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SADDLEBAG 12 VOLT POWER OUTLET KIT
J054092013-07-17
GENERAL
Kit Number
69200091
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Prior or concurrent installation of a Battery Charging Harness (Part No. 94624-97, -97A or -97B) is required for proper installation of this kit.
A USB Adapter (Part No. 69200357) is available for use with this power outlet, and can be purchased separately from a Harley-Davidson dealer.
NOTE
DO NOT use the USB Adapter with the vehicle's cigar lighter, as it could damage the lighter socket.
Tools and Supplies Required
Electrical Contact Lubricant (Part No. 99861-02) or equivalent is required after battery cable disconnection. This item is available from a Harley-Davidson dealer.
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. 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. (00333b)
NOTE
This instruction sheet refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Electrical Overload
NOTICE
It is possible to overload the vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. (00211d)
WARNING
When installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a)
The power outlet itself does not use any additional current, but make sure the current draw of any item to be plugged into it does not exceed the capacity of the vehicle electrical system.
Kit Contents
See Figure 1 and Table 1.
PREPARATION
NOTE
For 2007 and later vehicles equipped with security siren:
  • Verify that the Hands-Free Fob is present.
  • Turn the ignition key switch to IGNITION.
For Vehicles With Main Fuse:
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Refer to the service manual and follow instructions to remove the main fuse. Remove the seat. Retain all seat mounting hardware.
For Vehicles With Main Circuit Breaker:
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
NOTE
For 2004 and later Sportster® models, the negative battery cable is most easily disconnected at the engine crankcase.
  1. Refer to the service manual and follow instructions to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware.
INSTALLATION
1. If a battery charger harness HAS already been installed, re-route the charger connector to place it close to the rear fender support bracket. Temporarily remove the fuse from the charger harness If a battery charger harness HAS NOT already been installed, install the battery charger harness per the instructions in that kit with the following exceptions:
a. Route the charger harness connector toward the rear of the vehicle, close to the rear fender support bracket.
b. Remove the fuse from the charger harness until the power harness installation is complete.
2. Remove all items from the saddlebag. Remove the saddlebag from the vehicle.
NOTE
Check the following before choosing a mounting spot for the power outlet:
  • Do not mount the power outlet housing and bracket on a rib or complex curved surface inside the saddlebag.
  • Select a position for the power outlet harness to pass through the inboard wall of the saddlebag. Recommended position is as high and as far forward as possible.
  • Make sure the power outlet harness connector will easily reach the mating charger harness connector after passing through the saddlebag wall.
  • The power outlet can point in any orientation; vertical, horizontal or any angle. Allow room in front of the power outlet to install the mating connector of any anticipated electronic devices that may be used.
  • Check position of the screw heads and wire pass-through for clearance to all moving components.
3. Select a flat surface inside the saddlebag, on the inboard wall. See Figure 1. Using the outlet housing (5) as a template, mark the locations for the two mounting holes and the power outlet harness pass-through opening with a center punch. Note that the power outlet housing mounting holes are 50.8 mm (2 in) apart.
4. Drill two 9.5 mm (0.38 in) holes for mounting the power outlet. Drill a 16 mm (0.62 in) hole in the power outlet harness pass-through location.
5. Install a rubber grommet (7) into each of the 9.5 mm (0.38 in) power outlet mounting holes drilled in Step 4.
6. Place a washer (8) onto the threads of each hex socket screw (9). Insert the screws through the grommets, and place a second washer onto the screw threads.
7. Install the power outlet assembly (1) to the saddlebag side wall with the lock nuts (10). Tighten to 2.8–4 N·m (25–35 in-lbs).
8. Feed the two-way power outlet connector (B) and harness out through the 16 mm (0.62 in) hole in the saddlebag side wall, and route to the charger harness connector.
9. Use an adhesive-backed clip (11) to secure the power outlet harness to the inside of the saddlebag if needed. Use at least one adhesive-backed clip to secure the power outlet harness to the outside of the bag or the vehicle frame near the charger harness connector.
NOTE
Strain relief grommet is difficult to remove once pressed into saddlebag hole. Make sure grommet is well positioned on harness to allow easy connection to the charger harness.
10. Get the strain relief grommet (12) from the kit. With the large end facing the connector, snap the grommet onto the power outlet harness outside the saddlebag, and press the grommet into the wire hole.
11. Install the saddlebag onto the vehicle.
12. Connect the power outlet harness to the charger harness.
13. Install the fuse back into the charger harness.
RETURN TO SERVICE
NOTE
Verify that the ignition key switch is in the OFF position before installing the main fuse or attaching the negative battery cable.
1. Models with main fuse: Refer to the service manual and follow the instructions to install the main fuse. Models (except Sportster) with main circuit breaker:Sportster models with main circuit breaker: Refer to the service manual, and follow the instructions to connect the negative (-) battery cable at the engine crankcase.
a. Refer to the service manual and follow the instructions to attach the negative battery cable.
b. Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to the negative battery terminal.
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)
2. Refer to the service manual, and follow instructions to install the seat.
IN USE
NOTE
  • Power outlet is not switched. It will remain "ON" even with ignition key switch in "OFF" position.
  • DO NOT leave items connected to the power outlet unattended.
  • DO NOT mount electronic devices with a hard drive memory on the vehicle for use or charging while the vehicle is in operation. Vehicle vibration can permanently damage the device. Refer to the device instructions to determine if the version to be used has a hard drive memory.
SERVICE PARTS
Figure 1. Service Parts, Saddlebag 12 Volt Power Outlet Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Power outlet assembly (includes Items 1-6)
2
  • Socket, 12 V power outlet
91889-97
3
  • Bracket, power outlet
Not sold separately
4
  • Cap, power outlet
91844-97
5
  • Housing, power outlet
69200092
6
  • Harness, power outlet
69200090
7
Grommet (2)
11410
8
Flat washer, chrome (4)
6485
9
Screw, hex socket button head (2)
4015
10
Lock nut, with nylon insert (2)
7686
11
Clip, adhesive back (2)
Not Sold Separately
12
Grommet, strain relief
12100001
Items mentioned in text, but not included in kit:
A
USB Adapter (Part No. 69200357, available separately)
B
Two-way power outlet connector