1. | Remove the saddlebags according to Service Manual instructions. | |
2. | See Figure 1 and Table 1. Remove the screws fastening the stock upper front guardrail mounts to the guard rail. Discard the stock upper front guardrail mounts. | |
3. | Fasten the new front brackets (2, 5) where the stock upper front guardrail mounts were removed in step 2. Tighten the screws to 8.1–13.5 N·m (72–120 in-lbs). | |
4. | Loosely fasten the rear inside brackets (9) to the guardrail rear trim (12) using screws (16), spacers (15), flat washers (10), and keps nuts (11) as shown. | |
5. | Remove the inner and outer stock guardrail brackets. Discard the stock inner brackets | |
6. | Loosely fasten the guardrail side trim (1, 8) to the front brackets (2, 5). | |
7. | Remove the stock screws fastening the stock upper and lower guardrail tabs to the vehicle. Save the screws for installation. NOTE For steps 8 and 9, see the Service Parts illustration for exact orientation of the rear trim flange relative to the side trim flange, and rear inside bracket orientation relative to the guardrail tabs. | |
8. | Position the rear inside brackets (9), with rear trim loosely attached, on the outboard side of the stock upper and lower guardrail tabs. Loosely fasten the rear inside brackets (9) to the guardrail tabs and vehicle using the screws removed in step 7 | |
9. | Loosely fasten the side and rear trim flanges between the stock outer guardrail bracket and the new inner guardrail brackets (7, 13) using screws (6) and wave washers (3). | |
10. | If using Kit 90255-09, attach the skull medallions (18) securely with flat head screws (17) to the side trim rail inserts. | |
11. | Align all installed components and use the Allen wrench (14) from this kit to tighten the fasteners. |
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
---|---|---|---|---|---|---|
1 | Guardrail side trim, left-hand | Not Sold Separately | 13 | Bracket, inner guardrail, left-hand (not shown) | Not Sold Separately | |
2 | Bracket, front left-hand | Not Sold Separately | 14 | Allen wrench, 1/8 in. (not shown) | Not Sold Separately | |
3 | Wave washer, #10 (8) | 6065 | 15 | Spacer, aluminum, 1/2 in. O.D. (4) | Not Sold Separately | |
4 | Screw, 10-32 x .375 in. (4) | Not Sold Separately | 16 | Screw, 10-32 x 0.75 in. (4) | Not Sold Separately | |
5 | Bracket, front right-hand | Not Sold Separately | 17 | Screw, flat head, 4-40 x 0.25 in. (4), kit 90255-09 only | Not Sold Separately | |
6 | Screw, 10-24 x .50 in. (4) | Not Sold Separately | 18 | Skull medallion (2), kit 90255-09 only | Not Sold Separately | |
7 | Bracket, inner guardrail right-hand | Not Sold Separately | Stock Items: | |||
8 | Guardrail side trim, right-hand | Not Sold Separately | A | Lower guardrail | ||
9 | Bracket, rear inside (2) | Not Sold Separately | B | Outer guardrail bracket | ||
10 | Flat washer, #10 (8) | 6716 | C | Guardrail tab | ||
11 | Keps nut, 10-32 (4) | 7629 | D | Bolt | ||
12 | Guardrail rear trim (2) | Not Sold Separately | E | Upper guardrail | ||
NOTE: Items 2 & 5 replace stock upper front guardrail mounts. | F | Bolt and washer | ||||
G | Guardrail |