Kits | Suggested Tools | Skill Level |
---|---|---|
90200787, 90200788, 90202507, 90202508 | Safety Glasses, Torque Wrench |
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 |
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. |
1. | Remove saddlebags. See service manual. | |
2. | Remove seat. See service manual. | |
3. | Remove side covers. See service manual. |
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). |
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
| |
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. |
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. |