TURN SIGNAL RELOCATION KIT
J014792011-07-05
GENERAL
Kit Number
53820-00, 53859-02
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
LOCTITE® 243 Threadlocker and Sealant (blue) P/N 99642-97
Kent-Moore Crimping Tool P/N HD-38125-8 or equivalent
UltraTorch UT-100, Kent-Moore P/N HD-39969, Robinair Heat Gun P/N HD-25070 with Heatshrink Attachment P/N HD-41183 or other suitable radiant heating device.
WARNINGRider 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.
REMOVAL
NOTE
Models with a Softail Wide Tire Kit will utilize the hardware found in that kit.
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
| 1. | Remove the seat and disconnect the battery negative cable. | |||||||||||||
| 2. | Remove the two screws and lens from the tail lamp. | |||||||||||||
| 3. | See Figure 1 and Figure 2. Press the lock tabs (1) on the turn signal connectors, (2) and (3), with a terminal pick or small screw driver, and unplug the connectors. | |||||||||||||
| 4. | Push the turn signal connectors and wires through the openings on each side of the tail lamp base. | |||||||||||||
| 5. | Reach under the fender and locate the fender clips that hold the turn signal wires in place. Carefully pull the wires out of the clips and pull the turn signal connectors and wires out from under the fender. | |||||||||||||
| 6. | Push back the plastic conduit at the turn signal connectors and cut one turn signal wire approximately 1-1/2 inches (3.8 cm) from the connector. Cut the other wire about 2-1/2 inches (6.4 cm) from the connector. This allows "staggering" butt connectors so the conduit can be slipped over them. 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. | |||||||||||||
| 7. | Save the turn signal connectors with the short wires for later reinstallation. Pull the vinyl conduit off the turn signal wires and save. | 
Figure 1. Turn Signals-FLSTF, FLSTS Models 
Figure 2. Turn Signals-FXST, FXSTB, FXSTS Models |
Removing Turn Signal Support
Remove the turn signal lamps and lamp supports from the fender support brackets as follows:
For FXST/S/B Models:
NOTE
When removing the sissy bar, if so equipped, make sure the sissy bar does not contact the fender or the fender paint will be scratched.
- Remove the sissy bar/sideplate assembly, if so equipped.
- See Figure 3. Remove the two TORX® screws (1). Loosen, but do not remove screw (2). Repeat for opposite side.
NOTE
Support the fender before removing the fender hardware to prevent scratching of the fender paint.
| 1 | TORX Screw (2) |
| 2 | TORX Screw |
| 3 | Chrome hole plug (from kit) |
| 4 | Stock screw and washer |
| 5 | Stock screw and washer |
| 6 | Hole to be Plugged |
Figure 3. Hardware for FXST/S/B
| 1 | TORX Screw |
| 2 | TORX Screw |
| 3 | Chrome hole plug (from kit) |
| 4 | Stock screw and washer |
| 5 | Hole used as Drilling Template |
| 6 | Hole to be Plugged |
Figure 4. Hardware for FLSTF and FLSTS
- Being careful not to scratch the fender paint or damage the turn signal wires, gently lift the rear of the fender until the screws and washers (4) that hold the turn signal lamp supports in place can be removed. Remove the lamps and supports, then pull the turn signal wires through the fender holes. Discard the supports, screws and washers.
- Remove the two bolts (5) that attach the fender to the license plate bracket, and discard the bolts.
For FLSTF and FLSTS Models:
NOTE
Support the fender before removing the fender hardware to prevent scratching of the fender paint.
| 1. | See Figure 4. Remove the two TORX screws (1). The rear TORX screws (1) have washers and nuts inside fender (outside with Wide Tire Kit). Loosen, but do not remove, screw (2). Repeat for opposite side. | |
| 2. | Being careful not to scratch the fender paint or damage the turn signal wires, gently lift the rear of the fender until the bolts and washers (4) that hold the turn signal lamp supports in place can be removed. Remove the lamps and supports, then pull the turn signal wires through the fender holes. Discard the supports, bolts and washers. NOTE Apply masking tape to the area to be drilled to reduce the chance of paint damage. | |
| 3. | Carefully lower the fender into its correct position between the fender supports, lining up the holes used by bolts (1) and the original wire holes. Mark the fender on both sides of the bike using the rearmost fender support hole (5) as a template. | |
| WARNING Do not contact tire with drill bit when drilling fender holes. Drill bit contact with tire can lead to premature tire failure, which could result in death or serious injury. (00403f) | ||
| 4. | Carefully raise the fender and drill an 11/32 inch hole through each side of the fender in the marked locations. NOTE To prevent corrosion, apply a small amount of silicone sealant to the drilled-hole surfaces before installing the turn signal stalks. |
INSTALLATION
Installing Turn Signal Stalks
NOTE
Complete the following procedure on one side of the motorcycle before starting the other side.
WARNINGButton head screws from wide tire kit must be installed with button heads on inside of fender. Fastener contact with tire can lead to premature tire failure, which could result in death or serious injury. (00417b)
NOTE
Models with a Softail Wide Tire Kit will utilize the hardware found in that kit. The Wide Tire Kit Hardware will re-orient fasteners to come from the inside out.
| 1. | See Figure 3 and Figure 4. Install screws (1), but do not tighten. | 
Figure 5. Removing Stock Turn Signal Stalk | ||||||||||||||||
| 2. | See Figure 5. Remove lens (5) from rear turn signal housing (1). Remove bulb (4) from the socket of reflector (3). | |||||||||||||||||
| 3. | Carefully pry the reflector and grommet (2) from the housing. Gently pull the wires from the smooth hole in the housing and route them back out of the housing through the threaded hole. |
NOTE
The turn signal will be mounted in the rearmost fender support hole.
| 4. | See Figure 7. Thread jam nut (4) on stud and place the nylon washer (5) over stud (3). Route turn signal wires through stud (3). 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. | |
| 5. | Gently thread stud (3) into turn signal housing. Be careful not to twist wires as stud (3) and turn signal housing are assembled. | |
| 6. | For FXST/S/B Models: Route wires through rearmost hole in fender support bracket (C), spacer (7), fender hole and license plate bracket (A). For FLSTF and FLSTS Models: Route wires through rearmost hole in fender support bracket (C), spacer (7) and fender hole. | |
| 7. | For FXST/S/B Models: Apply Loctite 243 (blue) to the threads of the turn signal stalk. Thread the stalk into the threaded hole in the license plate bracket. Do not twist or damage the wires while the turn signal assembly is rotated. Tighten the stalk with a wrench on the stalk flats to 20.3 N·m (15 ft-lbs). For FLSTF and FLSTS Models: Apply Loctite 243 (blue) to the threads of the turn signal stalk. Install the stalk into the rearmost hole and secure with washer (8) and locknut (9) from kit. Tighten the stalk with a wrench on the stalk flats to 20.3 N·m (15 ft-lbs). | |
| 8. | See Figure 3 and Figure 4. One at a time, remove and install screws (1 and 2), one at a time. a. Remove screw. b. Clean threads of any old threadlocker material. c. Apply a small amount of Loctite 243 (Blue) to the screw threads. d. Install screw. e. Repeat for each screw (1 and 2). | |
| 9. | Tighten screws (1) and (2) to 28–37 N·m (21–27 ft-lbs). NOTE Models with a Softail Wide Tire Kit will utilize the hardware found in that kit. The Wide Tire Kit Hardware will re-orient fasteners to come from the inside out. | |
| WARNING Button head screws from wide tire kit must be installed with button heads on inside of fender. Fastener contact with tire can lead to premature tire failure, which could result in death or serious injury. (00417b) | ||
| 10. | Align turn signal to the proper position and lock it by gently turning jam nut (4) outward against nylon washer (5). | |
| 11. | Install rubber hole plug (2) in old turn signal housing harness hole. | |
| 12. | Install turn signal bulb and lens. NOTE For 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 for a snug fit. | |
| 13. | Install chrome hole plug (6) into the fender support hole previously used for the turn signal wire. | |
| 14. | Repeat procedure for the opposite side of the motorcycle. |
Reconnecting Turn Signal Wires
| 1. | Strip a 3/8 inch (9.5 mm) section of insulation from the ends of the four turn signal wires underneath the fender. NOTE Before splicing the wires, slide the conduit saved earlier over the turn signal wires running from the lamps. NOTE Be sure to match the wire colors before splicing. | |||||||
| 2. | See Figure 6. 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 connector. | 
Figure 6. Installed Sealed Butt Connectors | ||||||
| 3. | Match the color of the butt splice connector with the color of the crimp cavity of the crimping tool (Kent- Moore Part Number HD-38125-8 or equivalent). Crimp the wires into the connector. |
WARNINGBe 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.
| 4. | Using the UltraTorch UT-100 (Kent-Moore Part Number HD-39969), Robinair Heat Gun (HD-25070) with Heatshrink Attachment (HD-41183), 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. | |
| 5. | Route the harness back under the fender and slip the 2-place connectors through the openings in the tail lamp. | |
| 6. | Plug the connectors into the tail lamp as shown in Figure 1 or Figure 2. | |
| 7. | Reach under the fender and insert the harnesses into the fender clips that hold the turn signal wires in place. | |
| 8. | Install the tail lamp lens with two mounting screws. | |
| 9. | Connect the battery negative cable. | |
| 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) WARNINGBe sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury. (00478b) | ||
| 10. | Install seat and check the turn signals for proper operation. |
SERVICE PARTS
Figure 7. Service Parts: Turn Signal Relocation Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Connector, wire butt splice (4) | 70585-93 |
2 | Hole plug, rubber (2) | 58758-93 |
3 | Stalk, turn signal (2) (Kit No. 53820-00) | 68999-00 |
Stalk, turn signal (2) (Kit No. 53859-02) | 53664-02 | |
4 | Jam nut, turn signal stalk (2) (Kit No. 53820-00) | 68424-89 |
Jam nut (2) (Kit No. 53859-02) | 68991-02 | |
5 | Washer, nylon (2) | 54319-85 |
6 | Hole plug, chrome (2) (Not Shown) | 53830-00 |
7 | Spacer (2) | 59857-00 |
8 | Washer, plain (2) (for use with FLSTF and FLSTS only) | 6702 |
9 | Locknut, 5/16-18 (2) (for use with FLSTF and FLSTS only) | 7739 |
Items not included in kit | ||
A | License plate bracket (FXST/S/B only) | |
B | Fender | |
C | Fender support bracket | |
D | Turn signal housing | |