0/0
ADVANCED AUDIO INTERCOM KIT
J036522013-01-30
GENERAL
Kit Number
76440-06
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
NOTE
Even if this kit is not being installed by a Harley-Davidson dealer, the intercom software flash ( purchased separately) must be performed on the radio installed on the motorcycle at the dealer before the kit is installed.
ALL models will require the additional purchase of EITHER:
  • a Premium Stereo Helmet Headset (Part Number 77147-98) OR
  • a Hand-Held CB Microphone Kit (Part Number 76312-98)
Additional equipment will be required for proper installation of this Intercom Kit on your model motorcycle. See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
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
Table 1. Kit Contents
Description (Quantity)
Part Number
Passenger Headset Harness
Not Sold Separately
Tie wrap (10)
10006
INSTALLATION
  1. Have a Harley-Davidson dealer perform the intercom software flash ( purchased separately) to the previously installed AM/FM/CD Radio.
  2. Refer to the Service Manual and follow the instructions given to remove the seat and the left-side saddlebag.
  3. Follow the instructions in the Service Manual to remove the maxi-fuse.
  4. See Figure 1. Obtain the passenger headset harness (5) from the kit. With the headset receptacle (6) facing forward, capture the receptacle in the bracket on the underside of the left-side rear speaker housing.
  5. If the Advanced Audio High-Output Amplifier is installed under the Tour-Pak: Grasp the tie strap (7) on the end of the Vinyl spring sleeve (8), and use a tie strap from the kit to fasten the end of the spring to the lower left slot on the license plate holder. If stronger headset receptacle retention is desired, the spring assembly in the kit can be replaced with spring assembly 76300-06 (purchased separately). If no Amplifier is installed: Grasp the tie strap (7) on the end of the Vinyl spring sleeve (8), and hook the sleeve and the end of the spring onto the tab at the upper right of the license plate holder.
  6. Route the harness forward on the vehicle:
    1. along the left-side Tour-Pack support. Use a tie strap from the kit to fasten the harness to the support.
    2. Continue forward, tucking the harness inboard of the frame tube and avoiding the forward saddlebag guard mounting screw head so the harness does not get pinched by the seat. Use four tie straps from the kit to fasten the harness to the frame tube.
    3. Route the harness along the left side of the battery cavity and harness tray to the rear of the fuel tank.
135-place socket housing [28] to AM/ FM radio
26-place pin housing [6A], labelled "Interconnect"
38-place pin housing [76] to passenger headset
412-place pin housing [53] to console pod
5Passenger headset harness
6Rear headset receptacle
7Tie strap on spring and sleeve end
8Spring sleeve
98-place socket housing
Figure 1. Harness Connections
NOTE
If not already installed, the Fairing Speaker Switch and Left-Hand Control Switch Assembly (purchased separately, individually or as part of the Communication Switch Kit) must be installed at this time according to the instructions that follow.
  1. On the fairing cap, remove the inner left side hole plug. See the FAIRING CAP SWITCHES (FLHTC/U) section in the Service Manual. Install the fairing speaker switch in the opening as follows: If a cruise control switch IS present: See FAIRING CAP SWITCHES (FLHTC/U) in the Service Manual. Install the Fairing Speaker Switch (purchased separately or as part of the Communication Switch Kit) in the opening and connect the wiring already there. If a cruise control switch IS NOT present:
    1. Obtain the speaker switch adapter wire (purchased separately or as part of the Communication Switch Kit) and the butt splice connector included with the speaker switch.
    2. Refer to SEALED BUTT SPLICE CONNECTORS in the Service Manual. Splice the adapter wire to the black/green speaker switch lead.
    3. Insert the terminated end of the adapter wire into cavity 12 of the fairing cap switch connector [105B]
  2. Remove the original equipment left-hand control switch assembly per the HANDLEBAR SWITCHES, REMOVAL, LEFT HANDLEBAR CONTROLS instructions in the Service Manual.
  3. Install the new left-hand control switch assembly (purchased separately or as part of the Communication Switch Kit).
  4. Remove the outer fairing and windshield. Refer to OUTER FAIRING/WINDSHIELD REMOVAL in the Service Manual.
INSTALLATION (Continued)
1. ALL models: Install the Console Pod Assembly.
a. Note the routing of the main harness, fuel level sender/fuel pump conduit, and fuel vapor vent tube as they travel beneath the console.
b. Carefully cut the anchored cable strap securing the main harness, fuel level sender/fuel pump conduit, and fuel vapor vent tube to the left side of the frame backbone.
c. Open the fuel door on the console. Remove the two Allen head screws inboard of the rubber bumpers. These screws secure the console to the clip nuts on the canopy bracket. All models EXCEPT FLHX: Remove the Allen head screw to detach the flange at the rear of the console from the clip nut on the fuel tank weldment. FLHX models: Remove the bolt (with flat washer) at the rear of the fuel tank to release the console bracket. This also frees the rear of the tank from the frame backbone. Remove the two screws that fasten the fuel door to the console, and remove the door. Remove the hinge mounting clip, and the hinge pin. Save these parts for installation.
d. Lay a clean shop towel on the forward part of the rear fender. Remove the filler cap from the neck of the fuel tank. All models EXCEPT FLHX: Remove the console and lay it upside down on the shop towel. Install the filler cap. FLHX models: Remove the console and discard it. Install the filler cap. Obtain the new fuel tank console ( purchased separately). Install the fuel door to the new console, and tighten securely. Lay the console upside down on the shop towel. Install the bolt (with flat washer) to secure the rear of the fuel tank to the frame backbone. Tighten the bolt to 15-20 ft-lbs (20-27 Nm).
e. Feed the pin housing and console pod conduit through the top of the console, seating the Console Pod Assembly ( purchased separately) in the recess. Install three Phillips screws ( purchased separately) from the underside to secure the pod to the console. Alternately tighten the screws to 0.7–1.2 N·m (6–11 in-lbs). Route the pod harness toward the front of the console.
WARNING
Do not kink or pinch the fuel overflow line when installing console. A blocked line can cause an overfilled tank to leak. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00264a)
NOTE
Make sure the rubber molding (new rubber molding 71294-89 for FLHX models) on the bottom of the console is seated properly along its entire length.
FLHX models: Mount the adhesive-backed metal wire clip (Part Number 10103) to the underside of the console to hold the pod harness and Intercom harness.
Mount the plastic wire clip (Part Number 10120) to the underside of the console to hold the fuel vapor vent tube.
  1. Install the console to the tank.
    1. Remove the filler cap. Place the console over the filler neck onto the canopy. Route the Intercom harness forward under the left rear edge of the console. Route the cables from beneath the console in the same way as installed originally. Route the pod harness and Intercom harness forward along the left side of the fuel tank canopy and out under the left front edge of the console. Be sure that the hoses and wires are not pinched by the console during installation. Install the filler cap.
    2. All models EXCEPT FLHX: Install the Allen head screw removed earlier to fasten the rear flange of the console to the clip nut on the fuel tank weldment. FLHX models: Install the 1/4-20 clip nut ( purchased separately) onto the bracket on the fuel tank. Install the console extension ( also purchased separately) onto the rear of the console with the button-head screw ( purchased separately) and staked nut. ALL models: Tighten the screw to 25-30 in-lbs (2.8-3.4 Nm).
    3. Open the fuel door on the console. Install the two Allen head screws to secure the front of the console to the clip nuts on the canopy bracket. Alternately tighten the screws to 25-30 in-lbs (2.8-3.4 Nm).
    4. Snap the anchor of a cable strap from the kit into the hole on the left side of the frame backbone. Tighten the cable strap capturing the main harness, Intercom harness, fuel level sender/fuel pump conduit, and fuel vapor vent tube. Cut any excess cable strap material.
    5. Route the pod harness and Intercom harness down tight to the fuel tank and tie wrap tight to the main harness, as close to the fuel tank as possible.
    6. Continue the harnesses forward into the fairing, using tie wraps to fasten to the main harness.
WARNING
Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a)
  • Be sure wires do not pull tight when handlebars are turned fully to left or right fork stops.
  1. Obtain the overlay harness (purchased separately), unless already installed.
    1. See Figure 1. Plug the socket housing (9) on the end of the intercom harness into the overlay harness 8-place pin housing [76] (item 3)
    2. Plug the 35-place radio socket housing [28] (1) into the radio.
    3. Locate the interconnect harness audio connector [6B] near the back of the radio. Plug 6-way pin housing [6A] (2) on the overlay harness into socket housing [6B].
    4. Plug the overlay harness 12-place pin housing (4) labeled "Intercom" [53] into the socket housing coming from the console pod.
  2. Use tie straps from the kit to fasten the intercom and overlay harnesses to the existing harnesses inside the fairing.
  3. Verify that the Ignition/Light Key Switch is in the OFF position. Refer to the service manual and follow the instructions given to install the maxi-fuse.
  1. Test the intercom and the rest of the sound system for proper operation.
  2. Install the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD INSTALLATION in the Service Manual.
  3. Refer to the Service Manual, and follow the instructions given to install the left-side saddlebag and the seat.
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)