Boom! Audio Cruiser Amp And Speaker Kit - Harley
Contents
1. installation 5 Amplifier 6 TORX button head screw 1 4 20 x 0 62 inch 16 mm 2 7 Amplifier mounting bracket XL Sportster FLHR 8 Amplifier mounting bracket Dyna Softail FLD FXDWG FLST C F FB N FXST B C D Hex head screw 3 8 16 x 0 75 inch 19 mm 2 Hex locknut 3 8 16 2 Hex head screw 5 16 18 x 0 75 inch 19 mm Hex locknut 5 16 18 Fender washer 2 Hex locknut 1 4 20 2 2013 and earlier models TORX bution head screw 1 4 20 x 0 75 inch 19 mm 2 Figure 1 Amplifier and Bracket Installation See Figure 1 Install the amplifier and bracket to the frame crossmember between the front down tubes as shown For XL Sportster models Tighten the fasteners to 30 33 ft lbs 40 7 44 8 Nm For Dyna models Tighten the fasteners to 30 33 ft lbs 40 7 44 8 Nm For Softail models except Rocker The amplifier bracket installs behind the crossbar Tighten the fasteners to 19 ft lbs 25 8 Nm For Rocker models The amplifier bracket installs in front of the crossbar Tighten the fasteners to 19 ft lbs 25 8 Nm For Road King models Tighten the fasteners to 65 in Ibs 7 4 Nm Hand Control and Bracket Installation See Figure 2 Remove the front brake lever clamp screws from the vehicle Remove and retain the clamp 1 The screws can be discarded J05522 2 Obtain the hand control bracket 3 two spacers 2 two screws 6 and for 2004 and later XL S2. The amp and speakers can be operated with the ignition switch in either the ACC or IGNITION position NOTE DO NOT secure an audio player with a hard drive memory on or to the vehicle Vehicle vibration can permanently damage the device Refer to the audio player instructions to determine if the device to be used has a hard drive memory 8 of 10 SERVICE PARTS isO6088a SS Rs Figure 7 Service Parts Handlebar Mounted Speaker and Amplifier Kits Table 1 Service Parts Kit Item Description Quantity Part Number Kit 76262 08A 1 Speaker pod assembly chrome includes two of item 31 connected Not sold separately Handlebar Mounted gt Speaker clamp handlebar lower chrome 2 76558 08 Speaker Amplifier Kit Chrome 3 Speaker clamp handlebar upper chrome 2 76559 08 Kit 76320 08A 1 Speaker pod assembly black includes two of item 31 connected Not sold separately Handlebar Mounted 2 ker cl handl black 2 76090 08 Speaker Amplifier Speaker clamp handlebar lower black 2 Kit Black 3 Speaker clamp handlebar upper black 2 76089 08 J05522 9 of 10 Table 1 Service Parts Kit ltem Description Quantity Part Number Items common 4 Spacer handlebar speaker housing 4 Not sold separately to BOTH kits 5 Amplifier nand control wire harness assembly 70220 08 6 Sc
3. motorcycle as possible The upper clamps can be positioned so the speaker mounts are in front of or behind the bar e Ifthe vehicle is normally equipped with a windshield locate the clamps on the middle straight section of the bar so the speaker housings will clear the windshield e The Bar amp Shield trim badges on the speaker faces can be rotated to the desired orientation after installation by pushing with two fingers and turning e Check to be sure speaker and clamp positioning will not interfere with steering function control operation or visibility of instruments J05522 1 See Figure 3 Obtain the following items from the kit e speaker pod assembly 1 e two upper handlebar clamps 2 e two lower handlebar clamps 3 e four spacers 4 e four screws 5 e two screws 6 If mounting to 1 1 4 inch 31 8 mm diameter handlebars the spacers can be discarded NOTE Insert the spacers inside the clamps for vehicles with 1 0 inch 25 4 mm diameter handlebars Make sure the spacers seat in the recesses 7 inside the clamps 2 Secure each speaker clamp pair to the handlebar with two screws 5 and tighten to 60 in Ilbs 6 8 Nm 3 Position a speaker pod oriented with the speaker grille facing the rider as directly as possible onto each upper clamp Secure each speaker pod to the upper clamp with a hex head screw 6 Tighten the screw to 12 14 ft lbs 16 3 19 0 Nm is06078 Speaker
4. or 3 of the sealed cap ends of the Electrical Connection kit 4 See the service manual for detailed instructions on sealed splice connections 5 of 10 If wire harness part no 69200722 was previously spliced cut off existing splices See Figure 4 for multiple splice configuration If wire harness part no 69200722 was spliced in a prior install make sure the 8 way Molex connector is discon nected from vehicle connector 4 a Clip the cap off the black wire strip back crimp amp seal to BLACK wire of the wire harness of this kit b Clip the cap off the violet blue wire of 69200723 strip back crimp amp seal to orange white and the RED wire of the wire harness of this kit c DONOT REMOVE the sealed cap from the RED wire it is not used 5 Remove the weather cap from connector 4A and connect the 8 way connectors together For ALL OTHER Models NOTE Requires separate purchase of Speaker and Amplifier Relay Service Kit Part No 69200397 1 Route the speaker and amplifier harness to the area under the seat 2 See Figure 7 Get the electrical hardware pack 22 from THIS kit 3 Select the in line fuse holder 23 and one blue sealed splice connector 28 from the hardware pack 4 Get the relay kit Part No 69200397 purchased separ ately Refer to the instructions that follow BELOW for relay installation 5 See Figure 5 Find a suitable location under the seat for the relay 1 so t
5. pod 2 Upper handlebar clamp 2 Lower handlebar clamp 2 Spacer 4 TORX screw 4 Hex head screw 2 Recess inside clamp 4 DEO DTA ON Figure 3 Handlebar Mounted Speaker Installation 4 of 10 WIRE HARNESS CONNECTION General Splicing of wire leads is necessary in the installation of the speaker and amplifier kit to the motorcycle Find the instructions for a specific model in the sections that follow and refer to the service manual appendix for proper wire splicing procedures PINT IN Be sure to follow manufacturer s instructions when using the UltraTorch UT 100 or any other radiant heating device Failure to follow manufacturer s instructions can cause a fire which could result in death or serious injury 00335a e Avoid directing heat toward any fuel system component Extreme heat can cause fuel ignition explosion resulting in death or serious injury e Avoid directing heat toward any electrical system com ponent other than the connectors on which heat shrink work is being performed e Always keep hands away from tool tip area and heat shrink attachment For 2014 and later Sportster models Proceed to the next section For 2012 and later Dyna models Proceed to the next section For 2011 and later Softail models Proceed to the next sec tion For 2014 and later Touring models Proceed to THAT sec tion For ALL OTHER models Proceed to THAT section For 2012 and Later Dyna 2011 and La
6. 586 93 29 e Cable strap 10 10006 30 Conduit split loom convoluted 0 25 inch x 5 inch 6 4 mm x 127 mm long 62519 03 Service parts for speaker pod assembly 31 Speaker pod chrome 2 includes item 32 76223 08 Speaker pod black 2 includes item 32 76225 08 32 Speaker grille with trim ring and logo badge 2 76215 08 J05522 10 of 10
7. Road King models only Remove the handlebar cover from the vehicle Separate the left and right nacelle halves Remove the headlamp assembly per service manual instructions INSTALLATION Amplifier and Bracket Installation 1 See Figure 7 Select two screws 6 and the correct amp lifier mounting bracket item 7 or 8 from the kit For Road King and XL Sportster models select bracket 7 e For Dyna and Softail models select bracket 8 NOTE The wire exiting the amplifier must face downward 2 See Figure 1 Install the amplifier 5 part of the wire har ness assembly to the bracket with the screws 6 and tighten to 65 in lbs 7 4 Nm 3 If this kit is being installed on a vehicle with an engine guard except for Road King models use the engine guard hardware to secure the amplifier bracket If NOT being installed with an engine guard use hard ware from the kit to secure the amplifier bracket See Figure 7 e For XL Sportster models Select two screws 9 from the kit e For Dyna models Select one screw 9 and one locknut 10 from the kit e For Softail models Select screw 11 and locknut 12 from the kit e For Road King models Select two screws 15 two washers 13 and two locknuts 14 from the kit 2 of 10 isO6077 h Sportster XL installation Dyna FLD FXDWG installation 3 Softail FLST C F FB N FXST B C D and Rocker FXCW C installation N 4 Road King FLHR
8. battery cable before proceeding 00048a NOTE For 2004 and later XL Sportster models the negative battery cable is most easily disconnected at the engine crankcase s See the service manual Remove the seat and disconnect the negative black battery cable from the negative battery terminal Retain all seat mounting hardware 2 For ALL models Turn the ignition key switch OFF if not already done 3 See the service manual or instructions in the accessory kit Remove windshield Make sure to protect the wind shield from scratches during removal and installation and while off the vehicle For Carbureted Models PINT NIN Gasoline can drain from the carburetor fuel line when disconnected from fuel valve fitting Gasoline is extremely flammable and highly explosive which could result in death or serious injury Wipe up spilled fuel immediately and dispose of rags in a suitable manner 00256a J05522 4 Turn the fuel supply valve OFF Remove the fuel line from the valve For ALL models WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a 5 See the service manual Remove the instrument console if equipped from the fuel tank 6 See the correct section Carbureted or EFI Engine of the service manual for fuel tank removal instructions 7 For
9. cMOTOR HARLEY DAVIDSON WY J05522 INSTRUCTIONS REV 2015 05 12 BOOM AUDIO CRUISER AMP AND SPEAKER KITS HANDLEBAR MOUNT GENERAL Kit Numbers 76262 08A 76320 08A Models For model fitment information see the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only Installation Requirements The following models require separate purchase of an Electrical Connection Kit Part No 72673 11 e 2011 and later Softail models e 2012 and later Dyna FLD Switchback models e 2014 Sportster models The following models require separate purchase of a Speaker and Amplifier Relay Kit Part No 69200397 e 2000 2010 Softail models e 2010 2011 FXDWG Dyna Wide Glide models e 2004 2013 XL Sportster models e 1999 2013 Road King models The following models require separate purchase of Kit Part No 69200722 e 2014 and later Road King models Connection to a portable audio player purchased separately with a 1 8 inch 3 5 mm stereo output headphone jack or audio line out is required NOTES A Boom Audio Tank Pouch Part No 91003 10 can be used to secure a solid state portable audio player DO NOT secure a portable audio player with a hard drive memory on or to the vehicle For best sound quality an installed windshield is recommended An UltraTorch UT 100 Part No HD 39969 Robinair Heat Gun Part No HD 25070 with Heatshrink Attachment Part N
10. fuse holder to the 12V adapter wire 9 with the blue sealed splice connector 10 from the hardware pack 11 See Figure 6 Locate the B battery positive connector 1 on the main electrical harness under the seat a red wire with an unused gray connector Remove the cover 2 from the B connector 12 Connect the red 12V adapter wire connector on the wire harness assembly to the B connector is03793 1 B connector 2 Cover Figure 6 B Connector 6 of 10 13 See Figure 7 Select a ring terminal from the electrical hardware pack e Dyna Wide Glide models use the 5 16 inch 7 9 mm ID terminal 27 All models EXCEPT Dyna Wide Glide use the 1 4 inch 6 4 mm ID terminal 26 14 Select the free end of the black wire in the speaker and amplifier harness assembly Cut the black wire to easily reach the location of the vehicle ground Crimp the ring terminal to the black wire per the instructions in the service manual 15 Select the black wire from relay terminal 1 Attach both black wire ring terminals to the vehicle ground stud WIRE ROUTING 1 Use cable straps 29 from the electrical hardware pack to secure the amplifier wiring to the frame downtube For Road King models Use the existing P clamp on the left side of the frame near the steering head to secure the amplifier wiring WARNING Be sure that steering is smooth and free without interfer ence Interference with steeri
11. g device to seal the open end of the sealed splice connector 6 on the red blue wires in the Electrical Connection Harness g Pull the rubber boot out from the gray Digital Techni cian pin connector 91A Cut the boot off the wires h Connect the socket housing of the Electrical Connec tion Harness to connector 91A i Insert the rubber boot into the open pin connector of the Electrical Connection Harness j Proceed to WIRE ROUTING For 2014 and later Road King Models Electrical connectors are identified in the service manual by the number and letter shown here within brackets NOTE Wire harness part no 69200722 may have been previously installed during the installation of another accessory If it is already installed it is not necessary to replace it Use Y connector 70264 94A for additional 4 way connectors If accessory wires have already been spliced to 69200722 in a prior install it is possible to splice in up to three accessories 1 Locate the gray 8 way pin side Molex connector 4A under the left side cover It is located in the electrical caddy dir ectly over the Digital Tech Connector 91A If wire harness part no 69200722 is already connected to connector 4 from a prior install then disconnect it 2 Route the harness from the Electrical Connection Kit according to the instructions in that kit NOTE Do not connect the 8 way connectors now 3 The electrical connections will be made to 2
12. hat the terminals face down or horizont ally The terminals should not face upward 6 Cut the orange white wire 2 in the main electrical harness near the rear lighting connector 7 7 See the service manual appendix Use a suitable radiant heating device to splice and seal the two cut orange white wires to the sealed splice connector 4 on the orange white wire 3 from relay terminal 2 J05522 is07117a a z a 85 86 30 nd GRND A Relay Orange white wire in main electrical harness Orange white wire from relay terminal 2 Sealed splice connector on terminal 2 wire Speaker amplifier harness Sealed splice connector on terminal 3 wire Sealed splice connector on terminal 5 wire In line fuse holder 12V adapter wire B connector 10 Sealed splice connector from kit PHNDARYNS Figure 5 Wiring Diagram Speaker Amplifier Harness to Relay 8 Cut the speaker and amplifier harness 5 red and orange white wires to a suitable length to easily reach the sealed splice connectors on the relay Splice and seal the red and orange white wires to the sealed splice connector 6 on the red wire of relay terminal 3 9 Select the sealed splice connector 7 on the free end of the red wire coming from relay terminal 5 Splice the red wire on one end of the in line fuse holder 8 to the red wire of relay terminal 5 10 Splice the opposite end of the in line
13. ng could result in loss of vehicle control and death or serious injury 00371a e Make sure the wires do not restrict steering movement e Route the wires along the frame backbone under the tank Tie to existing wire bundles with cable straps especially at any change in direction 2 Coil excess wire under the fuel tank inside the nacelle or under the handlebar clamp where it does not interfere with steering function Install the 5A fuse 24 in the in line fuse holder on the red wire 3 Lay the harness along the frame backbone under the fuel tank and seat with the four way connector positioned near the steering head The connector may be placed inside the nacelle Road King models or handlebar clamp 4 Connect the four way connector from the speaker pods to the four way connector on the wire harness assembly 5 See Figure 7 The 3 5 mm connector from the hand control can be secured to the handlebar with cable straps or secured to the upper triple clamp or nacelle with the adhesive backed clip 21 from the kit If using the clip NOTES e Ambient temperature should be at least 60 F 16 C for proper adhesion of the clip to the vehicle e Allow AT LEAST 24 hours after applying the clip before exposing the area to vigorous washing strong water spray or extreme weather e The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature 6 Test fit the clip to the upper triple clamp
14. o HD 41183 or other suitable radiant heating device is required for the proper installation of this kit J05522 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Electrical Contact Lubricant Part No 99861 02 or equivalent is required after battery cable disconnection This item is available from a Harley Davidson dealer WARNING The rider s safety depends 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 00333a 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 addi tional electrical accessories or for neces
15. or nacelle before installation Do not remove the liner until ready to apply the clip J05522 7 Clean with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water Allow to dry completely 8 Remove the liner from the adhesive backing of the clip Carefully position the clip to the upper triple clamp or nacelle and press firmly into place Hold the clip in position with steady pressure for a few seconds 9 Secure the 3 5mm connector from the hand control to the clip RETURN TO SERVICE 1 For Road King models only See the service manual and assemble the left and right nacelle halves Assemble the handlebar cover to the vehicle For 2011 and later Softail models only Install the split conduit 30 over the brake line where it passes closest to the amplifier 2 ALL models See the correct section Carbureted or EFI Engine of the service manual for fuel tank installation instructions 3 Install the windshield if equipped to the vehicle per the instructions in the service manual or accessory kit Make sure to protect the windshield and speaker pods from scratches during installation WARNING Be sure that steering is smooth and free without interfer ence Interference with steering could result in loss of vehicle control and death or serious injury 00371a 4 Make sure the speaker pods do not interfere with steering function controls operation or visibility of instruments NOTE Verify that
16. portster models two screws 4 from the kit for ALL OTHER models two screws 4 from the kit Route the hand control 5 wire harness through the center of the hand control bracket 3 as shown Position the spacers into the clamp mounting cutouts Place the hand control bracket onto the spacers Install the clamp spacers and bracket to the brake master cyl inder with the two screws Tighten the screws to for 2004 and later XL Sportster models 108 132 in Ibs 12 2 14 9 Nm for ALL OTHER models 60 80 in Ibs 6 8 9 1 Nm Install the hand control 5 part of the wire harness assembly to the bracket with screws 6 Tighten securely Use cable straps from the electrical hardware pack to secure the wiring to the existing hand control wiring 3 of 10 is06076 Front brake lever clamp Spacer 2 Hand control bracket Hex socket button head screw 2 Speaker amplifier hand control 10 24 Phillips screw 2 DNMRONI Figure 2 Hand Control and Bracket Installation Speaker Installation NOTES Test fit to determine the desired location for the speakers on the handlebar Both speaker pods are wired together with a single electrical connector Do not separate for test fit or installation e The speaker clamps shall be positioned so the speakers are above the bar The speakers should appear symmet rical to the left and right of the handlebar clamp and should be placed as close to the center of the
17. rew button head TORX 1 4 20 x 0 62 inch 16 mm long 2 924 7 Bracket amplifier mounting Sportster and Road King models 76551 08A 8 Bracket amplifier mounting Dyna and Softail models Not sold separately 9 Cap screw hex head 3 8 16 x 0 75 inch 19 mm long 4 4713W 10 Hex locknut 3 8 16 Nylock 7778 11 Cap screw hex head 5 16 18 x 0 75 inch 19 mm long 3987 12 Hex locknut 5 16 18 Nylock 7739 13 Fender washer M6 2 Not sold separately 14 Hex locknut 1 4 20 Nylock 2 7686 15 Screw button head TORX 1 4 20 x 0 75 inch 19 mm long 6 923 16 Bracket hand control Not sold separately 17 Spacer hand control mounting 2 Not sold separately 18 Cap screw hex socket button head M6 x 45 mm long 2 Sportster Not sold separately Cap screw hex socket button head 3129 1 4 20 x 1 75 inch 44 4 mm long 2 except Sportster 19 Cap screw button head Phillips 10 24 x 0 5 inch 13 mm long 2 Not sold separately 20 Audio input cable 92383 09 21 Clip adhesive backed Not sold separately 22 Electrical hardware pack includes items 23 through 29 Not sold separately 23 e In line fuse holder 70306 02 24 e Fuse blade type 5A light tan 72331 95 25 e Adapter wire 12 V positive 76204 03 26 e Ring terminal 18 22 AWG 1 4 inch 6 4 mm stud 9858 27 e Ring terminal 18 22 AWG 5 16 inch 7 9 mm stud 9859 28 Sealed splice connector 14 16 AWG blue 3 70
18. sary wiring changes 0021 1c IWIN NIN 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 modi fied Exceeding the maximum amperage can lead to elec trical failures which could result in death or serious injury 00310a The Amp and Speaker Kit requires up to 4 0 A additional cur rent from the electrical system Kit Contents See Figure 7 and Table 1 1 of 10 Please dispose of materials responsibly PREPARATION NOTE For 2007 and later vehicles equipped with security siren Verify that the Hands Free Fob is present e Turn the ignition key switch to IGNITION For EFI Models AWARNING 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 Purge and disconnect fuel supply line For ALL Vehicles With Main Fuse WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 1 See the service manual Remove the main fuse and the seat Retain the seat and all mounting hardware For ALL Vehicles With Main Circuit Breaker WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative
19. ter Softail and 2014 and Later Sportster Models NOTE Requires separate purchase of Electrical Connection Kit Part No 72673 11 BK is07122 Digital Technician connector 91A Electrical connection harness Speaker and amplifier harness Red yellow wire sealed splice connector Black wire sealed splice connector Red blue wire sealed splice connector 1 2 3 4 5 6 Figure 4 Wiring Diagram Speaker Amplifier Harness to Electrical Connection Harness J05522 1 Install the Electrical Connection Harness a See Figure 4 Locate the Digital Technician connector 91A Item 1 a gray six way Deutsch connector with a rubber boot under the seat Place the Electrical Connection Harness 2 at the Digital Technician connector but DO NOT connect them now b Route the speaker and amplifier harness 3 wires over to the Electrical Connection Harness Cut the speaker and amplifier wires to a suitable length to easily reach the sealed splice connectors 4 and 5 on the Electrical Connection Harness c Splice both the red and the orange white speaker and amplifier wires to the red yellow wire sealed splice connector 4 in the Electrical Connection Harness d Splice the black speaker and amplifier wire to the black wire sealed splice connector 5 in the Electrical Connection Harness e Use a heat gun or suitable radiant heating device to shrink the connector to the wires f Use the heat gun or heatin
20. the ignition switch is in the OFF position before installing the main fuse or attaching the battery cable 5 Models with main fuse See the service manual and install the main fuse Models with main circuit breaker a For ALL models except XL Sportster See the service manual and attach the negative battery cable Apply a light coat of petroleum jelly or corrosion retardant material to battery terminals b For XL Sportster models only See the service manual and connect the negative battery cable at the engine crankcase 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 6 See the service manual and install the seat 7 Turn the ignition switch to IGNITION but do not start the motorcycle 8 Connect the audio input cable 20 from the kit to the female 3 5 mm stereo connector from the hand control 7 of 10 9 Connect the free end of the audio input cable to the headphone jack or line out of the portable audio player purchased separately a J05522 Turn on the audio player Set the player volume output at 75 80 percent of maximum Turn on the amp using the hand control on off push button switch The switch illuminates when power is on Use the handlebar control to adjust the volume level VOL increases the volume VOL decreases the volume d
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