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VRSCD SADDLEBAG MOUNTING KIT
J037252010-06-29
GENERAL
Kit Number
91440-06
Models
This kit fits 2002-2006 VRSCD models.
WARNING
Do 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 10 pounds (4.5 Kg.)
Additional Parts Required
This kit requires the separate purchase of VRSCR Saddlebag Kit 91401-06 or VRSCD Saddlebag Kit 91441-06. The saddlebag kit consists of a left and right saddlebag and instruction sheet.
Installation of this kit will require Loctite® 243 (blue) 99642-97, which is available from a Harley-Davidson Dealer.
Kit Contents
See Figure 16 and Table 1 Service Parts Table.
WARNING
Federal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b)
INSTALLATION
Prepare Bike for Hardware Installation
1. Use a suitable lift to support the motorcycle under the frame until the rear suspension is fully extended.
NOTE
To remove the tether from the hole in the frame, reach under the frame tube to align the metal tee (located on the end of the seat tether) with the tether cable.
2. See Figure 1. Unlatch and open seat. Remove tether (4) by sliding small clip (3) sideways through hole in frame.
NOTE
To remove the tubular plastic seat-hinge sleeve from the hinge, turn the sleeve to reveal the slotted length. Push on the slot with your finger to pop the sleeve off the hinge pins. Closing the seat slightly allows the sleeve to fall from the hinge-side of the seat, so be prepared to catch the sleeve.
3. Remove plastic sleeve (2) from hinge pins (1) and slide pins toward rear of bike. Remove seat.
1Hinge
2Sleeve
3Clip
4Remove tether from frame
Figure 1. Remove Seat
1Grabstrap
2Passenger Pillion
3Screw and Washer
Figure 2. Remove Passenger Pillion
4. See Figure 2. Remove screw and washer (3) securing passenger pillion to frame. Slide pillion under grabstrap (1) and forward to disengage from tongue to remove. Save pillion mounting screw and washer for later use.
1Turn signal module bracket
2Pillion mounting tongue
3Turn signal module bracket mounting nuts
4Grabstrap screw with washer
Figure 3. Remove Turn Signal Module, Bracket and Grabstrap
5. See Figure 3. Remove the turn signal module from its mounting bracket (1) by pulling module upward and back to release from bracket. Carefully place the module to side of bike and let hang.
6. Remove the two screws and washers securing the grabstrap to the fender and frame (4). Note the orientation of the grabstrap. Save screws and washers for later use.
7. Remove the two nuts securing the turn signal module bracket (3) to fender. Save nuts for later use.
1Fender mounting screws and washers
Figure 4. Remove Fender Mounting Screws
8. See Figure 4. Remove the two screws and washers. Save for later use.
1Taillight connector
2Fender mounting grooves
3Fender
Figure 5. Taillight Connector and Rear Fender
9. See Figure 5. Slide the fender toward the rear of the bike to remove fender from mounting grooves (2) in license plate/turn signal bracket. Disconnect tail light connector (1), then remove fender from tail section.
1Fender support
2License plate/turn signal bracket
3Screws
4Nuts (inside fender)
Figure 6. Remove Fasteners Securing License Plate and Turn Signal Bracket
10. See Figure 6. Remove two small screws (3), nuts (4) from both sides of fender support. Remove the license plate/turn signal bracket (2).
NOTE
When performing the following step, note the two plastic tabs on the license plate/turn signal bracket. The tabs align the license plate/turn signal bracket with the fender support.
11. Gently pull license plate/turn signal bracket out from fender support (noting plastic tabs), then carefully move assembly down just below fender support.
1Ear on fender support
2Flat head carriage bolt from kit
3Plastic tabs
Figure 7. Remove License Plate/Turn Signal Bracket and Install Saddlebag Mounting Bolt
12. See Figure 7. Obtain flat head carriage bolt (2) from kit. Install carriage bolt into square opening on fender support (1). Repeat for opposite side.
1Shock mounting bolt
2Shock mount support
3Rear fender support
Figure 8. Install Shock Mount Support (Left Side Shown)
13. See Figure 8. While holding the nut inside of fender with a 28 mm socket, back the shock mounting bolt (1) out just far enough to remove the shock mounting nut. Discard nut.
14. See Figure 8 and Figure 16. Obtain the Shock Mount Support from kit. Install shock mounting bolt through shock support (oriented as shown) and begin to tighten.
NOTE
If shock support is not butted completely against fender support, the remaining saddlebag support hardware will be installed too low resulting in interference and damage to the belt guard assembly.
15. While continuing to tighten shock mount support (2), secure the support, so it remains butted completely against fender support (3). Tighten the shock mounting bolt to 41–68 N·m (30–50 ft-lbs). After tightening, recheck the shock mount support position.
NOTE
There should be no space between shock mount support and rear fender support.
16. Perform Steps 13 through 15 for the right side.
NOTE
Apply Loctite 243 (blue) 99642-97 to last 4 threads of bracket screws.
1Adapter bracket
2Flange nut (behind fender support)
3Flange nut and hexscrew
Figure 9. Install Bracket (Left Side Shown)
17. See Figure 9. Obtain hex head screw and flange lock nut (3) and left adapter bracket (1) from kit. Install screw (from inside fender) through shock mount support, adapter bracket, then install lock nut. Tighten nut to snug front of support in position.
NOTE
The nuts will be tightened to specific torques after the rear support is installed and all supports are aligned.
18. See Figure 9. Obtain flange lock nut from kit. Fasten rear of saddlebag mount to flat head carriage bolt (2) installed earlier in Step 12 (located behind fender support). Tighten nut to snug rear of support in position.
19. Perform Steps 17 and 18 to mount the right side saddlebag support. Tighten hardware just snug enough to hold saddlebag support in position.
20. See Figure 7. Align and position the license plate/turn signal bracket onto fender support ensuring the two plastic tabs (3) are located properly.
1Screws with nuts securing license plate/turn signal bracket
2Tabs seated into fender holes
Figure 10. Reinstall License Plate/Turn Signal Bracket
21. See Figure 10. Install the two small screws and nuts (1) on each side to secure the license plate/turn signal bracket to the fender support. Make sure that the tabs (2) are located in the fender support. Tighten the screws and nuts to 8–12 N·m (6–9 ft-lbs).
1Taillight connector
2Fender mounting grooves
3Fender
Figure 11. Taillight Connector and Rear Fender
22. See Figure 11. Obtain the rear fender removed in Step 9. While holding the fender in place, connect the tail light connector (1).
23. Install fender with rear lip (ridge) of fender centered completely in the grooves. Push fender forward until the mounting holes at top of fender align with holes in fender support.
1Fender Screws
Figure 12. Reinstall Fender To Fender Support
24. See Figure 12. Install screws and washers removed in Step 8. Tighten screws to 8–12 N·m (6–9 ft-lbs).
1Grabstrap screw with washer
2Turn signal module
3Module bracket mounting nuts
Figure 13. Reinstall Turn Signal Module Bracket and Grabstgrap Hardware
25. See Figure 13. Install turn signal module bracket and nuts (3) removed in Step 7. Tighten nuts securely.
26. Install grabstrap, screws and washers removed in Step 6. Tighten screws to 8–12 N·m (6–9 ft-lbs) .
27. Install turn signal module (2) on bracket as shown.
28. Insert the pillion into position through the grabstrap.
29. Fasten the pillion to the frame using the mounting bolt from the stock pillion. Tighten to 11–14 N·m (97–124 in-lbs).
WARNING
After installing pillion, pull upward to be sure it is locked in position. While riding, a loose pillion can shift causing loss of control, which could result in death or serious injury. (00387a)
30. Position the seat (as if opened) onto the frame. Slide the seat forward to insert the seat-hinge pins into the bushings on the frame.
31. Clip the tubular plastic seat-hinge sleeve over the seat hinge.
32. Insert the seat tether into the hole in the motorcycle frame.
Install Saddlebag Support Hardware
NOTE
When installing the saddlebag mounting hardware, perform the procedures one side at a time to maintain fender support alignment.
The nuts will be tightened to specific torques after the rear support is installed and all supports are aligned.
Apply Loctite 243 (blue) 99642-97 to last four threads of saddlebag rack screws.
1. See Figure 14. Obtain saddlebag rack, four socket head capscrews and four flat washers (1) from kit. Align the rack and install the screws and washers through the rack and into the adapter brackets.
2. Tighten the adapter bracket fasteners to 48 N·m (35 ft-lbs).
3. Tighten the saddlebag rack fasteners to 25 N·m (18 ft-lbs).
1Socket head screws and washers
2Saddlebag rack
Figure 14. Install Rack (Left Side Shown)
Attach and Release Saddlebags
1. See Figure 15. Prior to attaching saddlebags, verify that the locking pin (2) is tightened to 5.6 N·m (50 in-lbs).
2. To attach saddlebag, hang hooks (1) on saddlebag over the release/attach assembly, ensuring that the isolator pad (3) locates between the hooks.
3. Verify that the locking pin (2) locates in the hole of the release mechanism (4). Push in on the bottom of the saddle bag until it locks into place. If it will not lock, remove saddlebag. Loosen the locking pin nut, back out pin one turn, and retighten. Repeat Steps 1 through 3, as necessary, until saddlebag locks properly into place.
4. Repeat procedure for opposite saddlebag.
WARNING
Federal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b)
WARNING
Do not operate motorcycle without saddlebags attached unless the saddlebag support bracket is also removed. The support bracket obscures stock reflectors. Low visibility of rider can result in death or serious injury. (00425e)
5. To release the saddlebag, press in on the release pin (5), tilt the bottom of the saddlebag outward, and lift it up and away.
6. Repeat procedure for opposite saddlebag.
1Hook
2Locking pin
3Isolator pad
4Release mechanism
5Release pin
Figure 15. Saddlebag Mounting Hardware
Saddlebag Operation and Care
Opening Saddlebag
To open saddlebag, first open zippers. Separate hook and loop strips by lifting outward on side flap and then lift lid up.
Closing Saddlebag
Lift outward on side flap while dropping lid down to top of bag. Press firmly downward to verify contact between lid and top of bag.
Press firmly inward on side flap to fully engage Velcro under flap.
Hook and Loop Fastener Care
If the hook and loops become "clogged" with lint, etc., carefully comb out foreign materials to restore strength.
SERVICE PARTS
Figure 16. VRSC Saddlebag Mounting Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
Hardware Kit
91226-06
1
  • Capscrew, hex head (2)
Not sold separately
2
  • Screw, hex socket (4)
Not sold separately
3
  • Screw, flat head (2)
4244
4
  • Washer, flat (4)
6812
5
  • Shock Support (2)
Not sold separately
6
  • Locknut, flanged, M10 (4)
Not sold separately
7
Saddlebag rack weldment
Not sold separately
8
Adapter Bracket, Right
91232-06
9
Adapter Bracket, Left
91330-06
Items mentioned in text, but not included in kit:
A
Saddlebag, Right
B
Saddlebag, Left