DETACHABLE TOP CASE

941000972021-08-24

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
53000751	Safety Glasses, Torque Wrench

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

KIT CONTENTS

Figure 1. Kit Contents: Detachable Top Case

Table 2. Kit Contents: Detachable Top Case Kit

Verify that all contents are present in the kit before installing or removing items from vehicle.
Item	Qty	Description	Part No.	Notes
1	1	Lid	Not sold separately
1	1	Base	Not sold separately
2	1	Backrest kit	52300680
3	1	Lockset, unkeyed (Includes items 4-9, 17, 18, 21)	90300167
4	1	Cylinder sub-assembly	Not sold separately
5	9	Tumbler spring	Not sold separately
6	17	Tumbler	Not sold separately
7	1	Screw	Not sold separately
8	1	Nut	Not sold separately
9	1	Grease (not shown)	Not sold separately	Kluber Lubrication: CENTOPLEX 1 DL 1 cc/1 mL/0.03 oz Observe good industrial hygiene practices Wash hands after handling Keep out of eyes Chemical Nature: Mineral oil, lithium calcium soap
10	1	Mount kit	53000812
11	1	Latch kit	53000851
12	1	Gasket kit	53000852
13	1	Label, warning	14002719
14	1	Lock Cylinder Hardware Kit (includes items 15, 16, 19, 20)	Not sold separately
15	1	Housing	Not sold separately
16	1	Locking spring	Not sold separately
17	1	Screw	Not sold separately
18	1	Washer	Not sold separately
19	1	Plastic Cover	Not sold separately
20	1	Screw, plastic cover	Not sold separately
21	1	Lockwasher	Not sold separately
22	1	Retention tumbler	Not sold separately	Not required for top case lock set

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.

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)

Installation Requirements

Separate purchase of Mounting kit (Part No. 53000800).

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)

INSTALL

Setting Key Lock

1.	Figure 2 Open top case and locate lockset. a. Pull on red tab (1) to release handle (2). b. Pull lever (3) beneath handle to open lid.
2.	Figure 3 On Original Equipment (OE) vehicle key, determine cut depth at each key station. NOTE Key stations 1 and 2 are unused for top case locks.
3.	Write values into Table 3.
4.	Table 3 Write key depth codes from Figure 3 based on cut depths measured. NOTE Cut depth codes to be second digit of tumble numbers. a. Stations 7,6,3: These stations use tumbler #11-14. b. Stations 8,5,4: These stations use tumbler #21-24.
5.	Figure 4 Install tumbler springs (5), see Figure 1 , into holes at stations 3,6 and 7 on side (A) of cylinder sub-assembly.
6.	Figure 4 Install tumblers (6), see Figure 1 , #11-14 in stations 3,6 and 7 per tumble numbers determined in Table 3. NOTE Place a piece of tape or hold installed tumbler springs and tumblers with a finger to hold spring and tumblers in place before installation of springs and tumbler on opposite side of cylinder sub-assembly.
7.	Figure 4 Install tumbler springs (5), see Figure 1 , into holes at stations 4,5 and 8 on side (B) of cylinder sub-assembly.
8.	Figure 4 Install tumblers (6), see Figure 1 , #21-24 in stations 4,5 and 8 per tumble numbers determined in Table 3.
9.	Figure 5 While holding tumblers fully in place, install key in assembled cylinder sub-assembly.
10.	Verify that all tumblers are assembled correctly. NOTE When key is fully inserted, all tumblers should be flush with outer diameter of cylinder. Note tumblers that are not flush. If tumbler is high on the spring side, replace with next higher number tumbler. If tumbler is high on the opposite side, replace with next lower number tumbler.
11.	Apply an even layer of grease around outer diameter of tumbler area.

Table 3. Key Lock Instructions

Station	Side	Tumbler No.
3	A	1__
4	B	2__
5	B	2__
6	A	1__
7	A	1__
8	B	2__

1	Red tab
2	Handle
3	Lever

Figure 2. Open Top Case

A	Tumbler Station
1	15.55 mm (.612 in)
2	14.45 mm (.569 in)
3	12.35 mm (.486 in)
4	11.25 mm (.443 in)
5	9.15 mm (.360 in)
6	8.05 mm (.317 in)
7	5.95 mm (.234 in)
8	4.85 mm (.191 in)
B	Cut Depths
	0.15 mm (.006 in) = Depth code 1
	0.75 mm (.030 in) = Depth code 2
	1.45 mm (.057 in) = Depth code 3
	2.25 mm (.089 in) = Depth code 4

Figure 3. Key Code Diagram

Figure 4. Spring and Tumbler Install Locations (Typical)

1	Screw
2	Lockwasher
3	Washer
4	Lock cylinder sub-assembly
5	Tumblers, installed and flush
6	O-ring
7	Key

Figure 5. Assembled Lockset

Install Lock and Top Case

1.	Figure 8 Position rotor, set to release position. a. Figure 6 Pull release lever to access rotor (1). b. Figure 7 Position rotor (1) by hand.
2.	Figure 9 Install housing (2) and locking spring (3) on lock cylinder (1). a. Figure 7 Align three slots (2) on housing to three teeth (3) on release lever.
3.	Figure 8 Install lockset. a. Align retention tumbler slot (1) to release position (2). b. Square boss on lockset must mate with square opening on rotor (3). c. Hold in place by hand.
4.	Figure 9 Install washer (4), lockwasher (6) and screw (5). Hand tighten.
5.	Check rotation and functionality of lock cylinder.
6.	Figure 10 Install cover (2) and screw (1). Hand tighten.
7.	Figure 12 Remove red tab (1).
8.	Figure 11 Once lockset is installed, key can be removed in position 1 or 2.

Rotor

Figure 6. Access to Rotor

1	Rotor
2	Housing slots
3	Teeth

Figure 7. Housing

Figure 8. Release Tumbler - Release Position

1	Lock cylinder
2	Housing
3	Locking spring
4	Washer
5	Screw, lock cylinder
6	Lockwasher

Figure 9. Install Lockset to Top Case

1	Screw, plastic cover
2	Cover, inside

Figure 10. Inside Cover Install

1	Lock position
2	Open position
3	Release position

Figure 11. Lock Positions (typical)

1	Red tab
2	Lock set

Figure 12. Top case Handle

Install Top Case

1.	Figure 13 Install mounting kit to mounting bracket. a. Install latch (3) with three screws (2) to front of mounting bracket (1). Tighten. Torque: 5.4–6.6 N·m (48–58 in-lbs) b. Install hook (4) with screws (5) to rear of mounting bracket (1). Tighten. Torque: 5.4–6.6 N·m (48–58 in-lbs)
2.	Center top case on mounting bracket.
3.	See Figure 13 and Figure 14. Slide top case to front latch (3), rock down until it clicks into rear hook (4) .

1	Mounting bracket
2	Screws (3)
3	Latch
4	Hook
5	Screws (2)

Figure 13. Mount Kit (53000812)

Figure 14. Top case Installation

LOCK POSITIONS

Close Position: case is locked.
Open Position: case is unlocked.
1. Open case: push down on lock cylinder.
2. Main handle will pop up.
3. Pull lever beneath handle to open lid.
Release Position: unlocks release lever.
Release case from vehicle.
1. Turn key to release position.
2. Push down on lock cylinder.
3. Main handle will pop up.
4. Pull release lever, lift case and remove from vehicle.

NOTE

Before riding make sure case is fully engaged to mounting plate and handle is closed, flush with case.

Supplemental Procedure Video

WARNING

Always review the appropriate service procedure prior to performing it. This video is intended to supplement, not replace, documented service procedures. Attempting service procedures without the proper training, tools, equipment, and manuals could result in death or injury to you or others. This could also damage the motorcycle or cause the motorcycle to operate improperly. (10406a)

Refer to: Pan America Sport Luggage Lock Install.mp4

This video is a supplement of the procedure covered in the document. This video can only be viewed through Service Information Portal (SIP).