SOFTAIL HARD SADDLEBAGS
941003582023-08-15
GENERAL INFORMATION
Table 1. General Information
Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
90202534 | Safety Glasses, Torque Wrench |  |
(1) Special tools or techniques required for installation
KIT CONTENTS
Figure 1. Kit Contents: Softail Hard Saddlebags
Table 2. Kit Contents: Softail Hard Saddlebags
 | Verify that all contents are present in the kit before installing or removing items from vehicle. | ||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
 | 1 | 2 | Lockset kit | 90300216 | |
| 2 | 4 | Screw, TORX, PLASTITE | 10200557 | |
| 3 | 1 | Saddlebag, right | Not sold separately | |
| 4 | 4 | Screw, TORX, socket head with lock patch | 10200033 | |
| 5 | 4 | Docking mount | 90201533 | |
| 6 | 4 | Docking spacer | 90201541 | |
| 7 | 1 | Saddlebag, left | Not sold separately | |
| 8 | 4 | Screw | 10200414 | |
| 9 | 1 | Docking rod, right | 90202266 | |
| 1 | Docking rod, left | 90202265 | ||
| 10 | 1 | Screw, TORX, button head | 4512A | |
| 11 | 1 | Mounting bracket grommet, left | 90201666 | |
| 12 | 1 | Mounting bracket grommet, right | 90201524 | |
| 13 | 1 | Screw, flange | 10200626 | |
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.
For any service related saddlebag parts, see the Softail Parts Catalog for FXLRST.
For procedures to disassemble and assemble the saddlebags, see the Softail Service Manual for FXLRST.
Installation Requirements
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.
These items are available at your local Harley-Davidson dealership.
- 2018 and later FXLR/S models: Separate purchase of Turn Signal Relocation Kit (Part No. 67801349) is required for this installation.
PREPARE
| 1. | Remove main fuse. See service manual. | |
| 2. | Remove seat. See service manual. | |
| 3. | Remove rear turn signal lamp assemblies from fender support. See service manual. a. Save signal lamp assemblies for turn signal relocation kit. |
REMOVE
| 1. | See Figure 2. Remove and discard fender support screws (1). |
| 1 | Screw (2) |
Figure 2. Fender Support Screws
ASSEMBLE LOCKSET KIT
| 1 | Tumbler (2 each of #11, 12, 13, 14, 21, 22, 23, 24) |
| 2 | Spring (6) |
| 3 | Gasket |
| 4 | Lockset |
| 5 | Lock housing |
| 6 | Retainer plate |
| 7 | Lock pin |
Figure 3. Lockset Parts
NOTE
See Figure 5. Key stations 1, 2, 3 and 4 are NOT used for this lockset assembly.
| 1. | See Figure 5. Measure cut depths at key stations 5, 6, 7, and 8 on Original Equipment (OE) key. | |||||
| 2. | Write values in the Measured Depth column of Table 3. NOTE Cut depth codes to be second digit of tumbler numbers (last column).
| |||||
| 3. | Based on cut depths measured, write key depth codes from Figure 5 into Depth Code column of Table 3. | |||||
| 4. | See Figure 6. Install springs into holes of stations 6 and 7 on Side A of lockset. | |||||
| 5. | Install tumblers into stations 6 and 7 per tumbler numbers determined in Table 3. | |||||
| 6. | Install springs into holes at stations 5 and 8 on Side B of lockset. | |||||
| 7. | Install tumblers into stations 5 and 8 per tumbler numbers determined in Table 3. | |||||
| 8. | While holding tumblers fully in place, insert key in assembled lockset assembly. | |||||
| 9. | Verify that all tumblers are assembled correctly. | |||||
| 10. | See Figure 7. With key inserted, apply grease to the assembled lockset assembly (2). | |||||
| 11. | Apply grease to the lock pin (5). | |||||
| 12. | Insert lock pin (5) into lock housing (3). NOTE See Figure 8. Boss (1) feature on lockset assembly must mate with lock pin hole (2). Verify that the lock pin moves by rotating the key and lock cylinder. | |||||
| 13. | With key inserted, install assembled lockset assembly (2) into lock housing (3). | |||||
| 14. | See Figure 7. Insert retainer plate (4) into lock housing (3). a. See Figure 4. Make sure retainer plate (1) is flush with surface of lock housing. b. Using punch and hammer, flatten four boss features (2) to keep retainer plate in place. | 
Figure 4. Retainer Plate | ||||
| 15. | Remove key. | |||||
| 16. | See Figure 7. Install gasket (1) to lockset (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 5. Key Code Diagram
| A | Side A |
| B | Side B |
| 5 | Station 5 |
| 6 | Station 6 |
| 7 | Station 7 |
| 8 | Station 8 |
Figure 6. Spring and Tumbler
| 1 | Gasket |
| 2 | Lockset assembly |
| 3 | Lock housing |
| 4 | Retainer plate |
| 5 | Lock pin |
Figure 7. Housing Assembly
| 1 | Lockset boss |
| 2 | Lock pin hole |
Figure 8. Mating Features
Table 3. Key Lock Instructions
Station | Side | Measured Depth | Depth Code | Tumbler No. |
|---|---|---|---|---|
5 | B | 2__ | ||
6 | A | 1__ | ||
7 | A | 1__ | ||
8 | B | 2__ |
INSTALL
Lockset Kit
| 1. | See Figure 9. Remove latch assembly. a. Remove screw (11). b. Remove latch lever (4) and O-ring (3). c. Remove screws (12). d. Remove latch assembly (1). | |
| 2. | Install lockset kit. a. Make sure lock (10) is in the unlocked position. NOTE Lock pin should be toward inner clamshell. b. Install lock (10) to latch assembly (1). c. Install screws (9). Tighten. Torque: 1.7–2.3 N·m (15–20 in-lbs) | |
| 3. | Install latch assembly. a. Position latch assembly (1) to inner clamshell (2). b. Install screws (12). Tighten. Torque: 1.1–1.7 N·m (10–15 in-lbs) c. Install O-ring (3) to latch lever (4). d. Install latch lever (4) and screw (11). Tighten. Torque: 2.3–3.4 N·m (20–30 in-lbs) |
Docking Rod
| 1. | See Figure 9. Install docking rod. a. Apply threadlocker to screws (8).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) b. Position docking rod (5) on inner clamshell (2). c. Install screws (8). Tighten. Torque: 17–21 N·m (13–15 ft-lbs) |
| 1 | Latch assembly |
| 2 | Inner clamshell |
| 3 | O-ring |
| 4 | Latch lever |
| 5 | Docking rod |
| 6 | Hinge screw (4) |
| 7 | Hinge (2) |
| 8 | Screw (2) |
| 9 | Screw (2) |
| 10 | Lock |
| 11 | Screw (1) |
| 12 | Screw (5) |
Figure 9. Latch Assembly
Saddlebag
| 1. | See Figure 10 and Figure 11. a. Slide docking mounts (4) on mounting screws (5). b. Slide spacers (3) on mounting screws (5). c. Apply threadlocker to mounting screws (5).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) d. Install mounting screws (5) through fender supports (2) into fender mount (1). Tighten. Torque: 29–37 N·m (21–27 ft-lbs) | |
| 2. | See Figure 10. Install right side mounting bracket grommet. a. Apply threadlocker to screw (9).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) b. Align and install mounting bracket grommet (7) to bracket (8). c. Install screw (9). Tighten. Torque: 11–14 N·m (97–124 in-lbs) | |
| 3. | See Figure 11. Install left side mounting bracket grommet. a. Apply threadlocker to screw (8).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) b. Position mounting bracket grommet (7) to frame (9). c. Install screw (8). Tighten. | |
| 4. | See Figure 12 and Figure 13 Install saddlebag. a. See Figure 12. Open saddlebag outer clamshell (3). b. See Figure 12. Pull out and turn lock knob (4) to the unlocked position (5). c. See Figure 13. Place saddlebag mounting bracket (2) on mounting studs (3) while aligning the saddlebag docking rod (4) with the mounting bracket grommet (5). Slide saddlebag completely forward. d. See Figure 13. Rotate lock knob to the locked position (6) until a click is heard. Without pulling out on the knob, verify that knob cannot rotate back to the unlocked position. NOTE Indicator flag (1) is for showing when lock knob is unlocked only. Do not use indicator flag to lock or unlock saddlebag from vehicle. e. See Figure 13. Verify the indicator flag is not showing and saddlebag is securely fastened. f. Pull saddlebag rearward to verify it is secure. |
| 1 | Fender mount |
| 2 | Fender support |
| 3 | Spacer (2) |
| 4 | Docking mount (2) |
| 5 | Mounting screw (2) |
| 6 | Docking rod |
| 7 | Mounting bracket grommet |
| 8 | Bracket |
| 9 | Screw |
Figure 10. Right Saddlebag
| 1 | Fender mount |
| 2 | Fender support |
| 3 | Spacer |
| 4 | Docking mount |
| 5 | Mounting screw |
| 6 | Docking rod |
| 7 | Mounting bracket grommet |
| 8 | Screw |
| 9 | Frame |
Figure 11. Left Saddlebag
| 1 | Lock |
| 2 | Latch lever |
| 3 | Outer clamshell |
| 4 | Lock knob |
| 5 | Unlocked position |
| 6 | Locked position |
Figure 12. Saddlebag Lock Knob
| 1 | Indicator flag (unlocked position) |
| 2 | Mounting bracket |
| 3 | Mounting stud (2) |
| 4 | Docking rod |
| 5 | Mounting bracket grommet |
Figure 13. Saddlebag Mounting Bracket
COMPLETE
| 1. | Install seat. See service manual. a. After installing seat, pull up on seat to verify that it is secure. | |
| 2. | Install main fuse. See service manual. |