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DYNA DOCKING HARDWARE KIT
J025522011-03-02
GENERAL
Kit Number
53533-02B
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
UltraTorch UT-100 (HD-39969) or Robinair Heat Gun (HD-25070) and Heatshrink Attachment (HD-41183)
Crimping tool (HD-38125-8 or equivalent).
Loctite® 243 Threadlocker and Sealant-Blue (99642-97)
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 3 and Table 1.
INSTALLATION
Install Front Docking Point
WARNING
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
1. Remove the seat and disconnect the battery cables, negative cable first.
NOTE
2. Complete ALL the following procedures (from "Installing the Front Docking Point" to "Reconnecting the Turn Signal Wires") on one side of the motorcycle before starting the other side. To keep the fender aligned the front docking point must be mounted first.
3. See Figure 3 and Table 1. Remove the stock center bolt from location (A) and flanged lock nut from the fender support.
4. Keep the countersunk side of the front docking point (1) facing toward the fender support. Insert button head bolt (2) through the docking point, fender support and fender. Install flat washer (9) and locknut (10) to the inside of the fender. Tighten to 16.3–24.4 N·m (12–18 ft-lbs).
1Housing
2Grommet
3Reflector
4Bulb
5Lens
6Support
7Flat washer
8Bolt
Figure 1. Removing Stock Turn Signal
Remove Turn Signal Support
  1. See Figure 1. Remove lens (5) from rear turn signal housing (1). Remove bulb (4) from the socket of reflector (3).
  2. Trace the turn signal wires along the underside of the rear fender. Cut the wires 3 to 6 inches (7.6-15.2 cm) past the internal fender clip.
    3. NOTE
    The wires must be cut to allow them to fit through the new turn signal stalk. They will be spliced back together later in the installation. It may be necessary to pull back the protective wire sheath to allow splicing.
  3. Carefully pry the reflector (3) and grommet (2) from the housing. Gently pull the wires from the housing and slide the conduit off the wires. Discard the conduit.
  4. Remove and discard the 5/16 inch bolt (8) and flat washer (7) that secure the turn signal housing and support (6) to the fender.
Install Turn Signal and Rear Docking Point
1. See Figure 3. Place the rear docking point (8) over the long threaded end of the new turn signal stalk (6) with the countersunk side facing the fender support.
2. Insert the stalk through the rear mounting hole in the fender support and fender. Apply Loctite 242 (blue) to the stud threads inside the fender.
3. Fasten a flat washer (9) and locknut (10) from the kit onto the turn signal stalk on the inside of the fender. With a wrench on the stalk's wrench flats, tighten the locknut to 16.3–24.4 N·m (12–18 ft-lbs).
4. Loosely install a jam nut (5), followed by a lock washer (4) onto the short threaded end of the turn signal stalk.
5. Place the recess cover (3) into position over the recess on the turn signal housing. Insert the wires from the reflector through the grommet into the turn signal housing, through the threaded hole and the recess cover, and into the turn signal stalk.
NOTE
Apply a drop of liquid soap to the wires to ease insertion through the stalk or use a thin wire to pull the wires through.
6. Route the wires through the stalk until they come out inside the fender
7. Screw the turn signal housing onto the stud. Be careful that the wires are not twisted or damaged as the stalk and housing are assembled. The lock washer will fit inside the hole in the recess cover. Hand tighten the jam nut against the lock washer.
8. While pulling the turn signal wires into the inside of the fender, guide the turn-signal socket and grommet into the housing.
9. Align the rear turn signal housing so that the lens, when installed, will be aimed rearward for proper visibility. While holding the turn signal housing in position, tighten the jam nut against the lock washer to 10.8–13.6 N·m (8–10 ft-lbs).
10. Install chrome hole plug (7) into the fender support hole previously used for the turn signal wire.
NOTE
To achieve a snug fit, the tines of the hole plug may need to be spread apart. Holding the cap end of the plug firmly, use a pliers to bend each of the tines outward slightly. Repeat as necessary to verify a snug fit.
Reconnecting the Turn Signal Wires
  1. Strip a 3/8 in. (9.5 mm) section of insulation from the ends of the four turn signal wires underneath the fender.
    2. NOTE
    Be sure to match the wire colors before splicing.
  2. See Figure 2. Insert the two black turn signal wires into opposite ends of a butt splice connector. Insert the two violet/brown wires into opposite ends of a second butt splice connector.
  3. Match the color of the butt splice connector with the color of the crimp cavity of the crimping tool. Crimp the wires into the connector.
  4. Repeat all the above procedures for the opposite side.
WARNING
Be sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)
  • Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/explosion resulting in death or serious injury.
  • Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed.
  • Always keep hands away from tool tip area and heat shrink attachment.
  1. Using the UltraTorch UT-100, Robinair Heat Gun with Heatshrink Attachment, or other suitable radiant heating device, heat the crimped splice to encapsulate the butt splice connection. Apply heat from the center of the crimp out to each end until the meltable sealant comes out of both ends of the connector.
  2. Install the turn signal bulbs into their sockets. Install the lenses to the turn signal housings.
1Stripped wire ends inserted into connector
2Wire ends crimped in connector
3Connector after heat has been applied
Figure 2. Sealed Butt Splice Connections
Final Assembly
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
WARNING
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)
  1. Connect the battery cables, positive cable first, then install the seat and check the turn signals for proper operation.
Maintenance
NOTE
In time, the docking points may wear causing the mating luggage rack or sideplates to become loose. The fit may be tightened using the following procedure.
  1. Loosen the docking hardware.
  2. Rotate the docking points clockwise approximately 45 degrees.
  3. Tighten the docking hardware to the appropriate torque values as indicated in the installation procedures.
  • This procedure can be repeated up to 3 times before replacement of the docking points is recommended.
SERVICE PARTS
Figure 3. Service Parts: Hardware Docking Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Docking point, front (2)
53683-96
2
Button head bolt, 3/8-16 x 2-1/4, chrome (2)
4154
3
Recess cover, turn signal (2)
68028-03
4
Lock washer, 5/16 inch (2)
7042
5
Jam nut, turn signal stalk (2)
68991-02
6
Stalk, turn signal (2)
53934-03
7
Hole plug, chrome (2)
56239-93
8
Docking point, rear (2)
53684-96A
9
Flat washer, 3/8 x 13/16 x 1/16 (4)
6701
10
Locknut, hex 3/8-16 (4)
7667
11
Wire connector, butt splice (4)
70585-93
Items mentioned in text, but not included in kit:
A
Center bolt location