AIR WING SADDLEBAG RAILS
J048492010-04-20
GENERAL
Kit Number
88299-09, 90200391
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
WARNINGRider 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)
INSTALLATION
| 1. | See the owner's manual and remove a saddlebag from one side of the motorcycle. | |||||||
| 2. | See Figure 1. Place the appropriate trim rail (1) for the saddlebag in the approximate mounting position on the cover. | |||||||
| 3. | Place a piece of 2 inch wide masking tape (2) on cover (under trim rail) at each of the three trim rail mounting points. | 
Figure 1. Mark Drill Point Locations | ||||||
| 4. | See Figure 2. Using a scissors or utility knife, cut three mounting pads (12, 13, 14) and three mounting washers (9, 10, 11) from the plastic retainer. Place the appropriate nylon mounting pad (12, 13, 14) over each of the three screw mounts on the trim rail. | |||||||
| 5. | See Figure 1. Position the appropriate template (removed from instruction sheet) over the tape and under the rear mounting points fo the trim rail. | |||||||
| 6. | Position trim rail in the final location. The distance between the rail and top surface of the cover should be consistent from one end to the other. | |||||||
| 7. | While holding the trim rail (mounting pads installed) in the desired position mark the mounting locations on the cover. a. Trace around the front mounting point with a felt tip pen. b. Position the template so that the mounting locations indicated on the template match the intended trim rail mounting locations. Tape the template in place. c. Remove the trim rail. d. Mark the center of traced circle and template indicated drill points with a center punch. e. Remove the template. | |||||||
| 8. | Drill a 1/16 inch pilot hole at each mounting point. | |||||||
| 9. | Enlarge the front mounting hole and the smaller rear mounting hole with a 7/32 inch drill bit. Enlarge the larger rear mounting hole with a 3/8 inch drill bit. | |||||||
| 10. | See Figure 2. Install trim rail with mounting pads (12, 13, 14) to saddlebag cover with screws (3), lockwashers (4), washers (5), and nylon mounting washers (9 or 10). Do not tighten screws. | |||||||
| 11. | Install hollow screw (6), washer (7), and nylon mounting washers (11). 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). Tighten hollow screw (6) to 3.4–5.6 N·m (30–50 in-lbs). | |||||||
| 13. | Repeat procedure for opposite side saddlebag trim rail. |
NOTICE
The trim rail is not intended for cargo. To prevent damage, do not strap cargo to the trim rail. (00603d)
SERVICE PARTS
Figure 2. Service Parts for Air Wing Saddlebag Trim Rail Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Trim rail, right (chrome) | 88338-09 |
Trim rail, right (black) | 90200393 | |
2 | Trim rail, left (chrome) | 88339-09 |
Trim rail, left (black) | 90200392 | |
3 | Screw, fillister head (4) | 1205 |
4 | Lockwasher (4) | 7069 |
5 | Washer, plain (4) | 6716 |
6 | Screw, hex head, hollow (2) | 4860 |
7 | Washer, plain (2) | 6235 |
8 | Mounting pad and washer set | 88347-09 |
9 |
| Not Sold Separately |
10 |
| Not Sold Separately |
11 |
| Not Sold Separately |
12 |
| Not Sold Separately |
13 |
| Not Sold Separately |
14 |
| Not Sold Separately |
TEMPLATE
Figure 3. Template