ALUMINUM SIDE CASES

941000922024-05-29

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
	1	1	Aluminum side case (clear) (right)	90202083
	2	1	Aluminum side case (black) (left)	90202104
	2	1	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
	10	1	Lid (black) (right)	90202405
	11	1	Lid (clear) (left)	90202404
	11	1	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

Instruction sheet is also available electronically. To verify you are using the most current version available, do one of the following:

Go to h-d.com/isheets
Scan QR code in upper left corner of the instruction sheet

NOTE

This instruction sheet may have a Supplemental Video to assist installer in clarifying a certain part of the assembly. A linked video would be located at the end of this instruction sheet.

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.

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 ACCESSORIES AND CARGO section within the SAFETY FIRST 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. (00021c)

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.	Figure 2 Pull latch (1) of lid (3) upwards.
2.	Remove it from latch bar (2).
3.	Open lid (3).

1	Latch
2	Latch bar
3	Lid

Figure 2. Opening Lid

INSERTION OF LOCK CYLINDER SET

NOTE

For lubrication ONLY use graphite powder!
Pay attention to correct alignment of clamping plates.
Figure 3 Make sure lock cylinder tab points towards latch.

1.	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.

1	Lock cylinder
2	Latch
3	Clamping plate
4	Key
5	90° rotation

Figure 3. Lock Cylinder Insertion

MOUNTING LID LIMITERS

NOTE

Pay attention to left-right specifications for limiters (in driving direction).

1.	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.

1	Screw (2)
2	Snap-Fit (2)
3	Lid limiter (2)
4	Nylon bushing (2)

Figure 4. Lid Limiter Mounting

REMOVING LID

NOTE

Figure 4 If lid limiters have been installed, they must be detached before removing lid.

1.	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.	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.	Figure 7 Make sure side cases are installed properly. Verify components are parallel to each other. If out of alignment adjust as needed.

1	Mounting rail
2	Side case carrier
3	Docking point
4	Latch
5	Latch hook

Figure 6. Installation of Aluminum Cases

1	Latch bracket
2	Flange button head screw

Figure 7. Proper Alignment

MAINTENANCE

1.	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.

1	Quick release fastener
2	Screws (6)
3	Screw
4	Springs
5	Mounting plate

Figure 8. Maintenance