Ill fitting saddlebag lids.

[John Schmidt]

I recently changed my Tourer hinges over to the I/S system prior to mounting a trunk. After installing the I/S hook system, the right bag lid simply doesn't fit down onto the bag as with the hinges. It has at least a 3/8"(or more) gap between the outer edge of the lid and the outer shoulder of the bag. Has anyone run into that before, and if so what did you do to rectify it? There really isn't any adjustments available but I suppose I could grind down the outer half of the latching mechanism so it would sit lower.

[Rocketman]

Sounds to me like you didn't swap quite all the parts needed.  I would recommend looking at yours and an original I/S bag side by side before you start grinding anything.

[John Schmidt]

First, I swapped the pieces between the two bags, just the part that bolts to the bag. That helped some, followed by removing something I hadn't noticed previously....some RTV sealer or similar. It had been piled on thick on that particular bag, possibly by the original owner. As suspected, most of the excess was on the outside portion of where the latch bolts to the bag. All parts were present and accounted for prior to making the change, and with this little dressing of the surface the lid now fits down where it should.

[Disco]

Hey John,

Here's what I did last month.

FYI, from the TX Board.

Last weekend, a couple of us DFW VRCCers swapped saddlebag/lid parts.  Stretch has IS bags and wanted them to open like Tourer bags.  I have Tourer bags and wanted them to open like IS bags.  Here are the results.

Stretch's IS Saddlebags/Lids now have Tourer hinges and my Tourer Saddlebags/Lids now have the IS Lid Stopper Stay & Saddlebag Lid Hooks.  These parts are interchangeable.
Stretch's IS bags/lids also have the Tourer Stopper Cables.  My Tourer bags/lids have no Stopper Cables - the lids detach from the bags.   

The significant difference between the Tourer and Interstate Saddlebag assemblies is the inside of the Lids. 
1. The Tourer Lids have one attachment point for the Stopper Cable.  The Interstate Lids have two attachment points for Stopper Cables. 
2. The Tourer Lids have no attachment points for the Stoppers (the rubber-covered metal pieces that rest against the bag when the lid is opened and hanging on the Stopper Cables).  The Interstate Lids have two attachment points for the Stoppers.

Bottom Line:
1. If you want your Tourer's Saddlebag Lids to completely detach when open, all you need are the Interstate Lid Stopper Stays & Lid Hooks (hinge replacements). 
2. If you want your Tourer's Saddlebag Lids to hang outboard of the Saddlebag when open, you need Interstate Lid Stopper Stays & Lid Hooks, Interstate Stopper Cables, (2) of the little brackets that attach the rear cable to the bag, the Interstate Stoppers that keep the lid off the bag's side, AND Interstate Lids. 
3. If you want your Interstate Saddlebag's Lids to open and hang forward like Tourer Lids, all you need are Tourer Hinges and Stopper Cables.

Hope this helps,

DFG

[John Schmidt]

The early Tourer bags didn't have the extra attachment points in the lids for the cables to attach to...such is the case with mine. Later versions the I/S and Tourer lids were the same, they just left the cables off the tourer installations. I know that might seem a bit "iffy" for some to accept, but after noting the difference 2-3 years back I asked some folks on the assembly line in Marysville. It was one of a few dozen questions I had during the plant tour I took prior to them shutting it down. One gal told me it got downright aggravating sometimes when they had a Tourer coming down the line and all they had were some I/S bags....i.e., someone screwed up. Didn't happen too often, and when they went to the same lids for all, the problem cleared up and the cost was less overall.

Sounded reasonable to me. I did get my lids to fit right finally, in the process of changing the fender rails now.

[Disco]

Thanks for the really inside info.  It does make more sense to have one lid.  The ones I have were originally Sedona Red & Cream.