BOOM! AUDIO FAIRING AMPLIFIER KIT
J052672011-11-10
GENERAL
Kit Number
76000169
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
Models (except FLTRU) not equipped with a Non-Ultra Overlay Harness (Part No. 70169-06) will require the separate purchase of a Radio Wire Harness (Part No. 69200106).
FLTRU models require no additional harness.
Loctite® 243 Medium Strength Threadlocker and Sealant - Blue (Part No. 99642-97) is required for proper installation of this kit.
Additional conduit may be needed to protect wiring in some installations.
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 3 and Table 2.
PREPARATION
NOTE
For 2007 and later vehicles equipped with security siren:
  • Verify that the Hands-Free Fob is present.
  • Turn the ignition key switch to IGNITION.
WARNING
To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a)
See the service manual to purge the fuel supply of high pressure gasoline and remove the fuel supply line.
Battery Disconnection:
1.
See the service manual and remove the main fuse.
2.
Turn the ignition key switch OFF.
3.
See the service manual and remove the seat. Retain all seat mounting hardware.
4.
For 2008 and later models: See the service manual to remove the ECM caddy from the top of the battery.
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)
5.
For ALL models: Disconnect the battery cables, negative (-) cable first.
6.
See the service manual to remove the fuel tank console and fuel tank.
AMPLIFIER INSTALLATION
1.
See the service manual to remove the outer fairing.
2.
See Figure 3. Apply a few drops of Loctite 243 - Blue to the screw (3) and stud (A) threads. Install the amplifier (1) onto the amplifier bracket (2), in the orientation shown, with two hex head screws (3), four plain washers (6), four lockwashers (5) and four hex nuts (4) from the kit. Tighten to 9.5–12.2 N·m (84–108 in-lbs).
3.
Remove the flanged nuts (B) from the two studs (C) on the clutch-lever side of the radio carrier bracket.
NOTE
Refer to the service manual for instructions on re-using fasteners with threadlocking agents.
4.
Install the amplifier and bracket onto the radio carrier bracket mounting studs (C). Loosely install the left-side turn signal and hand tighten the turn signal nuts to secure the lower portion of the amplifier bracket.
5.
Apply a few drops of Loctite 243 - Blue to the clean stud threads. Install the flanged nuts (B) onto the studs, and tighten to 9.5–12.2 N·m (84–108 in-lbs).
HARNESS ROUTING AND CONNECTION
NOTE
Electrical connectors are identified in the service manual by the numbers and letters shown here within brackets.
  1. See Figure 1. Locate the black six-way Deutsch socket housing [6B] (1) on the vehicle fairing/interconnect harness, mounted to the left fairing support, below the radio.
  2. If socket housing [6B] is NOT connected to an audio harness: If socket housing [6B] IS connected to an audio harness, unplug the connector halves. If cavities 4 and 5 of socket housing [6B] are populated with wires: If cavities 4 and 5 of socket housing [6B] are empty:
    1. get a Radio Wire Harness (Part No. 69200106, purchased separately).
    2. Route the shorter branch of the radio wire harness (with a six-way pin housing and yellow/orange and yellow/violet wires), over to the area of socket housing [6B] (1), but do not connect at this time. This pin housing (14) will now be known as connector [6A].
    1. Get the amplifier harness (2) from the kit, and two blue sealed splice connectors (Part No. 70586-93, purchased separately).
    2. Follow service manual instructions to splice the yellow/orange terminated wire (4) from the amplifier harness into the yellow/orange wire coming from cavity 4 of socket housing [6B] (1).
    3. Splice the yellow/violet terminated wire (5) into the yellow/violet wire coming from cavity 5.
    1. Remove the secondary locking wedge from socket housing [6B] on the vehicle fairing/interconnect harness per service manual instructions.
    2. Remove the plugs from cavities 4 and 5.
    3. Get the amplifier harness (2) from the kit.
    4. Follow service manual instructions to install the yellow/orange terminated wire (4) from the amplifier harness into cavity 4 of socket housing [6B] (1).
    5. Install the yellow/violet wire (5) into cavity 5.
    6. Install the secondary locking wedge into the socket housing per service manual instructions.
  3. Plug the six-way socket housing [6B] into the pin housing [6A] (14) on the radio wire harness (12) installed earlier or the vehicle audio harness pin housing [6A].
SPEAKER WIRING
Follow service manual instructions to remove the plugs from cavities 8, 15, 22 and 23 of the 23-way connector [149B] (3) on the amplifier harness. Retain the plugs for later installation.
Proceed to the correct section that follows:
  • For models with ONLY FRONT FAIRING speakers.
  • For models with ADDITIONAL speakers installed.
For Models With ONLY FRONT FAIRING Speakers:
  1. Install the terminated wires (15) coming from the two six-way connectors (16) on the radio wire harness to amplifier harness connector [149B] as shown in Table 1. This will enable installation of an additional pair of speakers, such as fairing lowers, saddlebag or Tour-Pak® speakers.
  2. Proceed to For ALL Models.
For Models with ADDITIONAL Speakers Installed
  1. Unplug the 35-way connector [28B] on the right side of the radio. Locate two twisted wire pairs, one brown and white/brown, the other green and light green/brown, in the connector.
  2. See the service manual and remove the twisted wires and terminals from cavities 1, 2, 24, and 25 of connector [28B].
  3. Extract at least 30.5 cm (12 in) of the twisted wire pairs from the main wire harness conduit, allowing enough for them to easily reach the amplifier.
  4. Insert the seal pins removed earlier from amplifier harness connector [149B] into the now-empty cavities in connector [28B].
  5. Re-tape and secure the main wire harness. Additional purchase of conduit is suggested to protect the twisted wire pairs.
  6. Install the terminated wires from radio connector [28B] to the 23-way amplifier connector [149B] as shown in Table 1. This will enable amplification of the additional speakers.
  7. Proceed to For ALL Models.
1Six-way socket housing [6B]
2Amplifier harness
323-way connector [149B]
4Yellow/orange terminated wire
5Yellow/violet terminated wire
6To left-side speaker
7To right-side speaker
8Battery branch of harness
9Red wire
10Black wire
11Fuse holder
12Radio wire harness
1335-way connector [28B]
14Six-way pin housing [6A]
15Insert into 23-way connector [149B] on amplifier harness
16Unconnected wiring
Figure 1. Harness Connection Diagram, Fairing Mounted Amplifier
For ALL Models
Table 1. Harness Wire Connections
Wire Color
To Connector [149B], Cavity
Brown
8
White/brown
15
Green
22
Light green/brown
23
  1. Visually inspect the front of connectors [28B] and [149B] to make sure the terminals are fully seated before closing the red connector locks.
  2. Plug the 35-way connector [28B] into the receptacle on the back of the radio. Listen for a definite "click". Plug the 23-way connector [149B] into the amplifier. Listen for a definite "click".
  3. NOTE
    Two branches of the amplifier harness, each with two socket and two spade terminals, connect to the front speakers.
  4. Route the short branch (6) of the amplifier harness (with white/orange and light-green/white wires) over to the left-side speaker.
  5. Carefully disconnect the interconnect harness socket terminals from the left-side speaker spade terminals.
  6. Install the socket terminals from the amplifier harness to the speaker spade terminals. The spade terminals are different-sized to prevent improper assembly.
  7. 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.
  8. Route the long branch (7) of the amplifier harness (with gray/red and light-green/black wires) to the right-side speaker.
  9. Carefully disconnect the interconnect harness socket terminals from the right-side speaker spade terminals.
  10. Install the socket terminals from the amplifier harness to the speaker spade terminals. The spade terminals are different-sized to prevent improper assembly.
  11. 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.
  12. See Figure 1. 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.
  13. NOTE
    Do not bind the long branch (8) of the amplifier harness inside the fairing in the next step.
  14. Use cable straps from the kit to fasten the amplifier and radio harnesses to existing harnesses inside the fairing.
  15. Route the long branch (8) of the amplifier harness through the center of the radio carrier bracket and rearward 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.
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. 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.
1Left-side front turn signal lamp
2Turn signal lamp mounting stud (2)
3Gasket
4Outer fairing
5Amplifier and bracket
6Inner fairing
7Lower fairing mount
8Acorn nut (2)
9Flat washer (2)
10View of turn signal bracket and inner fairing in direction of arrow A
Figure 2. Turn Signal Assembly to FLTR Fairings
OUTER FAIRING INSTALLATION
1.
See Figure 2. Install the outer fairing per service manual instructions, with the following exceptions:
a.
Before resting the outer fairing on the protected front fender, remove the left-side turn signal lamp (1) loosely installed earlier.
b.
After final tightening the six screws holding the inner and outer fairings together, install the left-side front turn signal lamp studs (2) through the holes in the turn signal lamp gasket (3), outer fairing (4), amplifier bracket (5), and inner fairing (6), guiding the turn signal wires into the relief slot in the lower fairing mount (7).
c.
Install the acorn nuts (8) and flat washers (9) onto the turn signal studs, but do not fully tighten at this time.
d.
Install the right-side turn signal lamp in the same manner.
e.
Tighten the turn signal acorn nuts to 6.8–9.5 N·m (60–84 in-lbs).
RETURN TO SERVICE
NOTE
To prevent possible damage to the sound system, 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)
1.
Connect the battery as follows:
a.
Install the red battery positive (+) cable terminal to the positive (+) side of the battery, followed by the amplifier harness fused red wire terminal.
b.
Install the black battery negative (-) cable terminal to the negative (-) side of the battery, followed by the amplifier harness black ground wire terminal.
c.
See Figure 1. 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.
d.
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.
e.
For ALL models: Install the main fuse per service manual instructions.
2.
Test the sound system for proper operation. If no sound, proceed to TROUBLESHOOTING.
3.
Upon satisfactory sound system operation, install the outer fairing and windshield per service manual instructions.
4.
Disconnect the amplifier harness black ground wire terminal and negative (black) battery cable from the negative (-) battery terminal.
5.
Refer to the service manual, and follow the instructions to install the fuel tank and console. Attach the negative battery cable and amplifier ground terminals.
6.
Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to the battery and amplifier harness terminals.
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)
7.
See the service manual and install the seat.
TROUBLESHOOTING
No Sound.
  1. Verify the wire connections at [6A] and [6B]. Make sure that the yellow/orange wires are installed in cavity 4 of both connector halves, and yellow/violet in cavity 5.
  2. At each connector involved in the installation :
  • Make sure all pin and socket terminals are fully seated at the mating face of the connector, and that they have not pushed back upon installation into the mating connection.
  • Gently tug on each wire individually from the rear of the connector to find any that are not seated in their lock.
SERVICE PARTS
Figure 3. Service Parts, Boom! Audio Amplifier Kit
Table 2. Service Parts
Item
Description (Quantity)
Part Number
1
Amplifier, fairing mounted
76192-06B
2
Bracket, fairing mounted amplifier
Not sold separately
3
Cap screw, hex head, 1/4-20 x 16 mm (0.62 in) long (2)
3767B
4
Hex nut, 1/4-20 (4)
7688
5
Lockwasher, split, 1/4 in (4)
7036
6
Plain washer, 1/4 in (4)
6703
7
Harness, amplifier
Not sold separately
8
Clip, metal, adhesive back, 0.62 in (16 mm)
10103
9
Cable strap (10)
10006
Items mentioned in text, but not included in kit:
A
Amplifier mounting stud (2)
B
Radio carrier bracket mounting nut (4)
C
Fairing bracket stud (4)
D
Inner fairing
E
Outer fairing