1. | See service manual. Remove main fuse and seat. Retain seat and all mounting hardware. |
1. | See the service manual. Remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. | |
2. | For ALL models: Turn the ignition key switch OFF if not already done. | |
3. | See the service manual or instructions in the accessory kit. Remove windshield. Make sure to protect the windshield from scratches during removal and installation, and while off the vehicle. |
1. | Turn the fuel supply valve OFF. Remove the fuel line from the valve. |
1. | See the service manual. Remove the instrument console (if equipped) from the fuel tank. | |
2. | See the correct section (Carbureted or EFI Engine) of the service manual for fuel tank removal instructions. | |
3. | For Road King models only: Remove the handlebar cover from the vehicle. Separate the left and right nacelle halves. Remove the headlamp assembly per service manual instructions. |
1. | Figure 7 Select two screws (6) and the correct amplifier mounting bracket (item 7 or 8) from the kit. |
2. | 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). | |
3. | If this kit is being installed on a vehicle with an engine guard (except for Road King 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 7. |
1 | Sportster (XL) installation |
2 | Dyna (FLD/FXDWG) installation |
3 | Softail (FLST/C/F/FB/N, FXST/B/C/D) and Rocker (FXCW/C) installation |
4 | Road King (FLHR) installation |
5 | Amplifier |
6 | TORX button head screw, 1/4-20 x 0.62 inch (16 mm) (2) |
7 | Amplifier mounting bracket (XL Sportster/FLHR) |
8 | Amplifier mounting bracket (Dyna/Softail) |
9 | Hex head screw, 3/8-16 x 0.75 inch (19 mm) (2) |
10 | Hex locknut, 3/8-16 (2) |
11 | Hex head screw, 5/16-18 x 0.75 inch (19 mm) |
12 | Hex locknut, 5/16-18 |
13 | Fender washer (2) |
14 | Hex locknut, 1/4-20 (2) (2013 and earlier models) |
15 | TORX button head screw, 1/4-20 x 0.75 inch (19 mm) (2) |
1. | Figure 1 Install the amplifier and bracket to the frame crossmember between the front down tubes as shown. |
1. | 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 screws (6) and: a. for 2004 and later XL Sportster models: two screws (4) from the kit. b. for ALL OTHER models: two screws (4) from the kit. | |
3. | Route the hand control (5) wire harness through the center of the hand control bracket (3) as shown. | |
4. | Position the spacers into the clamp mounting cutouts. 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: a. for 2004 and later XL Sportster models: 12.2–14.9 N·m (108–132 in-lbs). b. for ALL OTHER models: 6.8–9.1 N·m (60–80 in-lbs). | |
5. | Install the hand control (5, part of the wire harness assembly) to the bracket with screws (6). Tighten securely. | |
6. | Use cable straps from the electrical hardware pack to secure the wiring to the existing hand control wiring. |
1 | Front brake lever clamp |
2 | Spacer (2) |
3 | Hand control bracket |
4 | Hex socket button head screw (2) |
5 | Speaker/amplifier hand control |
6 | #10-24 Phillips screw (2) |
1. | Figure 3 Obtain the following items from kit: a. Speaker pod assembly (1) b. Two upper handlebar clamps (2) c. Two lower handlebar clamps (3) d. Four spacers (4) e. Four screws (5) f. Two screws (6) | |
2. | NOTE If mounting to 1 1/4 inch diameter handlebars, the spacers can be discarded. Insert the spacers inside the clamps for vehicles with 1.0 inch diameter handlebars. Make sure the spacers seat in the recesses (7) inside the clamps. | |
3. | 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 screw to 16.3–19 N·m (12–14 ft-lbs). |
1 | Speaker pod (2) |
2 | Upper handlebar clamp (2) |
3 | Lower handlebar clamp (2) |
4 | Spacer (4) |
5 | TORX screw (4) |
6 | Hex head screw (2) |
7 | Recess inside clamp (4) |
1 | Digital Technician connector [91A] |
2 | Electrical connection harness |
3 | Speaker and amplifier harness |
4 | Red/yellow wire sealed splice connector |
5 | Black wire sealed splice connector |
6 | Red/blue wire sealed splice connector |
1. | Install the Electrical Connection Harness: a. Figure 4 Locate the Digital Technician connector [91A] (Item 1, a gray six-way Deutsch connector with a rubber boot) under the seat. Place the Electrical Connection Harness (2) at the Digital Technician connector, but DO NOT connect them now. b. Route the speaker and amplifier harness (3) wires over to the Electrical Connection Harness. Cut the speaker and amplifier wires to a suitable length to easily reach the sealed splice connectors (4 and 5) on the Electrical Connection Harness. c. Splice both the red and the orange/white speaker and amplifier wires to the red/yellow wire sealed splice connector (4) in the Electrical Connection Harness. d. Splice the black speaker and amplifier wire to the black wire sealed splice connector (5) in the Electrical Connection Harness. e. Use a heat gun or suitable radiant-heating device to shrink the connector to the wires. f. Use the heat gun or heating device to seal the open end of the sealed splice connector (6) on the red/blue wires in the Electrical Connection Harness. g. Pull the rubber boot out from the gray Digital Technician pin connector [91A]. Cut the boot off the wires. h. Connect the socket housing of the Electrical Connection Harness to connector [91A]. i. Insert the rubber boot into the open pin connector of the Electrical Connection Harness. j. Proceed to WIRE ROUTING. |
1. | Locate the gray 8-way pin-side Molex connector [4A] under the left side cover. It is located in the electrical caddy, directly over the Digital Tech Connector [91A]. If wire harness (part no. 69200722) is already connected to connector [4] from a prior install, then disconnect it. | |
2. | Route the harness from the Electrical Connection Kit according to the instructions in that kit. Do not connect the 8-way connectors now. | |
3. | The electrical connections will be made to 2 (or 3) of the sealed cap ends of the Electrical Connection kit. | |
4. | See the service manual for detailed instructions on sealed splice connections. If wire harness (part no. 69200722) was previously spliced, cut off existing splices. Figure 4 for multiple splice configuration. If wire harness (part no. 69200722) was spliced in a prior install, make sure the 8-way Molex connector is disconnected from vehicle connector [4]. a. Clip the cap off the black wire, strip back, crimp & seal to BLACK wire of the wire harness of (this kit). b. Clip the cap off the violet/blue wire of 69200723, strip back, crimp & seal to orange/white and the RED wire of the wire harness of (this kit). c. DO NOT REMOVE the sealed cap from the RED wire-it is not used. | |
5. | Remove the weather cap from connector [4A] and connect the 8-way connectors together. |
1. | Locate the gray 3-way pin-side Molex [325B] under the right side cover, connected to the caddy. If wire harness (part no. 69201599) is already connected to connector [325B] from a prior install, then disconnect it. | |
2. | Route the harness from the Electrical Connection Kit according to the instructions in that kit. Do not connect the 3-way connectors now. | |
3. | The electrical connections will be made to 2 (or 3) of the sealed cap ends of the Electrical Connection kit. | |
4. | See the service manual for detailed instructions on sealed splice connections. If wire harness (part no. 69201599) was previously spliced, cut off existing splices. Figure 4 for multiple splice configuration. If wire harness (part no. 69201599) was spliced in a prior install, make sure the 3-way Molex connector is disconnected from vehicle connector [325B]. a. Clip the cap off the black wire, strip back, crimp & seal to BLACK wire of the wire harness of (this kit). b. Clip the cap off the violet/blue wire of 69201599, strip back, crimp & seal to orange/white and the RED wire of the wire harness of (this kit). c. DO NOT REMOVE the sealed cap from the RED wire-it is not used. | |
5. | Remove the weather cap from connector [325B] and connect the 3-way connectors together. |
1. | Route the speaker and amplifier harness to the area under the seat. | |||||||||||||||||||||
2. | Figure 7 Get the electrical hardware pack (22) from THIS kit. | |||||||||||||||||||||
3. | Select the in-line fuse holder (23) and one blue sealed splice connector (28) from the hardware pack. | |||||||||||||||||||||
4. | Get the relay kit (Part No. 69200397), purchased separately. Refer to the instructions that follow BELOW for relay installation. | |||||||||||||||||||||
5. | Figure 5 Find a suitable location under the seat for the relay (1), so that the terminals face down or horizontally. The terminals should not face upward. | |||||||||||||||||||||
6. | Cut the orange/white wire (2) in the main electrical harness near the rear lighting connector [7]. | |||||||||||||||||||||
7. | See the service manual appendix. Use a suitable radiant-heating device to splice and seal the two cut orange/white wires to the sealed splice connector (4) on the orange/white wire (3) from relay terminal 2. |
Figure 5. Wiring Diagram, Speaker/Amplifier Harness to Relay | ||||||||||||||||||||
8. | Cut the speaker and amplifier harness (5) red and orange/white wires to a suitable length to easily reach the sealed splice connectors on the relay. Splice and seal the red and orange/white wires to the sealed splice connector (6) on the red wire of relay terminal 3. | |||||||||||||||||||||
9. | Select the sealed splice connector (7) on the free end of the red wire coming from relay terminal 5. Splice the red wire on one end of the in-line fuse holder (8) to the red wire of relay terminal 5. | |||||||||||||||||||||
10. | Splice the opposite end of the in-line fuse holder to the 12V adapter wire (9) with the blue sealed splice connector (10) from the hardware pack. | |||||||||||||||||||||
11. | Figure 6 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. | |||||||||||||||||||||
12. | Connect the red 12V adapter wire connector on the wire harness assembly to the B+ connector. |
Figure 6. B+ Connector | ||||||||||||||||||||
13. | Figure 7 Select a ring terminal from the electrical hardware pack. |
1. | Use cable straps (29) from the electrical hardware pack to secure the amplifier wiring to the frame downtube. NOTE For Road King 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) | ||
2. | NOTE
| |
3. | 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 (Road King models) or handlebar clamp. | |
4. | Connect the four-way connector from the speaker pods to the four way connector on the wire harness assembly. | |
5. | See Figure 7. 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: | |
6. | NOTE
| |
7. | Clean with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water. Allow to dry completely. | |
8. | 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. | |
9. | Secure the 3.5 mm connector from the hand control to the clip. |
1. | For Road King models only: See the service manual and assemble the left and right nacelle halves. 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: See the correct section (Carbureted or EFI Engine) of the service manual for fuel tank installation instructions. | |
3. | Install the windshield (if equipped) to the vehicle per the instructions in the service manual or accessory kit. Make sure to protect the windshield and speaker pods 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. | Make sure the speaker pods do not interfere with steering function, controls operation or visibility of instruments. NOTE Verify that the ignition switch is in the OFF position before installing the main fuse or attaching the battery cable. | |
5. | Models with main fuse: See the service manual and install the main fuse. Models with main circuit breaker: a. For ALL models except XL Sportster: See the service manual and attach the negative battery cable. Apply a light coat of petroleum jelly or corrosion retardant material to battery terminals. b. For XL Sportster models only: See the service manual, and connect the negative battery cable at the engine crankcase. | |
6. | See service manual. Install seat. After installing seat, pull up on the seat to verify that it it secure. | |
7. | Turn the ignition switch to IGNITION, but do not start the motorcycle. | |
8. | Connect the audio input cable (20) from the kit to the female 3.5 mm 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 portable audio player (purchased separately). a. Turn on the audio player. Set the player volume output at 75-80 percent of maximum. b. Turn on the amp using the hand control on/off push-button switch. The switch illuminates 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 audio player with a hard drive memory on or to the vehicle. Vehicle vibration can permanently damage the device. Refer to the audio player instructions to determine if the device to be used has a hard drive memory. |
Kit | Item | Description (Quantity) | Part Number |
---|---|---|---|
Kit 76262-08A Handlebar-Mounted Speaker/Amplifier Kit (Chrome) | 1 | Speaker pod assembly (chrome)(includes two of item 31, connected) | Not sold separately |
2 | Speaker clamp, handlebar (lower, chrome)(2) | 76558-08 | |
3 | Speaker clamp, handlebar (upper, chrome)(2) | 76559-08 | |
Kit 76320-08A Handlebar-Mounted Speaker/Amplifier Kit (Black) | 1 | Speaker pod assembly (black)(includes two of item 31, connected) | Not sold separately |
2 | Speaker clamp, handlebar (lower, black)(2) | 76090-08 | |
3 | Speaker clamp, handlebar (upper, black)(2) | 76089-08 | |
Items common to BOTH kits | 4 | Spacer, handlebar speaker housing (4) | Not sold separately |
5 | Amplifier/hand control/wire harness assembly | 70220-08 | |
6 | Screw, button head, TORX, 1/4-20 x 16 mm (0.62 in) long (2) | 924 | |
7 | Bracket, amplifier mounting (Sportster and Road King models) | 76551-08A | |
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 | 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) | Not sold separately | |
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) (Sportster) | Not sold separately | |
Cap screw, hex socket button head, 1/4-20 x 44.4 mm (1.75 in) long (2) (except Sportster) | 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 | Not sold separately | |
22 | Electrical hardware pack (includes items 23 through 29) | Not sold separately | |
23 |
| 70306-02 | |
24 |
| 72331-95 | |
25 |
| 76204-03 | |
26 |
| 9858 | |
27 |
| 9859 | |
28 |
| 70586-93 | |
29 |
| 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) (includes item 32) Speaker pod, black (2) (includes item 32) | 76223-08 76225-08 | |
32 | Speaker grille, with trim ring and logo badge (2) | 76215-08 |