SADDLEBAG GUARD KIT
941004602024-01-23
GENERAL INFORMATION
Table 1. General Information
Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
90202657 | Safety Glasses, Torque Wrench |  |
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Saddlebag Guard kit
Table 2. Kit Contents: Saddlebag Guard kit
 | Verify that all contents are present in the kit before installing or removing items from vehicle. | ||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
 | 1 | 1 | Lower tube assembly, right | 90202682 | |
| 2 | 4 | Nut, flange | 7601 | |
| 3 | 2 | Locknut, large | 7531 | |
| 4 | 1 | Lower tube assembly, left | 90202683 | |
| 5 | 1 | Saddlebag guard, left | 90202669 | |
| 6 | 2 | Screw, socket head | 3601 | |
| 7 | 2 | Locknut, small | 7686 | |
| 8 | 2 | Screw, button head | 4924 | |
| 9 | 1 | Saddlebag guard, right | 90202655 | |
| 10 | 4 | Service kit (bumper and screw) | 49000243 | |
| 1 | Mounting bracket |
| 2 | Rubber mount |
| 3 | Washer (2) |
| 4 | Screw (2) |
| 5 | Flange nut |
| 6 | Locknut |
| 7 | Screw (5/16 x 1 in.) |
| 8 | Screw (3/8-16 x 2-1/2 in.) |
| 9 | Lower tube assembly (right) |
| 10 | Socket head screw |
| 11 | Locknut |
| 12 | Saddlebag guard (right) |
| 13 | Button head screw |
| 14 | Flange nut |
| 15 | Screw (3/8-16 in.) |
Figure 2. Saddlebag Guard Assembly
GENERAL
Models
For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.
Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets
Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.
Installation Requirements
WARNINGRider 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 the year and model motorcycle is required for this installation and is available from:
- A Harley-Davidson dealer.
- H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.
PREPARE
| 1. | Remove seat. See service manual. | |
| 2. | Remove left and right saddlebags. See service manual. |
REMOVE
| 1. | See Figure 3. Remove both saddlebag supports (5). a. Remove and retain screws (3), washers (4), mounting bracket (2) and rubber mount (1). b. Remove screw (6) and lock nut (7). Retain screw (6). c. Remove screw (8) and flange nut (9). Retain screw (8). d. Remove screw (11) and flange nut (12). Retain screw (11). |
| 1 | Rubber mount |
| 2 | Mounting bracket |
| 3 | Screw (2) |
| 4 | Washer (2) |
| 5 | Saddlebag support |
| 6 | Screw (5/16 x 1 in.) |
| 7 | Lock nut |
| 8 | Screw (3/8-16 in.) |
| 9 | Flange nut |
| 10 | Support casting |
| 11 | Screw (3/8-16 x 2-1/2 in.) |
| 12 | Flange nut |
Figure 3. Support Mounting Bracket
INSTALL
WARNINGIf Equipped: Front and/or rear guards are not intended to provide protection from bodily injury in a collision with another vehicle or any other object. (00022d)
| 1. | See Figure 2. Install rubber mount (2) to lower tube assembly (9). | |
| 2. | Install mounting bracket (1) into rubber mount (2). | |
| 3. | Insert lower tube assembly (9) into saddlebag guard (12). a. Loosely install socket head screw (10) and locknut (11). | |
| 4. | Install lower tube assembly (9) to support casting. a. Loosely install screw (8, removed earlier) and flange nut (5). b. Loosely install screw (7, removed earlier) and lock nut (6). | |
| 5. | Install saddlebag guard (12) to mid-frame. a. Loosely install button head screw (13). b. Loosely install screw (15) and flange nut (14). | |
| 6. | Loosely attach muffler to lower tube assembly (9). a. Adjust mounting bracket (1) to muffler. b. Install washers (3) and screws (4). c. Adjust entire assembly as needed. | |
| 7. | Tighten screw (7). Torque: 20–27 N·m (15–20 ft-lbs) | |
| 8. | Tighten screw (8). Torque: 40.5–50 N·m (30–37 ft-lbs) | |
| 9. | Tighten screw (13). Torque: 43.5–49 N·m (32–36 ft-lbs) | |
| 10. | Tighten screw (15). Torque: 43.5–49 N·m (32–36 ft-lbs) | |
| 11. | Tighten screw (10). Torque: 8–11.3 N·m (71–100 in-lbs) | |
| 12. | Tighten screws (4). Torque: 10.8–16.3 N·m (96–144 in-lbs) | |
| 13. | Repeat procedure on opposite side of vehicle. | |
| 14. | Install bumpers and screws. Refer to SERVICE. |
COMPLETE
| 1. | Install seat. After installing seat, pull up on seat to verify that it is secure. See service manual. | |
| 2. | Install saddlebags. See service manual. |
SERVICE
NOTE
Service kit has enough components for one side to be replaced.
Check flat-out bar for damage prior to replacing bumper.
Replace as needed.
| 1. | See Figure 4. Remove and discard screw (1) and bumper (2). | |
| 2. | Install bumper (2). | |
| 3. | Install screw (1). Tighten. Torque: 23–26 N·m (17–19 ft-lbs) |
| 1 | Screw (1) |
| 2 | Bumper (1) |
Figure 4. Bumper Replacement