DIRECTIONAL RELOCATION KIT - Harley
Contents
1. A Left side installed orientation shown B Fender support bracket C Stock screws D Wrench flats on stud E Stock turn signal housing J02427 4of42. 10 See Figure 2 Remove the lens and bulb from each rear turn signal housing 11 Carefully pry the socket out of each housing to remove the sockets and grommets 12 Gently pull the wires out of the turn signal housings 13 See Figure 4 Remove the four mid and rear screws 2 from the fender support brackets on both sides of the motorcycle 14 Loosen but do not remove the two forward screws 3 from the fender support brackets on both sides of the motorcycle 15 Gently lift the rear of the fender enough to remove the screws 4 fastening the turn signals to the fender sup ports Save the turn signal housings for installation 16 Lower the fender back into place Loosely fasten the screws 2 to the fender support NOTE Apply liquid soap to the turn signal wires and use a thin wire to pull wires through stud 17 For each turn signal thread the wires from the turn signal socket through the grommet as shown in Figure 2 and turn signal assembly as shown in Figure 6 Route the wires starting through the threaded hole inside the turn signal housing NOTE The notch cut into the special nut must be installed between the fender and fender support on the threads of the turn signal stud and with the notched side of the special nut facing the fender and open toward the front of the motorcycle 18 See Figure 3 and Figure 6 Route the wires for each turn signal assembly through the rearmost hole in the fender support
3. bracket then through the special nut 7 and to the inside of the fender Allow about 6 inches 150 mm J02427 of wire between the fender supports and the turn signal sockets isO1 RD Turn signal housing Threaded hole Turn signal recess cover Lock washer Hex jam nut Turn signal stud AO OR NS Wiring exit hole Figure 3 Rear Turn Signal Assembly To Stud 19 Route the turn signal wires in the following sequence a See Figure 3 Insert the wires from the turn signal housing through the wiring exit hole 7 and b see Figure 3 through the threaded hole 2 in the housing 1 from the inside c Position the recess cover 3 against the recess in the turn signal housing with the wires coming through the hole d Insert the wires into the end of the turn signal bar 6 and out the wire hole a short distance from the end of the bar 20 Screw the turn signal housing onto the threaded end of the turn signal stud being careful that the wires are not twisted or damaged as the housing is assembled to the bar The lock washer will fit inside the hole in the recess cover Hand tighten the jam nut against the lock washer 21 Apply Loctite 243 blue to the stud threads between the fender and fender support 22 Thread each stud into the special nuts taking care to maintain the position of the notch in the note described above Torque each stud 6 to 18 22 ft lbs 24 30 Nm 2 of 4
4. is01038 1 Fender support bracket 2 Screws 3 Forward screws 4 Turn signal screws 5 On FLSTF FLSTS only Figure 4 Hardware Removal 23 See Figure 4 Torque the fender support screws 2 and 3 to 21 27 ft lbs 28 37 Nm 24 See Figure 6 Loosely fasten the jam nuts 5 and washers 4 onto the studs 6 25 Screw the turn signal housings onto the studs while pre venting the turn signal socket wires from twisting 26 Align the rear turn signal housing so the lens when installed faces rearward for proper visibility Torque the jam nut 5 against the housing to 96 120 in Ibs 11 13 Nm 27 While pulling the turn signal wires into the inside of the fender guide each turn signal socket and grommet into its housing 28 Install the turn signal bulbs and lenses 29 Fasten a chrome hole plug 1 into the remaining hole in the fender support Butt Splice Connections 1 Strip 3 8 inch 10 mm of insulation from the cut ends of the turn signal wires 2 See Figure 5 Splice each set of cut wires into butt splice connectors Connect Black to Black in one connector and Violet Brown to Violet Brown in the other connector Repeat the splice for both left and right turn signal wire sets 3 Match the color of the butt splice connector with the color of the crimp cavity on the crimping tool Use the crimping tool Kent Moore Part Number HD 38125 8 or equivalent to crimp the wires into the connector
5. J02427 is01037 MY MY 1 Stripped wire ends inserted into connector 2 Wire ends crimped in connector 3 Connector after heat has been applied Figure 5 Sealed Butt Splice Connections 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 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 explo sion resulting in personal injury Avoid directing heat toward electrical system compo nents 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 See Figure 5 Use an UltraTorch UT 100 HD 39969 Robinair Heat Gun Kent Moor Part Number HD 25070 with Heatshrink Attachment HD 41 183 or other suitable radiant heating device to heat shrink the jacket of the butt 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 FINAL ASSEMBLY 1 2 3 Fasten the wires in conduit to the clips inside the fender Route the wires into the tail lamp housing Fasten the turn signal wire connector
6. cMOTOR HARLEY DAVIDSON WY J02427 INSTRUCTIONS REV 2002 07 17 DIRECTIONAL RELOCATION KIT GENERAL Kit Number 53933 03 Models This kit relocates the rear turn signals on 2003 and later Softail model motorcycles except FXSTD and FLSTC models Additional Parts Required WARNING The rider s safety depends 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 00333a 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 Loctite 243 blue Part Number 99642 99 is available from a Harley Davidson Dealer Kit Contents See Figure 6 and Table 1 INSTALLATION IWIN NIN To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a 1 Remove the seat according to service manual instructions 2 Disconnect battery cables negative cable first 3 Raise the motorcycle on a floor jack to lower the rear wheel for fender hardware access 4 See Figure 1 Remove the screws fastening the lens to the tail lamp 5 Ins
7. ide the tail lamp assembly use a terminal pick or small screw driver to press the locktabs on and unplug the connectors on black and violet brown turn signal wires J02427 isO1051 FLSTF FLSTS model tail light Lock tabs Left turn signal connector Right turn signal connector SN FXST FXSTB FXSTS model tail light Figure 1 Turn Signal Connectors 6 Remove the turn signal connectors and wires through the openings on each side of the tail lamp base 7 Reach under the fender to locate the fender clips fastening 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 8 On each set of turn signal wires hanging from under the fender e Remove a 2 inch 51 mm section of conduit 4 inches 100 mm from the turn signal connectors e Cut the black turn signal wire about 5 1 2 inches 140 mm from its connector e Cut the violet brown turn signal wire about 4 1 2 inches 114 mm from its connector e Save the cut wires with their turn signal connectors 9 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 of 4 is01040 Screw Lockwasher Turn signal housing support Turn signal housing Grommet Socket Bulb Lens ONOgTPena Figure 2 Stock Turn Signal Removal
8. s to their respective connections inside the tail lamp housing Install the tail lamp lens Tighten to 20 24 in Ibs 2 3 2 7 Nm 3 of 4 IWIN NIN 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 the battery cables to the battery positive cable first AWARNING 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 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 7 Install the seat according to the service manual instruc tions SERVICE PARTS is01036 e G s Figure 6 Service Parts Directional Relocation Kit Table 1 Service Parts Table Item Description Quantity Part Number 1 Chrome hole plug 2 53830 00 2 Butt splice wire connector 18 22 ga 4 70585 93 3 Recess cover 2 68000 02 4 Lockwasher 2 7042 5 Jam nut 2 68991 02 6 Rear directional stud 2 53663 03 7 Nut special 2 68900 03 Items shown but not included in kit
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