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:
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. See 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. See 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.