FLSTC DETACHABLE SADDLEBAG CONVERSION KIT
J062422015-04-02
GENERAL
Kit Numbers
90200641A
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
Models with original equipment (OE) sissy-bar, rigid mount
accessories or saddlebags alone require separate purchase of a Docking Hardware Kit (Part No. 90200669).
Models with detachable accessories (passenger upright, sissy
bar, luggage rack) require separate purchase of a Docking Hardware Kit (Part No. 90200670).
Loctite® 243 Threadlocker and Sealant - Blue (Part No. 99642-97) is required for the proper installation of this kit.
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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
PREPARATION
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
NOTE
- WITH security siren: With security fob present, turn ignition switch ON. See the service manual. Disarm security system. Turn ignition switch OFF. IMMEDIATELY remove the main fuse.
- WITHOUT security siren: See the service manual. Remove main fuse.
- Remove seat. See the service manual. Retain all seat mounting hardware.
REMOVAL
Remove Saddlebag and Lower Mounting Support
NOTE
Proper installation of this kit requires that all removal and installation tasks be completed for one side before beginning on the opposite side.
- See Figure 1. Remove acorn nut (6) and washer (7) from the lower front support (8).
- Remove flange nuts and washers (4) from inside saddlebag.
- Remove saddlebag.
- Remove studs (3). Remove rear passenger footpeg. Remove lower front support.
Replace Saddlebag Mounting Bracket
NOTE
Protect the saddlebag leather and buckles from scratches.
| 1. | Place saddlebag face down on a protected work surface. | |
| 2. | Drill out the saddlebag mounting bracket rivets. Discard mounting bracket. | |
| 3. | Remove warning labels from the inside of the saddlebag. | |
| 4. | See Figure 7. Install the new, correct-side saddlebag mounting bracket (1 or 2) to the saddlebag. a. Trim away any leather that interferes with the bracket mounting location. b. Apply a 5 cm (2 in) wide strip of masking tape to the inboard surface of the saddlebag, at the bracket mounting location. c. Position the 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 (1) into mounting bracket (3). Insert a screw (2) through each docking point and saddlebag to position the bracket. e. See Figure 7. Mark the center of each of the three mounting hole locations (A) onto the tape. f. Mark the center of the hole (B) that is between the two square holes on the bracket. g. Remove docking points from mounting bracket. h. Drill a 7.25 mm (9/32 in) hole at each marked location. i. Remove the tape from the saddlebag. j. Insert latch pin (part of Latch Repair Kit, Item 3) through the mounting bracket. Position the latch in the bracket. 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 (7). Install label inside the saddlebag. Align with saddlebag holes. l. NOTE: Insert screws and washers from inside
the saddlebag. Install the mounting bracket (1 or 2) to the saddlebag. Secure with screws (8), washers (9) and nuts (10). Tighten to 8.1–10.8 N·m (72–96 in-lbs). m. Install knob (C, part of Latch Repair Kit). Align set screw with the detent on the latch pin. Tighten set screw securely. n. Insert plastic plugs (11) into the saddlebag holes. When using a flat top kit, insert the plugs from inside the saddlebag. The flat top bracket captures the plug between the bag and the flat top bracket. |
| 1 | Fender mounting brackets |
| 2 | Fender support and cover |
| 3 | Stud (2) |
| 4 | Flange nut and washer (2) |
| 5 | Saddlebag |
| 6 | Acorn nut |
| 7 | Washer |
| 8 | Lower front support |
Figure 1. Remove Saddlebag
| 1 | Docking point (2) |
| 2 | Screw (2) |
| 3 | Mounting bracket |
Figure 2. Mark Drilling Locations
INSTALLATION
NOTE
Proper installation of this kit requires that all removal and installation tasks be completed for one side before beginning on the opposite side.
Install Docking Hardware Kits (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).
| 1 | Screw (2) |
| 2 | Docking point (2) |
Figure 3. Docking Point Installation (Without Other Detachable Accessories)
WITH Other Detachable Accessories: See Figure 4. Insert screws (1) through mini docking points (2), 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).
| 1 | Screw |
| 2 | Docking point (2) |
| 3 | Front docking point |
| 4 | Spacer |
Figure 4. Docking Point Installation (With Other Detachable Accessories)
Install Lower Front Docking Point
WITHOUT Other Detachable Accessories:
| 1. | See Figure 5. Install lower front saddlebag support assembly (3). | |
| 2. | Install mini docking point (2) onto screw (1). | |
| 3. | Apply Loctite 243 - Blue to the clean screw threads. | |
| 4. | Install screw into the threaded hole of lower front support (3). Tighten screw to 16.3–24.4 N·m (12–18 ft-lbs). |
| 1 | Screw |
| 2 | Docking point |
| 3 | Lower front support |
Figure 5. Lower Front Docking Point (Without Other Detachable Accessories)
WITH Other Detachable Accessories:
| 1. | See Figure 6. Install lower front saddlebag support assembly (3). | |
| 2. | Install mini docking point (2) and spacer (4) onto screw (1). | |
| 3. | Apply Loctite 243 - Blue to the clean screw threads. | |
| 4. | Install screw (1) into the threaded hole of lower front support (3). Tighten screw to 16.3–24.4 N·m (12–18 ft-lbs). |
| 1 | Screw |
| 2 | Docking point |
| 3 | Lower front support |
| 4 | Spacer |
Figure 6. Lower Front Docking Point (With Other Detachable Accessories)
Saddlebag Installation
- Open the saddlebag.
- See Figure 7. Pull knob (C, inside saddlebag at upper rear corner). Rotate knob to the unlock position (clockwise for left saddlebag, counterclockwise for right saddlebag).
- Approach the motorcycle holding the saddlebag. Rotate so the lower support arm is slightly downward. Insert the large diameter of the keyhole (D, at the lower support arm end) over the lower front mini docking point (E).
- Engage the thickness of the end of the lower support arm with the reduced diameter plastic groove of the docking point.
- WITHOUT Detachable Accessories: Swing the saddlebag body down so the standard docking points on the fender support/strut cover slide into the slots (F) in the bracket on the back of the saddlebag. WITH Detachable Accessories: Swing the saddlebag body down so the outer mini docking points (stacked on top of the standard docking points on the fender support/strut cover), slide into the slots (F) in the bracket on the back of the saddlebag.
- Slide the saddlebag forward, making sure that it is fully seated into all three docking points.
- Pull knob (C) outward. Rotate knob toward the LOCK position until it snaps into place. Push saddlebag toward the rear of the vehicle to make sure that the latch is fully engaged.
- Verify that the saddlebag is secure on all three docking points. Verify that the locking latch is secure. Gently pull the saddlebag toward the rear of the vehicle to make sure that the latch is fully engaged
Install Remaining Docking Hardware and Saddlebag
After completing the installation for one side, repeat the same tasks to install the docking points and saddlebag on the opposite side.
COMPLETION
NOTE
Verify that the ignition switch is OFF before installing the main fuse.
| 1. | Verify that the ignition switch is OFF. See the service manual. Install 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. | See the service manual. Install seat. |
MAINTENANCE
Docking Point Screws
NOTICE
Failure to tighten hardware to the specified torque could result in damage to the installed accessory. (00508b)
After 800 km (500 mi) of riding with saddlebags installed, check the tightness of the docking point mounting screws. Make sure that proper torque is maintained. Tighten screws as 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 Docking Points
NOTE
In time docking points wear, causing the saddlebag connections to become loose. The fit can be tightened using the following procedure:
- Mark each docking point to indicate the current top position.
- Remove the docking hardware.
- Remove all existing threadlocking agent from the docking point screw and mounting hole threads.
- Apply Loctite 243 - Blue to the last four threads of the docking point screws.
- Loosely install the docking points with the screws.
- Rotate docking points clockwise approximately 45° from the previous position.
- Tighten the docking hardware.
- 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.
- This procedure can be repeated up to three times before new docking points must be installed.
SERVICE PARTS
Table 1. Service Parts
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, latch and set screw, Item 4 ) (2) | 90200665 |
4 |
| 10200139 |
5 | Label, lock/unlock (right) | Not sold separately |
6 | Label, lock/unlock (left) | Not sold separately |
7 | Label, warning (2) | Not sold separately |
8 | Hex head cap screw (6) | 4702 |
9 | Flat washer (6) | 6036 |
10 | Locknut (6) | 7686 |
11 | Plug, push-in (4) | Not sold separately |
12 | Saddlebag support assembly, lower front (2) | Not sold separately |
Items mentioned in text, but not included in
kit: | ||
A | Mounting hole location (3) | |
B | Hole between two square holes | |
C | Latch knob | |
D | Keyhole at end of lower support arm | |
E | Lower front mini docking point | |
F | Slots (2) in bracket on back of saddlebag. | |
SERVICE PARTS
Figure 7. Service Parts: Softail Detachable Saddlebag Conversion Kit