w w w.hdonline s h o p .d e - HARLEY
Contents
1. cMOTOR HARLEY DAVIDSON NU J02153 INSTRUCTIONS REV 2004 11 23 SADDLEBAG GUARDRAIL TRIM GENERAL Kit Number 90206 02 90214 05 Models This kit fits 1993 and later Electra Glide Classic and Ultra Classic 1998 and later Road Glide 1993 1996 Tour Glide Ultra Classic and 1993 and later Electra Glide Standard with Chrome Saddlebag Guard Kit Part Number 90839 93A Additional Parts Required INT NIN The rider s safety depends 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 00333a 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 the Service Parts illustration Remove the screws fastening the stock upper front guardrail mounts to the guard rail Discard the stock upper front guardrail mounts J02153 3 Fasten the new front brackets 2 5 where the stock upper front guardrail mounts were removed in step 2 Tighten the screws to 72 120 in Ibs 8 1 13 5 Nm 4 Loosely fast2. en the rear inside brackets 9 to the guardrail rear trim 12 using screws 4 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 Align all installed components and use the Allen wrench 14 from this kit to tighten the fasteners e Tighten screws at the upper and lower guardrail tabs to 15 20 ft lbs 20 27 Nm e Tighten the fasteners from this kit 4 6 11 to 30 50 in Ibs 3 4 5 6 Nm 11 Install the saddlebags 1 of 2 SERVICE PARTS is01698 Figure 1 Service Parts Saddlebag Gua
3. rdrail 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 12 Guardrail rear trim 2 Not Sold Separately 2 Bracket front left hand Not Sold Separately 13 Bracket inner guardrail left hand Not Sold Separately not shown 3 Wave washer 10 8 6065 14 Allen wrench 1 8 in not shown Not Sold Separately 4 Screw 10 32 x 375 in 1 8 in _ Not Sold Separately Stock Items hex drive grade 5 8 5 Bracket front right hand Not Sold Separately A Lower guard rail 6 Screw 10 24 x 50 in 1 8 in hex Not Sold Separately B Outer guardrail bracket drive grade 5 4 7 Bracket inner guardrail right hand Not Sold Separately C Guardrail tab 8 Guardrail side trim right hand Not Sold Separately D Bolt 9 Bracket rear inside 2 Not Sold Separately E Not Sold Separately 10 Flat washer 10 8 6716 F Bolt and washer 11 Keps nut 10 32 4 7629 G Guardrail NOTE Items 2 and 5 replace stock upper front guardrail mounts J02153 2 of 2
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