BOOM! AUDIO STAGE II TOUR-PAK AMPLIFIER INSTALLATION KIT
J063252016-05-25
GENERAL
Dealer installation is recommended.
Kit Number
76000751
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
This kit must be installed:
  • Before installation of the Boom! Audio Stage II Tour-Pak Speaker Kit (Part No. 76000526).
  • After installation of a PRIMARY fairing-mounted amplifier.
The amplifier (Part No. 76000277A) installed with this kit must be purchased separately from a Harley-Davidson dealer.
FLHX, FLHXS and FLHXSE models require installation of an original equipment (OE) rigid Tour-Pak Mounting Rack. See a Harley-Davidson dealer for the correct parts, available separately. Install per the service manual.
ALL models: If installing more than TWO amplifiers, only one AUDIO IN Three-Way Y-Connector (Part No. 69201092) AND one Battery+ Three-Way Y-Connector (Part No. 70270-04A) are needed. These connectors could be included in other kits. Purchase separately from a Harley-Davidson dealer as needed.
NOTE
DO NOT mix Stage I and Stage II speakers on the same vehicle.
NOTICE
Radio EQ MUST be updated by a Harley-Davidson dealer BEFORE operating the audio system. Operating the audio system prior to radio EQ update will IMMEDIATELY damage the speakers. (00645d)
Radio EQ update using the Digital Technician® II diagnostic tool is:
  • Recommended before speaker INSTALLATION
  • Required before audio system OPERATION.
  • Only available through authorized Harley-Davidson dealers.
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. 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. (00333b)
NOTE
This instruction sheet references service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
Electrical Overload
NOTICE
It is possible to overload your vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. See an authorized Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories or for necessary wiring changes. (00211c)
WARNING
When installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a)
The amplifier installed with this kit requires up to 8 amps more current from the electrical system.
Kit Contents
See Figure 9 and Table 1.
PREPARATION
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. See the service manual to perform the following generalized steps:
  2. See the service manual to perform the following generalized steps:
    1. Remove seat. Retain all seat mounting hardware.
    2. Remove the ECM caddy from the top of the battery.
    3. Disconnect both battery cables, negative battery cable first.
    4. Remove battery.
    5. Remove right side cover.
    6. Remove left side cover.
    7. Remove the two bolts attaching the electrical caddy under the left side cover.
AMPLIFIER INSTALLATION
1.
Clean the capacity label inside the Tour-Pak with a 50-50 mixture of isopropyl alcohol and distilled water. See Figure 9. Apply the new load limit label (2) covering the original label. Note the revised load limit due to the amplifier installation.
2.
Install the brackets (4 and 8) to amplifier (A) with screws (6). Alternately tighten to 9.5–12.2 N·m (84–108 in-lbs).
3.
Remove all items from Tour-Pak®. Remove Tour-Pak. Remove Tour-Pak liner (if present). Place Tour-Pak on a protected surface.
NOTE
  • Disconnect speakers. Remove speakers from speaker pods to avoid damage to wiring inside.
  • Note wire locations in connectors. To aid in drilling, de-pin both connector halves. Pull wires away from drilling area.
  • Use of a step drill bit is recommended to prevent damage to the speaker pod covering.
4.
See Figure 1. Drill a new25 mm (1.0 in) hole (3) in each speaker pod (1), away from the existing grommet (2), approximately where shown.
NOTE
These holes are for leads [36TB] and [37TB] of the amplifier harness ( Figure 9 , Item 3), which connect during installation of the Boom! Audio Stage II Tour-Pak Speaker Kit.
5.
Lightly sand the speaker housings around the grommet holes.
6.
Pull wires back through holes. Repin connectors.
NOTE
If the amplifier is installed before the Tour-Pak is mounted, it is not possible to secure the Tour-Pak.
7.
See Figure 2. Place hex nuts (1) into hex pockets (3) on the Tour-Pak support (5).
8.
Install Tour-Pak. See the service manual. Tighten screws to 6.8–8.1 N·m (60–72 in-lbs).
9.
Cover the rear fender with a towel. Slide the amplifier with brackets in from the side.
10.
Install the amplifier. Secure with flat washers (7), lockwashers (8) and screws (6). Tighten screws to 6.8–8.1 N·m (60–72 in-lbs).
1Speaker pod
2Existing hole and grommet, speaker pod
3New hole, 1.0 in (25 mm)
4Grommet, round
Figure 1. Grommet Installation
1Nut (4)
2Tour-Pak
3Hex pocket, Tour-Pak support (4)
4Tour-Pak support
5Amplifier bracket
6Screw (4)
7Flat washer (4)
8Lockwasher (4)
Figure 2. Amplifier Installation
AMPLIFIER HARNESS INSTALLATION
NOTE
These tips help make sure all wiring fits under the seat, especially in multiple amplifier installations:
  • See Figure 5. Begin routing the amplifier harness from the large 23-way connector [149] (1), moving forward on the vehicle. The large connector does not fit through narrower passages.
  • Route the remainder of the harness forward on the vehicle through the space between the Tour-Pak support (3) and fender (4).
  • Route all wire harnesses under the frame rail to avoid pinching by cover or seat.
  • Make connections [36TB] (right pod speaker) and [37TB] (left pod speaker) during installation of the Boom! Audio Stage II Tour-Pak Speaker Kit.
  • Take care to route ALL amplifier harness branches away from spark plug wires. Close proximity induces spark noise into the audio system.
  • When routing wires from right to left sides of the vehicle, tuck harnesses under the frame tray behind the battery. Keep the battery compartment accessible.
  • Route the six-way black, pink-wired audio connectors under the right frame rail, into the right side cover. Bundle in front of ABS module, if present.
  • Locate the black, four-way Molex connector [296A] near the back of the underseat area. FLHX/FLTRX models: On a jumper harness coming from the fairing. FLHTCU/FLHTK models: On an adapter harness with two 16-way ([162C] and [162D]) and two four-way ([296A] and (297B]) connectors. With ONLY ONE Stage II amplifier installed in the rear: Remove the plug in the [296A] connector. Connect the amplifier harness. With TWO or more Stage II amplifiers installed in the rear: Plug the audio input harness into connector halves [296A] and (297B] on the interconnect harness (2). Plug amplifier harness (3) connector [296A] into the audio input harness.
  • Confirm that the amplifier harness connectors and harness routing are clear of all moving parts.
  • Route the battery terminal branch to the battery terminals, but DO NOT connect the battery cables now.
  • If more than two amplifiers or other accessories already use the ground post of the battery, use one of the frame ground studs.
  • If more than two amplifiers are installed on the vehicle, ONE Battery+ Three-Way Y-Connector (available separately) is required.
  • Once routing is finalized, secure with cable straps (10) and retainers (1).
123-Way connector [149]
2Amplifier harness
3Tour-Pak support
4Rear fender
Figure 3. Harness Routing
1.
Complete Routing harness:
a.
Route kit harness forward along frame rails following main harness under backbone.
b.
Route harness along the right side of battery cavity between the battery and reverse solenoid. Place the red fuse wire and black ground wire in front of the battery.
c.
See Figure 4. Locate the 2-way Delphi CAN connector [319B] (1) under the right side cover.
d.
The cap is a terminating resistor pack secured to the electrical caddy. Remove connector [319B] from the resistor pack.
e.
Connect [319A] from the harness provided with the kit (See Figure 5 item 8) to [319B] of the vehicle.
f.
If this is the only (rear) amplifier connection in this installation, connect the [319B] side of the harness (See Figure 5 item 9) from the kit back into the terminating resistor pack from step "B" above. If multiple rear amplifiers are used, daisy chain [319B] from this harness to [319A] of the next amplifier harness. Always verify that the remaining connector [319B] is connected to the terminating resistor of the vehicle.
2.
a.
Locate connector 299 on the vehicle (under the inner fairing, see service manual for location). This connector may already be connected to a faring amplifier.
b.
Install 69200921 "Y" (See Figure 7 ) to vehicle side 299, with one end to the fairing amplifier harness.
c.
Install the 69201545 (See Figure 6 ) jumper to the other end of the 69200921 "Y" inside the fairing. (If a 69201545 jumper has already been installed on vehicle skip ahead to "e" Do not install more than one 69201545 jumper.)
d.
Route the 69201545 jumper though the inner faring and into the wire trough following the fairing harness routing.
e.
Locate the end of the 69201545 jumper under the RH side cover near the [319] connectors. If a 69201545 is present from a prior install use a 69200921 "Y" under the RH side cover to connect [299].
NOTE
If more than one amplifier is installed in rear of vehicle, up to two 69200921 connectors may be used.
1CAN connector [319B]
Figure 4. CAN Connector [319B], Under Right Side Cover
1Amplifier connector [149]
2Left side tour-pak mid/tweeter [37TB]
3Amplifier input connector [296B]
4Positive battery terminal [B+]
5Inline B+ connector [160A/B]
6Amplifier fuse
7Negative battery terminal [B-]
8New CAN connector [319A] to OE harness
9CAN connector [319B] to terminating resistor, or daisy chain to additional amplifier harness
10Tour-pak woofer speaker connector [297A]
11Right side tour-pak mid/tweeter [37TB]
12Accessory/Ignition connector [299]
Figure 5. Main Amplifier Harness
1Accessory power [299A]
2Accessory power [299B]
Figure 6. Wire Harness, Jumper
1Accessory power [299B]
2Accessory power [299A]
Figure 7. Accesssory Power Wire Harness
1Left fairing speaker (may be installed)
2Amplifier, fairing, powers fairing speakers, amplifier number 1 (installed earlier)
3Right fairing speaker (installed earlier)
4Accessory/Ignition connector [299]
5CAN connector [319B] to terminating resistor, or daisy chain to additional amplifier harness
6New CAN connector [319A] to OE harness
7Connection to battery [B+ and B-]
8Amplifier input connector [296B]
9Left Tour-Pak speaker (installed using this kit)
10Right Tour-Pak speaker (installed using this kit)
11Amplifier connector [149]
12Amplifier, Tour-Pak, powers Tour-Pak speakers, amplifier number 4 (installed using this kit)
13Jumper harness (part number 6901545)
Figure 8. Speaker Stage II Boom! Audio Tour-Pak Amplifier Installation Kit
COMPLETION
NOTE
To prevent possible damage to the sound system, verify that the ignition switch is OFF before attaching the battery cables.
WARNING
Connect positive (+) 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. (00068a)
1.
Install battery. See the service manual.
2.
See the service manual. Connect the battery terminal branch to the battery terminals (red positive cable first).
a.
Position the + ring terminal onto the positive battery terminal. Install the bolt.
b.
Position the in-line fuse holder in a location that can be easily accessed.
c.
Position the - ring terminal onto the negative battery terminal. Install the bolt.
d.
Tighten both bolts to 6.8–7.9 N·m (60–70 in-lbs).
3.
Install the electrical caddy under the left side cover with the two bolts removed earlier. Tighten both bolts to 8.1–10.8 N·m (72–96 in-lbs).
4.
Install the ECM caddy per the service manual.
5.
Apply a light coat of petroleum jelly or corrosion retardant material to battery terminals.
6.
See the service manual. Install seat. After installing seat, pull up on the seat to verify that it is secure.
7.
See the service manual. Install main fuse.
SERVICE PARTS
Figure 9. Service Parts, Amplifier Installation Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Bracket, wire retainer (4)
69200342
2
Capacity label (not shown)
14001001
3
Wire harness, Tour-Pak Amplifier
Not sold separately
4
Amplifier bracket, left side
Not sold separately
5
Capscrew (4)
2551W
6
Screw (4)
926
7
Grommet, round (2)
12100073
8
Amplifier bracket, right side
Not sold separately
9
Lockwasher (4)
7036
10
Cable strap (6)
10006
11
Flatwasher (4)
6703
12
Nut (4)
10100065
13
Jumper harness
96201545
14
Power Connector
69200921
Item mentioned in text, but not included in kit:
A
Amplifier
Wiring Diagram Information
Wire Color Codes
For Solid Color Wires: See Connector/Wiring Diagram Symbols (Typical) . The alpha code identifies wire color.
For Striped Wires: The code is written with a slash (/) between the solid color code and the stripe code. For example, a trace labeled GN/Y is a green wire with a yellow stripe.
Wiring Diagram Symbols
See Connector/Wiring Diagram Symbols (Typical) . Brackets [] indicate connector numbers. The letter inside the brackets identifies whether the housing is a socket or pin housing.
A=Pin: The letter A and the pin symbol after a connector number identifies the pin side of the terminal connectors.
B=Socket: The letter B and the socket symbol after a connector number identifies the socket side of the terminal connectors. Other symbols found on the wiring diagrams include the following:
Diode: The diode allows current flow in one direction only in a circuit.
Wire break: The wire breaks are used to show option variances or page breaks.
No Connection: Two wires crossing over each other in a wiring diagram that are shown with no splice indicating they are not connected together.
Circuit to/from: This symbol indicates a complete circuit diagram on another page. The symbol is also identifying the direction of current flow.
Splice: Splices are where two or more wires are connected together along a wiring diagram. The indication of a splice only indicates that wires are spliced to that circuit. It is not the true location of the splice in the wiring harness.
Ground: Grounds can be classified as either clean or dirty grounds. Clean grounds are identified by a (BK/GN) wire and are normally used for sensors or modules.
NOTE
Clean grounds usually do not have electric motors, coils or anything that may cause electrical interference on the ground circuit.
Dirty grounds are identified by a (BK) wire and are used for components that are not as sensitive to electrical interference.
Twisted pair: This symbol indicates that the two wires are twisted together in the harness. This minimizes the circuit's electromagnetic interference from external sources. If repairs are necessary to these wires, they should remain as twisted wires.
1Connector number
2Terminal code (A=pin, B=socket)
3Solid wire color
4Striped wire color
5Socket symbol
6Pin symbol
7Diode
8Wire break
9No connection
10Circuit to/from
11Splice
12Ground
13Twisted pair
Figure 10. Connector/Wiring Diagram Symbols
Table 2. Wire Color Codes
ALPHA CODE
WIRE COLOR
BE
Blue
BK
Black
BN
Brown
GN
Green
GY
Gray
LBE
Light Blue
LGN
Light Green
O
Orange
PK
Pink
R
Red
TN
Tan
V
Violet
W
White
Y
Yellow
1Positive ring terminal [B+]
2Inline B+ connector [160A/B]
3Amplifier fuse
4Right side speaker (mid/tweeter) connector [36TB]
5Rear speaker pod woffer [297A]
6Fairing amplifier connector [149B]
7Negative ring terminal [B-]
8Left side speaker (mid/tweeter) connector [37TB]
9Amplifier input [296B]
10Accessory/Ignition power [299B]
11CAN connector [319B]
12CAN connector [319A]
Figure 11. Main Amplifier Wiring Harness (Fairing)
1Accessory/Power [299B]
2Accessory/Power [299A]
Figure 12. Rear Jumper Wire Harness
1Accessory power [299B], socket
2Accessory power [299A], pin
3Accessory power [299A], pin
4Accessory power [299B], socket
5Accessory power [299A], pin
6Accessory power [299A], pin
Figure 13. Accessory Power Harness