position latch so the two square projections of the latch are captured in the square holes in the saddlebag rear bracket (latch is in closed position).
  4. Install lockpin (7) through latch hole (C) in saddlebag rear bracket (A) and aligned with the D-hole of the latch.
    5. NOTE
    If installing kit 90200665, skip to step 7.
  5. Install tube spacer (4) (inside saddlebag) over lockpin (7) and into the hole in saddlebag plastic back. Position spacer as follows:
    1. Outside saddlebag: Slide spacer into the inner diameter of the latch spring until it is up against the top of the latch extruded boss.
    2. Inside saddlebag: Spacer should protrude into inside of saddlebag approximately 3.3 mm (0.125 in) above saddlebag plastic back surface.
    6. NOTE
    If the spacer is protruding further than 3.3 mm (0.125 in) into the saddlebag, rotate and/or move spacer while pushing spacer into hole so it installs inside the spring inner diameter.
  6. Install O-ring (3) onto end of spacer inside saddlebag. Slide O-ring over spacer until it rests against the plastic back of the saddlebag.
  7. Install a few threads of the setscrew (2) into knob (1).
  8. Align and install knob (1) onto end of lockpin (7). The threaded hole for the setscrew (2) should face forward inside the saddlebag (to the right for the right-side saddlebag and to the left for the left-side saddlebag).
  9. Snug the setscrew to the indent of the lockpin while holding the lockpin in place with the knob.
  10. If not installing the lock position label (8 or 9), skip to step 12.
    11. NOTE
    Some applications of this label may cover rivets or contours in the saddlebag plastic back. Use good judgment to position the label so that it remains secure with use.
  11. If installing lock position label:
    1. Chose the correct label (8 or 9) for the appropriate side saddlebag.
    2. Verify the label installation area is clean and free of debris.
    3. Remove the adhesive backing of the label and position behind the knob with the orange, locked-position arrow in line with the locked-position knob pointer.
  12. Install saddlebag onto motorcycle. Open and close latch several times to verify kit is properly installed.
  13. Close latch by rotating knob toward the front (clockwise for right-side saddlebag, counterclockwise for left-side saddlebag). Knob pointer should align with the locked position of the label.
SERVICE PARTS
Figure 2. Service Parts: Detachable Saddlebag Latch Spring Kit
Table 1. Service Parts: Detachable Saddlebag Latch Spring Kit
Item
Description (Quantity)
Part Number
1
Knob, latch
Not Sold Separately
2
Setscrew, #10-24 x .0.25 long
10200139
3
O-ring (not included in 90200665)
11900007
4
Spacer, tube (red, not included in 90200665)
Not Sold Separately
5
Spring, compression
Not Sold Separately
6
Latch
Not Sold Separately
7
Lockpin
Not Sold Separately
8
Label, lock/unlock, left saddlebag (not included in 90200665)
Not Sold Separately
9
Label, lock/unlock, right saddlebag (not included in 90200665)
Not Sold Separately
Items mentioned in text but not included in kit:
A
Rear bracket, saddlebag
B
Plastic back, saddlebag
C
Latch hole