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REV. 2005-04-04
FRONT DETACHABLE DOCKING KIT
GENERAL
DETACHABLE ACCESSORIES
Kit Number
For models using the following detachable accessories, complete these steps:
53803-06
Models
Table 1. DetachableAccessories
This kit fits all 1997 and later FL Touring models except
FLHTC/I Electra Glide Classic) and FLHTCUI (Ultra Classic
Electra Glide).
This kit also fits 1994 through 1996 models with additional parts
when installing Backrest Kit (52805-97A).
NOTES
Figure 1 shows the mounting locations for the Front Docking
Kit (53803-06) and Rear Docking Kit (53804-06).
These kits must be installed to allow for the proper mounting
of certain Detachable Harley-Davidson Genuine Motor
Accessories.
Description (Quantity)
Detachable Solo
53260-02
Detachable Passenger Sissy Bar
Upright (separate purchase of Kit
53660-05 is required)
52805-97A
Detachable Passenger Sissy Bar
Upright
52933-97A
Detachable Passenger Sissy Bar
Upright
52935-04
1.
Refer to the Service Manual and follow the instructions
given to remove the saddlebags.
2.
Remove fender support cover on side that has air fitting(s)
and save for installation.
3.
Remove air fitting(s) from bracket and discard bracket.
4.
Remove and discard existing screws (3) shown in Figure
2 from each side of the motorcycle. Save washer from
bottom screw for saddlebag bracket installation.
is000327
Part Number
Tour-Pak
is00343
1. Front Docking Kit (53803-06). Also Kit 53660-05
and 53658-05 for 1994-1996 Models.
2. Rear Docking Kit (53804-06).
Figure 1. Docking Point Locations
1
Additional Parts Required For 1994-1996 Models
Detachable Passenger Sissy Bar Upright (52805-97A)
accessory requires the purchase of kit 53660-05 (Figure 1,
item 1) and 53658-05, consisting of two 5/16-18 locknuts.
(Figure 1, item 2). These kits are available separately from
your Harley-Davidson Dealer.
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 8, Figure 9, and Table 3.
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1.
2.
3.
4.
Saddlebag support
Saddlebag bracket
Original equipment screws
Weld nut (not shown)
Figure 2. Original Equipment Screws (left side shown)
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NOTES
See Figure 1. The instructions and hardware used will differ,
depending upon whether the Front Docking Kit (53803-06) is
installed alone or with Rear Docking Kit (53804-06).
See Figure 8. The front docking-point mounting brackets (1)
are side-specific. The letters stamped near the lower holes
must face outward, and identify the front (F) and rear (R) positions.
12. Fasten air hose and fitting(s) as needed:
a.
For 1997-2001 models: Fasten two air fittings
through the lowest two holes (marked "F" and "R") in
the right-side bracket.
b.
For 2002 models: This model only has one air fitting,
which must be mounted in the hole marked "F" on
the right-hand side bracket.
c.
For 2003 and later models:
5.
Position the mounting bracket (1) on one side of the
motorcycle.
6.
Front Docking Kit Installed Alone. See Figure 8. Install
the mounting bracket as follows:
(2) Locate rearmost unused hole on underside of
fender strut, just in front of left shock.
a.
Install 5/16-18 x 1 in. (25 mm) long screw (8) in the
upper front hole.
(3) Use tie wrap to anchor air hose to this hole and
prevent it from getting kinked or pinched.
b.
Install 1/8 in. (3.2 mm) thick spacer (5) on each screw,
between the mounting bracket (1) and the original
equipment saddlebag support bracket (A).
(4) Re-install air hose to air valve, and install air valve
in hole marked "F" on left-hand side bracket.
c.
Finger-tighten both screws.
Front Docking Kit Installed With Rear Docking Kit. See
Figure 9. Install the mounting bracket as follows:
a.
7.
8.
(5) Add air to shock absorbers according to instructions in the Service Manual.
is00354
Install 5/16-18 x 1 in. (25 mm) long screw (8) from
front docking kit (53803-06) in the upper front hole of
bracket (1), and through front of bracket (B) from rear
docking kit (53804-06), placed between mounting
bracket (1) and original equipment saddlebag support
bracket (A).
b.
Install 5/16-18 x 2-1/4 in. (57 mm) long screw and
lockwasher (D), docking point (C), and 0.386 in. (9.8
mm) thick spacer (E) from rear docking kit (53804-06)
in the upper rear hole of bracket (B) from rear docking
kit (53804-06), placed between mounting bracket (1)
and original equipment saddlebag support bracket
(A).
c.
Finger-tighten both screws.
1. Air hose
2. Tie wrap
Install 1/4-20 screw (item 9, length is 1 in. or 7/8 in.
depending on model) and washer (previously saved)
through slot in saddlebag mounting bracket (G).
Figure 3. Air Hose Routing for 2003 and Later Models
For FLHR, FLHT, or FLTR models: See Figure 9. Insert
threads through bottom hole of mounting bracket (1), directly under screws previously installed.
13. See Figure 6, Figure 8, and Figure 9. Place a washer (6)
onto the threads of a button-head screw (4) from this kit.
Place a docking point (3), oriented as shown, over the
screw threads, followed by a spacer (5).
For FLHRC or FLHRS models: See Figure 9. Place 9/16
in. (14.3 mm) thick spacer (11) onto screw threads, and
insert threads through the bottom hole of mounting bracket
(1), directly under screws previously installed.
9.
(1) Remove left-side shock-absorber air hose from
air valve, and reroute it underneath top shock mount.
Place 1/8 in. (3.2 mm) thick spacer (10) onto screw
threads, and insert threads through saddlebag support
bracket (A) and into clip nut. Torque screw to 10-14 ft-lbs
(13.6-19.0 Nm).
10. Torque both upper screws to 15-19 ft-lbs (20.3-25.8 Nm).
11. Repeat Steps 5 through 10 for opposite side.
14. Insert screw threads as follows:
a.
For 1994-1996 models: Through rearmost hole (H)
in the mounting bracket (1).
b.
For 1997 and later models: Through frontmost hole
(H) in mounting bracket (1).
c.
Insert screw threads through larger hole in bracket
(53805-99, item K, part of Rack or Sissy Bar Upright
Kit) and fasten loosely in place with locknut (7). Leave
locknut slightly loose for docking-point adjustment in
the next step.
15. See Figure 4. Remove the existing Phillips screw (1) from
the hole directly behind the upper shock absorber
mounting bolt on side with frame cover still installed.
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(different detachables latch in different locations). Torque
fasteners to 45-47 ft-lbs (61.0-63.7 Nm).
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1
2
is00347
Y
1
5
3
6
4
1. Existing screw
2. Shock absorber mounting bolt
3. Fender support cover
3b
3a
Figure 4. Front Docking Point Locations
Figure 6. Proper Alignment of Latch in Docking Point
16. See Figure 8 and Figure 9. Obtain a docking point bushing
(14 or N), screw (12), and flat washer (13) from the kit.
17. Place the flat washer over the threads of the screw, followed by the bushing.
18. Re-install fender support cover previously removed using
docking point screw in place of Phillips screw.
19. Insert the screw threads through the smaller hole in
bracket 53805-99 (item A, part of the Solo Tour-Pak Rack
or Sissy Bar Upright Kit), and the chrome rear fender
support cover. Thread the screw into the weld nut in the
fender support (or nut (O) for 1994-96 models).
Table 2. Proper Alignment of Latch in DockingPoint
Item
Description (Quantity)
Numbers and letters are same as Service Parts List.
1
Mounting bracket
Docking point
3a Docking point neck
3b Raised surface of docking point
4
Button head screw
20. See Figure 5. Rotate the bushing notch (4) into the "correct" position (1).
Spacer
Flat washer
21. Tighten screw to 19 ft-lbs (26 Nm).
Locknut
22. Repeat steps 1 through 6 for opposite side.
Bracket from rack or upright kit
Items not in Service Parts list.
is00342
Luggage rack or sissy bar upright sideplate
Luggage rack or sissy bar upright latch
is00351
1
1.
2.
3.
4.
Correct installation
Incorrect installation
Rear shock absorber
Front docking point bushing notch
Figure 5. Position of Docking Point Notch
23. See Figure 6. Fasten detachable passenger backrest
uprights or luggage rack to docking points as described
in the instruction sheet for that accessory.
Push the forward notches of the accessory completely
into the docking points in position (1), then fasten the rear
notches into the docking points in appropriate position
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1. Front docking kit (53803-06)
2. Rear docking kit (53804-06)
3. Saddlebag support bracket
Figure 7. Front and Rear Docking Kits
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SERVICE PARTS
L
is00352
5
M
10
1
8
A
7
K
11
G
F
9
5
6
14 , N
13
12
4
H
2
J
R
F
Figure 8. Service Parts: Front Docking Kit Installed Alone
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is00353
L
B
M
10
1
E
7
K
11
D
14 , N
5
3
13
6
9
12
4
H
G
2
R
F
Figure 9. Service Parts: Front Docking Kit Installed with Rear Docking Kit (53804-06)
Table 3. Service Parts: Front Detachable DockingKit
Item
1
Description (Quantity)
Part Number
Mounting bracket, right side
53759-96B
Mounting bracket, left side (not shown)
53758-96C
Tie wrap
10073
Docking point (2)
53684-96A
Screw, button head, hex socket, 3/8-16 x 2 in. (51 mm) (2)
4215
Washer, hardened, 3/8 in. I.D., 1/8 in. (3.2 mm) thick (6)
6532
Flat washer, chrome, 3/8 in. I.D., 1/16 in. (1.6 mm) thick (2)
94067-90T
Hex locknut, Nylok, thin, 3/8-16 (2)
7667
Capscrew, hex head, 5/16-18 x 1 in. (25.4 mm) (4)
4017
Capscrew, hex head, 1/4-20 x 7/8 in. (22.2 mm) (2) (for all models except FLHRC/I and FLHRS/I) 3802W
Capscrew, hex head, 1/4-20 x 1-1/2 in. (38.1 mm) (2) (for models FLHRC/I and FLHRS/I)
2872W
10
Spacer, 1/4 in. I.D., 1/8 in. (3.2 mm) thick (2)
5735
11
Spacer, 1/4 in. I.D., 9/16 in. (14.3 mm) thick (2) (for models FLHRC/I and FLHRS/I)
5839
12
Screw, button head, hex socket, 5/16-18 x 1 in. (2)
94394-92T
13
Washer, flat (2)
94066-90T
14
Bushing, docking point - notched (2)
53123-96
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Table 3. Service Parts: Front Detachable DockingKit
Item
Description (Quantity)
Part Number
Items mentioned in text, but not included in kit:
A
Original equipment saddlebag support bracket
Rear docking-point bracket from Kit 53804-06
Docking point from Kit 53804-06
2-1/4 in. (57 mm) long button-head screw and lockwasher from Kit 53804-06
0.385 in. (9.8 mm) spacer from Kit 53804-06
Original equipment washer
Original equipment saddlebag mounting bracket
Notes:
H
The docking point on each side must be mounted in the front (forward) hole for 1997 and later models, and in the back
(rearward) hole for 1994 through 1996 models.
For 1997 through 2001 models, the two air fittings mount in the two bottom holes.
For 2002 models, mount the single air fitting in the front (forward) hole on the right-side bracket.
For 2003 and later, the air fitting must be relocated to the forward hole on the left-side bracket.
Bracket from Luggage Rack or Sissy Bar Upright Kit.
Locknut from kit 53658-05 (for 1994 through 1996 models).
Weld nut on saddlebag support bracket (A) (for 1997 and later models).
Weld nut on saddlebag support bracket (A).
Bushing, docking point - no notch (2) (from Kit 53660-05, for 1994 through 1996 models).
Nut (2) (from Kit 53660-05, for 1994 through 1996 models).
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