1. | Remove saddlebags. See service manual. | |
2. | See Figure 6. Install support board (7) to inner saddlebag lid (A). | |
3. | See Figure 1. Place support board against lid seam and trace a marker line on leather. |
1. | See Figure 1. Apply an even coat of adhesive to saddlebag lid and non-textured side of support board. | |||||||||||||||||||||||||
2. | Bond together with firm pressure and allow one hour for adhesive to set. |
Figure 1. Inner Saddlebag Lid Support Board | ||||||||||||||||||||||||
3. | Remove center chrome stud from saddlebag lid. | |||||||||||||||||||||||||
4. | See Figure 2. Install anti-rotation ring (1) where chrome stud was just removed. a. Install with prongs facing inner saddlebag lid. | |||||||||||||||||||||||||
5. | Draw a circle on inside of anti-rotation ring (1). | |||||||||||||||||||||||||
6. | Cut out marked circle. |
Figure 2. Cut Hole for Lock Assembly | ||||||||||||||||||||||||
7. | See Figure 6 and Refer to Table 1. Install lock assembly (8) to saddlebag lid (A). a. Install flat washer (f) to cam lock (g). b. Insert cam lock (g) through hole in saddlebag lid. c. Install anti-rotation ring (e) with prongs facing leather. d. Install nut (d) over anti-rotation ring (e). Tighten. e. Install cam plate (c), T-bar (b) and screw (a). Tighten screw to cam lock. f. Use key (h) to check lock operation. | |||||||||||||||||||||||||
8. | See Figure 3 or Figure 4. Install inner supports (1, 2). a. Use temporary hardware: 5/16 screws (3), nuts (4) and washers (5) (not included in kit). | |||||||||||||||||||||||||
9. | See Figure 4. If installing this kit with Quick Detach Saddlebag Conversion Kit (Part No. 90200641): a. Use hardware provided in that kit to install inner supports to saddlebag. b. Large washers from that kit should be discarded when installing inner supports. | |||||||||||||||||||||||||
10. | See Figure 5. Install lock plate (1) on outside of saddlebag tub. a. T-bar (not shown, under saddlebag lid) must be in a horizontal position. b. Close saddlebag lid. c. Center lock plate (1) with lock assembly (2). d. Carefully lift saddlebag lid and mark location of lock plate (1). e. Using a wood block inside saddlebag, drill 3/16 inch holes using lock plate as a template. f. See Figure 6. Position lock plate (2) and install blind rivets (3). g. Install washers (1) from inside of saddlebag tub and over head of blind rivet (3). Pop rivets into place. |
Figure 3. Temporary Hardware Installation
Figure 4. Temporary Hardware Installation With Detach Saddlebag Kit (90200641)
Figure 5. Positioning lock plate | ||||||||||||||||||||||||
11. | Repeat steps for opposite saddlebag. |
1. | Remove temporary hardware from saddlebag. | |
2. | Install saddlebags. See service manual. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Plain washer, Type A (8) | 6717 |
2 | Lock plate (2) | 90200063 |
3 | Rivet, blind (8) | Not sold separately |
4 | Lock plate (2) | Not sold separately |
5 | Inner support, right side (not shown) | Not sold separately |
6 | Inner support, left side | Not sold separately |
7 | Support board (2) | Not sold separately |
Lock Assembly Components (See Installation Requirements): | ||
8 | Lock Assembly (a-h) | |
a | Screw (2) | Not sold separately |
b | T-Bar (2) | Not sold separately |
c | Cam plate (2) | Not sold separately |
d | Nut (2) | Not sold separately |
e | Anti-rotation ring (2) | Not sold separately |
f | Flat washer (2) | Not sold separately |
g | Cam lock (2) | Not sold separately |
h | Key (2) | 71452-91A |
Items mentioned in text, but not included in kit: | ||
A | Saddlebag lid | |
B | Saddlebag tub | |
C | Detachable Saddlebag Conversion Kit |