Instructions - 840

INSTALLATION GUIT}E FOR THE RK.OI
Road King Classie Saddlebag tocks
wx RK-001 security system for the Road King Classic, semirigid leather covered
saddlebags' The following instructions willtake you step by step through the installation process. Care should be taken
to protect the bag at all times during the installation. A blanket or other soft surface should be used to prevent marrino or
scratching the leather. Take your time and follow the instructions to the letter.
Thank you for purchasing the INERTIA
BECAUSE OF VARIATIONS IN THE SADDLEBAGS THEMSELVES, THE FINAL FIT OF THE LOCK ON THE BAG CAN
NOT BE GUARANTEED BY INERTIAWX. PROBLEMS WTH THE LOCK SYSTEM ITSELF WILL BE ACCOMMODAIED
CONTENTS:li Right and Left side, striker plate/bolt assembly
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Right side backing plateit
n rI
Left side backing platet
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Il
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tl
Right side lock and latch assemblyi i
Left side lock and latch assembly
Right and Left side, rail clamp assembly
10-32 threading die
Drilln Hammer- Needle nose pliers Scissors¡ì
3/16" & 5/16" Drill bits r r
1/4" drive ratchet g/9" & 7/16" gocketsr
Pockef knife 3/4" hole puncht ; #2 phillips screwdriver Flat blade
screwdriver Adjustable wrenchß/16" Allen wrench Diagonal cutting
pliersl r
Hacksaw
TOOLS:
t
INSTALLATION
1. Pry the keepers up from the emblem stud enough to get diagonal
cutting pliers across the surface. Twist the keeper until it breaks off.
Repeat for opposite stud. Remove emblem
2.
NOTE: We recommend that you practice on the back stud, flrst.
It will be cut off
.
\Mth the threading die provided, thread the front stud, Olk THH STUÞ
FIRST. Thread the stud squarely. Mako one half turn at a time, always
backing up one-half turn each time to clear chips.
3. Cut off the back stud (at the pointed end of the bag's emblem) with a
hacksaw. Hacksaw must have a fine tooth metalcutting blade. Allow
blade to slide along the flat edges of the removed saddlebag emblem as
shown. Abrade or file off any sharp edges on the remaining stud.
4. lnsert threaded stud through the hole in the backing plate (L). place
cloverleaf spring (K) over the stud and onto the backing plate with the
dome facing up. Place flat washer (J) on the stud and tighten the nylon
cap nut (l) untila smooth open/close rotation is achieved. see illustration
on page 3. Emblem should snap in place and not rattle. Emblems may be
distofted by the oríginal installation. lt may be necessary to straighten the embtem. lf so,
protect the emblem with a soft material and clamp it in a vise well away from the threaded
stud area. Gently bend the emblem to conform evenly with the backing plate.
@ Road K¡ng is a ¡egistered trademark of Harley-Davidson
@ 2005 INERTIA wrx, lNC, All Riqhts Reserued
Paoe
1
5. Pin template
on the bag with #10 screws (T) provided.
Place a piece of tape on the bag aligned with the bottom
edge of the template. Scribe two lines where indicvated.
7. Make one 3/4" hole where shown with a punch or hole
saw or drill. lf drilling, arways cut the reather off first usino a
sharp knife. Punches, knock-out or gasket type do the bãst
job. Drilltwo 5/16" holes for the backing plate shown.
9. Place internal tooth washer (H) over lock ancj install
large lock nut (G). lnstall stop cam (F) as shown at right.
11. Tighten the latch in place with the chrome acorn nuts
(A) provided. Attach lock cam with internal tooth washer
(C) and nut (B). Refer to exploded view for clarification.
Page2
6.
Cut off the bottom portion of the template and save. lt
will be used for mounting ther striker bolt plate later.
8. lnstall the lock (M) through the backing plate and insert
the backing plate through the hotes in the bag. tnstall
guard plate (N) as shown Orient key slots with the center
slot pointed straight up as shown at right.
10. lltrok tlre s¡trrng (t_) [o ct,lltnr:ct tlle latch and the lock
cam (D) as shown. Place the rotary latch (O) over the
backing plate studs with the print facing toward you.
12. Align the striker bott template with the top edge of the
bag with the two lines on the templaste direcfly over the
two lines that you made on the masking tape. Drill holes.
ITEM
QTY,
A
4
E
F
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DÊSCRIPTION
1/4-20 ACORN NUT (2/baq)
1t4-20 HEX NUT (l/side)
1/4" INTERNAL TOOTH WASHER (1/baq)
LOCK CAM (1/baq)
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H
J
K
@
L
@
@
M
agt
STOP CAM II,
LOCK BODY NUT (1/bas)
3/4'INTERNAL TOOTH WASHER 11lbaoì
10-32 NYLOCK NUT f1lbao)
FLAT WASHER NO. 10 l'tlbaol
SPRING. 3/16'CLOVER DISH (1/bao)
RKOOI BACKING PLATE ( 1 LEFT. 1 RIGHI
TUBULAR LOCK (1/baq)
GUARD PL.ATE 11 LEFT, 1 RIGHT)
ROTARY LOCK (1 LEFT. 1 RIGHT)
2
2
2
2
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2
2
2
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L or R STRIKER BOI-T ASSY.
ITEM
EXISTING BAG EMBTEM
(THRÉAD THI9 STUD WTH
THE NO,10.32 DIE PROVIDED)
QTY,
DESCRIPTION
X 3/4 Truss Head Screw
RIGHT SIDE LOCK ASSEMBLY
L & R RAIL CLAMP ASSEMBLY
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STRIKER BOLT ASSEMBLY
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I\lt ta\tI
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EXISTING BAG EMBLEM
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(THRE,AD THIS STUO WÏH
THE NO.IO-32 DIE PROMDED)
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L &R RAIL CLAMP ASSEMBLY
Page 3
LEFT SIDE LOCK ASSEMBLY
13. With the hardware provided, installthree truss
head screws (T) through the bag . Place the striker
plate over the screws on the inside of the bag and
tighten with the acorn nuts (S) provided.
14. lnstall the striker bolt (R) in the plate with the
shoulder bolt head facing out. Tghten in place
using the acorn nut (Q) provided.
15. Open the bag. Drillout and remove the rivets
holding the FRONT railclamp ONLY. The replacement
of this clamp greatly reduces the ability to distort the bag
when locked.
16. Using the hardware provided, bolt the rigid rail
clamp (U) in place with the bolt heads (V) inserted
through the clamp and the bag. Secure with the
acorn nuts (S) provided.
15. Left side bag is now complete
16. Repeat all steps for the right side
Paoe 4
bag.
#10 screws through the grey circles fo poslfron the template
LEFT
RKOOl
Templates
05/01/05
_€frCut along dotted
LEFT SIDE
Mark here with felt tip pen.
Do not use a ballpoint pen
or pencil. lt may mar the
RKOOl
Templates
Place masking tape along the
bottom edge of the template.
lnseft#10 screws through the grey circles to
Mark here with felt tip pen.
Do not use a ballpoint pen
or pencil. lt may mar the leather
RIGHT
05lo1l05
holes here
+
Cut along dotted line
RIGHT SIDE
Mark here with felt tip pen.
Do not use a ballpoint pen
or pencil. lt may mar the
Place masking tape along the
bottom edge of the template.
Mark here with felt tip pen.
Do not use a ballpoint pen
or pencil. lt may mar the leather