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TOURING SADDLEBAG LID RAIL KIT
J055732012-04-02
GENERAL
Kit Number
90200737
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
This kit does not fit models with leather covered saddlebags, or models equipped with Saddlebag Wing Tips (Part No. 53826-00B).
NOTICE
The trim rail is not intended for cargo. To prevent damage, do not strap cargo to the trim rail. (00603d)
Installation Requirements
Silicone sealant, a drill and various small bits, masking tape, a grease pencil or felt tip pen in a color other than the saddlebag lid, and a soft pencil will be needed to install this kit.
The help of an assistant will aid in the proper positioning of the rails to the saddlebag lid.
WARNING
Rider and passenger safety depend upon the correct installation of this kit. 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. (00308b)
Kit Contents
See Figure 1 and Table 1.
INSTALLATION
NOTE
If proper care is taken to protest surrounding parts, this installation can be done without removing the saddlebags from the vehicle.
  1. See the owner's manual to remove the saddlebag from one side of the motorcycle if desired.
    2. NOTE
    The trim rails are side-specific. The forward portion of the rail is angled to fit the cover.
  2. See Figure 1. Place the correct trim rail (1 or 2) in the approximate mounting position on the saddlebag lid.
  3. Place a piece of 51 mm (2 in) wide masking tape on the saddlebag lid, under each of the three trim rail mounting bosses (A).
  4. Cut the three same-size mounting pads (8) and washers (7) from the mounting pad and washer set (6).
    5. NOTE
    The pad and washer with the larger mounting hole will not be used, and can be recycled or properly disposed of.
  5. Place a black nylon mounting pad onto each of the three mounting bosses on the trim rail.
  6. Place the trim rail, with mounting pads installed, into final position on the saddlebag lid.
  • The distance between the rail and top surface of the lid should be consistent from one end to the other.
  • Give particular attention to trim rail alignment with any pin striping on the saddlebag lid.
  • All three mounting pads should rest squarely on the saddlebag lid, and should be over the tape strips. Reposition the tape if necessary.
1. While holding the trim rail firmly in place, have an assistant trace the outline of the three mounting pads onto the tape.
2. Remove the trim rail. Mark the center of the three traced circles with a center punch.
3. Drill a 1.6 mm (1/16 in) pilot hole at each mounting point. Enlarge the mounting holes with a 5.5 mm (7/32 in) drill bit.
4. Remove the tape. Lightly sand to remove burrs and sharp edges.
NOTE
  • Clean the inside and outside lid surfaces of debris, markings and tape residue with a 50-50 mixture of isopropyl alcohol and distilled water. Allow to dry thoroughly.
  • Apply a small amount of silicone sealant between the underside of the saddlebag lid and the rubber washers, and around the screw threads to prevent water leakage.
  • Brace or tie the saddlebag lid securely in the open position during rail installation to prevent hand or finger injury, or scratching of the saddlebag lid finish.
5. Install the trim rail to the saddlebag lid with three screws (3), lockwashers (4), flat washers (5) and black nylon washers (7), but do not fully tighten.
NOTE
The nylon mounting pads and washers should compress only slightly when the screws are properly secured.
6. Alternately tighten the screws to 3.1–3.5 N·m (27–31 in-lbs).
7. Repeat for the opposite side saddlebag lid rail.
NOTICE
The trim rail is not intended for cargo. To prevent damage, do not strap cargo to the trim rail. (00603d)
SERVICE PARTS
Figure 1. Service Parts, Touring Saddlebag Lid Rail Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Rail, saddlebag lid (right)
Not sold separately
2
Rail, saddlebag lid (left)
Not sold separately
3
Machine screw, fillister head, #10-24 (6)
1205
4
Split lockwasher (6)
7069
5
Flat washer (6)
6716
6
Mounting pad and washer set (2) (each includes items 7-8)
90875-08
7
  • Mounting washer (3)
Not sold separately
8
  • Mounting pad (3)
Not sold separately
Items mentioned in text:
A
Trim rail mounting boss (6)