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TOURING AIR WING SADDLEBAG LID RAIL KIT
J055972013-03-15
GENERAL
Kit Number
90200792, 90200793
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
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 drill bits, masking tape, a grease pencil or felt tip pen, and a soft pencil are needed to install this kit.
Use an assistant to help position the saddlebag lid rails.
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
1. See the owner's manual and remove a saddlebag from one side of the motorcycle.
2. See Figure 1. Locate the three drill points (B) on the inside of the saddlebag lid.
3. Place a piece of 50 mm (2 in) wide masking tape (A) on top of the lid over the drill points. The tape will help prevent paint chipping.
4. Drill a pilot hole at each drill point with a 1/16 in (1.6 mm) drill bit.
5. Enlarge the holes for screw (3) with a 7/32 in (5.5 mm) drill bit.
6. Enlarge the hole for screw (12) with a 3/8 in (10 mm) drill bit.
7. 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 nylon 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.
8. Cut two mounting pads (8), mounting pad (10), two nylon washers (7), and nylon washers (9) from the mounting pad and washer set (6).
9. Install the appropriate nylon mounting pad (8 and 10) over each foot of the trim rail.
10. Install trim rail with mounting pads to saddlebag lid with screws (3), lockwashers (4), washers (5), and nylon mounting washers (7). Do not tighten screws.
NOTE
Orient washer (11) to fit along the side of the saddlebag lid.
11. Install hollow screw (12), washer (11), and nylon mounting washers (9).
NOTE
Nylon mounting pads and washers should compress only slightly when screws are properly secure.
12. Tighten screws (3) to 3.1–3.5 N·m (27–31 in-lbs).
13. Tighten hollow screw (12) to 3.4–5.6 N·m (30–50 in-lbs).
14. Repeat procedure for other saddlebag.
SERVICE PARTS
Figure 1. Service Parts: Air Wing Saddlebag Rail Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Trim rail, right (chrome)
90200794
Trim rail, right (black)
90200796
2
Trim rail, left (chrome)
90200795
Trim rail, left (black)
90200797
3
Screw, fillister head (4)
1205
4
Lockwasher (4)
7069
5
Washer, plain (4)
6716
6
Mounting pad and washer set (2)
90875-08
7
  • Nylon washer, small hole (2)
Not Sold Separately
8
  • Mounting pad, small hole (2)
Not Sold Separately
9
  • Nylon washer, large hole
Not Sold Separately
10
  • Mounting pad, large hole
Not Sold Separately
11
Washer, special (2)
10600025
12
Screw, hex head, hollow (2)
4860
13
Filler, light, chrome (2)
Not Sold Separately
14
Screw, socket head (4)
Not Sold Separately
Items mentioned in text, but not included in kit:
A
50 mm (2 in) wide masking tape
B
Drill point indicators on the inside of the saddlebag lid (3)