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SOFTAIL DETACHABLE SADDLEBAG CONVERSION KIT
J055452012-11-02
GENERAL
Kit Numbers
90200641
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
  • Models equipped with stock sissy-bar, rigid mount accessories, or saddlebags alone require the separate purchase of a Docking Hardware kit (90200669)
  • Models equipped with detachable accessories (passenger upright, sissy bar, luggage rack) require a Docking Hardware Kit (90200670).
Tools and Supplies Required
Loctite® 243 Threadlocker and Sealant - Blue (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 7 and Table 1.
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 6.8 kg (15 lb).
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 main fuse.
  2. Remove the seat per service manual instructions. Retain all seat mounting hardware.
1Nut (2000-2002 models) (2)
2Fender mounting brackets (2003 and later models)
3Fender support and cover
4Stud
5Flange nut and washer
6Saddlebag
7Acorn nut
8Washer
9Isolator
10Lower front support
Figure 1. Saddlebags
NOTE
Follow the procedure to remove and install the saddlebag from one side of the motorcycle, then perform the procedure on the other side.
Remove Saddlebag
  1. See Figure 1. Remove acorn nut (7) and washer (8) from the lower support. Remove the isolator from the lower support.
  2. Remove flange nuts and washers (5) from inside saddlebag.
  3. Remove saddlebag from motorcycle.
  4. Remove studs (4).
Replace Saddlebag Mounting Bracket
1. Move saddlebag to a work surface. Protect the saddlebag leather and buckles from scratches.
2. Drill out the saddlebag mounting bracket rivets. Discard mounting bracket.
3. Remove warning labels from the inside of the saddlebag.
4. Install mounting bracket to the saddlebag as follows:
a. Trim away any leather that interferes with the bracket mounting location.
b. Apply a 2 in. (5 cm) wide strip of tape to the surface of the saddlebag where the bracket will mount.
c. Position mounting bracket onto the saddlebag. Align the bracket with the large holes on the back of the saddlebag.
d. See Figure 2. Insert docking points into the mounting bracket. Insert a screw through the docking point (8) and saddlebag to properly position the bracket.
e. Mark the center of each of the three mounting hole locations onto the tape.
f. Mark the center of the hole that is between the two square holes on the brackets.
g. Remove the docking points from the mounting bracket.
h. Drill a 9/32 in hole at each marked location.
i. Remove the tape from the saddlebag.
j. See Figure 7. Insert latch pin (part of service kit 3) through the mounting bracket. Position latch in the bracket and align the square mounting bosses with the square holes in the bracket. Install the spring over the pin and latch.
k. Remove backing tape from warning label and install it inside the saddlebag. Align with the saddlebag holes.
l. Install the mounting bracket (1 or 2) to the saddlebag and secure with screws (6), washers (7) and nuts (8). Insert screws from inside the saddlebag. Tighten to 8.1–10.8 N·m (72–96 in-lbs).
m. Install knob onto the latch pin (all part of service kit 3). Align set screw with the detent on the latch pin. Tighten set screw.
n. Insert plastic plugs (9) into the holes in the saddlebag. When using a flat top kit, the plugs need to be inserted from the inside of the saddlebag. The flat top bracket then captures the plug between the bag and the flat top bracket.
1Docking point (2)
2Screw (2)
3Mounting bracket
Figure 2. Mark Drilling Locations
INSTALLATION
NOTE
Proper installation of this kit requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side.
Install Docking Hardware Kit(s) (Sold Separately)
Without Other Detachable Accessories: See Figure 3. Insert screws (1) through mini docking points (2). Install screws into fender support mounting bracket (inside fender). Tighten screws to 28–36 N·m (21–27 ft-lbs).
With Other Detachable Accessories: See Figure 4. Insert screws (1) through mini docking points (2) and front docking point (3) and rear spacer (4). Install screws into fender support mounting bracket (inside fender). Tighten screws to 28–36 N·m (21–27 ft-lbs).
1Screw (2)
2Docking point (2)
Figure 3. Docking Point Installation (Without Other Detachable Accessories)
1Screw
2Docking point (2)
3Front docking point
4Spacer
Figure 4. Docking Point Installation (With Other Detachable Accessories)
Install Lower Front Docking Point
1Screw
2Docking point
3Lower front support
4Spacer
Figure 5. Lower Front Docking Point (With Other Detachable Accessories)
1Screw
2Docking point
3Lower front support
Figure 6. Lower Front Docking Point (Without Other Detachable Accessories)
With Other Detachable Accessories:
1. See Figure 5. Install mini docking point (2), spacer (4) onto screw (1).
2. Apply Loctite 243 - Blue to threads of screw.
3. Install screw into the lower front support (3). Tighten screw to 16.3–24.4 N·m (12–18 ft-lbs).
Without Other Detachable Accessories:
1. See Figure 6. Install mini docking point (2) onto screw (1).
2. Apply Loctite 243 - Blue to threads of the screw.
3. Install screw into threaded portion of lower front support (3). Tighten screw to 16.3–24.4 N·m (12–18 ft-lbs).
Saddlebag Installation
  1. Open the saddlebag.
  2. Pull on knob (3) (located in upper rear corner inside saddlebag) and rotate it to the unlock position (clockwise for left saddlebag, counterclockwise for right saddlebag).
  3. Approach the motorcycle with the saddlebag tipped slightly forward and insert the large diameter of the keyhole end of the lower support arm (8, 9) over the lower front mini docking point.
    1. The thickness of the end of the lower support arm should engage in the reduced diameter plastic groove of the mini docking point at the lower front docking point location.
    2. With Detachable Accessories: Swing body of saddlebag down so the outer mini docking points, which are stacked on top of the standard docking points on fender support cover (strut cover), slide into slots of bracket on back of saddlebag.
    3. Without Detachable Accessories: Swing body of saddlebag down so the standard docking points on fender support cover (strut cover) slide into slots of bracket on back of saddlebag.
  4. Slide the saddlebag forward on the motorcycle making sure it is fully seated into all three docking points.
  5. Pull the knob outward and rotate it towards the LOCK position until it snaps into place. Push saddlebag towards the rear of the vehicle to make sure the latch is fully engaged.
  6. Verify that the saddlebag is secure on all three docking points. Verify that the locking latch is secure. Gently pull the saddlebag towards the rear of the vehicle to make sure the latch is fully engaged
Install Opposite Docking Hardware and Saddlebag
After completing the installation for one side of the motorcycle, repeat the same tasks to install the docking points and saddlebag on the opposite side.
Final Assembly
NOTE
Verify that the ignition/light key switch is in the OFF position before installing the main fuse/attaching the battery cables.
1. Verify that the ignition/key switch is turned to the OFF position. Refer to the service manual and follow the instructions given to install the main fuse.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
2. Refer to the service manual, and follow instructions to install the seat.
MAINTENANCE
Docking Point Screws
NOTICE
Failure to tighten hardware to the specified torque could result in damage to the installed accessory. (00508b)
After 500 miles of on road use with the saddlebags installed, it is necessary to check the torque on the docking point mounting screws. Check to make sure the proper torque is maintained and tighten screws if necessary.
  • Upper docking point screws, 28.5–36.6 N·m (21–27 ft-lbs).
  • Lower front docking point screws, 16.3–24.4 N·m (12–18 ft-lbs).
  • Saddlebag lower support arm screws, 6.8–10.2 N·m (60–90 in-lbs).
Saddlebag Docking Points
NOTE
In time, the docking points may wear causing the saddlebag connections to become loose. The fit may be tightened using the following procedure:
  1. Remove docking hardware (screws).
  2. Clean threadlocker residue off of screw threads.
  3. Apply Loctite 243 - Blue to last four threads of docking point screws.
  4. Install screws loosely for now.
  5. Rotate docking points clockwise approximately 45° from their previous position.
  6. Tighten the docking hardware as follows.
  • 28.5–36.6 N·m (21–27 ft-lbs) for upper docking points.
  • 16.3–24.4 N·m (12–18 ft-lbs) for lower front docking points.
  1. Repeat as required, up to three adjustments. After the third adjustment, new docking points must be installed.
SERVICE PARTS
Figure 7. Service Parts: Softail Detachable Saddlebag Conversion Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Mounting bracket, right
Not Sold Separately
2
Mounting bracket, left
Not Sold Separately
3
Latch, repair kit (includes knob, pin, spring and latch) (2)
90200665
4
Label, lock/unlock, right
Not Sold Separately
5
Label, lock/unlock, left
Not Sold Separately
6
screw (6)
4702
7
Washer, flat (6)
6036
8
Locknut (6)
7686
9
Plug, push-in (4)
Not Sold Separately