How can you get saddle bag open, that latch is screwed up?

The solution to this problem, unfortunately, will involve the destruction of two hinge pins; since the hinge is sold only as an assembly, the entire hinge will have to be replaced. I'm sorry about that, but I thought you ought to know that before you start the repair.

Look at each end of the hinge (on the outside of the bag); you will notice a hole and (it may take a flashlight to see it) the end of a hinge pin within. Those hinge pins will have to be driven toward the center of the hinge until the hinge halves separate; that's much less than an inch, but is SEEMS more like 30 feet. Use a nail set that fits loosely in the hole, or a hardened nail about the same size with the tip ground flat.

Once the hinge halves separate, you'll find that you can lift that side of the saddlebag cover only a very short distance; the nylon fabric hinge cover on the inside keeps the cover from opening more than a VERY few inches. The hinge cover is secured by 3mm hex bolts; use a 3mm allen wrench to remove the bolts and the saddlebag top should swing open far enough for you to get your hand inside.

Take a flashlight and examine high on the opposite side of the saddlebag, inside the bag just underneath the cover; there are two catches covered by a broad plastic shield. Use your 3mm allen to remove the plastic shield, then use a small socket to remove the bolts holding the catches to the bottom part of the saddlebag. You can now lift the top of the saddlebag off and reveal the bottom of the catch.

The cover of the catch is secured by 1/4-turn fasteners, you'll see the phillips-head slots. Turn the screwheads until all fasteners are obviously loose; the cover can then be removed. There is a bent catch actuator arm beneath; push the top (free end, well, actually MIDDLE) of the arm toward the outside of the saddlebag cover, and the catches you removed from the saddlebag can be freed and remounted on the saddlebag.

You'll see the bottom of the release button through the catch actuator assembly; push it out, back to its' normal position. You're likely to find one of two things wrong: the actuator arm (4XY-2841A-00-00) is bent or broken, the lock assembly (4XY-W2843-00-00) has a bent or broken actuator tab or lever. A bolt may also be missing from either the actuator arm or lock assemblies; that would typically cause misalignment or binding.

Replace the hinge, reassemble the saddlebag top with the appropriate repair parts, mount and take a nice, long ride to relieve the frustration.

If you dont mind replacing the lock drive a flat blade screwdriver into the key lock with a hammer and turn hard, it will force lock open or bust it appart ,either way it will open but will be ruined ,check availability of new lock first and get price for lock smith to open it safely if you dont want to ruin it,but before you do that have you tryed giving it a liberal spray with oil the lock may just be dry.