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ALUMINUM SIDE CASES
941000922023-09-26
GENERAL INFORMATION
Table 1. General Information
Kits
Suggested Tools
Skill Level(1)
90202082, 90202088
Safety Glasses, Torque Wrench
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Aluminum Side Cases
Table 2. Kit Contents: Aluminum Side Cases
Verify that all contents are present in the kit before installing or removing items from vehicle.
Item
Qty
Description
Part No.
Notes
1
1
Aluminum side case (black) (right)
90202103
Aluminum side case (clear) (right)
90202083
2
1
Aluminum side case (black) (left)
90202104
Aluminum side case (clear) (left)
90202084
3
1
Lockset (2-keys)
90300164
4
2
Snap-Fit
Not sold separately
5
2
Lid limiter
Not sold separately
6
2
Nylon bushing
Not sold separately
7
4
Screw
Not sold separately
8
2
Medallion
14101429
9
2
Reflector (red)
67900205A
10
1
Lid (clear) (right)
90202403
Lid (black) (right)
90202405
11
1
Lid (clear) (left)
90202404
Lid (black) (left)
90202406
12
2
Lid limiter kit (includes 4-7)
90202407
13
4
Nylon bushing
90202340
14
1
Gasket (right)
90202505
Service part
15
1
Gasket (left)
90202506
Service part
16
2
Hinge cover
90202786
Service part
17
2
Lid latch
90202789
Service part
18
2
Lower hinge
90202790
Service part
19
2
Latch
90202791
Service part
Items mentioned in text, but not included in kit.
A
1
Flange button head screw
9.5 N·m (7 ft-lbs)
B
1
Latch bracket
C
1
Locknut
D
1
Docking point
E
1
Flat head screw
9.5 N·m (7 ft-lbs)
GENERAL
Models
For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.
Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets
Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.
Installation Requirements
WARNING
Rider and passenger safety depend upon the correct installation of this kit. 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. (00308b)
WARNING
See the Accessories and Cargo section in your owner's manual. Improper cargo loading or accessory installation can cause component failure and adversely affect stability, handling and performance, which could result in death or serious injury. (00021b)
  • Do not exceed 22 lbs (10 kg) total weight contents and attachments per bag.
  • Periodically recheck load.
WARNING
Do not exceed the motorcycle's Gross Vehicle Weight Rating (GVWR) or Gross Axle Weight Rating (GAWR). Exceeding these weight ratings can lead to component failure and adversely affect stability, handling and performance, which could result in death or serious injury. (00016f)
Separate purchase of Side Mounting Kit (Part No. 94100093) is required for installation.
OPEN LID
NOTE
For lubrication ONLY use graphite powder!
NOTE
Pay attention to correct alignment of clamping plates.
1. See Figure 2. Pull latch (1) of lid (3) upwards.
2. Remove it from latch bar (2).
3. Open lid (3).
1Latch
2Latch bar
3Lid
Figure 2. Opening Lid
INSERTION OF LOCK CYLINDER SET
NOTE
Pay attention to correct alignment of clamping plates.
NOTE
For lubrication ONLY use graphite powder!
1. See Figure 3. Insert lock cylinders (1) into latches (2).
2. Secure lock cylinders with clamping plates (3).
3. Insert keys (4) into lock cylinders.
4. Open or close lock cylinder.
1Lock cylinder
2Latch
3Clamping plate
4Key
590° rotation
Figure 3. Lock Cylinder Insertion
MOUNTING LID LIMITERS
NOTE
Pay attention to left-right specifications for limiters (in driving direction).
1. See Figure 4. Open lid. Attach snap-fit (2) at lid frame. Tighten screws (1), hand tighten, fully seated.
Torque: 0.5 N·m (4 in-lbs)
2. Attach lid limiters (3) at case frame. Tighten screws, hand tighten, fully seated. Press lid limiters onto snap-fits.
Torque: 0.5 N·m (4 in-lbs)
3. Before closing lid for first time, lid limiters must be compressed. While closing lid, make sure that lid limiters are not pinched between lid and case.
4. To remove lid from case, remove lid limiters from snap-fits first.
1Screw (2)
2Snap-Fit (2)
3Lid limiter (2)
4Nylon bushing (2)
Figure 4. Lid Limiter Mounting
REMOVING LID
NOTE
See Figure 4. If lid limiters have been installed, they must be detached before removing lid.
1. See Figure 5. Press quick release fastener down until it clicks into place and button pops out.
2. Remove lid from case.
3. Press button of quick release fastener to lock replaced lid in place. Make sure that quick release fastener snaps above.
Figure 5. Lid Removal
INSTALL
NOTE
Make sure that all four docking points (3) rest on at same time.
NOTE
Make sure closed latch is under sufficient tension! If not latch hook must be readjusted!
NOTE
Secure aluminum case with separately available lock cylinder set at side case carrier before riding!
1. See Figure 6. Install four openings of the mounting rails (1) onto docking point (3) of the mounting side case carrier (2). Press aluminum case slightly downward, until it properly rests on mounting side case carrier (2).
2. Place latch (4) over latch hook (5).
3. Close latch (4) and check proper fit of aluminum case on mounting side case carrier (2).
4. See Figure 7. Make sure side cases are installed properly. Verify components are parallel to each other. If out of alignment adjust as needed.
1Mounting rail
2Side case carrier
3Docking point
4Latch
5Latch hook
Figure 6. Installation of Aluminum Cases
1Latch bracket
2Flange button head screw
Figure 7. Proper Alignment
MAINTENANCE
1. See Figure 8. Loosen six screws (2) on inner side of case and remove quick release fastener (1).
2. Loosen screw (3).
3. Loosen clip carefully.
4. Remove quick release fastener (1) and springs (4) from mounting plate (5).
5. Clean components with clean water and let air dry.
6. Install part in reverse order.
1Quick release fastener
2Screws (6)
3Screw
4Springs
5Mounting plate
Figure 8. Maintenance