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CHROME CB INTERCOM CONSOLE KIT
J037282007-08-07
GENERAL
Kit Number
77140-05
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Kit Contents
See Figure 4 and Table 1.
Table 1. Kit Contents
Description (Quantity)
Part Number
Chrome pod
77139-06
CB intercom insert
77141-05
Self-tapping screws (3)
2754
NOTE
A Service Manual for your model motorcycle is available from your Harley-Davidson Dealer.
REMOVAL
1. Remove seat according to the Owner's Manual instructions.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNING
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)
2. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.
3. See Figure 1. Open fuel door (1) on console (2). Remove two Allen head screws (3) inboard of rubber bumpers. These screws secure console to clip nuts on the canopy bracket.
4. Remove Allen head screw (4) to detach flange at rear of console from clip nut on fuel tank weldment.
1Fuel door and lock
2Console
3Screws (2)
4Screw
5Filler cap
Figure 1. Fuel Tank Console
1Cap and lock ring
2Headset receptacle and wire harness
3Screws (3)
4Pod
Figure 2. Original Equipment CB Intercom Console Pod
5. Remove filler cap (5) from neck of fuel tank. Remove console (2) turning it to the side and being careful not to damage wiring.
6. See Figure 2. Remove three screws (3) to release pod (4) from console. Discard screws.
7. See Figure 3. Raise headset receptacle cap (1). Obtain a pin punch and place it in either notch of lock ring (2). Rotate in counterclockwise direction until loose.
8. Remove lock ring (2) and cap (1) from headset receptacle (3).
9. Remove headset receptacle from pod. Discard pod.
1Cap
2Lock ring
3Headset receptacle
Figure 3. Headset Receptacle, Cap, and Lock Ring
INSTALLATION
WARNING
Rider and passenger safety depend upon the correct installation of this kit. 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. (00308b)
  1. Obtain new pod from kit. From inside pod, insert threaded end of headset receptacle through side hole.
  2. Place receptacle cap over end of headset receptacle so that it seats in recess of pod.
  3. See Figure 3. Open cap (1), and with notches on the outboard side, thread lock ring (2) onto headset receptacle (3).
  4. Place pin punch in either notch of lock ring (1) and rotate in a clockwise direction until tight.
    5. NOTE
    Before securing new pod to console, insert self-tapping screws from kit in chrome pod to begin thread.
  5. See Figure 4. Feed pin housing and conduit through top of console seating pod in recess. Install three self-tapping screws (1) from kit to secure chrome pod (2) to console. Alternately tighten to 20-30 in-lbs (2.3-3.4 Nm).
    6. NOTE
    A blocked overflow hose can cause excess gasoline to remain above the filler neck insert. Fuel expansion can cause an overfilled tank to overflow through the filler cap vent.
  6. See Figure 1. Place console (2) over filler neck onto canopy. Be sure that hoses and wires are not pinched by the console during installation. Reinstall filler cap (5).
  7. Install Allen head screw (4) to fasten rear flange of console (2) to clip nut on fuel tank weldment. Tighten screw to 25-30 in-lbs (2.8-3.4 Nm).
  8. Open fuel door (1) on console. Install two Allen head screws (3) to secure front of console to clip nuts on canopy bracket. Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
  9. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten bolt to 60-96 in-lbs (6.8-10.9 Nm).
  10. Install seat according to the Owner's Manual instructions.
    11. NOTE
    Before installing CB intercom insert, place on chrome pod to ensure part is properly aligned.
  11. See Figure 4. Peel off adhesive strip from back of CB intercom insert (3).
  12. Place CB intercom insert (3) on chrome pod (2) and press firmly into position.
    13. NOTE
    Allow 24 hours for adhesive to cure before exposure to water.
1Self-tapping screws (3)
2Chrome pod
3CB intercom insert
Figure 4. Chrome CB Intercom Console Kit