SADDLEBAG GUARD KIT
J046572011-12-12
GENERAL
Kit Number
90892-09
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
For FLTR Models: Separate purchase of Saddlebag Supports (90781-09 and 49194-09), Antenna Bracket (76516-09) and nut (7531) are required for installation of this kit. See your Harley-Davidson dealer for additional information.
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)
NOTE
This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Kit Contents
See Figure 3 and Table 1.
REMOVAL
  1. Remove saddlebags from motorcycle following the instructions in the service manual.
  2. See Figure 3. Remove grab strap screw and washer (G). Remove grab strap (H). Remove seat following the instructions in the service manual.
  3. If equipped, remove seat bumper (R) and screw (Q).
  4. Remove left and right side covers (located in front of saddlebags) by removing screw from bottom of side cover. Save hardware and side covers for final assembly.
  5. For FLTR Models: See Figure 3. For All Other Models: See Figure 3.
    1. Support muffler assembly with a block of wood or other suitable method. Remove the screws (F) securing saddlebag guards to muffler supports.
    2. Remove screws (B and C) and nut (E). Save screws (B and C) for installation. Discard nut (E).
    3. Remove bolt (M) and nut (P). Save bolt (M) for installation. Discard nut (P).
    4. Remove support (D) and discard. Repeat for other side.
    5. Remove stud receptacle (I) and save for installation.
    6. See Figure 1. Remove antenna bracket (1), mounting fasteners (2), antenna mounting nut (5), washer (4) and antenna adapter (3). Save the antenna and hardware, discard the bracket.
    1. Support muffler assembly with a block of wood or other suitable method.
    2. Remove upper and lower bolts (N and C) and nut (E) securing left and right forward saddlebag guards to frame. Discard saddlebag guards, but save hardware.
    3. Remove screw (K) and nut (L). Save for installation.
1Antenna bracket
2Bracket mounting fastener (2)
3Antenna adapter
4Washer
5Nut
Figure 1. Remove Antenna and Bracket
INSTALLATION
1.
For FLTR Models: See Figure 3. For All Other Models: See Figure 3.
a.
Install left saddlebag support (J) (purchased separately) into left forward guard (1).
b.
Install the rear saddlebag support mounting screw (B) through the air suspension bracket (A) and saddlebag support (J). Install screw finger-tight.
c.
Install bolt (M) and nut (P) (purchased separately). Tighten finger-tight.
d.
See Figure 2. Install antenna bracket (purchased separately) with hardware (removed earlier).
e.
Install new left forward saddlebag guard (1) with upper bolt (16) and lower bolt (C) with nut (13).
2.
Install screw (14) and nut (15). Tighten finger-tight.
3.
Insert one rear guard rail mount (4) into rounded, tubular end of the rear guard (3) aligning with the lower hole on the forward guard (1).
4.
Insert a hex cap screw (6) through the front guard rail mounts (5) as shown.
5.
Install saddlebag side guard rail (3) into the guard mount on the forward guard. Tighten the screw finger-tight.
6.
Install screw (7) and tighten finger-tight.
7.
Repeat Steps 2 through 6 for the upper hole on the forward guard.
NOTE
Each of the four guard rail clamps (8-11) vary slightly. Two fit together for the right side of the motorcycle and two fit together for the left side. The inner clamps have two holes drilled through them.
8.
Match up the inner clamps (9 and 11) with the outer clamps (8 and 10).
NOTE
Be sure that to correctly position the inner clamps on the side guard rails, before tape on inner clamp contacts side guard rails. Tape is very sticky and will be difficult or impossible to remove once it has made contact with side guard rail surface.
9.
Peel off paper from outer surface of tape. Position clamps in desired position on side guard rails (3). Install TORX screws (12). Screw heads should face in toward motorcycle. Tighten each screw a little at a time until secure.
10.
Repeat all steps for opposite side of vehicle.
11.
For FLTR Models: Tighten the rear saddlebag support mounting screw (B) to 20–27 N·m (15–20 ft-lbs).
12.
Tighten the rear guard screws (7) to 20–27 N·m (15–20 ft-lbs).
13.
Tighten the forward guard upper screw (16) to 43–49 N·m (32–36 ft-lbs).
14.
Tighten the lower screw (C) and nut (13) to 43–49 N·m (32–36 ft-lbs).
15.
Tighten saddlebag support screw (14) and nut (15) to 8–11 N·m (70–100 in-lbs).
16.
Tighten front guard rail mount screws (6) to 8–14 N·m (72–120 in-lbs).
17.
Tighten the clamp screws (12) to 3–6 N·m (30–50 in-lbs).
18.
For FLTR Models: Tighten fender bracket screw (M) and nut (P) to 20–27 N·m (15–20 ft-lbs).
19.
For FLTR Models: Install muffler with screws (F) and remove wooden support. Tighten screws to 10.8–16.3 N·m (96–144 in-lbs). For All Other Models: Remove wooden muffler support.
20.
Install seat and grab strap (H). Tighten grab strap screw (G) to 16.3–20.3 N·m (12–15 ft-lbs).
21.
Install left and right side covers with original hardware.
WARNING
Front and/or rear guard(s) can provide limited leg and cosmetic vehicle protection under unique circumstances. (Fall over while stopped, very slow speed slide.) It is not made or intended to provide protection from bodily injury in a collision with another vehicle or any other object. (00022b)
22.
Install saddlebags with the original hardware following the instructions in the service manual.
1Antenna base assembly
2Antenna mast
3Locknut (2)
4Lockwasher
5Antenna mounting bracket (purchased separately)
6TORX screw (2)
7Saddlebag rear support bracket
Figure 2. Antenna Mounting Bracket
SERVICE PARTS
Figure 3. Service Parts: Saddlebag Guard Kit (Left Side Shown)
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Forward guard, left
49172-09
2
Forward guard, right
49188-09
3
Rear guard (4)
49193-09
4
Guard rail mounts, rear (4)
90945-93A
5
Guard rail mounts, front (4)
90943-93A
6
Screw, hex cap 0.312-18 x 1.75 inch (4)
3584
7
Screw 0.312-18 x 0.63 inch (4)
3676
8
Outer clamp, left
90934-93A
9
Inner clamp, left
90936-93A
10
Outer clamp, right
90946-93A
11
Inner clamp, right
90935-93A
12
Screw, #10-24 x 0.50 inch TORX (4)
1750
13
Nut, 0.375-16 UNC (2)
7601
14
Screw, 0.25-20 x 1.25 inch (2)
3601
15
Locknut, 0.25-20 UNC (2)
7686
16
Screw, 0.375-16 x 0.875 inch (2)
4924
Items mentioned in text, but not included in kit:
A
Air suspension mounting bracket
B
Rear saddlebag support mounting screw
C
Lower saddlebag guard screw
D
Saddlebag support (FLTR models only)
E
Lower saddlebag guard nut
F
Muffler screw (2)
G
Grab strap mounting hardware
H
Grab strap
I
Stud receptacle
J
Saddlebag support (separate purchase for FLTR models)
K
Stock screw
L
Stock nut
M
Stock screw
N
Stock screw
O
Stock fender bracket
P
Nut (separate purchase for FLTR models)
Q
Screw (2)
R
Seat bumper (2)