Double-Stacked Electra Glo Light Rails
J007632006-06-23
GENERAL
Kit Number
90534-97
Models
This kit fits 1997 and later FLHTC, FLHTCU and 1998-2003 FLTR models. Will also fit FLHT and FLHR (except 1998 and later FLHRC and FLHRS) models with separate purchase of additional hardware. Ask your Harley-Davidson Dealer to refer to P&A Bulletin #569 for details. (Will not fit 2006 and later FLHX models.)
NOTE
A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer.
NOTE
This kit will not fit motorcycles equipped with fishtail endcaps.
NOTE
The current draw for this kit is 7.2 amps.
NOTICE
It is possible to overload the vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. (00211d)
INSTALLATION
Installing Triple Saddlebag Guard Rail
| 1. | Remove saddlebags and side covers. | |||||||||||||||
 WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) WARNINGDisconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) | ||||||||||||||||
| 2. | See Figure 1. Remove screws (1) that secure saddlebag side rails (2) to fender support (3). | |||||||||||||||
| 3. | See Figure 2. Remove screws (1) that secure mufflers to muffler support, and screws (2) that secure muffler support to rear bumper and fender support. Save hardware. | |||||||||||||||
| 4. | See Figure 1. Remove screws securing muffler support (4) to forward saddlebag guard (5). Save hardware. | |||||||||||||||
| 5. | Remove screws holding forward saddlebag guards (5) to motorcycle, and remove guards. Save screws. | 
Figure 1. Remove Saddlebag Hardware 
Figure 2. Remove Muffler Hardware | ||||||||||||||
| 6. | Disassemble side rails from forward saddlebag guards. Discard forward guards. Remove side rail clamps from side rails. | |||||||||||||||
| 7. | See Figure 9. Install forward saddlebag guards (5 and 6) using original hardware removed in step 5. | |||||||||||||||
| 8. | Install tubed ends of muffler supports into tubes on forward saddlebag guards. | |||||||||||||||
| 9. | See Figure 3. Using 7/8 in. screws from kit (1), install guard rail mounting brackets (2) as follows: As viewed from rear of motorcycle, screw (1) goes through bracket (2), rear bumper (3), chrome fender support (4), and muffler support (5), in order. Tighten screws securely with original flanged locknuts. | 
Figure 3. Guard Rail Mounting Bracket Installation | ||||||||||||||
| 10. | Reinstall original screws (6) through remaining holes in fender support and muffler support and tighten securely with original flange nuts. | |||||||||||||||
| 11. | Reinstall original screws, removed in step 4, through holes in muffler supports and forward saddlebag guards. Secure snugly with original locknuts. | |||||||||||||||
| 12. | Reinstall mufflers to muffler supports using original hardware removed in step 3. | |||||||||||||||
| 13. | Install the four original side rails in their original locations using the top two positions in the new forward saddlebag guards. | |||||||||||||||
| 14. | See Figure 9. Install guard rails (7), front guard rail brackets (39), guard rail mounts (12), and screws (2) in lowest position on forward saddlebag guards. | |||||||||||||||
| 15. | At rear of assembly, install new bottom guard rails (7) onto rear guard rail brackets (10 and 11) using screws (1) and flanged locknuts (4). |
Installing Electra Glo Light Rails
NOTE
Install the lower light rails first by performing steps 1 through 8, then repeat the same steps for the upper light rails. After lower and upper light rails are in place continue with installation at step 9.
| 1. | Remove front guard rail brackets from guard rails on each side. See Figure 4 and Figure 9. Position guard rail brackets from kit (19) on guard rails with mounting tabs positioned on inboard side of rails. NOTE This kit contains three different length bushings. Proper placement of these bushings is important to the correct installation of this kit. Determine differences between all bushings and follow directions carefully when installing bushings in proper locations. | |||||||||||||||||||||
| 2. | See Figure 5. Place medium length nylon bushings (1) into middle mounting locations on side housings (Item 5 in Figure 5, Item 27 on Figure 9). | 
Figure 4. Saddlebag Guard Rail Mount (shown with lower light bar in place) 
Figure 5. Side Light Bar and Bushings | ||||||||||||||||||||
| 3. | See Figure 9. Loosely install outer center chrome saddlebag guard clamps (8) using center mounting brackets (17), 3/8 in. buttonhead Allen screws, and wave washers from kit. Center bracket is formed to fit over wire trough in center of light bar. | |||||||||||||||||||||
| 4. | See Figure 4. Using 3/8 in. buttonhead Allen screws and wave washers, mount side housings to guard rail mounts. Returning to middle mounting location, tighten screws holding center brackets in place. | |||||||||||||||||||||
| 5. | See Figure 9. Install inner mounting plates (13) onto rear housings (28) by placing a short nylon bushing into each mounting hole. Make sure mounting plates are located on inboard side. Use 5/8 in. buttonhead Allen screws, wave washers, fender washers, and locknuts to secure mounting plates to rear housings. | 
Figure 6. Rear Light Bar Mounting (both rails shown installed) | ||||||||||||||||||||
| 6. | See Figure 6. Remove Torx screws holding guard rails to fender strut. Place two metal P-clamps over each wiring harness exiting rear section of light rail. After insuring side and rear light rails are nested properly at rear outboard mounting location (See Figure 7), attach inner mounting plate and P-clamps to fender strut with longer Torx screws from kit (item 36 on Figure 9.) as shown in Figure 6. Install long nylon bushings into mounting holes at rear outboard mounting location. | |||||||||||||||||||||
| 7. | See Figure 9. Install rear saddlebag clamps (8) with rear mounting brackets (16) using 5/8 in. buttonhead screws and wave washers. Use nylon P-clamps to hold wire in place. | |||||||||||||||||||||
| 8. | Make electrical connections between side and rear light rails. For each connection, remove rear side lens and push female connector through grommet in side rail. Plug into male connector on side rail, making sure that tang is facing outward on female connector. Reinstall lens and trim ring. NOTE To prevent lenses from being damaged, use care not to over-tighten trim nuts. | |||||||||||||||||||||
| 9. | Continue to route left and right wiring harnesses along fender struts and frame, utilizing supplied cable straps. Connect left and right side harnesses under seat just in front of battery. See Figure 8. Use switch harness provided in kit to connect upper and lower light rails to accessory plug located under seat. This plug is operated by utilizing accessory switch located on inner fairing. NOTE Failure to properly install nylon and metal P-clamps could cause wires to rub against saddlebag resulting in scratches on the saddlebags painted surface. | |||||||||||||||||||||
| WARNING Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) | ||||||||||||||||||||||
| 10. | Reconnect battery, positive cable first. | 
Figure 7. Rear to Side Light bar Connection (lower light bar shown) 
Figure 8. Switch Harness | ||||||||||||||||||||
| WARNING After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) | ||||||||||||||||||||||
| 11. | Test lights for proper operation. Reinstall saddlebags, making sure adequate clearance exists between rear of bags and light bars. If necessary, loosen saddlebag mounting brackets and reposition saddlebags slightly forward. Retighten brackets and install seat. |
SERVICE PARTS
Figure 9. Service Parts: Double-Stacked Electra Glo Light Rails
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Screw, hex head, 5/16-18 x 5/8, (2) | 2882W | 32 | Side liteboard, RH rear (2) | 91058-93 | |
2 | Screw, buttonhead, 5/16-18 x 2-1/2, (2) | 3584 | 33 | Rear liteboard, RH (2) | 91059-93 | |
3 | Screw, hex head, 5/16-18 x 7/8, (2) | 3991 | 34 | Rear liteboard, LH (2) (not shown) | 91060-93 | |
4 | Flanged locknut (2) | 7531 | 35 | Cable strap (16) | 10006 | |
5 | Saddlebag guard, RH | 49032-97 | 36 | Screw, Torx (4) (not shown) | 3684 | |
6 | Saddlebag guard, LH (not shown) | 49033-97 | 37 | Switch harness (not shown) | 70264-94 | |
7 | Saddlebag guard rail (2) | 49193-93 | 38 | Fuse, 15 amp | 72347-94 | |
8 | Guard rail outer clamp, RH | 90917-93 | 39 | Guard rail mount (2) | 90945-93 | |
9 | Guard rail outer clamp, LH (not shown) | 90919-93 | ||||
10 | Guard rail bracket, RH | 90920-93 | Items 40-52 are available in the hardware kits listed below: | |||
11 | Guard rail bracket, LH (not shown) | 90922-93 | Left side kit | 91045-93 | ||
12 | Guard rail bracket, front (2) | 90943-93 | Right side kit | 91047-93 | ||
13 | Rear inboard bracket (4) | 90536-93 | Left rear kit | 90619-93 | ||
14 | Rear inside bracket, LH (2) (not shown) | 90614-93 | Right rear kit | 90628-93 | ||
15 | Middle inside brackets, LH (2) (not shown) | 90615-93 | ||||
16 | Rear inside bracket, RH (2) | 90617-93 | 40 | Nylon P-clamp | ||
17 | Middle inside bracket, RH (2) | 90618-93 | 41 | Inside rear bushing | ||
18 | Litebar bracket, LH front (2) (not shown) | 91030-93 | 42 | Center side bushing | ||
19 | Litebar bracket, RH front (2) | 91031-93 | 43 | Side rear bushing | ||
20 | Litebar lens, LH (4) (not shown) | 91032-93 | 44 | Steel P-clamp | ||
21 | litebar lens, RH (4) | 91033-93 | 45 | Fender washer, #10 | ||
22 | Litebar lens, rear (4) | 91034-93 | 46 | Wave washer, #10 | ||
23 | Rear litebar trim (4) | 91035-93 | 47 | Keps nut, 10-24 | ||
24 | Litebar trim, LH (4) (not shown) | 91036-93 | 48 | Buttonhead screw, 10-24 x 3/8 inch | ||
25 | Litebar trim, RH (4) | 91039-93 | 49 | Buttonhead screw, 10-24 x 5/8 inch | ||
26 | Side housing, LH (2) (not shown) | 91040-93 | 50 | 2-way nut | ||
27 | Side housing, RH (2) | 91041-93 | 51 | Push clip | ||
28 | Housing, rear (4) | 91042-93 | 52 | Keps nut. 8-32 | ||
29 | Side liteboards, LH front (2) (not shown) | 91055-93 | ||||
30 | Side liteboard, LH rear (2) (not shown) | 91056-93 | ||||
31 | Side liteboard, RH front (2) | 91057-93 | ||||