HARLEY DAVIDSON NOSTALGIC SADDLEBAG GUARD RAILS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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REMOVAL 1. If desired, remove the saddlebags. 2. Remove screws (C) and locknuts (D). Save for installation. 3. Remove reflectors with fishing line or dental floss. Use a sawing motion to remove the adhesive. Clean the surface thoroughly with an equal mixture of isopropyl alcohol and distilled water. Allow the surface to dry thoroughly. INSTALLATION 1. See Figure 1. Position the correct saddlebag guard rail (1 or 2) over the saddlebag guard and support assembly (A). Loosely install the screw (C) through the saddlebag-to- fender support bracket (B), through the saddlebag support (A) and through the inner hole of the saddlebag guard rail bracket. Install nut (D). Tighten finger-tight. NOTE Position the saddlebag guard rail as low as possible on the stock saddlebag guard and support assembly. 2. Install screws (6) and washers (5) through the clamp end of the saddlebag guard rail. Position clamp end around the upright of the saddlebag guard and install the clamp (3 or 4). Tighten screws finger-tight. 3. Align the saddlebag guard rail (1 or 2) parallel to the bottom of the saddlebag and muffler. Tighten the cap screw (C) and locknut (D) to 15-20 ft-lb (20-27 Nm) . 4. Tighten the clamp screws (6) to 22 in-lb (2.5 Nm) . NOTE The reflectors are location-specific. There are markings on the back of the reflector – “L BOTTOM” or “R BOTTOM”. 5. Peel the backing from the base of the new reflector (7 or 8). Without touching the reflector to the saddlebag guard, position the reflector and press the reflector to the saddlebag guard above the clamp (3 or 4) and press for 30 seconds. After releasing pressure, avoid direct contact with the reflector for at least 20 minutes. 6. Repeat all steps for the other side of the motorcycle. NOTE For ease of use, move the saddlebag buckles to the highest hole on the strap. 7. Install the saddlebags, if removed

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HARLEY DAVIDSON SADDLEBAG GUARD RAIL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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Installation NOTE A Service Manual for your vehicle is available from your Harley-Davidson Dealer. 1. Remove saddlebags from motorcycle according to Service Manual instructions. 2. Remove left and right side covers (located just ahead of saddlebags) by removing Phillips head screw from bottom of side cover. Save hardware and side covers for later reassembly. 3. Remove upper and lower bolts securing left and right forward saddlebag guards to frame. Remove Phillips head screws securing saddlebag guards to muffler supports. Discard saddlebag guards, but save hardware. 4. See Figure 1. Install new left and right forward saddlebag guards (1) with upper bolts (2), lower bolts (3) and Phillips head screw (4) saved from Step 3. 5. Insert one rear guard rail mount (6) onto rounded, tubular end of one of the saddlebag side guard rails (5). 6. Insert a hex cap screw (8) through one of the front guard rail mounts (7) as shown. 7. Line up saddlebag side guard rail (5) with attached rear guard rail mount (6) from Step 5 with lower hole in forward saddlebag guard rail (1). Insert hex cap screw (8) from front guard rail mount (7) through hole in forward guard rail (1) and into side guard rail assembly. Tighten finger tight. 8. See Figure 2. Install a side guard rail (2) in lower position on rear fender support (3) with pan head screw (1). Tighten finger tight. 9. Repeat Steps 5 through 8 in upper position. 10. Repeat Steps 5 through 9 for opposite side of vehicle. NOTE Each of the four guard rail clamps vary slightly. Two fit together for the right side of the motorcycle and two fit together for the left side. The inner right and left clamps have two holes drilled through them. 11. See Figure 2. Locate four guard rail clamps (4). Match up two left side and two right side guard rail clamps. Install one piece of cushion tape to the lower inner surface of right and left inner clamps. Peel off paper from outer surface of tape. Do not apply tape to the outside clamps. NOTE Be sure that you correctly position the inner clamps on the side guard rails, as directed in Step 12, before tape on inner clamp contacts side guard rails. Tape is very sticky and will be difficult or impossible to remove once it has made contact with side guard rail surface. 12. See Figure 2. Position clamps (4) in desired position on side guard rails (2). Install clamps (4) on left and right side of vehicle side guard rails using four Torx screws (5). Torx screw heads should face inward toward motorcycle. Tighten each screw a little at a time until secure. 13. Tighten hex cap screws and pan head screws installed in Steps 7 and 8.

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