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SADDLEBAG GUARDRAIL TRIM
J047242008-05-27
GENERAL
Kit Number
90251-09, 90255-09
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
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 1 and Table 1.
INSTALLATION
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.
  • Tighten screws at the upper and lower guardrail tabs to 20–27 N·m (15–20 ft-lbs).
  • Tighten the fasteners from this kit (4, 6, 11) to 3.4–5.6 N·m (30–50 in-lbs).
  1. Install the saddlebags.
SERVICE PARTS
Figure 1. Service Parts: Saddlebag Guardrail Trim
Table 1. Service Parts Table
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