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REV. 2007-04-13
DYNA SADDLEBAG KIT
GENERAL
PREPARE FOR SERVICE
Kit Number
1.
90126-XX
Remove seat according to the instructions in the Service
Manual.
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harleydavidson.com (English).
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)
Additional Parts Required
The rider's safety depends 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. (00333a)
Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
2.
REMOVAL
Remove Turn Signals
NOTE
This instruction sheet references Service Manual information.
A Service Manual for your model motorcycle is required for
this installation and is available from a Harley-Davidson dealer.
1.
Locate and separate tail lamp connector (8-place multilock)
under seat. Then remove wires from connector. Refer to
AMP MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
2.
1996-1998 Models: Pull turn signal wires through clips (if
present) and rear fender.
Kit Contents
This saddlebag kit includes the following kits and assemblies:
Table 1. Kit Contents
Kit/Assembly
Saddlebag Bracket Kit
(90212-01)
Disconnect battery cables, negative (-) cable first.
1999 and Later Models:
a.
See Figure 1. Remove two screws and tail lamp lens
(1) from base (2).
b.
See Figure 2. Using a Terminal Pick Tool (HD-41475100) (1), depress locking tabs and remove turn signal
connectors (2-place) (2, 3). Save connectors for kit
installation. Refer to AMP MULTILOCK ELECTRICAL
CONNECTORS in Service Manual.
c.
Remove wires from turn signal connectors. Note
location of terminal for proper reassembly.
d.
Remove turn signal wiring from clips under rear of
fender and pull wires out.
Figure/Table
Figure 18, Table 2
Saddlebag Bracket Hardware Figure 19, Table 3
Kit (90213-01A)
Saddlebag Assembly, R.H.
(90037-XX )
Figure 20, Table 4
Saddlebag Assembly, L.H.
(90038-XX)
Figure 20, Table 4
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 weight capacity is 7 lbs (3.18 Kg) in each saddlebag.
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1
3
68140-98
2
1
2
1. Tail lamp lens
2. Tail lamp base
1. Fender cover screw
2. Chrome hole cover location
3. Rear turn signal location
Figure 1. Remove Tail Lamp Lens
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Figure 4. Fender Cover and Hardware
1
2
3.
See Figure 3. Remove screw (1) from inside the rear
fender. Then remove turn signal (2) from mount (3).
4.
Carefully pull turn signal wiring out through turn signal
mount. Discard mount.
5.
Repeat steps for opposite turn signal.
6.
See Figure 4. Remove screw (1) from fender cover.
3
ASSEMBLY
NOTE
Proper installation of this kit requires that the tasks be completed for one side of the motorcycle first before continuing to
the opposite side.
Assemble Relocation Bracket and Turn Signals
1. Terminal pick tool
2. Left turn signal connector
3. Right turn signal connector
1.
For 3-Inch Signal Lamp:
a.
See Figure 5. Remove conduit from turn signal
housing. Cut a 1 inch section off conduit and slide it
over wiring.
b.
Moisten wires with wet shop towel and insert through
relocation bracket (Figure 18, Item 3, 4) until wires
exit from opposite end of tube. Slide conduit down to
protect wiring at entrance of relocation bracket.
c.
See Figure 6. Apply LOCTITE® 243 Threadlocker and
Sealant - Blue to threads of screw.
d.
Install turn signal to relocation bracket (1) using screw
(2) and lockwasher (3). Tighten securely.
e.
Install rubber plug (4) to cover opening of tube on
relocation bracket.
Figure 2. Remove Turn Signal Connectors
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2
3
1. Screw
2. Rear turn signal
3. Mount
Figure 3. Rear Turn Signal and Hardware
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For 2-3/8 Inch Signal Lamp:
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a.
See Figure 5. Moisten wires with wet shop towel and
insert wires through relocation bracket (Figure 17,
Item 3 and 4) until wires exit from opposite end of
tube.
b.
See Figure 7. Apply Loctite 243 (blue) to threads of
screw.
c.
Install turn signal to relocation bracket (1) using screw
(2), lockwasher (3), and spacer (4). Spacer should
be installed between turn signal and relocation
bracket. Tighten securely.
d.
Install rubber plug (5) to cover opening of tube on
relocation bracket.
5
4
3
1
2
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1.
2.
3.
4.
5.
2
1
Relocation bracket
Screw (4092)
Lockwasher (7042)
Spacer (5792)
Rubber plug (53644-00)
Figure 7. Install 2-3/8 Inch Turn Signals
3
4
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1.
2.
3.
4.
Wires existing relocation bracket
Conduit, 1 inch
Wires entering relocation bracket
Turn signal relocation bracket
2
1
Figure 5. Route Wiring into Relocation Bracket
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1
4
1. Butt splice connector (2)
2. Conduit
2
1.
2.
3.
4.
Relocation bracket
Screw (3538)
Lockwasher (7042)
Rubber plug (53644-00)
Figure 6. Install 3-Inch Turn Signals
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Figure 8. Install Wiring Harness
NOTE
Cutting one of the wires slightly shorter before installing connectors staggers the location of the butt splices and makes
sliding conduit over wiring much easier.
2.
See Figure 8. Match wire colors and splice wiring from
turn signal to harness using connector (1) (Figure 19, Item
16). Refer to SEALED BUTT SPLICE CONNECTORS in
Service Manual.
3.
Slide conduit from wiring harness over butt splices and
approximately 2 inches into relocation bracket tube.
4.
See Figure 9. Remove adhesive and install retaining clip
(Figure 19, Item 18) under fender cover in front of rear
shock (upper frame). Install two remaining clips under
fender cover (lower frame).
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2.
Assemble support hanger (3) in top holes of saddlebag
using two acorn nuts (4).
3.
Fasten bottom of saddlebag to support hanger with screw
(5), washer (2), and flange nut (6).
4.
Obtain turn signal and relocation bracket previously
assembled.
5.
See Figure 12. Assemble turn signal and relocation bracket
(1) on support hanger and saddlebag using two screws
(2), washers (3), and flange nuts (4).
6.
Tighten screws and nuts installed in Steps 3 and 5.
7.
Remove two screws and acorn nuts from Step 1.
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4
2
1
3
Figure 9. Retaining Clip Locations
2
Install Grommets and Spacers into Saddlebag
1.
2.
See Figure 10. Install two large grommets (1) to upper
holes in saddlebag and three small grommets (2) in lower
holes.
Install two large spacers (3) into upper grommets and
three small spacers (4) into lower grommets.
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3
5
6
1.
2.
3.
4.
5.
6.
Screw (2) (4107)
Washer (2) (6202)
Support hanger
Acorn nut (2) (94008-90T)
Screw (4219)
Flange nut (7531)
Figure 11. Assemble Support Hanger on Saddlebag
2
2
4
4
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1.
2.
3.
4.
1
Grommet, large (2) (11447)
Grommet, small (3) (90148-00)
Spacer, large (2) (90149-00A)
Spacer, small (3) (90186-00A)
Figure 10. Install Grommets and Spacers (Left Saddlebag
Shown)
2
3
4
Assemble Support Hanger and Relocation Bracket
on Saddlebag
NOTE
The screws and acorn nuts that hold the support hanger to the
saddlebag are removed when the saddlebag assembly is
installed on the motorcycle.
1.
See Figure 11. Insert two screws (1) and washers (2) in
top mounting location of support hanger.
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1.
2.
3.
4.
Turn signal and relocation bracket
Screw (2) (4219)
Washer (2) (6202)
Flange nut (2) (7531)
Figure 12. Assemble Relocation Bracket on Support
Hanger and Saddlebag
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Motorcycle with Detachable Docking Points (2005
and Earlier Models)
INSTALLATION
NOTE
1.
See Figure 13. From inside fender, insert one screw (1)
and washer (2) through both rear holes in fender cover.
2.
Remove front screw in fender cover.
3.
See Figure 13. From inside fender, insert one screw (1)
and washer (2) through both rear holes in fender cover.
From inside fender, insert one screw (1) and washer (2)
into front hole in fender cover.
4.
Place chrome cover (3) into recess at rear of fender cover.
2.
Remove front screw in fender cover.
5.
3.
From inside fender, insert one screw (1) and washer (2)
into front hole in fender cover.
Place detachable docking point onto each screw extending
from fender cover.
6.
Place saddlebag assembly onto screws extending from
fender cover.
7.
Apply Loctite 243 (blue) to threads of screws.
8.
Place one washer (2), detachable docking point, and acorn
nut (5) on each screw.
Tighten acorn nuts to 20-25 ft-lbs (27.1-33.9 Nm).
Proper installation of this kit requires that the tasks be completed for one side of the motorcycle first before continuing to
the opposite side.
Stock Motorcycle (2005 and Earlier Models)
1.
4.
Put chrome cover (3) into recess at rear of fender cover.
5.
Install saddlebag assembly onto screws extending from
fender cover.
6.
Apply Loctite 243 (blue) to threads of screws.
7.
Place one washer (2) and acorn nut (5) on each screw.
9.
8.
Tighten acorn nuts to 20-25 ft-lbs (27.1-33.9 Nm).
Stock Motorcycle (2006 and Later Models)
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4
3
1
1
5
1.
2.
3.
4.
5.
2
2
1.
See Figure 14. Place rear fender bracket (1) underneath
fender and though fender holes.
2.
Insert screw (2) and washer (4) through saddlebag from
the inside.
3.
See Figure 15. Place spacer (1) on front screw and spacer
(2) on rear screw.
4.
See Figure 14. Place chrome cover (5) into recess at rear
of fender cover.
5.
Apply Loctite 243 (blue) to threads of screws.
6.
Install saddlebag to fender using spacers and screws.
Tighten screws to 20-25 ft-lbs (27-34 Nm).
7.
Check under fender that screw threads do not protrude
into fender well.
3
Screw (2) (4106)
Washer (4) (6202)
Chrome cover (47531-06)
Spacer (2) (91414-00)
Acorn nut (2) (94008-90T)
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4
1
2
5
Figure 13. Saddlebag Mounting Hardware (2005 and Earlier)
3
4
2
3
Motorcycle with Non-Stock Wide Seat (2005 and
Earlier Models)
1.
See Figure 13. From inside fender, insert one screw (1)
and washer (2) through both rear holes in fender cover.
2.
Remove front screw in fender cover.
3.
From inside fender, insert one screw (1) and washer (2)
into front hole in fender cover.
4.
Place chrome cover (3) into recess at rear of fender cover.
5.
Place one spacer (4) onto each screw.
6.
Place saddlebag assembly onto screws extending from
fender cover.
7.
Apply Loctite 243 (blue) to threads of screws.
8.
Place one washer (2) and acorn nut (5) on each screw.
9.
Tighten acorn nuts to 20-25 ft-lbs (27.1-33.9 Nm).
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1.
2.
3.
4.
5.
Rear fender bracket (59484-06)
Screw, 4 in. (2) (3064)
Screw, 4-1/4 in. (2) (3065)
Washer (4) (6202)
Chrome cover (47546-06)
Figure 14. Saddlebag Mounting Hardware (2006 and Later)
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ROUTE TURN SIGNAL WIRING
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1
1.
Route wiring harness along bottom fender cover and insert
it into retaining clips previously installed.
2.
Adjust harness if necessary, then bend clip tabs to secure
wiring in place.
3.
See Figure 16. Continue routing wiring harness under front
of strut in front of fender and through middle boxed area
of frame to connector.
4.
Install pin terminals to cavities in turn signal connectors.
Refer to AMP MULTILOCK ELECTRICAL CONNECTORS
in Service Manual.
5.
1999 and Later Models: See Figure 1. Attach tail lamp
lens (1) to base (2) using two screws. Tighten screws to
20-24 in-lbs (2.3-2.7 Nm).
2
1. Spacer, front 0.57 in. (9236)
2. Spacer, rear 0.70 in. (9235)
Figure 15. Install Spacers
Motorcycle with Detachable Docking Points (2006
and Later Models)
1.
See Figure 14. Place rear fender bracket (1) under fender
and through fender holes.
2.
Insert screw (3) and washer (4) through saddlebag from
the inside.
3.
Place detachable docking points onto each screw.
4.
Apply Loctite 243 (blue) to threads of screws.
5.
Place chrome cover (5) into recess at rear of fender fender
cover.
6.
Install saddlebag to fender using detachable docking points
and screws. Tighten screws to 20-25 ft-lbs (27-34 Nm).
7.
Check under fender that screw threads do not protrude
into fender well.
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2
1. Wiring routed into boxed area of frame
2. Turn signal connector
Figure 16. Route Wiring to Connector
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RETURN TO SERVICE
Install Reflectors and Medallions
NOTE
Red reflectors are included in this kit and must be installed to
meet domestic and international requirements.
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.
Using a 50/50 isopropyl alcohol solution, thoroughly clean
the surface where the reflector will be installed.
2.
Allow the surface to dry completely before continuing.
3.
See Figure 17. Remove adhesive backing and install
Harley-Davidson medallion (1) in recessed area of saddlebag lid.
4.
Remove adhesive backing and install red reflector (2) in
recessed area of saddlebag bottom.
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1
5.
Let adhesive cure for 24 hours at no less than 60° F (16°
C).
6.
Repeat steps for opposite saddlebag.
Final Assembly
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
1.
Connect battery cables, negative (-) cable first.
2.
Install seat according to the instructions in the Service
Manual.
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)
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
3.
Check turn signals for proper operation.
4.
Check tail light for proper operation.
2
1. Harley-Davidson medallion
2. Red reflector
Figure 17. Install Medallion and Reflector
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SERVICE PARTS
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2
3
4
Figure 18. Service Parts: Saddlebag Bracket Kit (90212-01)
Table 2. Service Parts Table
Item
Description (Quantity)
Part Number
1
Hanger, saddlebag support R.H.
90210-01
2
Hanger, saddlebag support L.H.
90211-01
3
Relocation bracket, turn signal R.H.
90138-00
4
Relocation bracket, turn signal L.H.
90139-00
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SERVICE PARTS
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5
2
26
7
1
3
27
8
4
10
6
25
11
24
19
16
21
15
17
22
20
18
12
23
13
14
Figure 19. Service Parts: Saddlebag Bracket Hardware Kit (90213-01A)
Table 3. Service Parts Table
Item
Description (Quantity)
Part Number
1
Strap, cable (4)
10065
2
Grommet, large (4)
11447
3
Spacer, large (4)
90149-00A
4
Grommet, small (6)
90148-00
5
Spacer, small (6)
90186-00A
6
Wiring harness, turn signal (2)
70550-00
7
Hole plug cover, chrome (2)
56239-93
8
Plug, rubber (2)
53644-00
9
Loctite 243 (blue), 0.5 ml packet (Not Shown)
Not Sold Separately
10 Nut, flange locking 5/16-18 (6)
7531
11 Acorn nut, 3/8-16 (4)
94008-90T
12 Screw, 5/16-18 x 3/4 in. (2) (2-3/8 inch turn signal)
4092
13 Screw, hex head 3/8-16 x 4.4 in. (4)
4107
14 Screw, hex head 3/8-16 x 3-3/4 in. (4)
4106
15 Screw, button head 5/16-18 x 1-1/4 in. (6)
4219
16 Connector, sealed butt (4)
70585-93
17 Spacer (4)
91414-00
18 Clip, adhesive (6)
10102
19 Screw, button head 5/16-24 x 1/2 in. (2) (3-inch turn signal)
3538
20 Lockwasher (2) (2-3/8 and 3-inch turn signals)
7042
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Table 3. Service Parts Table
Item
Description (Quantity)
Part Number
21 Washer, flat 3/8 in. (18)
6202
22 Spacer, 0.150 in. (2) (2-3/8 inch turn signal)
65849-01
23 Spacer, 0.57 in. (4)
9236
24 Spacer, 0.70 in. (2)
9235
25 Acorn nut 5/16-18 (2)
7507
26 Screw, hex cap 3/8-16 x 4-1/4 in. (4)
3065
27 Screw, hex cap 3/8-16 x 4 in. (4)
3064
28 Screw, hex cap 5/16-18 x 1-1/4 in. (2) (Not Shown), all models except FXDWG and FXDF.
2871W
29 Bracket, rear fender (2) (Not Shown)
59484-06
30 Cover, chrome (2) (Not Shown), 2005 and earlier models.
47531-06
Cover, chrome (2) (Not Shown), 2006 and later models.
31 Screw, hex cap 3/8-18 x 7/8 in. (2) (Not Shown), FXDWG and FXDF models only.
47546-06
3991
NOTE: Loctite (Item 9) is only available in 6 ml tube, part number 99642-97.
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SERVICE PARTS
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8
3
19
24
6
28
15
18
17
4
21
14
22
10
27
16
20
11
26
9
25
2
13
23
12
5
7
1
Figure 20. Service Parts: Saddlebag Assemblies (R.H. 90037-XX and L.H. 90038-XX)
Table 4. Service Parts Table
Item
1
Description (Quantity)
Part Number
Saddlebag bottom, right side
90127-00
Saddlebag bottom, left side
90128-00
Saddlebag lid, right side
90129-00
Saddlebag lid, left side
90134-00
Reflector, red, right side
59287-92
Reflector, red, left side
59288-92
4
Plate, cam lock
91393-00
5
Keeper latch
91392-00
6
Medallion, H-D
90167-00
2
3
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Table 4. Service Parts Table
Item
Description (Quantity)
Part Number
7
Plate, lid hinge mount
90158-00
8
Plate, base hinge mount
90188-00
9
Plate, latch backing
90159-00
10 Cam, latch lever
91390-00
11 Latch assembly
90166-00
12 Hinge assembly
90151-00
13 Cover, latch
91391-00
14 Lever, latch
91386-00
15 Lock assembly (1 of 2)
90168-00A
16 Cam block
91389-00
17 Screw, self-tapping #10-16 x 1/2 in. (9)
5233
18 Washer, nonmetallic
91387-00
19 Nut, keps #10-32 (3)
7629
20 Screw, M6-6h x 25 (2)
1396
21 Screw, #8-32 x 3/8 in.
4241
22 Washer, flat, #8
6182W
23 Screw, button head, 1/4-20 x 1/2 in. (2)
936
24 Gasket
90174-00
25 Label, saddlebag
90248-00
26 Plate, hinge cover
91375-00
27 Screw, 1/4-20 x 1/4 in.
1397
28 Gasket, lock
Included with Item 15
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