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FXDWG DOCKING HARDWARE KIT
J025542011-06-15
GENERAL
Kit Number
53882-02B
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
A Packard Crimping Tool (Part No. HD-38125-8) is required for proper installation of this kit.
An UltraTorch UT-100 (Part No. HD-39969), Robinair Heat Gun (Part No. HD-25070) with Heatshrink Attachment (Part No. HD-41183), or other suitable radiant heating device is required for proper installation of this kit.
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
Preparation
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
  1. Refer to the service manual and follow instructions to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware.
Front Docking Point Installation
1. See Figure 3. Remove and save the fender support front screw.
2. Place the front docking point (2) all the way onto a new front screw (3), with the countersunk end of the docking point facing the fender support.
3. Fasten the screw through the fender support using a locknut (1). Tighten the screw to 28–37 N·m (21–27 ft-lbs).
Turn Signal Stalk and Rear Docking Point Installation
1. Reach under the fender to locate the fender clips fastening the turn signal wires in place. Carefully pull the wires out of the clips, then pull the wires out from under the fender.
2. Remove the cable strap located near the rubber grommet on the upper inside of the rear fender.
3. From each set of turn signal wires hanging from under the fender, remove a 51 mm (2 in) section of conduit from an accessible area of the wire.
4. Cut the wires in the middle of the area where the conduit was removed.
5. See Figure 1. Remove the lens (5) from the turn signal housing (1).
6. Remove the bulb (4) from the socket (3).
1Housing
2Grommet
3Reflector/Socket
4Bulb
5Lens
6Support
7Washer
8Bolt
Figure 1. Removing Stock Turn Signal Stalk
7. Remove and discard the bolt (8) and lockwasher (7), from inside the fender, fastening the rear turn signal housing and support (6) to the fender support.
8. Gently pull the turn signal housing, support, and wires away from the fender support until the cut ends of the wires, from within the fender, exit out the fender support.
9. Remove and discard the fender support rear bolt.
10. See Figure 3. Slide a rear docking point (11) over the long end of a turn signal stalk (9) with the countersunk side of the docking point facing the fender support.
11. Fasten the turn signal stalk through the rearmost hole in the fender support and into the license plate bracket. Tighten to 16–24 N·m (12–18 ft-lbs).
12. Thread the jam nut (8), oriented as shown, all the way onto the end of the turn signal stalk.
13. Route the turn signal wires through the turn signal housing threaded hole, recess cover (6), lockwasher (7), turn signal stalk (9) until they hang a couple inches into the fender. Allow the turn signal socket to hang a few inches outside the turn signal housing.
14. Screw the turn signal housing onto the stalk while preventing the turn signal socket wires from twisting.
15. Align the rear turn signal housing so the lens, when installed, faces rearward for proper visibility. Tighten to 11 N·m (96 in-lbs).
16. While pulling the turn signal wires into the inside of the fender, guide the turn signal socket into its housing.
17. Install the turn signal bulb and lens.
18. Fasten the stock fender support front screw, removed during front docking point installation, to the second from last hole in the fender support. Secure the screw from inside the fender using a thin locknut (12). Tighten to 30 N·m (22 ft-lbs).
NOTE
For a snug hole plug fit, spread apart the hole plug tines before installing the plug.
19. Install a chrome hole plug (10) in the fender support hole previously used for turn signal wires.
Sealed Splice Connections
  1. Strip 10 mm (⅜ in) of insulation from the cut ends of the turn signal wires.
  2. See Figure 2. Insert one stripped end of each same colored turn signal wire into opposite ends of a butt splice connector. Connect black to black in one connector, and violet/brown to violet/brown in the other connector.
  3. Match the color of the sealed splice connector with the color of the crimp cavity on the crimping tool. Use crimping tool HD-38125-8 or equivalent to crimp the wires into the connector.
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.
  • Always keep hands away from tool tip area and heat shrink attachment.
  1. Use an UltraTorch UT-100 (HD-39969), Robinair Heat Gun (HD-25070) with Heatshrink Attachment (HD-41183), or other suitable radiant heating device to heat shrink the jacket of the sealed splice connector to the wire. Apply heat from the center of the crimp outward to the crimp ends until the sealant encloses both ends of the connector.
  2. Repeat the installation procedures on the other side of the motorcycle.
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
1. Fasten the wires to the clips inside the fender.
2. Connect the negative battery cable to the battery.
WARNING
Be 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)
3. Check the 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)
4. See the owner's manual and install the seat.
Maintenance
NOTE
In time docking points may wear, causing the mating luggage rack or sideplates to become loose and rattle. The fit may be tightened using the following procedure.
  1. If desired, mark each docking point to indicate the current top position.
  2. Remove the docking hardware.
  3. Thoroughly remove all existing threadlocking agent from the docking point fastener and mounting hole threads before applying new Loctite 243 - Blue to the screw threads.
  4. Rotate the docking points clockwise approximately 45 degrees from the previous position.
  5. Tighten the docking hardware to the torque value 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: FXDWG Docking Hardware Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Locknut, thick, 3/8-16 (2)
7778
2
Docking point, front (2)
53683-96
3
Screw, button head 3/8-16x2-1/4 (2)
4154
4
Turn-Signal Recess Cover Service Kit (includes items 5 through 7)
68000-02
5
  • Connectors, sealed splice (4)
70585-93
6
  • Recess cover (2)
Not Sold Separately
7
  • Lockwasher (2)
7042
8
Jam nut
68991-02
9
Turn signal mount
53934-03
10
Chrome hole plug (2)
56239-93
11
Docking point, rear (2)
53684-96A
12
Locknut, thin, 3/8-16 (2)
7667
Items mentioned in text, but not included in kit:
A
Turn signal housing (stock)
B
Screw, 3/8-16 (stock)