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HANDLEBAR-MOUNTED SPEAKER AND AMPLIFIER KITS
J049162010-04-26
GENERAL
Kit Numbers
76262-08, 76320-08
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
2011 and later Softail models will require separate purchase of an Electrical Connection Kit (H-D Part No. 72673-11).
Connection to an audio device (MP3 player or similar device, purchased separately) with a 3.5 mm (⅛ in) stereo output (headphone jack or audio line out) is required.
NOTE
A Boom! Audio Tank Pouch (H-D Part No. 91003-10) can be used to secure a solid-state audio device.
DO NOT secure an MP3 player or similar device with a hard drive memory on or to the vehicle.
For best sound quality, an installed windshield is recommended.
Tools and Supplies Required
An UltraTorch UT-100 (HD-39969), Robinair Heat Gun (HD-25070) with Heatshrink Attachment (HD-41183), or other suitable radiant heating device is required for the proper installation of this kit.
Electrical Contact Lube (H-D Part No. 99861-02) or equivalent is required for the proper installation of this kit. This item is available from a Harley-Davidson dealer.
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 refers to service manual information. A service manual for this year/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)
WARNING
When 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)
The Speaker and Amplifier Kit requires up to 4.0 A additional current from the electrical system.
Kit Contents
See Figure 5 and Table 1.
INSTALLATION
Preparation
NOTE
For vehicles equipped with security siren:
  • Verify that the Hands-Free Fob is present.
  • Turn the ignition key switch to IGNITION.
For ALL vehicles with main fuse:
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Refer to the service manual and follow the instructions to remove the main fuse. Remove and retain the seat and all seat mounting hardware.
For ALL vehicles with main circuit breaker:
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 the instructions to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware.
NOTE
For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase.
2. For ALL models: Turn the ignition key switch OFF if not already done.
3. If equipped, remove the windshield from the vehicle per the instructions in the service manual or accessory kit. Be sure to protect the windshield from scratches during removal and installation, and while off the vehicle.
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)
WARNING
To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a)
4. Remove the fuel tank from the vehicle per the instructions in the service manual.
5. For FLHR/C/S (Road King®) models only: Remove the handlebar cover from the vehicle and separate the left and right nacelle halves per the instructions in the service manual.
Amplifier and Bracket Installation
  1. See Figure 5. Select two 1/4-20 x 16 mm (0.62 in) long TORX® head screws (6) and the correct amplifier mounting bracket (item 7 or 8) from the kit.
  • For Touring and Sportster models: select bracket (7).
  • For Dyna and Softail models: select bracket (8).
NOTE
The wire exiting the amplifier must face downward.
6. See Figure 1. Install the amplifier (5, part of the wire harness assembly) to the bracket with the screws (6), and tighten to 7.4 N·m (65 in-lbs).
7. If this kit is being installed on a vehicle with an engine guard (except for FLHR models), use the engine guard hardware to secure the amplifier bracket. If NOT being installed with an engine guard, use hardware from the kit to secure the amplifier bracket. See Figure 5.
  • For Sportster models: Select two 3/8-16 hex head screws (9) from the kit.
  • For Dyna models: Select one 3/8-16 hex head screw (9) and one hex locknut (10) from the kit.
  • For Softail models: Select the 5/16-18 screw (11) and hex locknut (12) from the kit.
  • For Touring models: Select two 1/4-20 x 16 mm (0.62 in) long TORX head screws (6), two fender washers (13) and two hex locknuts (14) from the kit.
  1. See Figure 1. Install the amplifier and bracket to the frame crossmember between the front down tubes as shown.
  • For Sportster models: Tighten the fasteners to 40.7–44.8 N·m (30–33 ft-lbs).
  • For Dyna models: Tighten the fasteners to 40.7–44.8 N·m (30–33 ft-lbs).
  • For Softail models except FXCW/C (Rocker): The amplifier bracket installs behind the crossbar. Tighten the fasteners to 25.8 N·m (19 ft-lbs).
  • For FXCW/C (Rocker) models: The amplifier bracket installs in front of the crossbar. Tighten the fasteners to 25.8 N·m (19 ft-lbs).
  • For Touring models: Tighten the fasteners to 7.4 N·m (65 in-lbs).
1Sportster installation
2Dyna installation
3Softail installation
4FLHR installation
5Amplifier
6TORX button head screw, 1/4-20 x 0.62 inch (16 mm) (4)
7Amplifier mounting bracket (Sportster/FLHR)
8Amplifier mounting bracket (Dyna/Softail)
9Hex head screw, 3/8-16 x 0.75 inch (19 mm) (2)
10Hex locknut, 3/8-16 (2)
11Hex head screw, 5/16-18 x 0.75 inch (19 mm)
12Hex locknut, 5/16-18
13Fender washer (2)
14Hex locknut, 1/4-20 (2)
Figure 1. Amplifier and Bracket Installation
Hand Control and Bracket Installation
  1. See Figure 2. Remove the front brake lever clamp screws from the vehicle. Remove and retain the clamp (1). The screws can be discarded.
  2. Obtain the hand control bracket (3), two spacers (2), two #10-24 Phillips screws (6) and:
  • for 2004 and later Sportster models: two M6 x 45 mm long hex socket button head screws (18) from the kit.
  • for ALL OTHER models: two 1/4-20 x 44.4 mm (1.75 in) long hex socket button head screws (18) from the kit.
  1. Route the hand control (5) wire harness through the center of the hand control bracket (3) as shown.
  2. Position the spacers into the clamp mounting cutouts, and place the hand control bracket onto the spacers. Install the clamp, spacers and bracket to the brake master cylinder with the two screws. Tighten the screws to:
  • for 2004 and later Sportster models: 12.2–14.9 N·m (108–132 in-lbs).
  • for ALL OTHER models: 6.8–9.1 N·m (60–80 in-lbs).
  1. Install the hand control (5, part of the wire harness assembly) to the bracket with the #10-24 screws (6), and tighten securely.
  2. Use cable straps from the electrical hardware pack to secure the wiring to the existing hand control wiring.
1Front brake lever clamp
2Spacer (2)
3Hand control bracket
4Hex socket button head screw (2)
5Speaker/amplifier hand control
6#10-24 Phillips screw (2)
Figure 2. Hand Control and Bracket Installation
Speaker Installation
NOTE
Test-fit to determine the desired location for the speakers on the handlebar.
Both speaker pods are wired together with a single electrical connector. Do not separate for test-fit or installation.
  • The speaker clamps shall be positioned so the speakers are above the bar. The speakers should appear symmetrical to the left and right of the handlebar clamp, and should be placed as close to the center of the motorcycle as possible.
  • The upper clamps can be positioned so the speaker mounts are in front of or behind the bar.
  • If the vehicle is normally equipped with a windshield, locate the clamps on the middle straight section of the bar so the speaker housings will clear the windshield.
  • The Bar & Shield trim badges on the speaker faces can be rotated to the desired orientation after installation by pushing with two fingers and turning.
  • Check to be sure speaker and clamp positioning will not interfere with steering function, control operation or visibility of instruments.
  1. See Figure 3. Obtain the following items from the kit:
  • speaker pod assembly (1)
  • two upper handlebar clamps (2)
  • two lower handlebar clamps (3)
  • four spacers (4)
  • four 1/4-20 x 19 mm (0.75 in) long TORX screws (5)
  • two 3/8-16 x 19 mm (0.75 in) long hex head screws (6)
If mounting to 31.8 mm (1¼ in) diameter handlebars, the spacers can be discarded.
NOTE
Insert the spacers inside the clamps for vehicles with 25.4 mm (1.0 in) diameter handlebars. Be sure the spacers seat in the recesses (7) inside the clamps.
8. Secure each speaker clamp pair to the handlebar with two TORX screws (5), and tighten to 6.8 N·m (60 in-lbs)
9. Position a speaker pod, oriented with the speaker grille facing the rider as directly as possible, onto each upper clamp. Secure each speaker pod to the upper clamp with a hex head screw (6). Tighten the screw to 16.3–19 N·m (12–14 ft-lbs).
1Speaker pod (2)
2Upper handlebar clamp (2)
3Lower handlebar clamp (2)
4Spacer (4)
5TORX screw (4)
6Hex head screw (2)
7Recess inside clamp (4)
Figure 3. Handlebar-Mounted Speaker Installation
Wire Harness Connection
General
Splicing of wire leads is necessary in the installation of the speaker and amplifier kit to the motorcycle. Find the instructions for a specific model in the sections that follow, and refer to the service manual appendix for proper wire splicing procedures.
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 on which heat shrink work is being performed.
  • Always keep hands away from tool tip area and heat shrink attachment.
For 2011 and later Softail models: Proceed to the next section.
For ALL OTHER models: Proceed to THAT section.
For 2011 and Later Softail Models
NOTE
Requires separate purchase of Electrical Connection Kit (H-D Part No. 72673-11).
  1. Install the Electrical Connection Kit per the instructions in that kit:
    1. Locate the Digital Technician connector [91A] under the seat. Place the Electrical Connection Harness at the Digital Technician connector, but DO NOT connect them at this time.
    2. Route the speaker and amplifier wires over to the Electrical Connection Harness. Cut the speaker and amplifier wires to a suitable length to easily reach the sealed splice connectors on the Electrical Connection Harness.
    3. Splice the orange/white speaker and amplifier wire to the red/yellow wires in the Electrical Connection Harness.
    4. Splice the black speaker and amplifier wire to the black wires in the Electrical Connection Harness.
    5. Splice the red speaker and amplifier wire to the red/blue wires in the Electrical Connection Harness.
    6. Use a heat gun or suitable radiant-heating device to shrink the connector to the wires.
    7. Pull the rubber boot out from the gray Digital Technician pin connector [91A].
    8. Connect the socket housing of the Electrical Connection Harness to connector [91A].
    9. Insert the rubber boot into the open pin connector of the Electrical Connection Harness.
    10. Proceed to WIRE ROUTING..
For ALL OTHER Models
1. See Figure 5. Get the electrical hardware pack (22) from the kit. Select the in-line fuse holder (23) and one blue sealed splice connector (28) from the hardware pack.
2. Cut the orange/white wire in the main electrical harness near the rear lighting connector [7A]. Splice the two cut orange/white wires to the free end of the orange/white wire in the amplifier/hand control/wire harness assembly per the instructions in the service manual appendix. Use a heat gun or suitable radiant-heating device to shrink the sealed splice connector to all three wires.
3. Use a heat gun or suitable radiant-heating device to shrink the sealed splice connectors to the wires.
4. Select the free end of the red wire in the wire harness assembly. Get two blue sealed splice connectors (28) and the 12V adapter wire (25) from the hardware pack. Splice the in-line fuse holder to the red wire per the instructions in the service manual. Splice the adapter wire to the opposite end of the in-line fuse holder.
5. See Figure 4. Locate the B+ (battery positive) connector (1) on the main electrical harness under the seat (a red wire with an unused gray connector). Remove the cover (2) from the B+ connector. Mate the red power wire connector on the wire harness assembly to the B+ connector.
1B+ connector
2Cover
Figure 4. B+ Connector
6. Select a ring terminal from the electrical hardware pack.
  • Dyna models: use the 7.9 mm (5/16 in) ID terminal (27).
  • All models EXCEPT Dyna: use the 6.4 mm (¼ in) ID terminal (26).
  1. Select the free end of the black wire in the wire harness assembly. Cut the black wire to easily reach the location of the vehicle ground. Crimp the ring terminal to the black wire per the instructions in the service manual.
  2. Attach the black wire ring terminal to the vehicle ground stud.
Wire Routing
  1. Use cable straps (29) from the electrical hardware pack to secure the amplifier wiring to the frame downtube. For FLHR models: Use the existing P-clamp on the left side of the frame near the steering head to secure the amplifier wiring.
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)
  • Make sure the wires do not restrict steering movement.
  • Route the wires along the frame backbone under the tank and tie to existing wire bundles with cable straps, especially at any change in direction.
  1. Coil excess wire under the fuel tank, inside the nacelle or under the handlebar clamp where it will not interfere with steering function. Install the 5A fuse (24) in the in-line fuse holder on the red wire.
  2. Lay the harness along the frame backbone, under the fuel tank and seat, with the four-way connector positioned near the steering head. The connector may be placed inside the nacelle (FLHR/C/S models) or handlebar clamp.
  3. Mate the four-way connector from the speaker pods to the four way connector on the wire harness assembly.
  4. See Figure 5. The 3.5 mm connector from the hand control can be secured to the handlebar with cable straps or secured to the upper triple clamp or nacelle with the adhesive-backed clip (21) from the kit. If using the clip:
    1. Ambient temperature should be at least 16 °C (60 °F) for proper adhesion of the clip to the vehicle.
    2. Test-fit the clip to the upper triple clamp or nacelle before installation. Do not remove the liner until ready to apply the clip.
  5. Clean the clip mounting area with a mixture of 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry thoroughly. Remove the liner from the adhesive backing of the clip. Carefully position the clip to the upper triple clamp or nacelle, and press firmly into place. Hold the clip in position with steady pressure for a few seconds.
    6. NOTE
    Allow AT LEAST 24 hours after applying the clip before exposing the area to vigorous washing, strong water spray or extreme weather.
    The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature.
  6. Secure the 3.5 mm connector from the hand control to the clip.
Return to Service
1. For FLHR/C/S (Road King) models only: Assemble the left and right nacelle halves per the instructions in the service manual. Assemble the handlebar cover to the vehicle. For 2011 and later Softail models only: Install the split conduit (30) over the brake line where it passes closest to the amplifier.
2. ALL models:. Install the fuel tank to the vehicle per the instructions in the service manual.
3. Install the windshield (if equipped) to the vehicle per the instructions in the service manual or accessory kit. Be sure to protect the windshield from scratches during installation.
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)
4. Check to be sure the speaker pods will not interfere with steering function, controls operation or visibility of instruments.
NOTE
Verify that the ignition key switch is in the OFF position before installing the main fuse or attaching the battery cable.
5. Models with main fuse: Refer to the service manual and follow the instructions to install the main fuse. Models with main circuit breaker: Refer to the service manual and follow the instructions to attach the negative battery cable. Apply a light coat of Harley-Davidson electrical contact lubricant (H-D Part No. 99861-02), petroleum jelly or corrosion retardant material to the negative battery terminal.
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)
6. ALL models: Refer to the service manual, and follow instructions to install the seat.
7. Turn the ignition key switch to IGNITION, but do not start the motorcycle.
8. Connect the audio input cable (20) from the kit to the female 3.5mm stereo connector from the hand control.
9. Connect the free end of the audio input cable to the headphone jack (or line out) of the audio device (MP3 player or similar device, purchased separately).
a. Turn the device on. Set the device volume output at 75-80 percent of maximum.
b. Turn the amp on using the hand control on/off push button switch. The switch will illuminate when power is on.
c. Use the handlebar control to adjust the volume level. VOL+ increases the volume. VOL- decreases the volume.
d. The amp and speakers can be operated with the ignition switch in either the "ACC" or "IGNITION" position.
NOTE
DO NOT secure an MP3 player or similar device with a hard drive memory on or to the vehicle.
SERVICE PARTS
Figure 5. Service Parts, Handlebar-Mounted Speaker and Amplifier Kits
SERVICE PARTS
Table 1. Service Parts
Kit
Item
Description (Quantity)
Part Number
Kit 76262-08
Handlebar-Mounted
Speaker/Amplifier
Kit (Chrome)
1
Speaker pod assembly (chrome)(includes two of item 30)
76223-08
2
Speaker clamp, handlebar (upper, chrome)(2)
Not sold separately
3
Speaker clamp, handlebar (lower, chrome)(2)
Not sold separately
Kit 76320-08
Handlebar-Mounted
Speaker/Amplifier
Kit (Black)
1
Speaker pod assembly (black)(includes two of item 30
76225-08
2
Speaker clamp, handlebar (upper, black)(2)
Not sold separately
3
Speaker clamp, handlebar (lower, black)(2)
Not sold separately
Items common
to BOTH kits
4
Spacer, handlebar speaker housing (4)
Not sold separately
5
Amplifier/hand control/wire harness assembly
Not sold separately
6
Screw, button head, TORX, 1/4-20 x 16 mm (0.62 in) long (4)
925
7
Bracket, amplifier mounting (Sportster and Touring models)
Not sold separately
8
Bracket, amplifier mounting (Dyna and Softail models)
Not sold separately
9
Cap screw, hex head, 3/8-16 x 19 mm (0.75 in) long (4)
4713W
10
Hex locknut, 3/8-16 Nylock (2)
7778
11
Cap screw, hex head, 5/16-18 x 19 mm (0.75 in) long
3987
12
Hex locknut, 5/16-18 Nylock
7739
13
Fender washer, M6 (2)
6914M
14
Hex locknut, 1/4-20 Nylock (2)
7686
15
Screw, button head, TORX, 1/4-20 x 19 mm (0.75 in) long (6)
923
16
Bracket, hand control
Not sold separately
17
Spacer, hand control mounting (2)
Not sold separately
18
Cap screw, hex socket, button head,
M6 x 45 mm long (2) (for Sportster)
1/4-20 x 44.4 mm (1.75 in) long (2) (for ALL OTHER models)
.
Not sold separately
3129
19
Cap screw, button head, Phillips, #10-24 x 13 mm (0.5 in) long (2)
Not sold separately
20
Audio input cable
92383-09
21
Clip, adhesive backed
10325
22
Electrical hardware pack (includes items 23 through 29)
76173-08
23
  • In-line fuse holder
70306-02
24
  • Fuse, blade type, 5A (light tan)
72331-95
25
  • Adapter wire, 12 V positive
76204-03
26
  • Ring terminal, #18-22 AWG (6.4 mm (¼ in) stud)
9858
27
  • Ring terminal, #18-22 AWG (7.9 mm (5/16 in) stud)
9859
28
  • Sealed splice connector, #14-16 AWG (blue) (3)
70586-93
29
  • Cable strap (10)
10006
30
Conduit, split loom, convoluted 6.4 x 127 mm ( x  in) long
62519-03
Service parts for speaker pod assembly:
31
Speaker pod (chrome) (2)
Speaker pod (black) (2)
76223-08
76225-08