SPORTSTER RIGID LEATHER SADDLEBAG KITS
J029692005-08-17
GENERAL
Kit Number
53050-04 (domestic) and 53148-04 (international)
Models
These kits fit 2004 and later XL models (except those equipped with rear axle covers or a Bobtail fender).
WARNINGDo 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 7 pounds (3.17 Kg).
Additional Parts Required
WARNINGRider 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)
INSTALLATION
Rear Fender Support Removal
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
| 1. | Refer to the Owner's Manual and follow the instructions to remove the seat and disconnect the negative battery cable. Retain all seat mounting hardware. | |||||||||||||
| 2. | Properly support motorcycle under frame with stand or suitable blocking to prepare for addition of saddlebags. | |||||||||||||
| 3. | See Figure 1. It is necessary to remove the taillight lens to access the Amp Multi-lock connector. Unplug the connectors for each turn signal and push them down and through the opening in the tail light and fender. | |||||||||||||
| 4. | From each set of turn signal wires hanging from under the fender, carefully pull the turn signal wires out of the clips and cut the wires about 4-6 in. (10.2-15.2 cm) from end. NOTE The wires must be cut to allow them to fit through the new turn signal bar. They will be spliced back together later in the installation. It will be necessary to remove the black conduit covering wire sheath to allow splicing. | |||||||||||||
| 5. | See Figure 1. Remove and discard the front and rear button head screws (1), two locknuts (2) and under fender clip nuts (3) from the left and right rear fender support covers. | |||||||||||||
| 6. | Carefully pull the turn signal assemblies (left and right) away from the fender support covers pulling the turn signal wires disconnected and previously cut out of the holes in the sides of the fender. Cut the black conduit from the turn signal wires. Discard the conduit. NOTE Rear turn signals must be relocated to new turn signal bar on the rear license plate bracket. | 
Figure 1. Rear Fender Support Removal |
Turn Signal Installation
- See Figure 2. Remove the lens (5) from the rear turn signal housing (1).
- Carefully pry the reflector (3) and grommet (2) from the housing (1). Gently pull the wires out from the housing wire hole.
- Remove and discard the support (6), stud (7), and nut (8).
- See Figure 3. Install the chrome jam nuts (4) onto either end of the turn signal bar. Route the turn signal wires:
- through the threaded hole in the turn signal housing (1),
- through the recess cover plate (3),
- through the new 5/16 lockwasher (2),
- insert wires into the turn signal bar (5) end,
- and out the hole a few inches from the end of the bar.
- While pulling the turn signal wires, guide each turn signal socket and grommet into its housing.
- Screw the turn signal housing (1) onto the threaded stud end being careful not to twist the wires. Leave the turn signal housing loosely fastened to the bar. Install bulb and lens.
- Repeat steps for other turn signal.
NOTE
Apply a drop of liquid soap to the wires to ease insertion through the stalk or use a thin wire to pull the wires through.
| 1 | Housing |
| 2 | Grommet |
| 3 | Reflector |
| 4 | Bulb |
| 5 | Lens |
| 6 | Support |
| 7 | Support stud |
| 8 | Nut |
Figure 2. Stock Turn Signal Stalk Removal
| 1 | Housing |
| 2 | Lockwasher |
| 3 | Recess cover |
| 4 | Jam nut |
| 5 | Turn signal bar |
| 6 | Black conduit |
Figure 3. Turn Signal Installation
License Plate Bracket Installation
- See Figure 6. Remove the existing license plate bracket from the fender, noting how assembly is put together. Discard the license plate bracket, but save the remaining hardware for installation of the new license plate bracket provided in the kit.
- Place new pad from kit onto fender, so that the three-hole pattern lines up with the three hole pattern in the fender. Mark the location on the pad for the fourth hole in the fender. Remove the pad from the fender and cut an "X" pattern in this location.
- Route wires for turn signals through hole in license plate bracket, pad, and fender.
- Install new license plate bracket and the turn signal bar with the two studs inserted through the license plate bracket holes and into the holes in the fender and thread on the nuts previously saved. Apply new red reflector to license plate bracket.
- Rotate turn signals so that they are horizontal and pointed to the rear. Tighten chrome jam nuts so that the lights cannot rotate during vehicle operation.
Butt Splice Connections
- Strip a 3/8 in. (9.5 mm) section of insulation from the cut ends of the signal wires.
- See Figure 4. Insert the two black turn signal wires into opposite ends of a butt splice connector. Insert the two violet wires into opposite ends of a second butt splice connector.
- Match the color of the butt splice connector with the color of the crimp cavity of the crimping tool (38125-8 or equivalent). Crimp the wires into the connector.
NOTE
Be sure to match the wire colors before splicing.
WARNINGBe sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)
- Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/ explosion resulting in death or serious injury.
- Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed.
- Always keep hands away from tool tip area and heat shrink attachment.
- Using the Ultra Torch UT-100 (39969), Robinair Heat Gun (HD-25070) with Heatshrink Attachment (41183), or other suitable radiant heating device, heat the crimped splice to encapsulate the butt splice connection. Apply heat from the center of the crimp out to each end until the meltable sealant comes out of both ends of the connector.
- For proper fit of conduit, make sure butt splices are staggered. Remove the connectors at the ends of the wires that were unplugged from tail light. Slide conduit over the two wires of turn signal. Push conduit up through hole in fender and back to directional bar hole.
- Repeat steps for the opposite side.
| 1 | Stripped wire ends inserted in connector |
| 2 | Wire ends crimped in connector |
| 3 | Connector after heat has been applied |
Figure 4. Sealed Butt Connecor Installed
Final Connection of Turn Signal Wires
| 1. | Reattach connectors to ends of wires. Route connectors through opening in fender behind tail lamp and plug in. | |
| 2. | First, wipe inside fender surface with isopropyl alcohol. Peel adhesive paper and press wire clips to fender, making sure wire clips are positioned so as not to make contact with tire during operation. NOTE Inspect turn signal wiring leads to ensure they are secured to the harness clips on underside of fender and are not loose or bunched. | |
| 3. | Secure both sets of wires to wire clips being sure that they are taut and not sagging down toward the tire. | |
| 4. | Reconnect negative battery cable. | |
| WARNING Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) | ||
| 5. | Turn ignition on and test for proper turn signal operation. |
Saddlebag Installation
| 1. | See Figure 5. From the underside of the fender, install two screws (6) from kit through fender and into fender support and cover, where two screws were previously removed. | |
| 2. | With short end of bushings facing outward, install short bushing (13) onto the front screw and long bushing (14) onto the rear screw. Slide saddlebag onto the screws until bushings are seated onto the saddlebag bracket. Thread flange locknuts (7) to screws on inside of saddlebag. Tighten both flange locknuts to 24-27 ft-lbs (33-37 Nm). Install thread protector cap (8) onto the ends of the screws. NOTE Two reflectors have been included with this kit to be mounted on the saddlebags. | |
| WARNING Federal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b) | ||
| 3. | Position the reflector (11) to the lower rear of the saddlebag and peal off adhesive paper and press in place. NOTE Ensure that the reflector is oriented right side up (writing on reflector is right side up) and horizontal to the ground. | |
| 4. | Install the hole plugs (9) and (10) in the fender support cover where the different size holes for the wires and the stud for the signal support bracket were located. | |
| 5. | Repeat steps for the opposite side. | |
| 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) | ||
| 6. | Refer to the Owner's Manual and follow the instructions to install the seat. |
SERVICE PARTS
Figure 5. Service Parts: Sportster Leather Saddlebag Kits
Table 1. Service Parts: Sportster Leather Saddlebag Kits
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Saddlebag without lock, right | 53099-04 | 10 | Plug, hole, 0.35 in. (2) | 68446-00 | |
2 | Saddlebag without lock, left (not shown) | 53113-04 | 11 | Reflector, red, right | 59287-92 | |
3 | Lock assembly (2) (includes lock and keys) | 53136-04 | 12 | Reflector, red, left (not shown) | 59288-92 | |
4 | Bezel, right | 53126-04 | 13 | Bushing, front, short (short end toward saddlebag) | 53022-04 | |
5 | Bezel, left (not shown) | 53131-04 | 14 | Bushing, rear, long (short end toward saddlebag) | 53021-04 | |
6 | Screw, hex hd 5/16-18 x 3 in. (4) | 4375 | ||||
7 | Locknut, flange 5/16-18 (4) | 7531 | Original Parts Retained (not part of kit). | |||
8 | Cap, thread protector (4) | Not Sold Separately | A | Frame fender support | ||
9 | Plug, hole 0.40 in. | 53377-04 | B | Frame fender support cover | ||
SERVICE PARTS
Figure 6. Service Parts: Sportster Leather Saddlebag Kits
Table 2. Service Parts: Sportster Leather Saddlebag Kits
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Bar, turn signal, domestic (Kit 53050-04) | 68967-04 | 9 | Wire conduit (2) | Not Sold Separately | |
2 | Bar, turn signal, international (Kit 53148-04) | 68965-04 | 10 | Connector, pre-insulated (4) | 70585-93 | |
3 | Cover, turn signal recess (2) | 68023-03 | 11 | Clip, adhesive backed (2) | 10102 | |
4 | Lockwasher, 5/16 (2) | 7042 | Original Parts Retained (not part of kit). | |||
5 | Jam nut, 5/16-18 (2) | 7849 | A | Stock hardware | ||
6 | Bracket, license plate | 60013-02 | B | Multi-lock connectors (rear taillight) | ||
7 | Pad, rear directional mount | 68456-89 | C | Cut an "X" at this point. | ||
8 | Reflector, red, license plate | 59988-72A | Note: Service Kit 68732-02A includes items 1, and 3 through 11; Service Kit 68733-02A includes items 2 through 11. | |||