Harley-Davidson J00839 (2001) Bedienungsanleitung
Harley-Davidson
Motor
J00839 (2001)
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INSTRUCTIONS
-J00839 REV. 7-3-01
SADDLEBAG SUPPORT KIT
General
This kit is designed for installation on all 1991 and later FXD
Dyna Glide model vehicles (except FXDS-CONV, FXDXT)
and 1996 and later FXDWG Dyna Wide Glide models. This
kit does not fit with detachable sideplates.
2000 and 2001 FXDX models require separate purchase of
hardware kit part number 90272-00.
2002 and later models require separate purchase of two
directionals, part number 68425-01 (domestic) or 68420-01
(international).
See the Service Parts illustration for kit contents.
A Service Manual is needed to install this kit. The rider's
safety depends upon the correct installation of this kit. If
the procedure is not within your capabilities or you do
not have the correct tools, have your Harley-Davidson
dealer perform the installation. Improper installation of
this kit could result in death or serious
injury. Installation – 1991 to 2001 Models
NOTE
A Service Manual for your vehicle is available at your local
Harley-Davidson dealer.
Installation – 1991 to 2001 Models
To protect against shock and accidental start-up of vehi-
cle, disconnect the battery cables, negative cable first,
before proceeding. Inadequate safety precautions could
result in death or serious injury.
Always disconnect the negative battery cable first. If the
positive battery cable should contact ground with the
negative cable installed, the resulting sparks may cause
a battery explosion which could result in death or seri-
ous injury.
1. Remove lens from rear directional housing on right side
of vehicle. Remove bulb from directional housing
socket.
2. 1991 – 1998 models only: See Figure 2. Trace right
directional wire routing along underside of rear fender.
Remove cable strap located on topside of rear fender
near the rubber grommet. Gently pull wire rearward
along underside of fender and into directional housing
to allow for additional length of wire within directional
housing.
3. 1999 – 2001 models only: Cut wire within directional
housing about 3/4 in. away from point where wire enters
directional housing support. From underside of rear
fender, withdraw end of wire that is within directional
housing support.
4. 1992 and earlier models only:
a. Remove (by turning counterclockwise) right
rear directional housing and lockwasher from its
support.
b. Remove the locknut and flat washer, from
underside of rear fender, securing the right-rear
directional housing support. Remove the
directional-housing support from the right-rear
fender support. Discard original directional housing
support. Save mounting nut and washer.
5. 1993 and later models only: Remove and discard 5/16
in. bolt and star washer securing rear directional to
fender. Bolt and washer are located on inside of fender.
6. Remove the button-head screw and flat washer from
middle of right-rear fender support. Discard screw; save
flat washer.
7. See Figure 1. Install lockwasher and right-rear
directional housing onto short threaded end (5/16-23 x
3/8 in.) of one rear-directional housing support from kit.
Tighten securely. Take care to avoid scratching or
marring component chrome finish.
8. 1993 and later models only: Install chrome snap cap
in fender-strut hole previously used for directional wire.
9. Position right saddlebag support bar from kit to right
rear fender support. Insert long threaded end of rear
directional housing support (now part of the directional
housing/support assembly) through rear mounting hole
in saddlebag support bar, rear fender support, sissy bar
side plate and rear fender. See service parts page for
exact hole locations.
10. Install original flat washer and locknut onto directional
housing on underside of rear fender. Tighten finger
tight.
11. Insert one chrome button head bolt (from kit) with one
original flat washer through front mounting hole in
saddlebag support bar, rear fender support, sissy bar
side plate and rear fender and into rear fender strut
bracket. Tighten bolt to 15 ft-lbs (20 Nm).
12. Align rear directional housing so that its lens, when
installed, will be aimed rearward for proper visibility.
While holding directional housing in position, tighten
locknut to 22 ft-lbs (29 Nm).
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®
Kit Number 90589-91D
13. Insert loose right directional wire (beneath fender)
through hollow directional housing support and into
directional housing.
14. Reconnect right directional wires within directional
housing using wire connector from kit. Wrap the
connector with electrical tape. Tuck wire connector
assembly within available space alongside lamp socket.
15. Install the bulb into the right directional-housing socket.
Fasten the lens to the directional housing.
16. Repeat steps 1 – 15 for the left saddlebag support bar.
17. Gently pull wire forward along underside of fender
through the grommet and into the area under the seat.
Install cable strap from kit to replace strap removed in
step 2.
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a bat-
tery explosion which could result in death or serious
injury.
18. Reconnect the battery cables to battery, positive cable
first.
Test directionals after finishing the installation. Weak,
intermittent, or non-operational lights may indicate a
poor connection or a short circuit in wires. The motor-
cycle must never be operated in this condition.
Operating a motorcycle in this condition could result in
death or serious injury.
Inspect bulb and socket. Examine wires for bare spots
or loose connectors. After securing components, test
directionals again for satisfactory operation.
19. Test both directionals for proper operation.
20. 1993 and later models only: Install rubber plug in wire
hole in directional housing.
Installation – 2002 and Later Models
To protect against shock and accidental start-up of
vehicle, disconnect the battery cables, negative cable
first, before proceeding. Inadequate safety precautions
could result in death or serious injury.
Always disconnect the negative battery cable first. If the
positive battery cable should contact ground with the
negative cable installed, the resulting sparks may cause
a battery explosion which could result in death or seri-
ous injury.
NOTE
The connection for directionals is inside the tail-lamp hous-
ing.
1. Remove the rear directionals from the vehicle according
to applicable Service Manual instructions. Save the
connector on the end of each set of wires, with a length of
wire and conduit. Discard all other hardware. For
installation, note how the wires are routed inside the
fender.
2. See the Service Parts illustration. Remove the stock
screw from the fender cover as indicated.
3. Feed the directional wires through the directional stalk
and thread the directional lamp (separate purchase) onto
the end of the directional stalk.
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Left Turn signal lamp
(save connector)
Right Turn signal lamp
(save connector)
Figure 2. Turn-Signal Connectors
i03917
Figure 1. Right Saddlebag Support Bar Installed on FXD
i03994
Original Equipment (bold)
Kit component
1. Saddlebag support
2. Rear fender support
3. Screw, button head
4. Flat washer
5. Sissy bar side plate
6. Rear fender
7. Rear fender strut
bracket (hidden)
8. Lockwasher, chrome
9. Rear directional
housing
10. Directional bar stud
11. Flat washer and locknut
(hidden)
12. Wire connector (hidden)
13. Plug (rubber or chrome)
-J00839 2 of 3
3
1
7
5
11
9
4
2
8
6
12
13
10
-J00839 3 of 3
Item Description Part Number
1 Screw, button head (2) 4118
2 Locknut (2) 7776W
3 Plug (chrome) (2) 56239-93
4 Plug (rubber) (2) 58758-93
5 Lockwasher (2) 94081-90T
Item Description Part Number
6 Directional bar stud (2) 68496-91
7 Wire connector (4) 70576-68
8 Support, saddlebag - left 90590-91B
9 Support, saddlebag - right 90591-91B
10 Cable strap 10006
1
8, 9
7
6
5
4
3
2
Service Parts
®
Saddlebag Support Kit
Date 9/98Part No. 90589-91D
sp90589c
10
On FXD and FXDL models,
the rear mounting point is
the rear hole on the fender-
support bracket. FXDWG
mounts in the second to
the last hole.
Remove stock
screw from here.
4. Route the directional wires through the hole in the fender
as shown in Figure 1. Measure the wires for length into
the tail-lamp housing. Allow enough wire for termination.
Remove the measured wires from the fender and cut the
wires to length.
5. Install the chrome snap cap in the fender-strut hole
previously used for directional wires.
6. Position right saddlebag support bar from kit to right rear
fender support. Insert long threaded end of rear
directional housing support (now part of the directional
housing/support assembly) through rear mounting hole in
saddlebag support bar, rear fender support, sissy bar side
plate and rear fender. See service parts page for exact
hole locations.
7. Install original flat washer and locknut onto directional
housing on underside of rear fender. Tighten finger tight.
8. Insert one chrome button head bolt (from kit) with one
original flat washer through front mounting hole in
saddlebag support bar, rear fender support, sissy bar side
plate and rear fender and into rear fender strut bracket.
Tighten bolt to 15 ft-lbs (20 Nm).
9. Align rear directional housing so that its lens, when
installed, will be aimed rearward for proper visibility. While
holding directional housing in position, tighten locknut to
22 ft-lbs (29 Nm).
10. Reconnect right directional wires within directional
housing using wire connector from kit. Wrap the
connector with electrical tape. Tuck wire connector
assembly within available space alongside lamp socket.
Plug the connector back into the tail-lamp housing. Route
the wires the same as the original equipment routing.
11. Repeat steps 1 – 10 for the left saddlebag support bar.
Always connect the positive battery cable first. If the posi-
tive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
12. Reconnect the battery cables to battery, positive cable
first.
Test directionals after finishing the installation. Weak,
intermittent, or non-operational lights may indicate a
poor connection or a short circuit in wires. The motorcy-
cle must never be operated in this condition. Operating
a motorcycle in this condition could result in death or
serious injury.
Inspect bulb and socket. Examine wires for bare spots
or loose connectors. After securing components, test
directionals again for satisfactory operation.
13. Test both directionals for proper operation.
1WARNING
1WARNING
Produktspezifikationen
| Marke: | Harley-Davidson |
| Kategorie: | Motor |
| Modell: | J00839 (2001) |
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