DETACHABLE SADDLEBAG
941000962021-08-24
GENERAL INFORMATION
Table 1. General Information
Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
90201973 | Safety Glasses, Torque Wrench, Drill (5 mm or equivalent), Center Punch |  |
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Detachable Saddlebags
Table 2. Kit Contents: Detachable Saddlebags 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 | Bag, right | 90202128 | |
| 2 | 1 | Bag, left | 90202127 | |
| 3 | 1 | Lock Set, unkeyed (includes items 4-9, 17-19) | 90300167 | |
| 4 | 1 | Cylinder 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:
|
| 10 | 1 | Reflector | 67900205A | |
| 1 | Reflector mount, right | 90202278 | ||
| 1 | Reflector mount, left | 90202132 | ||
| 1 | Reflector template | Not sold separately | ||
| 11 | 1 | Warning label | 14002719 | |
| 12 | 1 | Net kit | 90202134 | |
| 13 | 1 | Latch assembly kit, left | 90202129 | |
| 1 | Latch assembly kit, right | 90202130 | ||
| 14 | 1 | Third-point mount kit, left | 90202136 | |
| 1 | Third-point mount kit, right | 90202137 | ||
| 15 | 1 | Gasket kit | 53000852 | |
| 16 | 1 | Lid tether kit | 90202131 | |
| 17 | 1 | Screw | Not sold separately | Not used. Discard |
| 18 | 1 | Washer | Not sold separately | Not used. Discard |
| 19 | 1 | Lockwasher | Not sold separately | Not used. Discard |
| 20 | 2 | Bungee hook | 90202133 | |
| 21 | 1 | Retention tumbler | Not sold separately | |
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
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)
WARNINGSee 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.
WARNINGDo 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 Video
Video 1. Pan America Sport Luggage Cases Lock Install
This video is a supplement of the procedure covered in the document and can only be viewed through Service Information Portal (SIP).
INSTALL
Reflectors
| 1. | Figure 2 Adhere drill template on lid. | |
| 2. | Use center punch to mark drill locations. | |
| 3. | Drill holes using a 5 mm drill or equivalent. | |
| 4. | Remove adhesive backer from reflector bracket and install on inside of lid. | |
| 5. | Secure reflector mount (4) on outside of lid to reflector bracket with screws. Hand tighten. | |
| 6. | Install reflector (5). | |
| 7. | Repeats steps on opposite side. |
| 1 | Drill template location, inside lid, left side shown |
| 2 | Drill template location, outside lid, right side shown |
| 3 | Reflector template |
| 4 | Reflector mount |
| 5 | Reflector |
Figure 2.
Setting Key Lock
| 1. | Figure 3 On Original Equipment (OE) vehicle key, determine cut depth at each key station. NOTE Key stations 1 and 2 are unused for saddlebag locks. | |
| 2. | Write values into Table 3. | |
| 3. | 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. | |
| 4. | Figure 5 Install screw (1) and nut (2) to cylinder sub-assembly (4). a. Notch (3) on nut (2) should be coincident with side (A) of cylinder. | |
| 5. | Figure 5 Remove O-ring (6) from cylinder assembly (4). | |
| 6. | Figure 6 With key inserted, insert cylinder assembly into lockset opening on saddlebag. a. Notch (2) on nut should align with "open" lock position. | |
| 7. | Figure 6 Using key, rotate clockwise to release position (3), release latch (4) will pop up. | |
| 8. | Figure 6 Remove lock cylinder sub-assembly and key from lockset opening on saddlebag. | |
| 9. | Figure 6 Install O-ring (6) onto cylinder assembly (4). | |
| 10. | Figure 4 Install tumbler springs (5), see Figure 1, into holes at stations 3,6 and 7 on side (A) of cylinder sub-assembly. | |
| 11. | 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. | |
| 12. | Figure 4 Install tumbler springs (5), see Figure 1, into holes at stations 4,5 and 8 on side (B) of cylinder sub-assembly. | |
| 13. | Figure 4 Install tumblers (6), see Figure 1, #21-24 in stations 4,5 and 8 per tumble numbers determined in Table 3. | |
| 14. | Figure 5 While holding tumblers fully in place, install key in assembled cylinder sub-assembly. | |
| 15. | 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. |
Table 3. Key Lock Instructions
Station | Side | Measured Depth | Depth Code | Tumbler No. |
|---|---|---|---|---|
3 | A | 1__ | ||
4 | B | 2__ | ||
5 | B | 2__ | ||
6 | A | 1__ | ||
7 | A | 1__ | ||
8 | B | 2__ |
| 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 | Nut |
| 3 | Notch |
| 4 | Cylinder sub-assembly |
| 5 | Tumblers, installed and flush |
| 6 | O-ring |
| 7 | Key |
Figure 5. Assembled Lockset
| 1 | Lockset |
| 2 | Notch |
| 3 | Lockset release position |
| 4 | Release latch |
Figure 6. Install Lockset into Saddlebag
Install Lock and Saddlebag
| 1. | See Figure 5. While holding tumblers fully in place, remove key from cylinder sub-assembly. | |
| 2. | Install tumbler spring (5) and retention tumbler (21), see Figure 1, in retention tumbler station (9). | |
| 3. | Insert key, this will hold all tumblers in place. | |
| 4. | Apply an even layer of grease around outer diameter of tumbler area. | |
| 5. | See Figure 6. Insert fully assembled lock cylinder into lockset opening on saddlebag. a. Notch (2) on nut should align with "release position" lock position. b. Press down firmly until retention tumbler clicks into place. | |
| 6. | Figure 8 Once lockset is installed, key can be removed in position 1 or 2. | |
| 7. | Figure 7 Install forward mount point (1) over passenger heel guard (2). | |
| 8. | Figure 7 Insert hooks (3) to passenger handhold base (4). | |
| 9. | Figure 7 Close saddlebag clamps (5) to lock saddlebag to passenger handhold base (4). |
| 1 | Forward mount point |
| 2 | Passenger heel guard |
| 3 | Hooks, saddlebag (2) |
| 4 | Passenger handhold base |
| 5 | Clamp, saddlebag |
Figure 7. Saddlebag Installation
| 1 | Lock position |
| 2 | Open position |
| 3 | Release position |
Figure 8. Lock Positions
LOCK POSITIONS
- Lock Position: lid is locked.
- Open Position: lid is unlocked.
- Open lid: push down on lock cylinder.
- Figure 8 Lid lever, right of lock cylinder, will flip up.
- Pull lever to open lid.
- After closing lid, push lid lever back down.
- Release Position: When key is in this position, release lever, left of lock cylinder, will flip up.
- Pulling lever will pop up carrying handle.
- Pulling up on carrying handle will release locking hook, allowing case to be removed from vehicle.
NOTE
Before riding make sure lid and release levers are in closed position, flush with case.
MAINTANENCE
Over time, dust and dirt can build up causing lock mechanism to become difficult to operate. If operation becomes difficult, apply white lithium grease to locations shown in Figure 9.
Figure 9. Lubrication - Lock Mechanism