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HARLEY DAVIDSON AIR WING SADDLEBAG LID RAIL LIGHTS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1. If saddlebag rails have not yet been installed: Perform the Air Wing Saddlebag Rail installation up to the point of final assembly of the rails to the saddlebag lids. If saddlebag rails are already installed: Open one saddlebag and remove all loose contents. Remove one saddlebag from the vehicle per service manual instructions. From the underside of the saddlebag lid, remove the fasteners retaining the saddlebag rail to the lid. Note fastener position and save all components for installation. 2. ALL installations: See Figure 3. Obtain a saddlebag rail light assembly (1) from the kit. 3. Insert the light wires through the hole (B) in the side of the saddlebag rail (A) mounting post, and out through the bottom of the post. 4. Install the light to the underside of the saddlebag rail rear cross bar with two screws (4) from the kit. Tighten the screws >securely. 5. Insert the light wires through the left rear saddlebag rail mounting pad (C) and the left rear hole (H) in the saddlebag lid (G). Assemble the saddlebag rail to the lid per the instructions in the Air Wing Saddlebag Rail Kit, feeding the wires through the left rear saddlebag rail nylon washer (D), plain washer (E) and the hex head hollow screw (F). Tighten the two Phillips head screws to 27-31 in-lbs (3.1- 3.5 Nm) . Tighten the hex head hollow screw to 30-50 in- lbs (3.4-5.6 Nm) .

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HARLEY DAVIDSON FLHRS SADDLEBAG LOCK SET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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INSTALLATION 1. Lay a clean pad or blanket on the work surface to protect the saddlebag leather surfaces. 2. Open the saddlebag lid. Remove the saddlebag from the motorcycle, leaving the lid open. See SADDLEBAG REMOVAL in the Service Manual. Lay the saddlebag flat on the pad or blanket with the inboard side facing up and the lid furthest from you. 3. See . Obtain the templates (10) from the kit. Lay the correct (left or right) template in the upper rear corner of the hard plastic inboard face of the saddlebag. Fit the template around the rear of the lid hinge and against the curve of the raised surface in the middle of the saddlebag, and tape it into place. is03044 Figure 1. Template Placement (Left Side Shown) 4. Drill four 3/16 (0.19)-inch holes in the saddlebag inboard face where indicated on the template. 5. Drill four 5/32 (0.15)-inch holes in the saddlebag inboard face as indicated on the template. 6. Remove the template. Cut out the area in between the four smaller holes to create a rectangular opening for the lock arm. Stand the saddlebag upright, with the cover open. 7. See the Figure 2. Obtain one lockset (1) and two screws (5) from the kit. Position the lockset to the saddlebag as shown, with the actuator rod protruding through the rectangular opening cut in step 6. Insert the screws through the lockset mounting holes and into the saddlebag. 8. Position a backing plate (3) over the screw threads inside the saddlebag. Fasten the lockset and backing plate to the saddlebag with two lockwashers (6) and hex nuts (7) from the kit. 9. Using a 3/16-in. hex wrench, remove the two screws holding the inside cover over the existing pushbutton lid release. Remove the cover. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) NOTE Make sure you are using the correct retaining-ring pliers. Verify that tips of pliers are not excessively worn or damaged. 10. Remove the retaining ring fastening the lid release cable to the pushbutton. Unhook the cable from the pushbutton lever, and pull the cable sheath out of the retaining channel on the inboard wall of the saddlebag. Remove the flat washer from the cable end. Do not discard the retaining ring and washer. 11. Trim about one inch (25 mm) from the rearmost part of the retaining channel, and re-insert the cable into the channel so the free end is at the rear of the saddlebag. 12. Insert the cable end through the hole in the backing plate, and slip the washer over the end of the cable fitting. Insert the cable into the slot in the lockset actuator rod so the ball on the end of the cable fits into the depression.

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HARLEY DAVIDSON SPORTSTER LEATHER SADDLEBAG KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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SADDLEBAG INSTALLATION 1. See Figure 3. Remove the rear shock absorber bolt (Figure 1, Item 1). Position the 0.531 x 0.75 x 0.25 inch spacer (7) and the front saddlebag bracket attachment hole over the rear shock absorber bolt location. Secure with the 1/2- 13 x 3.75 inch screw (5). 2. See Figure 3. Position the 0.325 x 0.75 x 0.25 inch spacer (8) and the rear saddlebag attachment hole over the second hole on the rear of the fender, fender support cover, and relocation pad. From the underside of the fender, insert a 5/16-18 x 3.00 inch screw (6) and secure with locknut (10). Tighten locknut (10) to 24-27 ft-lbs (32.5-36.6 Nm) . 3. Tighten the front screw (5) to 21-27 ft-lbs (28.5-36.6 Nm) . 4. See Figure 3. Assemble an isolator washer (12) onto an isolator bushing (13). Place a screw (15) through the bushing. 5. Place the screw and bushing assembly into the top hole inside the saddlebag back. 6. See Figure 3. Push a saddlebag isolator (14) over bushing with cone shape toward saddlebag. 7. Place saddlebag in position on bracket and insert the new screw (15) into the bracket. Do not tighten. 8. Repeat steps 4 through 7 for remaining holes. With all isolators in place, tighten screws to 96-120 in-lbs (10.8- 13.6 Nm) . 9. Repeat Steps 1 through 8 for the opposite saddlebag. 10. Raise rear wheel until the rear shock absorbers align with shock absorber mounting holes on the swingarm. Support the wheel to prevent it from falling during the following step. 11. See Figure 1. Attach rear shock absorber to swingarm by installing bolt (1), washer (2) and nut (4). Tighten bolt to 45-50 ft-lbs (61.1-67.9 Nm) . Repeat step on opposite side of motorcycle. INSTALL REFLECTORS 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) 1. See Figure 3. Measure approximately 1-1/2 in. (38 mm) from the bottom edge of the saddlebag. Orient the reflector horizontally and carefully center the reflector mount between the straps of bags with straps or locate it at the rearward portion of bags without straps. Mark hole location. 2. Using appropriate tool, make two 3/16 in. holes in sad- dlebag. 3. Install reflector mount (3) on saddlebag using two pushnuts (2). 4. Remove adhesive backing from reflector (4) and install on mount. 5. Repeat steps 1 through 4 for the opposite saddlebag. INSTALL SEAT 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) 1. See Service Manual instruction to install the seat

HARLEY DAVIDSON SOFTAIL REAR SADDLEBAG GUARDS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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INSTALLATION 1. Remove saddlebag, if equipped, from motorcycle. 2. Remove passenger footpeg or passenger footboard assembly (including footboard mount) from vehicle. 3. See Figure 1. Remove nut (1), seat strap bracket (if equipped) and 3/8 inch diameter bolt (2) from indicated position on rear fender support (immediately to the rear of the front seat) Discard the bolt, but save the nut for reinstallation. This location is where the upper part of the saddlebag guard will mount. 2 1 is03883 1. Rear fender support nut 2. Rear fender support screw Figure 1. Hardware Removal 4. See Figure 2. Install saddlebag guard (4) top flange (5) against fender support (3). Install 3/8-16 x 1-3/4 inch button head bolt with the seat strap bracket (if equipped) and hardware removed in Step 3 (if equipped) and nut in same direction as bolt removed in Step 3. Finger tighten only. 5. Position bottom flange (6) of saddlebag guard (4) against inboard surface of motorcycle frame (7) at location where passenger footpeg (2) (or passenger footboard bolt) attaches. If Heritage-Style Saddlebag relocation kit, Part Number 90238-00 is to be installed, the bracket should be positioned between the saddlebag guard flange and the motorcycle frame member. Follow installation instructions included with that kit. 6. See Figure 3. Determine your model application and follow the applicable installation procedure below: On models with passenger footpeg, but without saddlebag relocation bracket: Install 3/8-16 x 2-3/4 inch socket head cap screw (6) (For 2007 FLSTC Models, use the 3.5 inch long socket head cap screw (7) from kit) through footpeg support (B). Install support to frame. Tighten support bolt to 35-45 ft-lbs (47-61 Nm). Install lower saddlebag guard flange over bolt protruding from inboard surface of frame member. Install 3/8-16 lock nut to end of bolt. Tighten to 35-45 ft-lbs (47-61 Nm). Install footpeg (C) according to Service Manual instructions. On models with passenger footpeg and saddlebag relocation bracket: Install 3/8-16 x 2-3/4 inch socket head cap screw (6) (For 2007 FLSTC Models, use the 3.5 inch long socket head cap screw (7) from kit) through footpeg support. Install support to frame. Tighten support bolt to 35-45 ft-lbs (47-61 Nm). Position saddlebag relocation

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HARLEY DAVIDSON FLSTN SADDLEBAG GUARD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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REMOVAL All Models 1. If equipped with saddlebags, removal may ease installation. Follow the instructions in the appropriate Service Manual or Instruction Sheet. 2. See Figure 1. Remove and discard the forwardmost fender support bolt (1). Repeat for the other side. 3. See Figure 2. On the left side, remove the footrest support mounting bolt (1) and footrest support bracket assembly (2). Discard the mounting bolt. 2005 – 2006 Models 1. Loosen the exhaust shields as necessary following the instructions in the appropriate Service Manual. Move as necessary for access. 2. Loosen the exhaust header nuts following the instructions in the appropriate Service Manual. 3. See Figure 3. Remove bolt (1) connecting the exhaust system (2) to the support bracket (3). 4. See Figure 4. Remove the two rear muffler bracket bolts (1). 5. See Figure 5. Move mufflers enough to access the rear bolt attaching the exhaust mounting bracket to the frame. Remove bolt (1) and discard. 2007 – Later Models NOTE On 2007 – later models, the frame tab (4) has a plug instead of a bolt (see Figure 6, item 1). 1. Remove plug and discard. 1 is05313 1. Fender support bolt (discard) Figure 1. Remove Docking Hardware 1 2 is05320 1. Footrest support mounting bolt 2. Footrest support bracket assembly Figure 2. Footrest Support Bracket Assembl NSTALLATION Right Side See Figure 5 or Figure 6. 1. See Figure 7. Install upper screw (7) in the fender support. Tighten screw finger-tight. 2. Install the lower screw (4 or 5) with the saddlebag guard, washer (9) and locknut (6) inside the frame. Tighten screw finger-tight. 3. Tighten the upper screw to 30 ft-lbs (41 Nm) . 4. Tighten the lower screw to 40 ft-lbs (54 Nm) . Tighten nut to 30 ft-lbs (41 Nm) . 5. 2005 – 2006 Models: a. Loosely install the exhaust header bolts. b. See Figure 4. Loosely install two rear muffler bracket bolts (1). c. See Figure 3. Loosely install bolt securing exhaust system (2) to support bracket (3). d. Tighten exhaust header bolts following the instructions in the appropriate Service Manual. e. Tighten support bracket bolt and rear muffler bracket bolts following the instructions in the appropriate Service Manual. f. Tighten exhaust shields following the instructions in the appropriate Service Manual. 6. Install saddlebag (if removed) following the instructions in the appropriate Service Manual or Instruction Sheet. 1 2 3 4 is05333 1. Lower saddlebag guard screw 2. Upper saddlebag guard screw 3. Saddlebag guard 4. Exhaust support bracket Figure 5. Install Saddlebag Guard – Right Side Shown (2005 Models) -J04645 2 of 4
2 1 3 4 is05332 1. Lower saddlebag guard screw 2. Upper saddlebag guard screw 3. Saddlebag guard 4. Frame tab Figure 6. Install Saddlebag Guard – Right Side Shown (2007-Later Models) Left Side 1. Loosely install upper screw (7) through the saddlebag guard and the fender support. NOTE Spacer (8) must be installed with the chamfer facing out. 2. See Figure 7. For 2005-2006 Models: Install lower screw (3) through the saddlebag guard, saddlebag guard spacer (8), footpeg support and the frame. Tighten to 30 ft-lbs (41 Nm) . For 2007 and later Models: Install lower screw (10) through the saddlebag guard, footpeg support and the frame. Tighten to 30 ft-lbs (41 Nm) . 3. Tighten upper screw to 30 ft-lbs (41 Nm)

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HARLEY DAVIDSON NOSTALGIC SADDLEBAG GUARD RAILS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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REMOVAL 1. If desired, remove the saddlebags. 2. Remove screws (C) and locknuts (D). Save for installation. 3. Remove reflectors with fishing line or dental floss. Use a sawing motion to remove the adhesive. Clean the surface thoroughly with an equal mixture of isopropyl alcohol and distilled water. Allow the surface to dry thoroughly. INSTALLATION 1. See Figure 1. Position the correct saddlebag guard rail (1 or 2) over the saddlebag guard and support assembly (A). Loosely install the screw (C) through the saddlebag-to- fender support bracket (B), through the saddlebag support (A) and through the inner hole of the saddlebag guard rail bracket. Install nut (D). Tighten finger-tight. NOTE Position the saddlebag guard rail as low as possible on the stock saddlebag guard and support assembly. 2. Install screws (6) and washers (5) through the clamp end of the saddlebag guard rail. Position clamp end around the upright of the saddlebag guard and install the clamp (3 or 4). Tighten screws finger-tight. 3. Align the saddlebag guard rail (1 or 2) parallel to the bottom of the saddlebag and muffler. Tighten the cap screw (C) and locknut (D) to 15-20 ft-lb (20-27 Nm) . 4. Tighten the clamp screws (6) to 22 in-lb (2.5 Nm) . NOTE The reflectors are location-specific. There are markings on the back of the reflector – “L BOTTOM” or “R BOTTOM”. 5. Peel the backing from the base of the new reflector (7 or 8). Without touching the reflector to the saddlebag guard, position the reflector and press the reflector to the saddlebag guard above the clamp (3 or 4) and press for 30 seconds. After releasing pressure, avoid direct contact with the reflector for at least 20 minutes. 6. Repeat all steps for the other side of the motorcycle. NOTE For ease of use, move the saddlebag buckles to the highest hole on the strap. 7. Install the saddlebags, if removed

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HARLEY DAVIDSON SADDLEBAG WALL ORGANIZER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-02-2011

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INSTALLATION 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 load capacity of the wall organizer is 2.5 lbs (1.1 Kg). The combined load of wall organizer and saddlebag must not exceed 15 lbs (6.8 Kg). Saddlebag Without Liners 1. See Figure 1. Open saddlebag. NOTE On some HDI motorcycles, the bail wire has been removed from the quick release stud. In these cases, turn the stud by engaging the slotted end with a large screwdriver. 2. See Figure 2. Grasp bail wire (1) inside saddlebag and rotate front bail head stud (2) a full 1/4 turn in a counterclockwise direction. Remove front bail head stud (2) and flat washer (3). Discard washer but save stud for kit installation. 3. See Figure 3. Place flat washer (1) from kit on front bail head stud. 2 1 2 is03120 1. Anchor bracket (2) 2. Bail head stud and flat washer (2) Figure 1. Open/Close Saddlebag 1 2 3 5 4 6 7 is03114 1. Bail wire 2. Bail head stud 3. Flat washer (stock) 4. Spring plate 5. Wire form 6. Front bracket 7. Rear bracket Figure 2. Saddlebag Quick-Release Fasteners 4. With groove at end of stud held in a horizontal position, insert front bail head stud (2) and flat washer (1) through hole in wall organizer (3), saddlebag, and mounting bracket. When groove engages wire form of spring plate

HARLEY DAVIDSON CHROME SADDLEBAG LID TRIM KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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INSTALLATION 1. Remove all articles from inside, then thoroughly wash and dry the saddlebag lid. 2. Close the saddlebag lid. Cut a piece of masking tape at least 10 inches (25 cm) long and lay it lengthwise down the center of the top outer surface of the lid starting at the front. Mark a line lengthwise down the tape, measuring an equal distance from each side so the line is centered on the lid. 3. Obtain the template (7) from the kit, and position it on the line, with the short leg held against the front surface of the lid. Carefully mark the tape at the two arrows, then remove the template and set it aside. 4. At each of the marks made in Step 3, carefully drill a 1/8 inch (3 mm) diameter pilot hole. 5. Using the pilot holes drilled in Step 4, use a 9/32 inch (7 mm) diameter bit to finish drilling the holes for the trim piece. NOTES Before installing the lid trim, test fit to ensure adequate clearance of both mounting pads through the drilled holes in the saddlebag lid. The trim pieces are side-specific; the front legs are angled to match the lid front. If the pads do not fit loosely in the holes, it may be necessary to slightly enlarge the holes to provide clearance and maintain proper alignment of the trim on the lid. Clean the saddlebag lid inside and out, and the inside of the saddlebag with a soft cloth, making sure to remove any shavings left from drilling. 6. Obtain the correct saddlebag lid trim (1 or 2) and a trim gasket (3) from the kit. Peel the liner from the adhesive backing of the gasket. 7. Position the gasket onto the bottom surface of the trim, making sure the gasket remains inside the outer edges of the trim, and smooth it into place. 8. Obtain a pan head screw (6) from the kit. 9. Using a T25 TORX® drive head, start the screw part way into one of the holes on the underside of the trim, to form a few threads in the hole, then back the screw out of the hole. Repeat for the second hole. 10. Install the trim piece onto the lid, fitting the mounting pads into the holes drilled in Step 5. 11. Place a flat washer (5) from the kit onto the threads of the screw (6), followed by a rubber washer (4). Place two drops of Loctite® 243 (blue) onto the screw threads. 12. While supporting the lid trim in place, open the saddlebag lid and install the washers and screw through the lid into one of the trim mounting pads, finger tight. Repeat for the remaining trim mounting pad, with another screw, flat washer and rubber washer. 13. Apply a small amount of pressure to the trim piece above each screw and continue to tighten both screws to 25-28 in-lbs (2.8-3.2 Nm) . 14. Repeat steps 1 through 13 for the opposite saddlebag lid

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HARLEY DAVIDSON SADDLEBAG LID COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION NOTE To avoid failure, the fastening tab adhesive must be allowed to cure for 24 hours before installing these Lid Covers. NOTE Lid Cover installation may be easier with the saddlebags removed from the motorcycle. 1. See Figure 1. Open the saddlebag lid. Remove the two T-20 TORX® screws (5) attaching the check strap (3) to the lid. 2 4 2 3 1 6 7 4 4 6 5 is02962 1. Saddlebag lid cover 2. Hook and loop fastener, 1.5 inch 3. Check strap 4. Hook and loop fastener, 4.0 inch 5. Torx screws (2) 6. Hook and loop fastener, 6.0 inch 7. Anchor tab (install first) Figure 1. Saddlebag Lid Cover Installation 2. Wash the entire saddlebag lid, inside and out, with warm, soapy water. Rinse and dry thoroughly. 3. Use the alcohol prep pad provided in the kit to further clean the inside of the lid in the areas where the hook and loop strips will be attached. NOTE The Saddlebag Lid Covers are side-specific. A Bar-and-Shield logo is stitched into the rear face of each cover. NOTE DO NOT fasten the Saddlebag Lid Cover tabs to the hook and loop strips until the adhesive has cured for 24 hours. 4. Place the correct Saddlebag Lid Cover (1) over the saddlebag lid in its proper position. Bring the cover tabs over the edge of the lid to serve as a guide in positioning the hook and loop strips on the inside of the lid. Remove the protective backing from one hook and loop strip at a time. Use the corresponding tab on the cover only as a positioning guide, then fold it back out of the

HARLEY DAVIDSON SADDLEBAG GUARD RAIL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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Installation NOTE A Service Manual for your vehicle is available from your Harley-Davidson Dealer. 1. Remove saddlebags from motorcycle according to Service Manual instructions. 2. Remove left and right side covers (located just ahead of saddlebags) by removing Phillips head screw from bottom of side cover. Save hardware and side covers for later reassembly. 3. Remove upper and lower bolts securing left and right forward saddlebag guards to frame. Remove Phillips head screws securing saddlebag guards to muffler supports. Discard saddlebag guards, but save hardware. 4. See Figure 1. Install new left and right forward saddlebag guards (1) with upper bolts (2), lower bolts (3) and Phillips head screw (4) saved from Step 3. 5. Insert one rear guard rail mount (6) onto rounded, tubular end of one of the saddlebag side guard rails (5). 6. Insert a hex cap screw (8) through one of the front guard rail mounts (7) as shown. 7. Line up saddlebag side guard rail (5) with attached rear guard rail mount (6) from Step 5 with lower hole in forward saddlebag guard rail (1). Insert hex cap screw (8) from front guard rail mount (7) through hole in forward guard rail (1) and into side guard rail assembly. Tighten finger tight. 8. See Figure 2. Install a side guard rail (2) in lower position on rear fender support (3) with pan head screw (1). Tighten finger tight. 9. Repeat Steps 5 through 8 in upper position. 10. Repeat Steps 5 through 9 for opposite side of vehicle. NOTE Each of the four guard rail clamps vary slightly. Two fit together for the right side of the motorcycle and two fit together for the left side. The inner right and left clamps have two holes drilled through them. 11. See Figure 2. Locate four guard rail clamps (4). Match up two left side and two right side guard rail clamps. Install one piece of cushion tape to the lower inner surface of right and left inner clamps. Peel off paper from outer surface of tape. Do not apply tape to the outside clamps. NOTE Be sure that you correctly position the inner clamps on the side guard rails, as directed in Step 12, before tape on inner clamp contacts side guard rails. Tape is very sticky and will be difficult or impossible to remove once it has made contact with side guard rail surface. 12. See Figure 2. Position clamps (4) in desired position on side guard rails (2). Install clamps (4) on left and right side of vehicle side guard rails using four Torx screws (5). Torx screw heads should face inward toward motorcycle. Tighten each screw a little at a time until secure. 13. Tighten hex cap screws and pan head screws installed in Steps 7 and 8.

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