1. | Follow the service manual instructions to remove the seat. | |
2. | Refer to the service manual and follow the instructions to remove the main fuse. | |
![]() Disconnect 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) | ||
3. | For 2006 and 2007 models: See the service manual for battery removal instructions. For 2008 and later models: Refer to the service manual and follow the instructions to remove the ECM caddy from the top of the battery. Disconnect the battery cables, negative (-) cable first. | |
4. | For ALL models: Refer to the service manual, and follow the instructions to remove the fuel tank console and fuel tank. | |
5. | Front fairing speakers: a. Remove the outer fairing and windshield per service manual instructions. b. Follow the service manual instructions to remove the front fairing speakers and adapters. | |
6. | Rear speakers: a. Remove the speaker grilles and speakers from the speaker boxes per service manual instructions. |
1. | Remove the outer fairing and windshield per service manual instructions. NOTE
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2. | Remove the gray Molex 12-way main to interconnect harness connector [2] from the left-side (shifter side) fairing bracket (radio support bracket, 3). | |
3. | See Figure 2. Remove the four socket head screws (1) to release the radio from the left and right radio support brackets (2). Use the oblong holes in the brackets to access the screws, and support the radio as the screws are removed. | |
4. | With the amplifier connector facing the left (shifter) side of the vehicle, place the amplifier into position on top of the radio, with the amplifier brackets outside the radio support brackets. | |
5. | Apply a few drops of Loctite 243 - Blue to the clean radio screw threads. Align the threaded inserts in the sides of the radio with the amplifier bracket holes and the oblong holes in the left and right radio support brackets. NOTE DO NOT OVERTIGHTEN. Threaded inserts can be easily loosened or cross threaded. | |
6. | Starting at the rear, install the four socket head screws previously removed. Alternately tighten screws to: Torque: 4–5.1 N·m (35–45 in-lbs) Hex socket head screw |
1 | Audio to interconnect harness connector [6] |
2 | Main to interconnect harness connector [2] |
3 | Left-side fairing bracket |
4 | Right-side fairing bracket |
5 | Audio or radio harness connector |
6 | 35-way connector on back of radio |
7 | Left-side front speaker |
8 | Right-side front speaker |
1 | Socket head screw (4) |
2 | Radio support bracket (2) |
3 | Radio |
1. | Remove the secondary locking wedge from socket housing [6B] ( See Figure 1. , Item 1) on the vehicle per service manual instructions. Remove the plugs from cavities 4 and 5. | |||||||||
2. | See Figure 6. Follow service manual instructions to install the yellow/orange terminated wire (4) from the amplifier harness into cavity 4 of socket housing [6B] (1), and the yellow/violet terminated wire (5) into cavity 5. | |||||||||
3. | Install the secondary locking wedge into the socket housing per service manual instructions. | |||||||||
4. | Plug the six-way socket housing [6B] into the pin housing [6A] (14) on the radio wire harness (12) installed in the previous section or the vehicle audio harness. | |||||||||
5. | Plug the 23-way socket housing (3) into the receptacle on the side of the amplifier. Listen for a definite "click". NOTE Two branches of the amplifier harness, each with two socket and two spade terminals, connect to the front speakers. | |||||||||
6. | Route the short branch (6) of the amplifier harness (with white/orange and light-green/white wires) underneath the left-side fairing support bracket and over to the left-side speaker. | |||||||||
7. | Carefully disconnect the interconnect harness socket terminals from the left-side speaker spade terminals. | |||||||||
8. | Install the socket terminals from the amplifier harness to the speaker spade terminals. The spade terminals are different-sized to prevent improper assembly. | |||||||||
9. | Install the spade terminals from the amplifier harness to the socket terminals from the interconnect harness. The spade terminals are different-sized to prevent improper assembly. | |||||||||
10. | Route the long branch (7) of the amplifier harness (with gray/red and light-green/black wires) to the right-side speaker. | |||||||||
11. | Carefully disconnect the interconnect harness socket terminals from the right-side speaker spade terminals. | |||||||||
12. | Install the socket terminals from the amplifier harness to the speaker spade terminals. The spade terminals are different-sized to prevent improper assembly. | |||||||||
13. | Install the spade terminals from the amplifier harness to the socket terminals from the interconnect harness. The spade terminals are different-sized to prevent improper assembly. NOTE See Figure 3. Routing wires and conduit over the amplifier (1) and radio near the front (headlamp) side (3) will make installation of the outer fairing (2) difficult due to tight clearance. |
Figure 3. Fairing Mounted Amplifier Wiring Clearances | ||||||||
14. | See Figure 6. Use a cable strap from the kit to coil the unconnected wiring (16) of the radio wire harness. Optionally, the brown and white/brown wires and their connector [42A] can provide a signal to an additional left speaker. The green and green/brown wires and their connector [41A] can provide a signal to an additional right speaker. | |||||||||
15. | Route the amplifier and radio harnesses rearward along the side of the radio and amplifier or the area above the amplifier nearest the inner fairing ( See Figure 3. , area 4). Use cable straps from the kit to fasten the amplifier and radio harnesses to existing harnesses inside the fairing. | |||||||||
16. | See Figure 6. Route the remaining branch (8) of the amplifier harness rearward on the vehicle to the harness tray. Open the cover of the harness tray. Route the amplifier harness through the openings in the tray, using cable straps to fasten to the main harness. | |||||||||
17. | Route the harness along the right side of the battery cavity. Bring the red fuse wire (9) and black ground wire (10) into the front of the battery compartment. |
1. | NOTE To prevent permanent damage to the woofers and outer fairings, the original speaker adapters MUST be reused after the following modifications are made. | |
2. | NOTE The speaker grilles are side-specific. The grilles install so that the tweeter is to the outboard side of the vehicle. | |
3. | See Figure 5. Connect the wires from the grille-mounted tweeter to the spade terminals (1) and (2) on the back of the speaker. Different size spade contacts prevent improper assembly. | |
4. | Align the mounting holes in the speaker, adapter and grille. Use the two longer TORX® screws removed earlier to fasten all three components to the inner fairing through the two top holes. See Figure 4. Use a new Phillips head screw (6) from the kit in the lower outboard hole, capturing the fairing support brace under the screw head. The lower inboard hole is not used. | |
5. | Tighten screws: a. Lower: Torque: 2.5–3.2 N·m (22–28 in-lbs) b. Upper: Torque: 4.0–5.6 N·m (35–50 in-lbs) | |
6. | See Figure 5. Install the socket terminals from the vehicle harness to the spade terminals (3) and (4) on the back of the speaker. Different size spade contacts prevent improper assembly. | |
7. | Repeat Steps 1 through 6 for the remaining speaker on the opposite side of the vehicle, then proceed to Rear Speakers, All Models or RETURN TO SERVICE as appropriate. |
1 | OE Speaker adapter, modified (2) |
2 | Speaker grille (left shown, right opposite) |
3 | Tweeter |
4 | Premium speaker (2) |
5 | Spade terminals |
6 | Phillips head self-tapping screw (2) |
1. | Connect the battery as follows: a. Install the amplifier harness fused red wire terminal along with the red battery positive (+) cable terminal to the positive (+) side of the battery. b. Install the amplifier harness black ground wire terminal along with the black battery negative (-) cable terminal to the negative (-) side of the battery. c. Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. d. See Figure 6. Tuck the fuse holder (11) and amplifier connecting wires in front of the battery. NOTE It may be helpful to cut the cable strap on the strain relief arm of the fuse holder, and install a new cable strap to tie the arm in place after the fuse holder is in position. e. For 2006 and 2007 models: Refer to the service manual and follow the instructions to install the battery into the vehicle. For 2008 and later models: Be sure that all wire terminals connected to the battery are aligned with the openings in the ECM caddy. Refer to the service manual and follow the instructions to install the ECM caddy to the top of the battery. f. For ALL models: Install the main fuse per service manual instructions. | |
2. | NOTE Before installing the outer fairing, check that speakers are operating correctly, understanding that full sound quality and fidelity will not be achieved until the outer fairing is completely installed. | |
3. | Test the sound system for proper operation. Refer to the ADVANCED AUDIO SYSTEM section of the owner's manual and turn the radio or CD player ON. Make sure all speakers are working and front/rear fader function is operating correctly. If no sound, proceed to TROUBLESHOOTING. | |
4. | Upon satisfactory sound system operation, install the outer fairing and windshield per service manual instructions. | |
5. | Disconnect the negative (black) battery cable from the negative (-) battery terminal. | |
6. | Refer to the service manual, and follow the instructions to install the fuel tank and console. Attach the negative battery cable. | |
7. | See service manual and install seat. After installing seat, pull upward on seat to be sure it is locked in position. |
1 | Six-way socket housing [6B] |
2 | Amplifier harness |
3 | 23-way connector [149B] |
4 | Yellow/orange terminated wire |
5 | Yellow/violet terminated wire |
6 | To left-side speaker |
7 | To right-side speaker |
8 | Battery branch of harness |
9 | Red wire |
10 | Black wire |
11 | Fuse holder |
12 | Radio wire harness |
13 | 35-way connector [28B] |
14 | Six-way pin housing [6A] |
15 | Insert into 23-way connector [149B] on amplifier harness |
16 | Unconnected wiring |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Amplifier, fairing mounted | 76000071 |
2 | Harness, amplifier | Not sold separately |
3 | Cable strap (10) | Not sold separately |
4 | Screw, Phillips head, self-tapping (2) | Not sold separately |
5 | Speaker, premium (2) | 77026-10 |
6 | Speaker grille, left | Not sold separately |
7 | Speaker grille, right | Not sold separately |