1. | See Figure 1. From the back of one fairing, remove rear screws (1). | |||||||||||||||||||||||||||||||||
2. | See Figure 2. From the front, remove the screws (3), block-off panel (4) and glove box (2). Disconnect the vent door linkage. | |||||||||||||||||||||||||||||||||
3. | See Figure 3. Remove the three glove box screws. Remove the glove box assembly (2). | |||||||||||||||||||||||||||||||||
4. | See Figure 4. Remove screw (1). Remove linkage (2). Install on the new enclosure front. Tighten the screw to 1.3–2 N·m (12–18 in-lbs). | |||||||||||||||||||||||||||||||||
5. | See Figure 5. Prepare speaker enclosure and bottom tray for gasket seal installation. Clean with a mixture of 50-70 percent isopropyl alcohol and 50-30 percent distilled water. NOTE To ease assembly, first install the screws (see Figure 12 , item 10) into the enclosure without the tray. Remove the screws. |
Figure 1. Rear Screws
Figure 2. Locking Tab and Block-off Panel
Figure 3. Glove Box Screws
Figure 4. Vent Linkage Screw Figure 5. Gasket Mating Surface of Lower Fairing
Figure 6. Enclosure Assembly
Figure 7. Connect Linkage | ||||||||||||||||||||||||||||||||
6. | See Figure 6. Assemble the enclosure tray (4) to the front enclosure (2). Install two self-tapping screws (3). Remove the paper backing from one side of the double-sided foam gasket (5). Install the seal as shown. Trim and save excess foam gasket seal for later use. | |||||||||||||||||||||||||||||||||
7. | See Figure 7. Position the enclosure assembly. Connect the linkage. | |||||||||||||||||||||||||||||||||
8. | Remove the paper backing from the foam gasket seal before assembling the enclosure sub-assembly. Position the enclosure assembly. | |||||||||||||||||||||||||||||||||
9. | See Figure 8. From the rear, install three self-tapping enclosure screws (1). Tighten the screws to 1.3–2 N·m (12–18 in-lbs). |
Figure 8. Rear Screws
Figure 9. Block-off Panel and Locating Tab Foam | ||||||||||||||||||||||||||||||||
10. | See Figure 9. Fold a piece of trimmed gasket (1) over the locating tab (2) of the block-off panel. Install the panel (3). Apply a drop of Loctite 243-Blue to the clean screw (4) threads. Install the screws. Tighten to 7.3–8.4 N·m (65–75 in-lbs). | |||||||||||||||||||||||||||||||||
11. | See Figure 10. Cover the back side of the glove box in the hole drilling area with masking tape to prevent cracking or chipping of paint. Measure about 25 mm (1.0 in) inboard and 9.5 mm (⅜ in) up from the lower fairing cap mating flange. Mark the location to drill the hole. Drill a 25 mm (1.0 in) hole in the glove box wall. | Figure 10. Drill Location Figure 11. Captive Nuts | ||||||||||||||||||||||||||||||||
12. | See Figure 11. Insert the four captive nuts from inside the large opening. | |||||||||||||||||||||||||||||||||
13. | See the service manual. Install the lower fairing. DO NOT install the lower fairing cap now. | |||||||||||||||||||||||||||||||||
14. | Route the speaker wires through the hole in the lower fairing. |
15. | See Figure 12. Separate the split grommet (12). Install the grommet around the harness leg. Install into the drilled hole in the fairing. | |
16. | Install lower fairing cap. | |
17. | Repeat steps 1-16 for the remaining fairing. | |
18. | Secure wire harness with cable straps. Verify that wiring does not interfere with steering or suspension travel. NOTE The fairing lower speakers are side-specific. The left speaker trim ring has the text "BOOM! AUDIO STAGE II" at the top. The right has no text. | |
19. | See Figure 12. Attach the speaker wire connectors inside the speaker enclosure to the spade terminals on the back of the new woofer. Different size spade contacts prevent improper assembly. | |
20. | Connect the two-way audio connector of the amplifier harness to the mid-range and tweeter connector (D). | |
21. | Rotate the speaker assembly (1) so the tweeter (C) is 45 degrees outboard from the top. | |
22. | Install the speaker assembly onto the speaker enclosure with the four screws (5) from the kit. a. Start screws carefully to avoid pushing the captive nuts through the mounting holes. b. Use a cross-wise pattern to tighten all four screws to 1.13 N·m (10 in-lbs). | |
23. | Repeat steps 19-22 for the remaining speaker enclosure. |
1. | Make sure that wires, harnesses or lines do not pull tight when handlebars are turned fully to left or right fork stops. | |
2. | Verify that steering is smooth and clear from stop to stop. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Speaker assembly, lower fairing pod (left) (includes items 2-4) Speaker assembly, lower fairing pod (right) (includes items 2-4) | 76000627 76000626 |
2 |
| Not sold separately |
3 |
| Not sold separately |
4 |
| Not sold separately |
5 | Screw, pan head TORX, #6-32 x 25.4 mm (1.0 in) long (black) (8) | 10200294 |
6 | Captive nut (8) | 10100064 |
7 | Tray, speaker enclosure bottom (left) | 76000368 |
8 | Tray, speaker enclosure bottom (right) | 76000369 |
9 | Gasket seal, adhesive-backed (2) | 25700311 |
10 | Screw, TORX pan head, 1/4-14 x 19 mm (0.75 in) long, self-tapping, black (4) | Not sold separately |
11 | Screw, TORX pan head, #10-16 x 19 mm (0.75 in) long, self tapping, black (6) | 2995 |
12 | Grommet, harness seal (2) | 11410 |
Fairing Lower Speaker Box Kit (not part of Fairing Lower
Speaker Kit). | ||
A | Speaker box kit (includes left and right boxes) | |
B | Fairing lower (left shown) | |
Items mentioned in text: | ||
C | Tweeter | |
D | Mid-range and tweeter connector |