SERVICE KITS - PLASTIC SIDE CASES

941002972024-03-15

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
90202129, 90202130, 53000852, 90202136, 90202137, 90202131, 90202133, 90202134	Safety Glasses, Torque Wrench, Flathead Screwdriver

(1) Tightening to torque value or other moderate tools and techniques required

KIT CONTENTS

Figure 1. Kit Contents: Service Kits - Plastic Side Cases

Table 2. Kit Contents: Service Kits - Plastic 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	Latch assembly kit, right	90202130
1	1	Latch assembly kit, left	90202129
2	1	Gasket kit	53000852
3	1	Bungee loop kit	90202133	Serviced individually
4	1	Third-point mount kit, right	90202137
4	1	Third-point mount kit, left	90202136
5	1	Lid Tether kit	90202131
6	1	Net kit	90202134

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)

REPLACEMENT LATCH ASSEMBLY - SIDE CASES

Remove

1.	Insert key into lock.
2.	Unlock case and open lid. NOTE Do not remove key from lock cylinder to keep tumblers in place.
3.	Figure 2 Remove hardware. a. Remove screws (2). b. With pliers, remove gasket (1) just enough to access screws (4). c. Remove screws (4). d. Remove six screws (8). e. With pliers, remove plastic caps (5). Retain for later use. f. Remove bolts (7) and nuts (6).
4.	Figure 3 Remove latch assembly (1) by sliding it out away from saddlebag. NOTE Lid hooks need to be pushed to open position so not to catch on case frame when being removed.
5.	Remove lock cylinder. a. Figure 4 Insert small screwdriver in opening (1) to depress retention tumbler. b. While retention tumbler is depressed, push bottom of lock cylinder assembly to remove it. NOTE Do not remove key from lock cylinder to keep tumblers in place.

Install

1.	Install lock cylinder into new latch assembly. See isheet 94100096. NOTE Key to remain in lock cylinder when removing or install lock cylinder.
2.	Figure 2 Install cartridge mechanism by sliding it on saddlebag.
3.	Figure 2 Install hardware. a. Install bolts (7) and nuts (6). Tighten. Torque: 3–3.5 N·m (2–3 ft-lbs) until fully seated plus ¼ to ½ turn. b. Install plastic caps (5). c. Install six screws (8). Tighten. Torque: 2–2.5 N·m (1–2 ft-lbs) until fully seated hand tight d. Install screws (4). e. Install gasket (1). f. Install screws (2). Tighten. Torque: 0.5–1 N·m (4–9 in-lbs) until fully seated hand tight

1	Gasket
2	Screw (2)
3	Lid hooks
4	Screw, T20 torx (2)
5	Plastic cap (2)
6	Nut (2)
7	Bolt, M6 (2)
8	Screw, T20 torx (6)

Figure 2. Remove/Install Hardware

1	Latch Assembly
2	Bolt, M6 (2)

Figure 3. Remove/Install Latch Assembly

Opening

Figure 4. Remove Lock Cylinder

GASKET REPLACEMENT

Remove

Figure 5 Remove Original Equipment (OE) gasket (1) and rubber plug (2) using needle-nose pliers. Note orientation of gasket and rubber plug in groove.

Install

1.	Measure and cut new gasket to the same length as OE gasket.
2.	Figure 5 Install new rubber plug (2).
3.	Figure 5 Install new gasket (1). a. Insert at lowest part of side case. b. Push into groove all the way around side case. Reference orientation noted during removal. c. If gasket is too long, mark gasket, pull out of groove a couple of inches and cut gasket using a razor knife. d. Install remaining gasket into groove.

1	Gasket
2	Rubber plug

Figure 5. Remove/Install Gasket

BUNGEE LOOP REPLACEMENT

Remove

Figure 6 Remove OE screws (2) and bungee loops (1).

Install

Figure 6 Install new bungee loops (1) with OE screws (2) hand tight.

1	Bungee loop (2)
2	OE Screw (2)

Figure 6. Remove/Install Bungee Loop

THIRD POINT MOUNT REPLACEMENT

Remove

1.	Figure 7 Remove OE screw (2) from outside of side case.
2.	Open side case and remove four screws (2). Retain.
3.	Remove and discard third point mount (1).

Install

1.	Figure 7 Install new third point mount (1).
2.	Install OE screw (2) to outside of side case loosely.
3.	Install four screws (2) to inside of side case.

1	Third-point mount
2	OE Screw (5)

Figure 7. Remove/Install Third Point Mount

TETHERS

Remove

1.	Figure 8 Remove OE screws (4).
2.	Remove discs (2) and strap (3). Discard.
3.	Remove flat head screw into lid retainer (1). Discard screw and retainer.

Install

1.	Install new retainer (1) using OE screw.
2.	Install new disc (2) into one end of strap (3) with screw (4) to fasten to side case tub.
3.	Install new disc (2) into other end of strap (3) with screw (4) to fasten to lid retainer (1).

1	Retainer (2)
2	Disc (4)
3	Strap (2)
4	OE Screw (4)

Figure 8. Remove/Install Tether

NET

Remove

1.	Remove four hook-n-loops from slots (3) on bottom of side case.
2.	Remove both hooks from each side of side case.

Install

1.	Secure four hook-n-loops (2) through slots (3) on bottom of side case.
2.	Secure both hooks (1) to each side of side case.

1	Hook (2)
2	Hook-n-loop (4)
3	Slot, side case (4)

Figure 9. Remove/Install Net