INSTRUCTIONS - Harley
Contents
1. HARLEY DAVIDSON J02671 INSTRUCTIONS REV 07 31 2002 Kit Number 90707 00 SADDLEBAG LATCH SPRING KIT General This replacement latch spring fits all 1993 and later model FLHT and FLT hard saddlebags except FLHRCI Road King Classic This kit consists of one Saddlebag Latch Spring Part Number 90707 00 NOTE A Service Manual for your year and model motorcycle is available from your Harley Davidson dealer Removing the Old Spring 1 Lay a clean pad or blanket on the work surface to pro tect the saddlebag painted 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 closest to you 3 See Figure 1 Using a T 15 TORX drive head remove the two screws 2 holding the check strap 4 and latch assembly 3 to the saddlebag 1 Remove the remain ing two screws holding the latch assembly to the sad dlebag Set the saddlebag aside safely out of the way i04699 eps 1 Saddlebag 2 Torx Screws 4 3 Latch Assembly 4 Check Strap Figure 1 Saddlebag Cover Removal Left Side Shown CAUTION The remaining instructions assume that the latch IS NOT removed from the saddlebag lid If there is any doubt as to whether the procedure can be accomplished without scratching the painted surfaces of the lid then remove the2. pliers to bend the opened link back into its original posi tion capturing the pin so it will not back out of the hinge Reposition the lid so that it is upside down with the latch farthest from you Retrieve the saddlebag set aside ear lier and place it on the pad or blanket behind the lid Align the four holes in the latch with those in the saddle bag Install two T 15 TORX screws removed earlier through the inboard holes in the saddlebag and into the weld nuts in the latch Tighten the screws to 20 25 in lbs 2 3 2 8 Nm Align the holes in the check strap with the two outboard holes in the saddlebag Install two T 15 TORX screws through the holes in the check strap and saddlebag and into the weld nuts in the latch Tighten the screws to 20 25 in Ibs 2 3 2 8 Nm Close the saddlebag and install it on the motorcycle See SADDLEBAG INSTALLATION in the Service Manual 2 of 2
3. five remaining T 15 TORX screws to com pletely remove the latch 4 See Figure 2 Position the lid right side up with the latch closest to you Raise the latch slightly and rotate the bag hinge out so that it is in front of the latch with the two plastic rub bars pointed upward Se Rub Bars Pointed Up D pene a Bag Hinge Rotated Out TIET Figure 2 Left Hand Lid Right Side Up Latch on Near Side 5 See Figure 3 Rotate the rub bar segment of the hinge to expose the hinge pin and spring Using a flat tip screw driver carefully pry the crimped end loop open slightly NOTE The loop at the opposite end of the hinge is spot welded to prevent pin removal ni EEE s 4 Rotate Rub Bar Hinge Segment Down Pry Crimped Loop Open Figure 3 Rotate Hinge Down to Expose Spring 1 of 2 8864 tif J ne O O o O N y i En e A sassneenmenal ee Pe VEEP EREERERS i f d Grasp Pin Through Opening amp Push Out _ Grasp Pin amp Pull Out to Remove Spring i m i ee Rotate Rub Bar Hinge Segment Beneath Latch Figure 4 Left Hand Lid Upside Down Latch on Far Side 6 See Figure 4 Reposition the lid so that it is upside down with the latch farthest from you Rotate the hinge so that the plastic rub bars are positioned beneath the latch and the latch spring is exposed 7 Using a needle nose pliers grasp the pin through the Opening just alongside of the spring and
4. push the pin toward the end hinge loop opened in Step 5 Work the pin in this manner until the pin end extends out of the hinge If necessary pry the loop open a little more to allow pin movement NOTE DO NOT pull the pin out any further than necessary to remove and replace the spring Once the pin is protruding sufficiently from the hinge loops grasp the end with the needle nose pliers and slowly pull the pin out until the spring can be slid off the opposite end See Figure 5 Pull the pin out only as far as necessary to access the spring Note the orientation of the spring ends as the new spring will install the same way 8 Remove the old spring 8865 tif Figure 5 Pull Pin Out As Necessary to Remove Spring Left Side Shown J02671 Installing the New Spring 1 Orient the new spring in the same direction as the old Slide the new spring onto the end of the pin at the hinge opening Slide the pin back through the hinge loops Using the tapered end of the needle nose pliers push the end of the pin into the pried open loop See Figure 2 Reposition the lid so that it is right side up with the latch closest to you As before raise the latch slightly and rotate the bag hinge out so that it is in front of the latch with the two plastic rub bars pointed upward See Figure 3 Rotate the rub bar segment of the hinge to expose the hinge pin and spring Holding the lid down with your elbow if necessary use a
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