BOOM! AUDIO AMPLIFIER KIT
J036512010-05-28
GENERAL
Kit Number
76000068
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Separate purchase of additional parts or accessories is required for proper installation of this Amplifier Kit on your model vehicle. See the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and 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)
This amplifier requires up to 11 amps additional current from the electrical system.
Kit Contents
See Figure 7 and Table 1.
INSTALLATION
Preparation
NOTE
For vehicles equipped with security siren:
  • Verify that the Hands-Free Fob is present.
  • Turn the ignition key switch to IGNITION.
  1. Refer to the service manual and follow the instructions to remove the main fuse.
  2. Follow the service manual instructions to remove the seat.
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)
  1. 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.
  2. For ALL models: Refer to the service manual, and follow the instructions to remove the fuel tank console and fuel tank.
For Touring models only:
NOTE
If stronger headset receptacle retention is desired, the existing spring assembly can be replaced with new spring assembly 76300-06 (purchased separately).
  1. If a passenger headset harness is installed: Grasp the cable strap on the end of the vinyl spring sleeve, and unhook the sleeve and the end of the spring from the tab at the upper right of the license plate holder. Use a cable strap from the kit to fasten the end of the spring to the lower left slot on the license plate holder.
For ALL models: Proceed to the "Amplifier Installation" instructions for the correct year and model vehicle.
Amplifier Installation, 2008 and Earlier Touring Models
NOTE
The Tour-Pak®does not have to be removed from the vehicle to perform this installation.
1.
Open the Tour-Pak lid and remove all items from the Tour-Pak base.
2.
Models with rubber mat: Remove the mat. Models with molded liner: Open the map pocket and remove the acorn nuts with flat washers. Remove the map pocket and liner.
NOTE
Do not remove the screws (1) from the Tour-Pak attaching holes at this time.
Do not remove or loosen the rearmost locknut (6).
The luggage rack spacers (3) will drop free as the locknuts are removed.
1Hex head cap screw (4)
2Flat washer (8)
3Spacer (4)
4Nylon-cap lock nut (4)
5Luggage rack
6Rearmost lock nut (do not remove or loosen)
Figure 1. Tour-Pak Attaching Hardware, 2008 and Earlier Touring Models
3.
See Figure 1. Holding the hex head cap screws (1) at the bottom of the Tour-Pak, remove the four forward nylon cap locknuts (4), washers (2) and spacers (3) on the underside that fasten the Tour-Pak to the luggage rack (5) side rails. Do not remove or loosen the rearmost locknut (6). Do not remove the screws from the holes.
4.
See Figure 2. Obtain the two cushion bumpers (2) from the kit.
5.
Use isopropyl alcohol to thoroughly clean the rear fender surface in the area (4) behind the seat retention nut (3).
6.
Peel the liner from the adhesive backing on one of the bumpers, and fasten the bumper to the fender as shown, crosswise on center about 25 mm (1 in) behind the seat retention nut. Hold for a few seconds to set the adhesive.
7.
Peel the liner from the backing on the remaining bumper, and fasten that bumper about 25 mm (1 in) behind the first bumper.
NOTE
For standard or King Tour-Paks: Use the longer screws if the Tour-Pak interior color is gray. Use the shorter screws if the Tour-Pak interior color is black.
For chopped Tour-Paks: Use the longer screws.
1Amplifier
2Bumper (2)
3Seat retention nut
4Fender area to be cleaned
5About one inch (25 mm) from edge of nut
6About one inch (25 mm) from edge of bumper
Figure 2. Amplifier Installation, 2008 and Earlier Touring Models
8.
Obtain the amplifier (1) and correct attaching screws from the kit.
9.
Hold the amplifier with the mounting flanges up, and the electrical connector toward you. From the right side of the vehicle, slide the amplifier underneath the Tour-Pak, between the fender and the luggage rack side rails.
NOTE
Always install the mounting screws from inside the Tour-Pak. If the screws are installed from the bottom, the threaded ends can tear the rubber mat or molded liner, and scratch items (such as helmets) stored inside.
10.
See Figure 1. One at a time starting at the front, remove the Tour-Pak attaching screws (1) and flat washers (2), replacing them with new screws and flat washers from the kit. On the underside of the luggage rack, install the original spacers (3, concave side up), new flat washers (2) and nylon cap locknuts (4) on the screws. With the spacer concavity in line with the luggage rack rails, hold the nuts and tighten the screws until snug.
11.
In a crosswise pattern, alternately tighten the screws to 10.8–12.2 N·m (96–108 in-lbs). Be sure that the concavity of each spacer remains in line with the rail and has not rotated out of position.
12.
Install the rubber mat or molded liner. Close the Tour-Pak lid.
13.
Obtain the amplifier harness and plug the 23-way socket housing into the amplifier connector. Listen for a definite "click".
14.
Route the harness forward on the vehicle, along the right-side Tour-Pak support. Use a cable strap from the kit to fasten the main body and the long two-wire branch of the harness to the support. The amplifier mounting bracket and all hardware not used can be discarded. Proceed to Amplifier Harness Routing and Connection.
Amplifier Installation, 2009 and Later Touring Models
NOTE
The Tour-Pak must be removed from the vehicle to perform this installation.
1.
Refer to the service manual and follow the instructions to remove the Tour-Pak.
2.
See Figure 3. Obtain the two cushion bumpers (2) from the kit.
3.
Use isopropyl alcohol to thoroughly clean the rear fender surface in the area (4) behind the seat retention nut (3).
4.
Peel the liner from the adhesive backing on one of the bumpers, and fasten the bumper to the fender as shown, crosswise on center about 25 mm (1 in) behind the seat retention nut. Hold for a few seconds to set the adhesive.
5.
Peel the liner from the backing on the remaining bumper, and fasten that bumper about 25 mm (1 in) behind the first bumper.
NOTE
Cover the rear fender with an H-D Service Cover or clean shop towel to prevent scratching. Damage to the finish could result.
6.
Install the amplifier mounting plate (7) onto the top of the Tour-Pak rack (1).
a.
Slide one bent tab (8) under the rack side rail and rotate the mounting plate downward to position the second bent tab under the opposite side rail.
b.
Adjust the mounting plate to align the mounting holes (9) with the Tour-Pak mounting holes on the side rail assembly.
7.
Loosen (do not remove) the forward screws (10) holding the Tour-Pak rack. Remove the four rear screws (11) holding the rack.
1Tour-Pak rack
2Cushion bumper (2)
3Seat retention nut
4Fender area to be cleaned
5About one inch (25 mm) from edge of nut
6About one inch (25 mm) from edge of bumper
7Amplifier mounting plate
8Bent tab (2) on mounting plate
9Align mounting holes (4) with holes on rack
10Loosen forward screws (2)
11Remove rear screws (4)
12Amplifier
13Nylon-cap lock nut (4)
14Flat washer (4)
Figure 3. Amplifier Installation, 2009 and Later Touring Models
8.
Rotate the rack upward to install the amplifier (12).
a.
Hold the amplifier with the mounting flanges facing up, and the electrical connector toward you.
b.
From the right side, slide the amplifier underneath the Tour-Pak rack. Mount the amplifier on the studs of the mounting plate installed in step 6.
c.
Install flat washers (14) and locknuts (13) onto the studs. Tighten the nuts to 6.8–9 N·m (60–80 in-lbs).
d.
Rotate the Tour-Pak rack back downward and install the rear mounting screws. Tighten the front and rear mounting screws to 20.3–27.1 N·m (15–20 ft-lbs).
9.
Refer to the service manual and follow the instructions given to install the Tour-Pak.
10.
Obtain the amplifier harness and plug the 23-way socket housing into the amplifier connector. Listen for a definite "click".
11.
Route the harness forward on the vehicle, along the right-side Tour-Pak support. Use a cable strap from the kit to fasten the main body and the long two-wire branch of the harness to the support. Hardware not used can be discarded. Proceed to Amplifier Harness Routing and Connection.
Amplifier Installation, 2009 and Later Trike Models
NOTE
The body assembly must be removed from the vehicle to perform this installation.
The body should be placed on a mat to prevent damage to the leading edge of the fenders, and the bottom of the body at the rear of the fender openings.
1.
Refer to the service manual and follow the instructions to remove the body assembly.
2.
See Figure 4. For later bodies: Center the amplifier on the four pads at the top of the outside front body wall. Mark the drill locations using the amplifier as a template, then remove the amplifier. For earlier bodies (with no pads):
a.
Measure and determine the center (1) of the outside front body wall as shown.
b.
Lay a strip of 51 mm (2 in) wide masking tape from top to bottom over the approximate center of the outside front body wall.
c.
Very carefully measure again, and mark the center near the top of the tape strip. Measure and mark the center near the bottom of the strip. Draw a line from the top mark to the bottom mark.
d.
Facing the tape, measure 127 mm (5.0 in) from the center line to the left side of the outside front body wall (2). Measure 127 mm (5.0 in) from the center line to the right side of the outside front body wall.
e.
Lay a strip of 51 mm (2 in) wide masking tape from the top to approximately half way down the outside front body wall at the 127 mm (5.0 in) distance from the center line, on both the left and right sides.
f.
Measure down 50.8 mm (2.0 in) from the top edge of the front body wall on the left-side tape (3), and draw a horizontal line across the tape. Repeat on the right-side tape.
g.
Hold the amplifier (4) with the mounting flanges facing the body, and the electrical connector toward the left. Center the amplifier on the front of the body, with the upper mounting holes on the horizontal lines on the tapes. Mark the drill locations using the amplifier as a template, then remove the amplifier.
1Center of outside front body wall
2Measure 5.0 inch (127 mm) from center line
3Measure 2.0 inches (50.8 mm) from top edge
4Amplifier
5Locate ground cable here
Figure 4. Amplifier Installation, 2009 and Later Trike Models
3.
Drill the mounting holes as follows:
a.
Mark the center of the amplifier mounting holes on the tape with a center punch.
b.
drill four 3 mm (⅛ in) guide holes through the body wall,
c.
drill four 8 mm (5/16 in) holes through the guide holes.
4.
Remove the tape. Lightly sand the hole to remove burrs and sharp edges. Clean the body surface of tape residue with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water.
5.
See Figure 7. Place a large washer (7) onto the threads of the four button head screws (6) from the kit. From inside the trunk, insert the screws through the holes in the front body wall.
6.
Obtain the ground cable (12) from the kit. The ground cable includes a separate 6.4 mm (¼ in) ring terminal. Connect the installed 7.9 mm (5/16 in) ring terminal to the ground strap inside the trunk.
7.
Route the ground cable to the outside of the trunk through the wire grommet.
8.
Crimp the supplied 6.4 mm (¼ in) ring terminal onto the end of the ground cable.
9.
See Figure 4. Viewing from the outside of the body, install the ground cable ring terminal onto the upper left (5) screw threads (right side of the body).
NOTE
The paint has been removed from the underside of the amplifier mounting flange at the ground cable installation location.
10.
See Figure 7. With the amplifier connector facing left, mount the amplifier to the outside front body wall with the nylon lock nuts (5) and small washers (4). Tighten the nuts to 10.8–12.2 N·m (96–108 in-lbs).
11.
Refer to the service manual and follow the instructions given to install the body assembly.
12.
Obtain the amplifier harness and plug the 23-way socket housing into the amplifier connector. Listen for a definite "click".
13.
Guide the harness through the openings in the frame below the passenger pillion seat. The amplifier mounting bracket and all hardware not used can be discarded. Proceed to Amplifier Harness Routing and Connection.
Amplifier Harness Routing and Connection
  1. Continue to route the harness forward on the vehicle:
    1. Route the short two-wire branch of the harness to the right front of the Tour-Pak (or the right-rear speaker pod if equipped).
    2. Touring Models: Continue the long two-wire branch forward to the front of the fender, then cross over to the left side of the frame and back to the left front of the Tour-Pak (or the left-rear speaker pod if equipped). Trike Models: Route the long two-wire branch to the left front of the Tour-Pak (or the left-rear speaker pod if equipped).
    3. Continue the main branch forward, tucking the harness inboard of the frame tube and (on Touring models) avoiding the forward saddlebag guard mounting screw head so the harness does not get pinched by the seat. Use four cable straps from the kit to fasten the main branch and the long two-wire branch of the harness to the frame tube.
    4. Route the harness along the right side of the battery cavity. Bring the red fuse wire and black ground wire into the front of the battery compartment. Continue the main branch forward to the harness tray.
    5. Open the cover of the harness tray. Route the amplifier harness through the openings in the tray.
    6. Continue the amplifier harness forward into the fairing, using cable straps (10) to fasten to the main harness.
WARNING
Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a)
  • Be sure wires do not pull tight when handlebars are turned fully to left or right fork stops.
  1. Remove the outer fairing and windshield. Refer to the service manual.
  2. Route the three branches of the front section of the amplifier harness inside the fairing along the path of the interconnect harness to the top left of the inner fairing.
  3. FLHTCU Touring and FLHTCUTG Tri Glide models: Separate the audio harness pin housing [6A] from the interconnect harness socket housing [6B]. FLHT, FLHTC, FLHX and FLTR Touring, and FLHXXX Street Glide Trike models: Locate the interconnect harness audio connector [6B] near the back of the radio.
    1. If socket housing [6B] is already connected to overlay harness pin housing [6A]: Separate [6A] from [6B].
    2. If socket housing [6B] is not connected to an overlay harness: Obtain the overlay harness (Part No. 70169-06, purchased separately), but do not connect at this time. See Figure 5.
  4. ALL models: Refer to the service manual. Remove the secondary locking wedge on socket housing [6B].
  5. Remove the plugs from cavities 4 and 5.
  6. See Figure 6. Insert the yellow/orange wire (2) from the amplifier harness (1) into the empty cavity 4. Insert the yellow/violet wire (3) into cavity 5.
  7. Assemble the socket housing, and connect to the mating pin housing [6A] on the audio or overlay harness.
  8. NOTE
    FLHT, FLHTC and FLHX models, route the short branch (4) of the amplifier harness underneath the left-side fairing support bracket (5).
  9. Take the short branch of the amplifier harness (with white/orange and light-green/white wires) and route it to the left-side speaker (6).
  10. Carefully disconnect the interconnect harness socket terminals (7) from the left-side speaker spade terminals.
  11. Install the socket terminals (8) from the amplifier harness to the speaker spade terminals. The spade terminals are different-sized to prevent improper assembly.
  12. Install the spade terminals (9) from the amplifier harness to the socket terminals (7) from the interconnect harness. The spade terminals are different-sized to prevent improper assembly.
  13. Take the long branch (10) of the amplifier harness (with gray/red and light-green/black wires) and route it to the right-side speaker.
  14. Carefully disconnect the interconnect harness socket terminals from the right-side speaker spade terminals.
  15. Install the socket terminals from the amplifier harness to the speaker spade terminals. The spade terminals are different-sized to prevent improper assembly.
  16. 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.
  17. Use cable straps (10) from the kit to fasten the harnesses to the existing harnesses inside the fairing.
16-place pin housing [6A], (labeled "Interconnect")
Figure 5. Non-Ultra Overlay Harness
1Amplifier harness
2Yellow/orange wire
3Yellow/violet wire
4Short branch of amplifier harness
5Left-side fairing support bracket
6Left-side speaker
7Interconnect harness socket terminals (2)
8Amplifier harness socket terminals (2)
9Amplifier harness spade terminals (2)
10Long branch of amplifier harness
11Cable strap
Figure 6. Front Speaker Connections (FLH Shown)
WARNING
Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a)
  • Be sure wires do not pull tight when handlebars are turned fully to left or right fork stops.
14.
Go back to the seat area in front of the Tour-Pak.
a.
Remove the four screws from the rear speaker grille. Remove the speaker grille from the speaker pod.
b.
Remove the speaker from the speaker pod. Carefully disconnect the socket terminals from the speaker spade contacts.
c.
Install the socket terminals from the amplifier harness to the speaker spade contacts. The spade contacts are different-sized to prevent improper assembly.
d.
Use electrical tape to seal the original socket terminals to prevent short circuit. Tuck the taped terminals out of the way inside the speaker pod.
e.
With the spade contacts at the bottom, install the speaker back into the speaker pod. Align the holes in the speaker with those in the speaker pod.
f.
Align the holes in the speaker grille with those in the speaker. Install the four screws removed earlier. Alternately tighten the screws securely.
g.
Repeat for the opposite side of the vehicle.
NOTE
Verify that the ignition key switch is in the OFF position 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)
15.
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 (H-D Part No. 99861-02), petroleum jelly or corrosion retardant material to the battery terminals.
d.
Tuck the fuse holder 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.
16.
Test the sound system for proper operation.
17.
Install the outer fairing and windshield per service manual instructions.
18.
Refer to the service manual, and follow the instructions to install the fuel tank, console and seat.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
NOTE
In order to experience the increased bass response provided on models with BOOM! Audio Bass Booster Tour-Pak Ports AND the BOOM! Audio Amplifier, a system reflash using Digital Technician II at a Harley-Davidson dealer will be required. See the SERVICE PARTS section for software upgrade information.
SERVICE PARTS
Figure 7. Service Parts, Boom! Audio Amplifier Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Amplifier, 2/4 channel
Not sold separately
2
Cap screw, hex head, 1/4-20 x 64 mm (2½ in) long (4)
3768
3
Cap screw, hex head, 1/4-20 x 51 mm (2 in) long (4)
2881W
4
Flat washer, small diameter, heat treated (8)
6110
5
Hex lock nut, nylon insert, 1/4-20 (4)
7686
6
Screw, hex socket, button head, 1/4-20 x 32 mm (1¼ in) long (4)
2513
7
Flat washer, large diameter (4)
6036
8
Bracket, amplifier mounting
76540-09
9
Bumper (2)
76439-06
10
Cable strap (10)
10006
11
Harness, amplifier (not shown)
70178-06
12
Cable, ground (not shown). Includes one attached 5/16-inch (7.9 mm) ring terminal
and one separate 1/4-inch (6.4 mm) ring terminal.
Not sold separately
BOOM! AUDIO™ SOFTWARE UPGRADE
The purchase of this accessory entitles you to a specially developed sound equalization software that is used in conjunction with the Harley-Davidson BOOM! Audio Amplifier (Part No. 76000068). This unique equalization was designed to optimize the performance and sound response of the BOOM! Audio Bass Booster Tour-Pak Ports.
This special equalization software is available without charge from your dealer through Digital Technician II. Dealer labor rates may apply for the upgrade procedure.