SOFTAIL TURN SIGNAL RELOCATION KIT

J026962011-05-27

GENERAL

Kit Number

53959-06, 54268-10

Models

For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).

Tools and Supplies Required

Proper installation of this kit requires the use of the following tools, available from a Harley-Davidson dealer:

ROBINAIR HEAT GUN (Part Number:HD-25070) , ULTRA TORCH UT-100 (Part Number:HD-39969) or equivalent
HEAT SHIELD ATTACHMENT (Part Number:HD-41183)
PACKARD CRIMPING TOOL (Part Number:HD-38125-8) or equivalent
FLAT BLADE L-HOOK (Part Number:HD-41475-100)

Loctite^® 243 Threadlocker and Sealant - Blue (H-D Part Number 99642-97) is available at a Harley-Davidson dealer.

WARNING

Rider 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)

NOTE

A service manual for this year/model motorcycle is available from a Harley-Davidson dealer.

Kit Contents

See Figure 6 and Table 1.

REMOVAL

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)

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)

Refer to the owner's manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware.

Raise the motorcycle on a floor jack to lower the rear wheel for fender hardware access.

See Figure 1. Remove two screws and tail lamp lens (1) from base (2).

1	Tail lamp lens
2	Tail lamp base

Figure 1. Remove Tail Lamp Lens

See Figure 2. Using a Terminal Pick Tool (1), press locking tabs and disconnect turn signal connectors (2-place, Items 2 and 3) from circuit board.

Feed turn signal wiring and connector through opening in circuit board assembly and into rear wheel area.

NOTE

FXST/S/B tail lamp and connectors are positioned 180° from orientation shown in Figure 2.

Reach under fender to locate clips fastening turn signal wires in place. Carefully pull wires out of clips, and pull turn signal connectors and wires out from under fender.

a. Remove 51 mm (2 in) section of conduit 102 mm (4 in) from turn signal connectors.

b. Cut black turn signal wire about 140 mm (5½ in) from its connector.

c. Cut violet/brown turn signal wire about 114 mm (4½ in) from its connector.

d. Save cut wires with respective turn signal connectors.

Remove the sissy bar and/or sideplate assembly, if equipped.

NOTE

Support the fender before removing the fender hardware to prevent scratching the fender paint.

1	Terminal pick tool
2	Left turn signal connector
3	Right turn signal connector

Figure 2. Remove Turn Signal Connectors

See Figure 3. Remove lens and bulb from each rear turn signal housing ( Figure 6 , Item A).

Carefully pry socket out of each housing to remove sockets and grommets.

1	Screw
2	Lockwasher
3	Turn signal housing support
4	Turn signal housing
5	Grommet
6	Socket
7	Bulb
8	Lens

Figure 3. Stock Turn Signal

10.

Gently pull wires out of turn signal housings.

11.

See Figure 4. Remove four middle and rear screws (1) from fender supports (5) on both sides of motorcycle.

12.

Loosen, but do not remove, two forward screws (2) from fender supports on both sides of motorcycle.

13.

Gently lift rear of fender enough to remove screws (3, 4) fastening turn signals to fender supports. Save turn signal housings for kit installation.

14.

Lower fender back into place. Loosely fasten screws (1) to fender support.

INSTALLATION

NOTE

Lightly apply liquid soap to the turn signal wires and use a thin wire to pull wires through stalk.

1.	Thread wires for each turn signal from turn signal socket through grommet ( Figure 3 ) and turn signal assembly ( Figure 6 ).
2.	See Figure 6. Route wires starting through threaded hole inside turn signal housing (A). NOTE The notch cut into the special nut must be installed between the fender and fender support, on the threads of the turn signal stalk, with the notched side of the special nut facing the fender and open toward the front of the motorcycle.
3.	See Figure 6. Route wires for each turn signal assembly through rearmost hole in fender support (B), through special nut (2), and inside fender. Allow about 152 mm (6 in) of wire between fender supports and turn signal sockets.
4.	Apply Loctite 243 - Blue to threads of stalks between fender and fender support.
5.	Thread each stalk into special nuts, taking care to maintain the position of the notch in the nut. Tighten each stalk (3) to 20.3 N·m (15 ft-lbs).
6.	See Figure 4. Tighten fender support screws (1) and (2) to 28–37 N·m (21–27 ft-lbs).
7.	See Figure 6. Loosely fasten jam nuts (4) onto stalks (3).
8.	Screw turn signal housings onto stalks while preventing turn signal socket wires from twisting.
9.	Align turn signal housing so lens, when installed, faces rearward for proper visibility.
10.	Tighten jam nut (4) against the housing to 11–13 N·m (96–120 in-lbs).
11.	While pulling turn signal wires into inside of fender, guide each turn signal socket and grommet into its respective housing.
12.	Install turn signal bulbs and lenses.
13.	Fasten hole plug (1) into remaining hole in fender support.

1	Screw (4)
2	Screw (2)
3	Screw (2)
4	Screw (2) (FLSTF and FLSTS models only)
5	Fender support (2)

Figure 4. Fender Support Hardware

SEALED SPLICE CONNECTIONS

1.	Strip 9.5 mm (⅜ in) of insulation from the cut ends of the turn-signal wires.
2.	See Figure 5. Splice each set of cut wires into sealed splice connectors. a. Connect black to black in one connector and violet/brown to violet/brown in other connector. b. Repeat splice for both left and right turn signal wire sets.
3.	Match color (red) of the sealed splice connector with color of crimp cavity on crimping tool. Use the Packard Crimping Tool or equivalent to crimp the wires into the connector. NOTE Always keep hands away from tool tip area and heat shrink attachment. Avoid directing the heat toward any fuel system component. Extreme heat can cause fuel ignition/explosion resulting in personal injury. Avoid directing heat toward electrical system components other than the connectors on which heat-shrink work is being performed. Be sure to turn the "ON/OFF" switch to the "OFF" position after use.
	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)
4.	See Figure 5. Using an Ultra-Torch, Heat Gun with Heatshield Attachment, or other suitable radiant heating device: a. Heat shrink the jacket of the sealed splice connector to the wire. b. Apply heat from the center of the crimp outward to the crimp ends until the sealant encloses both ends of the connector.

1	Stripped wire ends inserted into connector
2	Wire ends crimped in connector
3	Connector after heat has been applied

Figure 5. Sealed Splice Connectors

FINAL ASSEMBLY

1.	Fasten wires in conduit to clips inside fender.
2.	Route wires into tail lamp housing.
3.	Fasten turn signal wire connectors to their respective connections inside tail lamp housing.
4.	See Figure 2. Install tail lamp lens (1) on base (2) using two screws.
	WARNING Connect positive (+) 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. (00068a)
5.	Connect battery cables, positive (+) cable first.
	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)
6.	Check turn signals for proper operation.
	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)
7.	Install seat according to the instructions in the owner's manual.

SERVICE PARTS

Figure 6. Service Parts: Softail Turn Signal Relocation Kit

Table 1. Service Parts

Kit	Item	Description (Quantity)	Part Number
Kit 53959-06 Chrome	1	Hole plug, chrome (2)	53830-00
	2	Special nut, chrome (2)	68900-03
	3	Stalk, rear directional, chrome (2)	53960-06
	4	Jam nut, chrome (2)	68991-02
	5	Recess cover, chrome (2)	68028-03
Kit 54268-10 Black	1	Hole plug, black rubber (2)	Not sold separately.
	2	Special nut, black (2)	Not sold separately.
	3	Stalk, rear directional, black (2)	54269-10
	4	Jam nut, black (2)	7344
	5	Recess cover, black (2)	68864-10
Items common to BOTH kits	6	Lockwasher (2)	7042
Items common to BOTH kits	7	Sealed splice connector, #18-22 AWG (red) (4)	70585-93
Items mentioned in text, but not included in kit:
	A	Turn signal housing
	B	Fender support