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: 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	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
13	1	Latch assembly kit, right	90202130
14	1	Third-point mount kit, left	90202136
14	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

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)

WARNING

See the Accessories and Cargo 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. (00021b)

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 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.	See 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.	See 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.	Refer to 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.	See 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.	See Figure 5. Remove O-ring (6) from cylinder assembly (4).
6.	See 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.	See Figure 6. Using key, rotate clockwise to release position (3), release latch (4) will pop up.
8.	See Figure 6. Remove lock cylinder sub-assembly and key from lockset opening on saddlebag.
9.	See Figure 6. Install O-ring (6) onto cylinder assembly (4).
10.	See 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.	See 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.	See 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.	See Figure 4. Install tumblers (6), see Figure 1, #21-24 in stations 4,5 and 8 per tumble numbers determined in Table 3.
14.	See 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	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.	See Figure 8. Once lockset is installed, key can be removed in position 1 or 2.
7.	See Figure 7. Install forward mount point (1) over passenger heel guard (2).
8.	See Figure 7. Insert hooks (3) to passenger handhold base (4).
9.	See 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.
1. Open lid: push down on lock cylinder.
2. See Figure 8. Lid lever, right of lock cylinder, will flip up.
3. Pull lever to open lid.
4. 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.
1. Pulling lever will pop up carrying handle.
2. 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