INSTRUCTIONS - Harley
Contents
1. Conduit Wires Exiting Bracket Wires Entering Bracket Signal Relocation Bracket Figure 5 Install Wiring and Conduit into Bracket See Figure 6 Apply LOCTITE 243 Blue to screw P N 3538 Using screw and lock washer P N 7042 attach lamp to signal relocation bar as shown Tighten securely Repeat step 11 for the opposite signal i03116 tif Install Rubber Plug to Opening Screw and Lock Washer Figure 6 Installing 3 inch Turn Signals Standard Style 2017 12 Deuce Style Signal Lamps See Figure 5 Obtain left signal lamp housing and left turn signal relocation bracket P N 90139 00 Cut wiring 12 inches from entrance to lamp housing Moisten wires with wet paper towel or rag and insert wires through relocation bracket as shown until wires exit from opposite end of tube See Figure 7 Apply LOCTITE 243 Blue to screw P N 4092 Using screw lock washer P N 7042 and spacer P N 65849 01 attach lamp to signal relocation bar as shown Spacer should be installed between signal and signal relocation bar Tighten securely Repeat step 12 for the opposite signal 103353 tif _ Lock Washer t I Screw lt Install Rubber Plug Figure 7 Installing 2 3 8 inch Turn Signals Deuce Style 13 Install small black rubber plug P N 53644 00 to cover opening of tube on bracket Repeat for opposite side 14 See Figure 8 Obtain Wiring Harness and two Sealed Butt Connectors from kit Following instructi2. of 7 Install Saddlebag Support NOTE When performing Steps 7 through 23 completely perform procedures for one side before continuing to the opposite side This will ensure fender will remain supported during installation 7 See Figure 3 Remove remaining bolt from inside fender securing strut to fender i03113 tif Remove remaining Hardware Fender Strut 9 removed with Bolt Turn Signal Assembly Install Chrome Plated Hole Cover Figure 3 Remove Remaining Strut Hardware 8 Obtain chrome plated hole cover P N 56239 93 and press into hole of original turn signal wire entrance location Repeat for the opposite side NOTE Before proceeding to the next step determine which of the following cases pertains to your installation and install accordingly Case 1 Installing kit onto stock motorcycle Case 2 Installing kit onto stock motorcycle with non stock wide seat Case 3 Installing kit onto motorcycle with detachable docking points 9 See Figure 4 Obtain left saddlebag support Case 1 Apply Loctite 243 blue provided in kit onto threads of two bolts P N 4164 Install washers P N 6701 onto bolts From the inside of the fender place bolt and washer through hole in fender and strut Secure bolt into threads of saddlebag support Case 2 Apply Loctite 243 blue provided in kit onto threads of two bolts P N 4164 Install washers P N 6701 onto bolts From the inside of the fender pl
3. 098 and four large flat washers P N 6416 Install saddlebag to support with screw through washer and grommet in saddlebag then through washer P N 6416 and into threaded portion of saddlebag support Repeat for the remaining screw and two washers Do not tighten completely at this time 19 Obtain screw P N 4219 washer P N 6333 and flange nut P N 7531 and secure bottom portion of saddlebag to support 20 Obtain left turn signal assembled previously Insert screws P N 4219 and washers P N 6333 into saddlebag then into left turn signal bracket and through saddlebag support Install flange nuts P N 7531 21 Return to all screws and flange nuts installed in Steps 18 through 20 and tighten all hardware securely 22 Return to left side wiring harness and route harness along bottom of strut and insert into retaining clips installed in Step 15 Adjust if necessary then bend clip tabs to capture wiring in place p a Screws and a j Washers Install Washer between Saddlebag and Support Secure Saddlebag to Ft y Lower Support using Screw Washer and Flange Nut Screws Washers for Mounting Turn Signal Relocation Bracket Figure 11 Install Saddlebag to Support 23 See Figure 12 Continue routing wiring harness under front of strut in front of fender and through middle boxed area of frame to Connector 7 Turn Signal Connector 7 into boxed area of frame Figure 12 Route Wi
4. 93 Part No 90126 00 Date 11 00 Dyna Fiberglass Saddlebag Kit Description Qty Nut flange locking 6 Grommet 6 Spacer 4 Spacer 6 Screw hex head 4 Spacer 4 Screw hex head 4 Washer 4 Hole plug cover chrome 2 Plug black rubber 2 Screw 5 16x18x1 2 Spacer 150 inch 2 Loctite 243 5 ml not shown Part Number 7531 90148 00 90149 00 90186 00 4164 91414 00 4218 6701 56239 93 53644 00 4092 65849 01 94635 98 6 of 7 Part No 90126 00 Date 11 00 Dyna Fiberglass Saddlebag Kit Service Parts oo kit i03126 tif Saddlebag Left P N 90147 00 Saddlebag Right P N 90141 00 Item Description Qty Saddlebag lid right hand Saddlebag lid left hand Reflector red right hand DORWON Reflector amber right hand O Reflector red left hand Reflector amber left hand 7 Plate cam lock 8 Keeper latch 9 Medallion H D 10 Plate lid hinge mount 11 Plate base hinge mount 12 Plate latch backing 13 Cam latch lever 14 Latch assembly J01924 Saddlebag bottom right hand Saddlebag bottom left hand Saddlebag Assembly Part No Item Description Qty 90127 00 15 Hinge assembly 90128 00 16 Cover latch 90129 00 17 Lever latch 90134 00 18 Lock assembly 1 of 2 59287 92 19 Cam block 59289 92 20 Screw 10 16x1 2 self tap 9 59288 92 21 Washer non metallic 59290 92 22 Nut keps 10 32 3 91393 00 23 Screw M6 6Hx25 2 91392 00 24
5. MOTOR HARLEY DAVIDSON Uy General J01924 This saddlebag kit is designed to fit 1996 and later Dyna Model Motorcycles except 2000 and 2001 FXDX and 2001 FXDXT See Service Parts Pages for kit contents 4AWARNING Additional weight can affect motorcycle stability handling characteristics and safe operating speed Do not exceed 7 Ibs 3 2 Kg maximum load in each saddlebag Evenly distribute weight between each saddlebag Improper loading may lead to instability which could result in an accident and death or serious injury Installation NOTE A Service Manual for your vehicle is available at your Harley Davidson Dealer 1 Remove seat 4AWARNING To protect against shock and accidental start up of vehicle disconnect the negative battery cable before proceeding Inadequate safety precautions could result in death or serious injury 4AWARNING Always disconnect the negative cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in death or serious injury 2 Disconnect battery cables negative cable first 3 On FXDS Conv models follow instructions in Service Manual and remove existing saddlebags and mounting hardware Remove Turn Signals 4 Refer to the Appendix covering Amp Electrical Connectors in applicable Service Manual and locate left and right signal wiring at turn signal connector under se
6. Screw 8 32 90167 00 25 Washer flat 8 90158 00 26 Screw button head 1 4 20x1 2 2 90188 00 27 Gasket 90159 00 28 Label saddlebag 91390 00 29 Plate hinge cover 90166 00 30 Screw 1 4 20x1 4 Part No 90151 00 91391 00 91386 00 90168 00A 91389 00 5233 91387 00 936 90174 00 90248 00 91375 00 1397 7017
7. ace bolt and washer through hole in fender and strut Place spacer P N 91414 00 between strut cover and saddlebag support Secure bolt into threads of saddlebag support Case 3 Apply Locktite 243 blue provided in kit onto threads of two bolts P N 4218 Install washers P N 6701 onto bolts From the inside of the fender place bolt and washer through hole in fender and strut Place detachable docking point between strut cover and saddlebag support Secure bolts into threads of saddlebag support 10 If installing 3 inch Standard Style Signal Lamps proceed to step 11 If installing 2 3 8 inch Deuce Style Signal Lamps proceed to step 12 J01924 Install Bolts i from inside fender Install Docking Points between Strut and Support If Docking Points are not present install Spacers P N 91414 00 between Strut and Support Figure 4 Install Saddlebag Support 11 Standard Style Signal Lamp See Figure 5 Obtain left signal lamp housing removed previously and left turn signal relocation bracket P N 90139 00 Remove conduit and cut wiring 12 inches from entrance to lamp housing Cut a 1 inch section off conduit and slide it over wiring up to the entrance of the lamp housing Moisten wires with wet paper towel or rag and insert wires through relocation bracket as shown until wires exit from opposite end of tube Slide conduit down to protect wiring at wire entrance of relocation bracket i03115 tif 1 inch
8. at Unplug connector and following instructions in Service Manual remove terminals from connector ai On 1996 to 1998 Models pull turn signal wires through clips if present and fender On 1999 and later models perform the following a Remove two screws securing tail stop lamp lens assembly and remove lens assembly INSTRUCTIONS REV 11 8 00 Kit Number 90126 00 DYNA SADDLEBAG KIT i03111 eps PAJO ng Figure 1 Disconnect Turn Signals 2000 Shown b See Figure 1 Disconnect left and right turn signal 2 Place connectors from sockets Cut wires at connector as close to terminal end as possible Discard connectors and terminals c Gently pull turn signal wiring out from tail stop lamp assembly and from clip under rear of fender 6 See Figure 2 Remove rear turn signals according to the following FXD 1999 FXDX FXDL and FXDWG Remove signal lamp assembly by removing bolt inside rear fender Remove lamp housing from bracket and pull wiring through bracket Repeat for the opposite side Discard lamp brackets FXDS CONV Unscrew the lamp housing from the turn signal bar and pull wiring through fender and bar Repeat for the opposite lamp Remove nuts under fender securing turn signal bar Discard bar i03112 eps Bolt inside Fender B Lamp Housing Lamp Bracket All except FXDS Conv NI Turn Signal Bar FXDS Conv Figure 2 Rear Turn Signal Mounting Hardware 1
9. ons in Service Manual under Installing Sealed Butt Connectors match wire colors and splice wiring from turn signal to harness Slide conduit from harness over Butt Splices and approximately 2 inches into bracket tube NOTE Cutting one of the wires slightly shorter before installing connectors will Stagger the location of the butt splices and make sliding conduit over wiring much easier i03117 tif Butt Connectors Note Staggered Locations Slide Conduit from Harness over Butt Connectors after Installation Figure 8 Install Wiring Harness J01924 15 See Figure 9 Obtain three adhesive backed wire harness retaining clips P N 10102 Remove adhesive and install clip under fender strut in front of rear shock as shown in upper portion of Figure 8 Install two remaining clips under fender strut at locations shown in lower portion of Figure 8 Figure 9 Install Wire Harness Retaining Clips 16 See Figure 10 Obtain left saddlebag 3 small grommets P N 90148 00 and 2 large grommets P N 11447 Install the large grommets to the upper two holes and 3 small grommets to lower 3 holes in the saddlebag assembly as shown 17 Install two large spacers P N 90149 00 into the upper grommets and three small spacers P N 90186 00 into the lower grommets as shown Smaller Grommets and Spacers Figure 10 Install Grommets and Spacers 3 of 7 18 See Figure 11 Obtain two large screws P N 4
10. ring to Connector 7 24 Follow instructions in the Service Manual to install pin terminals to cavities in Turn Signal Connector 7 25 Repeat Steps 7 through 24 for the right saddlebag J01924 If Necessary install Amber Reflectors to Saddlebags NOTE In the next step red reflectors are pre installed to meet the US and Canadian requirements Amber reflectors are provided and can be installed to meet the requirements of markets other than the US or Canada Federal Motor Vehicle Safety Standard FMVSS 108 requires all motorcycles to be equipped with side reflectors Install or have Dealer install the reflectors supplied with this kit Visibility is a major concern to motorcyclists Failure to install all side reflectors could result in an accident and death or serious injury 26 If amber reflectors need to be installed perform the following See Figure 13 Locate reflector mounting location under the Harley Davidson Logo Gently pry out existing reflector i03123 tif Reflector Location Figure 13 Install Reflectors 27 Use isopropyl alcohol to thoroughly clean the area then let dry completely Remove adhesive backing and install amber reflector Repeat for opposite saddlebag Let adhesive cure for 24 hours 28 Connect battery cables positive cable first Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting spark
11. s may cause a battery explosion which could result in death or serious injury 29 Install seat After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift position during vehicle operation causing loss of control of vehicle and death or serious injury Check for proper turn signal lamp operation before riding motorcycle Visibility is a major concern for motorcyclists Failure to have proper turn signal lamp operation could result in death or serious injury 30 Check turn signals for proper operation 4of7 Tiny Service Parts i03124 tif Mounting Bracket Kit 90150 00 Item Description Part Number 1 Bracket mounting right hand 90136 00 2 Bracket mounting left hand 90137 00 3 Bracket turn signal mounting right 90138 00 4 Bracket turn signal mounting left 90139 00 JO1924 Part No 90126 00 Date 11 00 Dyna Fiberglass Saddlebag Kit 5 of 7 Tan Service Parts i03125a tif Hardware Kit 90106 00A Item 1 Description Aty Cable strap 4 Clip adhesive 6 Grommet 4 Screw hex socket button 2 Screw button socket head 4 Screw hex socket button head 6 Reflector amber right hand Reflector amber left hand Washer plain 6 Washer plain 8 Lockwasher hi collar 2 Harness turn signal wire 2 Connector sealed butt 4 J01924 Part Number 10065 10102 11447 3538 4098 4219 59289 92 70585
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