SOFTAIL EXPANDABLE SADDLEBAGS
941003542023-01-09
GENERAL INFORMATION
Table 1. General Information
Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
90202332 | Safety Glasses, Torque Wrench |  |
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Softail Expandable Saddlebags
Table 2. Kit Contents: Softail Expandable 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 | 2 | Reflector kit, includes item 2 | 59480-04A | |
| 2 | 4 | Washer clips | Not sold separately | |
| 3 | 1 | Saddlebag, expandable, right | Not sold separately | |
| 4 | 1 | Saddlebag, expandable, left | Not sold separately | |
| 5 | 2 | Holdfast™ docking hardware, rear | 52300730 | |
| 6 | 4 | Docking pin | 90202550 | |
| 7 | 4 | Screw, black | 10201382 | |
| 8 | 2 | Holdfast™ docking hardware, front | 52300729 | |
| 9 | 12 | Nut | 10100179 | |
| 10 | 1 | Lock mechanism, left | 90202554 | |
| Lock mechanism, right | 90202553 | |||
| 11 | 12 | Screw | 10201415 | |
| 12 | 2 | Inner lock housing | 90202544 | |
| 13 | 2 | Dry bag (not shown) | 93300169 | |
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
The kit can be used with Softail Detachable Racks or with Detachable Sissybar. See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
Separate purchase of Harley-Davidson Leather Protectant kit (Part No. 93600034) is recommended for cleaning of saddlebags.
2018-Later Softail models FXLR, FXLRS, FXBB, FXBBS, FLSL, FXST: Separate purchase of Turn Signal Relocation kit (Part No. 67800802A or 67800830A) is required.
2018-Later Softail models FXBB, FXBBS, FLSL with side mount license plate: Separate purchases of each component to assemble the Center Mounted License Plate Holder is required. See Figure 2.
- Support, rear fender, reinforcement (Part No. 59500448, Item 6) (Qty 1)
- Foam tape urethane (Part No. 11100010, Item 4) (Qty 3)
- Housing, three-way socket (Part No. 69201406, Item 12) (Qty 1)
- Terminal, socket, 18 AWG (Part No. 69201442, Item 11) (Qty 2)
- Seal pin (Part No. 69201427, Item 10) (Qty 2)
- Wire seal (Part No. 69201301, Item 13) (Qty 1)
- Cable strap, anchored (Part No. 10177, Item 9) (Qty 2)
- Lamp, license plate, Item 14 (Part No. 73504-11, Item 15) (Qty 1)
- Holder, license plate (Part No. 67900316, Item 3) (Qty 1)
- Tape, pad foam (Part No. 11100236, Item 2) (Qty 2)
- Reflector, red (Part No. 69490-07, Item 1) (Qty 1)
- Screw, (Part No. 4091, Item 8) (Qty 2)
- Screw, (Part No. 3612, Item 7) (Qty 2)
- Screw, (Part No. 4365, Item 5) (Qty 2)
- Standoff, long: black (Part No. 69933-08) (Qty 1) or chrome (Part No. 69438-06) (Qty 1)
WARNINGRider 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 references service manual information. A service manual for the year and model motorcycle is required for this installation and is available from:
- A Harley-Davidson dealer.
- H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.
WARNINGDo not exceed saddlebag weight capacity. Put equal weight in each bag. Too much weight in saddlebags can cause loss of control, which could result in death or serious injury. (00383a)
NOTE
Maximum saddlebag weight capacity is 6.8 kg (15 lb).
PREPARE
| 1. | Remove main fuse. See service manual. | |
| 2. | Remove seat. See service manual. |
REMOVE
Rear Fender
| 1. | Remove rear fender. See service manual. | |
| 2. | Remove left fender strut from fender. See service manual. a. Disconnect license plate and left signal harnesses. See Electrical Diagnostic Manual (EDM). b. Remove left turn signal with harness. c. Remove and discard side mount license plate bracket with harness. d. Remove and discard short turn signal standoff. | |
| 3. | Remove right fender strut from fender. See service manual. a. Disconnect right signal harnesses. See EDM. b. Remove right turn signal with harness. |
ASSEMBLE CENTER MOUNT LICENSE PLATE HOLDER
NOTE
See Installation Requirements for vehicle models.
| 1. | See Figure 2. Peel backing and install two mounting pad tape (4) pieces to bracket assembly (6). | |
| 2. | Peel backing and install mounting pad tape (4) piece to license plate holder (3) | |
| 3. | Peel backing and install two mounting pad tape (2) pieces to license plate holder (3). | |
| 4. | Install license plate holder (3) to bracket assembly (6) with screws (5, 7). | |
| 5. | Tighten screws (5). Torque: 7.11–8.69 N·m (63–77 in-lbs) | |
| 6. | Tighten screws (7). Torque: 2.03–2.37 N·m (18–21 in-lbs) | |
| 7. | Peel backing and install reflector (1) to license plate holder (3). | |
| 8. | Install tail lamp housing (14,15) and screws (8). Tighten. Torque: 1.1–2.25 N·m (10–20 in-lbs) | |
| 9. | See Figure 3. Route harness (2) through inner fender support assembly (1). | |
| 10. | See Figure 2. Connect pins to 3-pin connector (12). See EDM. |
| 1 | Reflector |
| 2 | Mounting pad tape (2) |
| 3 | License plate holder |
| 4 | Mounting pad tape (3) |
| 5 | Screw, inner mounting (2) |
| 6 | Bracket assembly |
| 7 | Screw, outer mounting (2) |
| 8 | Screw, lamp (2) |
| 9 | Cable strap (2) |
| 10 | Seal pin |
| 11 | Terminal, 18 AWG |
| 12 | Housing, threee-way socket |
| 13 | Wire seal (3) |
| 14 | Bulb |
| 15 | Lamp |
Figure 2. License Plate Bracket
| 1 | Inner fender support assembly |
| 2 | Harness |
Figure 3. Inner Fender Support Assembly (Typical)
INSTALL
Turn Signal Relocation
NOTE
See Installation Requirements for vehicle models.
| 1. | Install Turn Signal Relocation kit to fender struts. a. Install Turn Signal Relocation kit. Follow kit instructions. b. Install standoff on left turn signal. c. Route harness in fender struts. d. Install center mount license plate, fender struts to fender. See service manual. | |
| 2. | Install rear fender. See service manual. | |
| 3. | See Figure 4. Connect connector (3). |
| 1 | Right lamp connector |
| 2 | Left lamp connector |
| 3 | License plate light connector |
Figure 4. Turn Signal Lamp Connector
Docking Points
| 1. | Install new docking points to vehicle fender. a. See Figure 7. Open saddlebag, depress and rotate inner lock knob (1) 90° to unlock position. b. See Figure 7. Press release button (2) and lift lock handle (3). c. See Figure 1. Remove docking pins (6). d. See Figure 5. Install rear docking hardware (3), docking pin (1) and screw (4). e. See Figure 5. Install front docking hardware (2), docking pin (1) and screw (4). f. Torque screws (4). Tighten. Torque: 38–43 N·m (28–32 ft-lbs) |
| 1 | Docking pin |
| 2 | Docking hardware, front |
| 3 | Docking hardware, rear |
| 4 | Screw |
Figure 5. Docking Points (left side shown)
Docking Point Adjustment
| 1. | Adjust docking point tightness NOTE If the upright or rack rattles once installed, docking points must be adjusted. The black plastic docking point insert is elliptical. When "T"s on docking point are on top and bottom, docking point fit is at its loosest. When "T"s are at front and rear, docking point fit is at its tightest. a. See Figure 6. To adjust, rotate (3) in small increments so the "T" (1) is no longer on top and approaches either position (2). b. At each increment, check fit with accessory. c. Continue rotation in small increments and test until desired tightness is achieved. The tightest possible position is when the "T"s reach position (2). d. Tighten docking point screws. Torque: 38–43 N·m (28–32 ft-lbs) |
| 1 | Loosest position (T location) |
| 2 | Tightest position (T location) |
| 3 | Possible rotation direction |
Figure 6. Docking Point Flats
SADDLEBAGS
Install
| 1. | See Figure 7. Press release button (2) and lift lock handle (3). | |
| 2. | Tip saddlebag slightly and slide onto docking points. | |
| 3. | Making sure saddlebag is fully seated into docking points. | |
| 4. | Press down on lock handle (3) to secure saddlebag to vehicle. a. Lock mechanism will be heard engaging with docking points. b. Locking handle will pop up is saddlebag is not secured properly to vehicle. | |
| 5. | See Figure 1. Install reflectors (1). a. Locate plate within the outer pocket of saddlebag. b. Locate and cut through the two holes. c. Install reflectors and secure with two washer clips (2). |
Remove
| 1. | See Figure 7. Press handle button (2) and lift lock handle (3). |
Lock / Unlock Saddlebags to Vehicle
| 1. | See Figure 7. Lock saddlebag to vehicle: a. Open saddlebag, press and rotate inner lock knob (1) 90° to lock position. | |
| 2. | See Figure 7. Unlock saddlebag to vehicle: a. Open saddlebag, depress and rotate inner lock knob (1) 90° to unlock position. |
NOTE
To prevent access to inside of saddlebag, secure zippers with a padlock.
| 1 | Inner lock knob, lock/unlock |
| 2 | Release button |
| 3 | Lock handle |
Figure 7. Lock/Unlock/Latch
| 2 | Docking |
| 1 | Saddlebag, expandable |
Figure 8. Expandable Saddlebags Installed
COMPLETE
| 1. | Install seat. After installing seat, pull up on seat to verify that it is secure. See service manual. | |
| 2. | Install main fuse. See service manual. |
MAINTENANCE
Cleaning Fastener Threads
To attain proper clamp load, always clean fastener threads and threaded holes prior to assembly.
NOTE
Never use a thread-cutting tap or die to clean threads.
- Clean all threadlocking material from fastener threads and threaded holes.
- Use a wire brush or thread-chasing die to clean fastener threads.
- Use a thread chaser to clean threaded holes.
- Use PJ1 cleaner or equivalent to remove all traces of oil and contaminants from threads.
- Clear all threaded holes with low-pressure compressed air.
Always verify cleanliness of blind holes before assembly. Tightening a screw with dirt, water or oil in the hole can cause castings to crack or break.
Docking Points
In time docking points wear, causing the installed detachable accessory to become loose and rattle. Tighten the fit using the following method.
| 1. | Record the current "T" position for each docking point. Remove screw from rear docking point. | |
| 2. | Remove threadlocker from the docking point screws and mounting hole threads, see CLEANING FASTENER THREADS, before applying threadlocker to screw heads. Install docking points, screws and washers. Tighten finger-tight.LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) | |
| 3. | See Figure 6. If "T"s are not in tightest position (2), rotate docking points slightly, moving "T"s toward (2) until a tight fit of the detachable accessory is achieved at each location. | |
| 4. | Secure docking point screws. Tighten. Torque: 38–43 N·m (28–32 ft-lbs) | |
| 5. | If the docking point "T"s are in position (E): a. Remove screw from rear docking points. b. Rotate each docking point until the "T" on opposite side reaches loosest position (1). c. Remove threadlocker from docking point screws and mounting hole threads, see CLEANING FASTENER THREADS, before applying threadlocker to the screw threads. Install the screws and washers. Tighten finger-tight.LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) d. Check detachable accessory at each docking point, rotating the "T" toward (2) until a tight fit of the detachable accessory is achieved at each location. Secure docking point screws. Tighten. Torque: 38–43 N·m (28–32 ft-lbs) | |
| 6. | After multiple adjustments, if the detachable accessory continues to rattle or remains loose, replace the docking points. |
Docking Point Screws
NOTICE
Failure to tighten hardware to the specified torque could result in damage to the installed accessory. (00508b)
| 1. | After 500 miles of on the road use with saddlebags installed, it is necessary to check the torque on the docking point mounting screws. Check to make sure the proper torque is maintained and tighten screws if necessary. Tighten. a. Front and rear docking point screws. Torque: 38–43 N·m (28–32 ft-lbs) |
Saddlebag Care
Harley-Davidson Leather Protectant kit (Part No. 93600034) is recommended for cleaning of saddlebag lids.
- Use a soft textile brush, cloth or sponge with soap and water for cleaning the other parts of the saddlebag. Rinse with clean water.
- Do not use strong cleaning agents, rough cleaning tools or high pressure washer.
- Clean product after riding in salty conditions to avoid salt damage.
Contains one or more of the following materials:
- Aluminum
- Stainless steel
- Steel
- Nylon
- ABS
- Leather
- Acrylic
- Polyester
- EVA