SADDLEBAG GUARD KIT

J055992023-06-07

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level
90200787, 90200788, 90202507, 90202508	Safety Glasses, Torque Wrench

KIT CONTENTS

Figure 1. Kit Contents: Saddlebag Guard Kit

Table 2. Kit Contents: Saddlebag Guard Kit

	Item	Qty	Description	Part No.	Notes
	1	1	Saddlebag guard, front, right (shown)	90200507	Kit 90200787 (chrome)
		1	Saddlebag guard, front, right (shown)	90200789	Kit 90200788 (black)
		1	Saddlebag guard, front, right (shown)	90202540	Kit 90202507 (chrome)
		1	Saddlebag guard, front, right (shown)	90202538	Kit 90202508 (black)
	2	1	Saddlebag guard, front, left (not shown)	90200506	Kit 90200787 (chrome)
		1	Saddlebag guard, front, left (not shown)	90200790	Kit 90200788 (black)
		1	Saddlebag guard, front, left (not shown)	90202539	Kit 90202507 (chrome)
		1	Saddlebag guard, front, left (not shown)	90202537	Kit 90202508 (black)
	3	2	Screw, TORX, button head 3/8-16 x 7/8 in	4924
	4	4	Flanged locknut, 3/8-16	7601
	5	1	Tube assembly, right (black) (shown)	90200504
	6	1	Tube assembly left (black) (not shown)	90200505
	7	2	Cap screw, hex socket head, 1/4-20 x 1¼ in	3601
	8	2	Hex locknut, 1/4-20 with nylon insert	7686
	9	2	Flanged locknut, 5/16-18	7531
Items mentioned in text, but not included in kit:
	A	2	Original Equipment (OE) rubber exhaust mount
	B	2	OE exhaust mounting bracket
	C	4	OE hex head screw 5/16-18 x 1/2 in
	D	4	OE split lockwasher
	E	2	OE TORX head self tapping screw, 5/16-18 x 1 in
	F	2	OE Screw 3/8-16
	G	2	OE saddlebag support casting (right side shown)
	H	2	OE TORX head screw, 3/8-16 x 2¾ in

NOTE

Verify that all contents are present in the kit before installing or removing items from vehicle.

GENERAL

Models

For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com

Verify use of most current version of instruction sheet at: www.harley-davidson.com/isheets

Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.

Installation Requirements

NOTE

For vehicles equipped with security siren: Verify that Hands-Free Fob is present.

WARNING

Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)

WARNING

If Equipped: Front and/or rear guards are not intended to provide protection from bodily injury in a collision with another vehicle or any other object. (00022d)

NOTE

This instruction sheet references service manual information. A service manual for the year and model motorcycle is required for this installation and is available from:

A Harley-Davidson dealer.
H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information, see Frequently ask questions about subscriptions

Figure 2. Remove Saddlebag Support (right side shown)

Table 3. Original Saddlebag Support Items

Item	Description	Notes
1	Rubber exhaust mount	Retain
2	Exhaust mounting bracket	Retain
3	Hex screw (2), 5/16-18 x 1/2 in	Retain
4	Split lockwasher	Retain
5	Saddlebag support	Remove and discard.
6	TORX screw, self tapping, 5/16-18 x 1 in	Retain
7	Flange nut	Remove and discard.
8	Screw, 3/8-16	Retain
9	Locknut	Remove and discard.
10	Saddlebag support casting
11	TORX screw, self tapping, 3/8-16 x 2 ¾ in	Retain
12	Locknut	Remove and discard.

PREPARE

1.	Remove saddlebags. See service manual.
2.	Remove seat. See service manual.
3.	Remove side covers. See service manual.

REMOVE

1.	Figure 2 Unfasten existing saddlebag support tube from muffler. a. Remove and retain hex screws (3), lockwashers (4), rubber mount (1) and bracket (2) securing muffler to saddlebag support tube (5).
2.	Unfasten current saddlebag support tube from saddlebag support casting. a. Remove screw (6) and flange nut (7) retaining rear of saddlebag support tube to saddlebag support casting (10). b. Retain screw (6) for later use. c. Discard nut (7).
3.	Unfasten front of saddlebag support from frame downtube. a. Remove screw (8) and locknut (9) retaining front of saddlebag support. b. Retain screw (8) for later use. c. Discard nut (9).
4.	Unfasten rear of saddlebag support tube from support casting. a. Remove screw (11) and flange nut (12) retaining rear of saddlebag support tube to support casting (10). b. Retain screw (11) for later use. c. Discard nut (12).

INSTALL

1.	Figure 1 Install rear of new saddlebag support tube (5 or 6) to saddlebag support casting (G). a. Loosely install screw (H, removed earlier) and flange nut (4).
2.	Install front saddlebag guard (1 or 2) to saddlebag support tube (5 or 6). a. Install short tube on guard (1 or 2) onto front of saddlebag support tube (5 or 6).
3.	Install guard to vehicle upper frame tube and frame downtube. a. Loosely install screw (3) to secure front saddlebag guard (1 or 2) to upper frame. b. Loosely install screw (F, removed earlier) and flange nut (4) to secure guard to frame downtube.
4.	Align holes in saddlebag guard short tube and saddlebag support tube. a. Install hex socket head screw (7). b. Install locknut (8). Do not fully tighten.
5.	Loosely assemble muffler to saddlebag support rail. a. Attach muffler to support rail. Install flanged hex head screws (C), lockwashers (D), rubber mount (A) and bracket (B) that was removed earlier. NOTE For models Except FLHX/S: Install screw (E), from rear, through fender rear support bracket, saddlebag support casting (G) and inboard hole of saddlebag support tube as shown in Figure 1. For FLHX/S models: Install screw (E), from front, through inboard hole of saddlebag support tube, saddlebag support casting (G) and fender rear support bracket as shown in Figure 1 inset.
6.	Tighten screw (E, removed earlier) and flange nut (9) from rear of saddlebag support tube to saddlebag support casting (G). Torque: 20–27 N·m (15–20 ft-lbs)
7.	Tighten screw (H) and flange nut (4). Torque: 40.5–50 N·m (30–37 ft-lbs)
8.	Tighten screw (3) at upper frame tube. Torque: 43.5–49 N·m (32–36 ft-lbs)
9.	Tighten screw (F) and nut (4) at frame downtube. Torque: 43.5–49 N·m (32–36 ft-lbs)
10.	Tighten screw (7) and locknut (8) at front of saddlebag support tube. Torque: 8–11.3 N·m (71–100 in-lbs)
11.	Tighten hex screws (C). Torque: 10.8–16.3 N·m (96–144 in-lbs)
12.	Repeat procedure on opposite side of vehicle.

COMPLETE

1.	Install seat. After installing seat, pull up on seat to verify that it is secure. See service manual.
2.	Install side covers. See service manual.
3.	Install saddlebags. See service manual.