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DYNA DOCKING HARDWARE KIT
J006612011-02-28
GENERAL
Kit Number
53527-95B
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.
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. Remove the center bolt from the fender support. This will be the location for the front docking point. The rear docking point will mount at the rear hole on the fender support bracket along with the turn signal.
4. Place the countersunk side of the front docking point (2) so that it faces towards the fender support. Insert the bolt (1) through the docking point (2) and into the fender. Then install the washer (8) and locknut (11) on the inside of the fender. Tighten to 37 N·m (27 ft-lbs).
1Lens
2Directional housing
3Bulb
4Housing support
5Screw, lens (2)
6Bolt and lockwasher
Figure 1. Remove Stock Stalk
Installing Kit Turn Signal Stalks and Rear Docking Point
1. See Figure 1. Remove lens (1) from rear turn signal housing (2). Remove bulb (3) from directional housing socket.
2. Trace turn signal wires routing along underside of rear fender. Remove cable strap located on topside of rear fender near the rubber grommet. Bend internal fender clips outward. Do not remove wires from the clips. Gently pull all excess wire rearward along underside of fender and into turn signal housing to allow for additional length of wire within turn signal housing. Bend fender clips back into place.
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. Cut wires within turn signal housing about 3 in. away from point where wires connect to the bottom of the bulb socket. From underside of fender, withdraw end of wires that are within turn signal housing support (4) into the inner fender area.
4. Remove and discard 5/16 in. bolt and lockwasher (6) securing rear turn signal to fender. Bolt and washer are located on inside of fender.
5. See Figure 3. Install lockwasher (4) and rear turn signal housing onto short threaded end (5/16-24 x 3/8 in.) of turn signal stalk (5) from kit. Tighten securely. Take care to avoid scratching or marring component chrome finish.
6. Insert the wires through locknut (10), washer (8) and through the rear hole of the fender support.
7. Remove and discard the vinyl conduit on the turn signal wires back to the fender support. Be careful not to cut the turn signal wires.
8. Place the rear docking point (3) on the long threaded end of turn signal stalk (5) so that the countersunk side will face the fender support. Insert the turn signal wires through the long threaded portion of the turn signal stalk (5). If the wires bind inside the turn signal stalk (5), apply a drop of liquid dish soap on the end of the wires and insert again. Wipe off excess dish soap from the turn signal wires. Insert rear turn signal stalk through rear mounting hole in rear fender support, and rear fender.
9. Install flat washer (8) and locknut (10) onto turn signal stalk on inside of rear fender. Tighten finger-tight.
10. Align rear turn signal housing so that its lens, when installed, will be aimed rearward for proper visibility. While holding turn signal housing in position, tighten locknut to 30 N·m (22 ft-lbs) .
11. Install chrome hole plug (6) in fender support hole previously used for turn signal wire. In order to achieve a snug fit, the tines of the hole plug may have to be spread apart. To spread the tines, hold the cap end of the plug firmly and using a pliers, bend each of the tines outward slightly. Repeat this as necessary to achieve 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.
  2. Install seat.
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 three times before replacement of the docking points is recommended.
SERVICE PARTS
Figure 3. Service Parts: Dyna Docking Hardware Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Bolt, button head, 3/8-16 x 2-1/4 in (2))
4154
2
Docking point, front (2)
53683-96
3
Docking point, rear (2)
53684-96A
4
Lockwasher (2)
94081-90T
5
Stalk, turn signal (2)
53698-96
6
Plug, hole, chrome (2)
56239-93
7
Plug, hole, rubber (2)
58758-93
8
Washer, 3/8 x 13/16 x 1/16 in (4)
6701
9
But splice wire connectors (4) (not shown)
70585-93
10
Locknut, hex 3/8-24 (2)
7776W
11
Locknut, hex 3/8-16 (4)
7778
Items mentioned in text, but not included in kit:
A
Fender support
B
Turn signal housing