Fat Bagger 500 User Manual

INSTALLATION INSTRUCTIONS

FBI REMOVABLE TRUNK MOUNT FBI500, FBI500-09 for H-D® Tour-Pak™

NOTE: This mounting unit has no allowance for mounting of license plate frame, remote mount amplifier or other
items mounted on underside of OE mount. Customer is responsible for relocation of such items on bike.

1. The FBI Removable Trunk mount is available for two year-range fitments. FBI500 fits 1996-2008 H-D
Touring Models while FBI500-09 fits 2009 and later.

a. FBI500 for 1996-2008 mounts on your existing backrest mounting hardware for the rear

attachment points but new stainless steel spool/bushings are provided to replace front mounting
points—the vast majority of these touring models came with the backrest hardware on them. If
your bike does not have them, call FBI for a hardware kit sold separately.

b. FBI500-09 for 2009-Up includes mounting hardware necessary for mounting this unit on your

bike. Actually you will still use the spacer behind each rear shock top mount for the front
mounting points and new Stainless Steel posts/bolts provided with this kit for the rear points-­replace and install them into the bolt holes that secure the saddlebag support rails into the
fender strut.

2. Remove Existing Tour Pak from your motorcycle and lay it on its top on a padded bench.

3. Remove the bolts which attach the Tour Pak to its original H-D mounting bracket and set that bracket
aside—it will not be re-used.

4. To determine where you want to position the trunk atop this new mount, it is best to put the mount on
your bike, set the trunk on it and decide where you want it to be in a front-to-back location to provide
optimal comfort for the passenger. Use a marker to mark through the holes in the mount to indicate
where to drill holes for the ¼”x1” bolts included which you’ll use to attach the trunk to the new mount.

NOTE: You will most likely need to drill 4 holes in the bottom of the trunk since there are variations in the
placement of the original holes and because you may want it further forward or back than the original
holes would locate it.

5. Put the trunk back on your padded bench then drill the holes you just marked in for the ¼”x1” bolts
included with this kit.

6. Now place the FBI Mount on the bottom side of the Trunk and bolt it into place.

7. Install your Tour Pak with the new mount onto your bike.

138 East Lincoln Ave. | Chariton, Iowa 50049 | [phone] | fax: [phone] | www.fatbaggers.com

INSTALLATION INSTRUCTIONS

FBI Removable Trunk Mount Holes drilled in Trunk, Unit Mounted Unit installed and mounted on bike

138 East Lincoln Ave. | Chariton, Iowa 50049 | [phone] | fax: [phone] | www.fatbaggers.com

INSTALLATION INSTRUCTIONS

FBI FIXED TRUNK MOUNT

for ’96-’08 H-D® KING Tour-Pak™

NOTES:

NOTE: This mounting unit has no allowance for mounting of license plate frame, remote mount amplifier or other items

•

mounted on underside of OE mount. Customer is responsible for relocation of such items on bike.

• Installation process is generally the same for installation on a bike with a stock fender or an FBI

fender—hardware components vary slightly.

• This kit has been set up with the assumption that your bike already has H-D mounting hardware for

a backrest. If it does not, you will need to get the HD backrest rear mounting kit #53803-06. Call
FBI to purchase or for more information.

• See images at the end of these instructions for general reference photos to help in the installation

process.

REMOVING THE ORIGINAL TOUR-PAK FROM YOUR BIKE:

1. Begin by removing your complete Tour Pak and its mounting assembly from your motorcycle. This process
will vary depending on if you have the bolted mount or the H-D removable mount assembly or other
aftermarket units. Once removed, lay it on its top on a padded bench and remove the bolts which attach the
Tour Pak itself to the mounting apparatus. If you initially just removed the Tour Pak from the mounting
apparatus, then now remove the apparatus as well.

2. Now if your bike has them (typically on Ultras), remove the H-D 4-Point Mounting hardware and “chrome
hoops” from your bike as well. This will not be reused. If your bike already has the H-D backrest docking
hardware, remove the front mounting spools and remove the rear mounting posts but leave the black
bracket that they are attached to.

3. We will first install the new FBI mount on your bike, and then mount the Tour Pak on top of it later.

INSTALLING THE NEW TRUNK MOUNT ON YOUR BIKE:

4. HARDWARE: note that the hardware kit includes (4) stepped spacers with bolts and flat washers (two sets

each of two different length stepped spacers), and (2) round spacers with a round notch out of them. The top
mounting point of the shock has to be spaced out so the mounting unit clears the shock. The (2) round
spacers have a round notch out of them for the stepped spacer that mounts right next to it to mate to. See
expanded instructions below. SEE IMAGE #1

5. INSTALLATION OVERVIEW: Installation is very tricky for one person—an extra set of hands is very helpful.
You will temporarily install the chrome (or black) mount onto the bike, position your Tour Pak to mark
mounting holes to be drilled, take the mount off, drill the holes, bolt the Tour Pak on then re-mount the entire
assembly onto your bike. Continue for expanded instructions.

6. Remove top shock bolt on one side and pull bolt out to allow you to insert a round spacer with notch onto the
bolt between the shock and the frame. Turn the spacer to point the round notch toward the rear of your bike.
Wait to tighten shock bolt back down. Repeat for other side.

7. HINT: This step is lots easier with an extra set of hands handy! Of the (4) stepped spacers in the kit, install
the (2) short stepped spacers (with long step end toward the frame) in the front holes of the FBI mount from
the inside out. Install the long stepped spacers in the rear holes of the mount (again, with long step end
toward the frame).

138 East Lincoln Ave. | Chariton, Iowa 50049 | [phone] | fax: [phone] | www.fatbaggers.com

Page 2

8. Holding these four spacers in place on the FBI mount, lower the mounting unit into place over the bike and
align the holes of the mount with the front and rear backrest mounting holes. Insert the (2) short chrome
bolts with washers in the front mounting holes (you’ll see that these front spacers mate up to the shock
spacers installed earlier) and the (2) long chrome bolts with washers in the rear mounting holes. Thread all
(4) bolts in, make sure that all spacers are in place and set through the fender against the fender strut, then
tighten these (4) bolts and the (2) shock bolts.

INSTALLING YOUR TOUR PAK ON THE NEW FBI MOUNT:

9. With the Tour Pak upside down on its top on a padded bench, remove the bolts which attach the Tour Pak to
its original H-D mounting bracket, remove the mount and set it aside—it will not be re-used.

10. To determine where you want to position the trunk atop the new FBI mount, set the trunk on it and decide
where you want it to be in a front-to-back location to provide optimal comfort for the passenger.

11. Use a marker to mark up through the holes in the mount to indicate where to drill holes for (4) ¼”x1” bolts,
included, which you’ll use to attach the trunk to the new mount. NOTE: You will most likely need to drill 4
holes in the bottom of the trunk since there are variations in the placement of the original holes and because
you may want it further forward or back than the original holes would locate it.

12. Put the trunk back on your padded bench then drill the holes you just marked in for the ¼”x1” bolts included
with this kit.

13. Now set the Tour Pak back on top of the mount, on your bike, and bolt it into place using the ¼”x1” bolts and
flat washers provided.

14. Your installation is now complete.

IMAGE #1 HARDWARE KIT: Left to right,
(2) Round spacers with notch, (2) Short
Stepped spacers, (2) Long Stepped
Spacers.

IMAGE #2 FBI Fixed Trunk Mount

IMAGE #3 FBI Fixed Trunk Mount mounted in

place on a bike.

138 East Lincoln Ave. | Chariton, Iowa 50049 | [phone] | fax: [phone] | www.fatbaggers.com

INSTALLATI ON INSTRUCTIO N S

FBI500-09-FIX REMOVEABLE TRUNK MOUNT

For use with 2009-UP H-D® KING Tour-Paks™

NOTE: This mounting unit has no allowance for mounting of license plate frame, remote mount amplifier or other items
mounted on underside of OE mount. Customer is responsible for relocation of such items on bike.

REMOVING THE SADDLEBAGS & ORIGI NAL TOUR-P A K FROM YOUR BIKE:

1. Begin by removing your saddlebags and set them well away from your work area. Now remove your
complete Tour Pak and its mounting assembly from your motorcycle. This process will vary depending
on if you have the bolted mount or the H-D removable mount assembly or other aftermarket units. Once
removed, lay it on its top on a padded bench and remove the bolts which attach the Tour Pak itself to the
mounting apparatus. If you initially just removed the Tour Pak from the mounting apparatus, then now
remove the apparatus as well.

2. Now, if your bike has them, remove the H-D 2-point or 4-Point Mounting hardware that bolt into the
fender struts from your bike as well. These components will not be reused with this installation. See
images #1-3 of images with th e 2-point, 4-point and no hardware for reference.

3. We will first install the new FBI mount on your bike, and then mount the Tour Pak on top of it later.

INSTALLING THE NEW FBI TRUNK MOUNT O N YOUR BIKE:

4. HARDWARE KIT INCLUDES: See Image #5
a. (2) stepped bushings
b. (2) thick washers with recessed back side and small hole
c. (2) ¼” X 1-1/4” Bolts
d. (2) thick washers with recessed back side and large hole
e. (2) large narrow washers
f. (4) ¼”X1” Hex Head Bolts with (4) nuts and (8) washers

5. Items a, b, and c above are used for the rear attachment points and items d and e are used for the front
attachment points.

6. REAR ATTA CHMENT POINTS—the rear attachment point of the FBI mount utilizes existing bolt holes
in the fender struts. There is a chrome rail that comes up from the bottom saddlebag support framing
and bolts into the fender strut on each side of the bike. See IMAGES #7 & #8. Remove these 2 bolts to
prepare for installation of new hardware. The 2 stock bolts will not be reused.
a. See IMAGE #6. Take one of the c. bolts in the hardware kit and slip it through washer/spacer item b.

above with the recessed side of the spacer facing away from the bolt head.

Page 2—FBI500-09-FIX Removable Trunk Mount

138 East Lincoln Ave. | Chariton, Iowa 50049 | [phone] | fax: [phone] | www.fatbaggers.com

b. Then also put the bolt through stepped washer item a. above, with the longest step of the bushing

towards the bolt head and the short side towards the end of the bolt.

c. Start this bolt with spacers into the left hole you opened up by removal of the existing bolt. Leave

very loose for now.

d. Repeat steps a. through c. for the right side. See IMAGES #6 & #10 for the bolt with spacers

installed.

7. FRONT ATTA CHMENT POINTS—the front attachment for the FBI Mount utilizes the stub/spacer on the
fender strut which the rear shock bolts to. Installation requires removing the top bolt through the rear
shock, inserting supplied spacers then putting the stock shock bolt back in place.
IMPORTANT: BEFORE REMOVING THE TOP REAR SHOCK BOLT, your bike must be secured and
lifted just enough to take the weight off the rear wheel—use a motorcycle floor jack, a motorcycle lift or
similar then also secure the bike to keep it from falling over. Do not lift high enough to lift the rear wheel
off the ground or the rear wheel and swingarm will drop when you remove the shock bolt and could
cause injury.
a. Loosen the bolt from the top of the left rear shock. You do not need to pull the bolt all of the way out.

Pivot shock with bolt forward or back as best for your bike just far enough to place provided
spacers/washers over the frame stub the shock was bolted to.

b. See IMAG E #9 for how to place the washers/spacers provided over the frame stub. Place the

narrow washer item e. over the frame stub, then place the thick washer item d. over the stub and
against the narrow washer.

c. Pivot the s hock with bolt back into place then push the bolt back into place and start the bolt a few

threads only leaving it very loose for now.

d. Repeat steps a. through c. for the right side. See IMAGE #6 with spacers on bolt ready for install.

8. INSTALLING THE FBI TRUNK MOUNT—the FBI mount will now be set into place so that at the front
points and rear points of attachment, the “legs” of the mount split (go between) the spacers you just put
in place. See IMAGES #10 & #11. If there doesn’t seem to be enough space for the mount to go
between the spacers, either you need to loosen the bolts, the spacers are inserted incorrectly (recessed
areas facing the wrong way of stepped spacers in backwards). In some cases you may need to insert
the mount on one side then spring/slightly bend the other side of the mount in or out to go between the
spacers. Once the mount is set into place, tighten the shock bolts and the rear attachment point bolts.
See IMAGES #12-14 with the mount set into place.

INST ALLING YOUR H-D TOUR PAK ONTO THE NEW FBI MOUNT:

9. Having already removed the Tour Pak from its original mounting apparatus in steps 1 and 2, now
carefully set the Tour Pak onto the new FBI mount. Look at the underside of the Tour Pak to notice the
recessed area in the bottom of it. This recess will restrict how far forward you can position the Tour Pak
on the mount; you can mount it all the way forward if you like. Otherwise, you’ll see that you can move
the Tour Pak back on the mount to allow more room for the passenger—be sure that the front mounting
holes stay well within the front edge of the bottom of the Tour Pak. You may want to have your
passenger carefully sit on the bike to determine the ideal location for the Tour Pak.

138 East Lincoln Ave. | Chariton, Iowa 50049 | [phone] | fax: [phone] | www.fatbaggers.com

Page 3—FBI500-09-FIX Removable Trunk Mount

need to be removed

need to be removed

removed.

NOTE: Even though you have mounting holes in the bottom of your Tour Pak already, you will most
likely need to drill 4 holes in the bottom of the trunk since there are variations in the placement of the
original holes and because you may want it further forward or back than the original holes would locate
it.

10. Once the location of the Tour Pak is determined, use a fine point marker to reach up through the holes in
the FBI mount and mark the front 2 and the rear two holes on the bottom of the Tour Pak to indicate
where to drill holes for (4) ¼”x1” bolts, included, which you’ll use to attach the trunk to the new mount. If
you want to be able to move the Tour Pak to a different position periodically, decide which four holes are
best to use.

11. Place your Tour Pak upside down on a padded bench or work surface then use a 5/16” bit to drill the
holes you just marked for the ¼”x1” mounting bolts.

12. Now set the Tour Pak back on top of the mount, on your bike, and bolt it into place using the ¼”x1” bolts,
nuts and flat washers (one washer above and one below the holes in the Tour Pak) provided. See

IMAGE #15.

13. Replace your saddlebags. Your installation is now complete.

INSTALLATION REFERENCE IMAGES

IMAGE #1 Sample of 2-Point

Backrest Hardware that would

IMAGE #2 Sample of 4-Point
Backrest Hardware that would

IMAGE #3 Rear Fender with all
stock mounting hardware

138 East Lincoln Ave. | Chariton, Iowa 50049 | [phone] | fax: [phone] | www.fatbaggers.com

Page 4—FBI500-09-FIX Removable Trunk Mount

mounting hardware.

IMAGE #6

IMAGE #5

flat washers are also included.

point.

IMAGE #4 View of the space
behind the front shock-­serves as the front mounting

Removable Trunk Mount Kit. In addition,
(4) ¼” X 1” Hex Head Bolts with nuts and

Hardware included with

Rear mounting
hardware to go together like
this and bolt into fender strut.

IMAGE #7 Note the chrome saddlebag support
rail that comes up and is bolted into the fender
strut. That bolt is removed & replace with new rear

IMAGE #9 With top shock bolt removed and shock
pivoted out of the way, Install front mounting
hardware as shown—narrow washer on first, then the
thick washer with recessed back and large hole.
Recess in back of washer faces toward bike.

Page 5—FBI500-09-FIX Removable Trunk Mount

138 East Lincoln Ave. | Chariton, Iowa 50049 | [phone] | fax: [phone] | www.fatbaggers.com

IMAGE #8 Close-up of bolt to be
replaced at top of chrome rail

IMAGE #10 With front and rear mounting hardware
in place and left loose, place FBI Mount into the
front mounting points then lower it onto the rear
points—the “legs” of the chrome mount are to split
the spacers.

IMA GE #11 FBI Close-Up of
mount set into place.

IMAGE #12 Full
view of FBI Fixed
Trunk Mount set
into place

IMAGE #13 Side view of FBI Fixed
Trunk Mount bolted in place.

IMAGE #14 Close-up view of FBI
Fixed Trunk Mount bolted in
place.

IMAGE #15 FBI Fixed Trunk
Mount with Tour Pak bolted on.

Thank you for your order of Fat Baggers, Inc. Product.

PLEASE NOTE: FBI recommends that our products be installed by a professional technician to ensure an

accurate and safe installation for the rider.
Once you’ve read completely through these instructions and looked through all boxes to make sure you’ve

located all components, for technical assistance, call FBI [phone].

138 East Lincoln Ave. | Chariton, Iowa 50049 | [phone] | fax: [phone] | www.fatbaggers.com