ROAD TECH® RISER MOUNT RADIO KIT
J027152007-06-05
GENERAL
Kit Number
76362-03, 76363-03, 76363-08
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Separate purchase of additional parts or accessories may be required for proper installation of this Radio kit on your model motorcycle. Refer to the latest Harley-Davidson Genuine Motor Accessories and Genuine Motor Parts catalog for a list of required parts or accessories for your model.
Tools and Supplies Required
An UltraTorch UT-100 (H-D 39969), Robinair Heat Gun (H-D 25070) with Heatshrink Attachment (H-D 41183), or other suitable radiant heating device is required for the proper installation of this kit.
Loctite® 271 (Red) Threadlocker and Sealant (H-D Part Number 99671-97) is required for the proper installation of this kit.
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.
Electrical Overload
NOTICE
It is possible to overload the vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. (00211d)
WARNINGWhen installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a)
This radio kit requires up to 2.0 amps additional current from the electrical system.
INSTALLATION
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNINGDisconnect negative (-) 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. (00049a)
| 1. | Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware. | |||||||||||||
| 2. | Remove the battery from the vehicle. | 
Figure 1. Handlebar Clamps and Cover | ||||||||||||
| 3. | See Figure 1. Refer to HANDLEBAR REMOVAL in the Service Manual to remove and discard the original equipment (O.E.) handlebar cover (1) and the handlebar clamp screws (2). Save the fork lock plate (6) for re-installation. Leave the upper handlebar clamps (3) in place. | |||||||||||||
| 4. | See Figure 5. Install the four spacers (12) and the riser mounting plate assembly (10) from the kit over the upper handlebar clamps. Make sure that the handlebar has remained centered. Check that the knurled areas on the outboard side of each riser are equal. | |||||||||||||
| 5. | Secure the mounting plate, spacers and upper clamps to the lower handlebar clamps (risers) with the four two-inch (51 mm) long hex socket head screws (13) from the kit.. | |||||||||||||
| 6. | Tighten the screws as follows: a. Tighten the front screws until the upper and lower handlebar clamps make contact. b. Tighten the rear screws to 21.7–27.1 N·m (16–20 ft-lbs). c. Tighten the front screws to 21.7–27.1 N·m (16–20 ft-lbs). | |||||||||||||
| 7. | Install the rubber grommet (11) from the kit into the riser mounting plate assembly (10) so the thin cross-section, larger-footprint surface is on the top side of the plate. | |||||||||||||
| 8. | Obtain the antenna bracket (15), mounting base (17), amplifier (16) and cable (19) from the kit. | 
Figure 2. Antenna Mounting | ||||||||||||
| 9. | See Figure 2. Remove the two nuts (3) holding the left-side saddlebag support rail (2) to the bottom tab of the saddlebag support bracket (1). Install the antenna bracket (4) as shown, with the legs of the channel pointing up, and the antenna mounting surface to the rear. | |||||||||||||
| 10. | See Figure 5. Press the end of the antenna cable (19) into the housing on the amplifier (16). | |||||||||||||
| 11. | Disassemble the flange nut (18) from the antenna mounting base (17). Insert the stud on the antenna base through the larger hole in the antenna bracket (15) and the locating pin through the smaller hole. | |||||||||||||
NOTICE Avoid damaging the low-noise amplifier. Do not over-tighten the flange nut. (00343a) | ||||||||||||||
| 12. | Slide the antenna cable and amplifier assembly onto the stud with the cable side closest to the bracket. Rotate the amplifier on the stud so the cable points toward the fender and slightly downward. Fasten the amplifier to the bracket and antenna base with the flange nut removed earlier. Tighten securely. | |||||||||||||
| 13. | Obtain the boot (20) from the kit and install it over the amplifier, tight against the antenna bracket, with the side opening shielding the antenna cable. Secure the boot to the cable with a tie strap (30) from the kit. | |||||||||||||
| 14. | Route the antenna cable up the rear of the saddlebag support bracket. Secure the cable with a tie strap at the bottom of the saddlebag support bracket and another tie strap just below the saddlebag mounting bracket. | |||||||||||||
NOTICE Damage to antenna cable can cause poor radio reception. Route cable under the seat avoiding interference with the seat pan. (00344a) | ||||||||||||||
| 15. | Continue routing the cable forward, traveling just above the fender support and into the area under the seat. Secure the cable to the frame tube under the seat with a tie strap. | |||||||||||||
| 16. | Rotate the hinged section of the antenna base (17) so the threaded hole faces upward. Obtain the antenna mast (21) from the kit. Place a few drops of Loctite® 271 (Red) on the antenna mast threads, and assemble the mast to the antenna base. | |||||||||||||
| WARNING When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) | ||||||||||||||
| 17. | Loosen the fuel tank. Refer to FUEL TANK, PARTIAL REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual. Lift the tank upward at the rear to provide clearance to route the radio wire harness and antenna cable underneath the tank. | |||||||||||||
| 18. | For 2005 and earlier models: Continue bringing the antenna cable forward, routing the cable beneath the left side of the fuel tank, and up between the nacelle and the cast lower triple clamp to exit to the left of the riser mounting plate. For 2006 and later models: a. Starting at the front of the wire trough, and working rearward from side to side, carefully insert the blade of a flat-tip screwdriver into the slots, and release the catches to remove the trough cover. b. Route the antenna cable forward inside the wire trough. | |||||||||||||
| 19. | Obtain the radio wire harness (22) from the kit. | |||||||||||||
| 20. | Carefully route the Deutsch 12-way socket housing on the end of the harness up between the nacelle and the cast lower triple clamp, on the left-hand side, to exit between the riser mounting plate rear screws. The connector should point upward and be positioned slightly above the rod on the mounting plate. | |||||||||||||
| 21. | For 2005 and earlier models: Route the other end of the radio harness rearward beneath the left side of the fuel tank and into the area under the seat. For 2006 and later models: Route the radio harness rearward inside the wire trough. | |||||||||||||
| 22. | Loosely install the handlebar clamp cover (1) from the kit onto the riser mounting plate. See NACELLE INSTALLATION in the Service Manual. Do not fasten the cover at this time. | |||||||||||||
| 23. | Obtain the radio (3) and heat shrink tube (29) from the kit. Slide the heat shrink tube onto the antenna cable from the radio. Mate the antenna cable connector from the radio to the antenna cable installed earlier. Slide the heat shrink tube back over the cable connection. | |||||||||||||
| 24. | Refer to SEALED BUTT SPLICE CONNECTORS in the Service Manual for proper butt splicing procedures. |
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.
| 25. | Using the UltraTorch UT-100 (H-D 39969), Robinair Heat Gun (H-D 25070) with Heatshrink Attachment (H-D 41183), or other suitable radiant heating device, heat the tubing to encapsulate the antenna connection. Apply heat from the center of the tubing out to each end. | |||||||
| 26. | Obtain the wire protector tube (31) from the kit. Slip the tube onto the antenna cable segment nearest the radio. Feed the encapsulated connection down inside the clamp cover on the left side of the riser mounting plate. Position the tube to protect the encapsulated connection. | |||||||
| 27. | Complete the installation of the handlebar clamp cover per the NACELLE INSTALLATION instructions. Install the fork lock plate removed in Step 3. | |||||||
| 28. | Install the radio assembly onto the riser mounting plate. Fit the tab (7) into the rubber grommet installed in Step 7. Position the mounting bracket (4) and clamp (5) directly over the rod on the mounting plate (10). | |||||||
| 29. | Tighten the two #10-24 button-head TORX® screws (8) to secure the radio clamps to the rod. Make certain the outboard gaps are equal on each side of the rod clamps. Tighten the screws to 6.8–9 N·m (60–80 in-lbs). | |||||||
| 30. | Connect the 12-way Deutsch socket housing from the radio harness to the pin housing on the underside of the radio. | |||||||
| 31. | Install the riser shroud cover (2) with the four flat head TORX screws (14) from the kit, covering the radio harness. Tighten securely. | 
Figure 3. Electrical Connections Under Seat | ||||||
| 32. | For 2003 and earlier models: See Figure 5 and the correct MAIN HARNESS Wiring Diagram (for Carbureted or EFI Model) in the Service Manual. For 2004 and later models: a. Crimp the #10 ring terminal (26) from the kit onto the end of the Red wire from the radio harness according to the CRIMPING INSTRUCTIONS in the Service Manual. b. Fasten the ring terminal to the Silver battery power (BAT) post on the circuit-breaker (see Figure 3 , Item 1). Tighten the nut to 2.3–4 N·m (20–35 in-lbs). c. Refer to the SEALED BUTT SPLICE CONNECTORS section in the Service Manual. Splice the Orange/White wire into the accessory feed (Orange/White) wire of the accessory circuit [7] using a butt-splice connector (27) from the kit. d. Crimp the 1/4 inch ring terminal (24) from the kit onto the end of the Black wire from the radio harness. Attach the Black wire to one of the ground posts (see Figure 3 , Item 2 or 3). e. See Figure 4. Locate the B+ (battery positive) connector (1) on the main electrical harness under the seat (a Red wire with an unused, covered Gray connector). Remove the cover (2) from the connector. f. See Figure 5. Obtain the adapter harness (24) from the kit and plug it into the B+ connector. g. Refer to the SEALED BUTT SPLICE CONNECTORS section in the Service Manual. Splice the Red wire from the radio harness onto the adapter harness Red wire using a butt-splice connector (27) from the kit. h. Splice the Orange/White wire into the accessory feed (Orange/White) wire of the main harness [7A] using the second butt-splice connector from the kit. i. Crimp a 1/4 inch ring terminal (25) from the kit onto the end of the Black wire from the radio harness. Attach the Black wire to one of the ground posts (see Figure 3 , Item 1). | 
Figure 4. B+ Connector | ||||||
| 33. | For ALL models: Turn the handlebar to the full left and full right steering stops, making sure that the radio harness and antenna cable are not pulled tight. |
WARNINGBe 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)
- Wires and cables must not pull tight when handlebars are turned fully to left or right fork stops.
- Be sure wires and cables are clear of fork stops at steering head so they will not be pinched when fork is turned against stops.
| 34. | Check the harness and antenna cable for wear points or pinch points along their entire length. Fasten the harness and cable to the frame tube or existing harness under the fuel tank as needed with tie straps (30) and adhesive clips (28) from the kit. For 2006 and later models: Place the cover over the wire trough. Starting at the front and working rearward from side to side, engage the catches to latch the cover. Verify that all latches are fully engaged. | |
| WARNING When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) | ||
| 35. | Lower the fuel tank to its proper position and re-fasten the tank by attaching the rear mounting screw. Refer to FUEL TANK, INSTALLATION AFTER PARTIAL REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual. | |
| 36. | Re-install the battery into the motorcycle. | |
| WARNING 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) | ||
| 37. | Verify that the Ignition/Light Key Switch is turned to the OFF position. Apply a light coat of petroleum jelly or corrosion retardant material to the battery terminals. Refer to the Service Manual and follow the instructions given to re-attach the battery cables (positive cable first). | |
| 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) | ||
| 38. | Turn the Ignition/ Light/ Key switch to IGNITION. Test the radio for proper operation, then install the seat. |
Radio Operation and Care
Refer to the Harley-Davidson® Road Tech Radio Manual for operation and care instructions.
Radio Warranty
This product is warranted against all defects in material workmanship for a period of 90 days from the date of purchase. When installed by an authorized Harley-Davidson dealer the product is covered by a one year warranty. Please see your authorized Harley-Davidson dealer for warranty and service issues.
DEALERS ONLY, please follow instructions below for warranty and service claims related to the radio only:
- Send the radio, properly packaged and freight prepaid, to the Clarion Factory Service Center below. Freight collect shipments are not accepted.
- Include a description of the malfunction. Include dealership name, return address and phone number.
- In-Warranty: Include a copy of customer's receipt or other proof-of-purchase date for in-warranty verification. Out-of-Warranty:Include a full prepayment dealership check in the flat-rate amount of $130.00 (U.S.).
Clarion will service the radio and make return shipment by UPS ground, freight prepaid, within four (4) business days of receipt.
For further questions regarding service, contact Clarion Customer Service Department at (800) 347-8667.
Clarion Corporation of America, Inc.
Factory Service Center
661 West Redondo Beach Blvd.
Gardena, CA 90247-4201
Phone: (800) 347-8667
SERVICE PARTS
Table 1. Service Parts Table
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Kit 76362-03 2002 and earlier | 1 | Cover, handlebar clamp (includes cover shroud, Item 2) | 67876-03 |
2 |
| 76216-03 | |
Kit 76363-03 2003 through 2007 | 1 | Cover, handlebar clamp (includes cover shroud, Item 2) | 76209-03A |
2 |
| 76216-03 | |
Kit 76363-08 2008 and later | 1 | Cover, handlebar clamp (includes cover shroud, Item 2) | 76209-08 |
2 |
| 76216-03 | |
Parts common to ALL kits | 3 | Radio assembly | 76358-03 |
4 | Bracket, mounting | 76113-03 | |
5 | Clamp, mounting bracket | 76116-03 | |
6 | Plate, backing | 76235-03 | |
7 | Tab, housing retaining | 76140-03 | |
8 | Screw, button head, TORX®, #10-24 x 1/2 in (2) | 3658 | |
9 | Screw, button head, TORX, 1/4-20 x 1/2 in (4) | 4365 | |
10 | Plate assembly, riser mounting | 76117-03 | |
11 | Grommet, tab | 76158-03 | |
12 | Spacer, mounting plate (4). For Kit 76362-03. Spacer, mounting plate (4). For Kit 76363-03. Spacer, mounting plate (4). For Kit 76363-08. | 76159-03 76159-03 76249-07 | |
13 | Screw, hex socket head, 5/16-18 x 2 in (4) | 4326A | |
14 | Screw, flat head, #10-24 x 1/2 in (4) | 1750 | |
15 | Bracket, antenna | 76237-03 | |
16 | Antenna, low noise amplifier | 76196-03 | |
17 | Base, antenna mounting (includes flange nut, Item 18) | 76206-03 | |
18 |
| 76207-03 | |
19 | Cable, antenna | 76174-03 | |
20 | Boot, antenna | 69532-03 | |
21 | Mast, antenna | 76210-03 | |
22 | Wire harness assembly (includes fuse, Item 23) | 76203-03 | |
23 |
| 72331-95 | |
24 | Harness, adapter, radio Red (positive) wire to B+ connector | 76204-03 | |
25 | Terminal, ring, 1/4 in (2) | 9858 | |
26 | Terminal, ring, #10 | 9857 | |
27 | Connector, sealed butt splice (2) | 70586-93 | |
28 | Clip, nylon, adhesive back (3) | 10187 | |
29 | Tube, heat shrink, 1/2 in (12.7 mm) x 4 in (101 mm) long | 72162-03 | |
30 | Tie strap, black, 7.75 in (20 cm) long (10) | 10006 | |
31 | Protector, wiring, 0.25 in (6.4 mm) x 5 in (127 mm) long | 62519-03 | |
32 | Owner's manual (not shown) | 99574-03 |
Figure 5. Service Parts, Riser Mount Radio Kits