Kits | Suggested Tools | Skill Level(1) |
---|---|---|
76001163, 76001164 | Safety glasses, torque wrench, power drill, drill bit set (including 25/64-inch and 3/4-inch), masking tape, deburring tool, isopropyl alcohol, clean shop rags, appropriate cutting tool (reciprocating saw or hand saw) |
Verify that all contents are present in the kit before installing or removing items from vehicle. | |||||
---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
1 | 1 | Sub woofer, primary (right saddlebag) | Not sold separately | ||
1 | Sub woofer, secondary (left saddlebag) | Not sold separately | |||
2 | 2 | Washer, EPDM | 57765-99 | ||
3 | 1 | Plug panel, right | 76001188 | ||
1 | Plug panel, left | 76001176 | |||
4 | 2 | Thumb screw | 10500211 | ||
5 | 1 | Drill template, right saddlebag | 76001189 | ||
1 | Drill template, left saddlebag | 76001177 | |||
6 | 1 | Internal harness | 69203012 | ||
7 | 1 | External harness, primary (right saddlebag) | 69203031 | ||
1 | External harness, secondary (left saddlebag) | 69203032 | |||
8 | 6 | Cable strap | 10065 | ||
9 | 6 | Retainer | 69200342 | ||
10 | 1 | Label, saddlebag fastener | 14003212 | ||
11 | 1 | Inner bezel, right | 76001186 | ||
1 | Inner bezel, left | 76001185 | |||
12 | 1 | Outer bezel assembly, right | 76001187 | ||
1 | Outer bezel assembly, left | 76001175 | |||
13 | 1 | Screw, saddlebag mount | 10201365 | ||
14 | 8 | Screw | 10201347 | ||
15 | 1 | Top enclosure panel, right | 76001170 | ||
1 | Top enclosure panel, left | 76001193 | |||
16 | 3 | Tapping screw | Not sold separately | ||
Items mentioned in text, but not included in kit | |||||
A | 1 | Right saddlebag | |||
B | 1 | Left saddlebag |
1 | Front speakers (fairing) |
2 | 2nd Set of speakers (fairing lowers, saddlebags, Tour-Pak) |
2a | 3rd Set of speakers (fairing lowers, Tour-Pak) |
3 | Primary amplifier |
4 | Right subwoofer (primary) |
5 | Secondary amplifier |
6 | Left subwoofer (secondary) |
1. | Remove both saddlebags. See service manual. | |
2. | Remove side covers. See service manual. | |
3. | Remove main fuse. See service manual. | |
4. | Remove seat. See service manual. | |
5. | Remove left side caddy. See service manual. | |
6. | Remove top caddy. See service manual. | |
7. | Remove lower backbone caddy. See service manual. |
1. | See Figure 8. Position drill template on right saddlebag. NOTE Do not modify left saddlebag unless a second subwoofer is being installed. a. Mask off entire drill template (2) area on right saddlebag (1) with masking tape. b. Install drill template (2). c. Secure entire perimeter of drill template (2) with tape. d. Install tapping screws (3) to hold down drill template (2). | |
2. | See Figure 9. Using a marker, trace drill template outline (1) onto saddlebag's masking tape. | |
3. | See Figure 8. Modify right saddlebag (1). a. Drill pilot holes in drill locations (4, 5, 6) using 1/8-inch drill bit. b. Relief Holes: Drill six 25/64-inch relief holes (4). c. Screw Holes: Drill eight 25/64-inch screw holes (6). NOTE When riding in rain, water will potentially come through the bezel grille. Drain hole is required for water drainage. d. See Figure 10. Drainage Holes: Drill two 1/4-inch drainage holes (3) in the approximate location. e. See Figure 9. With drill template still in place and using an appropriate saw, cut along the outer part of template outline (1). f. Remove tapping screws (3), drill template and tape from saddlebag. g. Grommet Hole: Drill 3/4-inch grommet hole (5) where tapping screw (3) was removed. h. Deburr holes and template outline by lightly sanding the surface. i. Clean all surfaces of the body work with 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry completely. | |
4. | See Figure 1. Install saddlebag fastener label (10). a. Install label near rear mounting lever screw. | |
5. | See Figure 11. Test fit inner (2) and outer (1) bezels on saddlebag. a. Install and lightly tighten screws (8). b. Make sure components fit properly. c. Remove screws and bezels (1, 2). d. Make adjustments as needed. | |
6. | Remove VHB tape backing from bezel. | |
7. | See Figure 12. Apply silicone caulk (3) to inner (1) and outer (2) bezels. NOTE To assist in preventing water intrusion in saddlebag, silicone caulk is applied as an extra measure of protection. | |
8. | See Figure 11. Install inner (2) and outer (1) bezels on saddlebag. a. Install screws (3). NOTE DO NOT over tighten bezel screws. b. See Figure 13. Tighten in sequence. Torque: 0.4–0.6 N·m (4–5 in-lbs) Bezel screws | |
9. | See Figure 14. To maximize seal performance, use wooden wedges on inner bezel (1). Hold in place for 24 hours. a. For maximum corner adhesion, place wooden wedge in area as directed by arrow. | |
10. | See Figure 15. Install harness 69203012 (5) into right saddlebag. a. See Figure 17. Rotate grommet until proper harness routing is achieved. | |
11. | See Figure 15. Connect harness 69203031 (4) to harness 69203012 (5). NOTE Kit 90201540 needs to be installed for securing saddlebags. See Refer to Installation Requirements. | |
12. | Install right saddlebag. a. Install OE rear saddlebag mount screw. b. See Figure 1. Install saddlebag front mount screw (13) from kit. Tighten. Torque: 5–5.6 N·m (44–50 in-lbs) Saddlebag front mount screw | |
13. | Connect harness 69203031 to: a. See Figure 3. For single subwoofer, single amplifier and two speaker setup. Harness connector will need to be rewired. Refer to Rewire Harness 69203031. Failure to rewire connector will result in no audio. NOTE: If saddlebag speakers are added after subwoofer is installed, the original configuration of harness 69203031 will have to used. Wires in cavities one and four. b. Primary amplifier harness connector [351A] (audio out). See Figure 3. Equipped with Single Subwoofer, Single Amplifier, Two Speakers. c. Secondary amplifier harness connector [352A_1] or [352A_2] (audio out). See Figure 4. Equipped with Single Subwoofer, Dual Amplifiers, Four or Six Speakers. | |
14. | See Figure 16. Route and secure harnesses with cable straps. a. Make sure harnesses do not interfere with moving parts. b. Use factory harness anchor points. | |
15. | See Figure 19. Install subwoofer (2). | |
16. | See Figure 15. Connect harness 69203012 (5) into subwoofer connector (2). See Figure 19. | |
17. |
1 | Right saddlebag |
2 | Drill template |
3 | Tapping screw (3) |
4 | 25/64-inch relief hole (6 drilled) |
5 | 3/4-inch grommet hole (1 drilled) |
6 | 25/64- inch screw hole (8 drilled) |
1 | Template outline |
1 | Left saddlebag |
2 | Right saddlebag |
3 | ¼-inch drain hole locations |
1 | Outer bezel |
2 | Inner bezel |
3 | Screw (8) |
1 | Inner bezel |
2 | Outer bezel |
3 | Silicone caulk |
1 | Inner bezel |
2 | Wood blocks (2) |
1 | Harness 69203012 |
2 | Outline of left saddlebag |
3 | Harness 69203032 |
4 | Harness 69203031 |
5 | Harness 69203012 |
6 | Outline of right saddlebag |
1 | Anchor point |
2 | Rear fender strut |
1 | Right saddlebag |
2 | Harness routing |
3 | Grommet (Harness 69203012) |
1 | Right saddlebag |
2 | Outer bezel |
3 | Grille |
1 | Right subwoofer |
2 | Subwoofer connector |
2 | Right saddlebag |
1. | See Figure 20. Repeat procedures 1-8 from right saddlebag. | |
2. | See Figure 15. Install harness 69203012 (5) into right saddlebag. a. See Figure 17. Rotate grommet until proper harness routing is achieved. | |
3. | See Figure 15. Connect harness 69203032 (3) to harness 69203012 (5). | |
4. | Install left saddlebag. a. Install OE rear saddlebag mount screw. b. See Figure 1. Install front saddlebag mount screw (13) from kit. | |
5. | Connect harness 69203032 to: a. Secondary amplifier harness connector [352A_1] or [352A_2] (audio out). See Figure 7. Equipped with Dual Subwoofers, Dual Amplifiers, Four Speakers. | |
6. | Route and secure harnesses with cable straps. a. Make sure harnesses do not interfere with moving parts. b. Use factory harness mounting points. | |
7. | See Figure 19. Install subwoofer (2). | |
8. | See Figure 15. Connect harness 69203012 (5) into subwoofer connector (2). See Figure 19. |
1 | Left drill template |
2 | 3/4 inch grommet hole (1 drilled) |
3 | Left saddlebag |
1. | Disconnect subwoofer. | |
2. | Remove subwoofer from saddlebag. | |
3. | See Figure 1. Position EPDM washer (2) on inner side of plug panel (3). | |
4. | See Figure 21. Position plug panel (1) over inner bezel. | |
5. | Install thumb screws (2). Tighten. |
1 | Plug panel |
2 | Thumb screw (2) |
3 | Right saddlebag |
1. | 1. See Figure 22. Use special tool to remove terminals from connector. Special Tool: MOLEX ELECTRICAL CONNECTOR TERMINAL REMOVER (HD-48114) | |
2. | Remove light-blue wire (5) from cavity one (1). | |
3. | Install light-blue wire (5) into cavity three (3). | |
4. | Remove light-blue/black wire (6) from cavity four (4). | |
5. | Install light-blue/black wire (6) into cavity two (2). |
1 | Cavity one |
2 | Cavity two |
3 | Cavity three |
4 | Cavity four |
5 | Light blue wire |
6 | Light blue/black wire |
1. | Install lower backbone caddy. See service manual. | |
2. | Install top caddy. See service manual. | |
3. | Install left side caddy. See service manual. | |
4. | Install seat. See service manual. | |
5. | Install main fuse. See service manual. | |
6. | Install side covers. See service manual. | |
7. | Install both saddlebags. See service manual. |