BOOM!™ AUDIO CUSTOM TOURING SYSTEM - Harley
Contents
1. Item Description Quantity Part Number 1 Speaker 5 25 inch 133 mm diameter right side 77033 11A Speaker 5 25 inch 133 mm diameter left side 77042 11A Screw hex slotted washer head Hi Lo 10 12 x 1 5 inch 38 mm long 6 10200013 Speaker tweeter 1 0 inch 25 4 mm diameter 2 77036 11A Housing lower fairing speaker right side unpainted Not sold separately Housing lower fairing speaker left side unpainted Not sold separately 5 Speaker lower fairing 6 5 inch 165 mm diameter 2 76000201 6 Wire harness lower fairing speaker 2 72676 11 7 Pin housing two way AMP Superseal 2 72009 05 8 Grommet 2 11410 Items mentioned in text but not included in kit A Fuel gauge B Voltmeter C Back clamp two inch 50 8 mm diameter gauge 4 D Nut back clamp 8 E Lower fairing F Glove box door and tether G Lower fairing cap H Vent l Lock nut 2 J Screw glove box door 6 K Rubber washer Part No 7415A 2 J05408 12 of 15 SERVICE PARTS is07012 289B 288B GND1 149B 8 past R uA ss Figure 11 Service Parts Boom Audio Custom Touring System Front Amplifier and Audio Harness See Table 4 Table 4 Service Parts Boom Audio Cus2. 26 from the kit Feed the jumper harness connectors 149R and 42S from the outside through the rectangular opening cut in the saddlebag inboard wall so the 12 way panel mount connector 288 Item T fits into the opening 1 Left jumper harness panel mount connector 288A 2 Right jumper harness panel mount connector 289A 3 Plug cover 2 4 Rear amplifier bracket and cover 5 Speaker basket 2 6 Bottom opening closest to speaker connector 7 Wire retainer 10 8 Cable strap 10 9 Amplifier connector 149R 10 Left speaker connector 42S 11 iPod module and bracket 12 iPod connector 274 13 Right speaker connector 41S 14 Saddlebag capacity label 2 15 Begin gasket installation in this area Figure 8 Harness Routing Inside Saddlebags J05408 3 10 11 12 13 See Figure 8 Install the plug cover 3 over the panel mount connector 1 and jumper harness from the inside of the saddlebag Insert two screws through the connector flange and saddlebag wall and into the threaded holes in the plug cover Tighten to 35 40 in Ibs 3 95 4 52 N m Route the harness a downward to the bottom of the saddlebag and b rearward along the inboard wall c Route the long leg of the harness with connector 42S across the rear of the saddlebag
3. d forward along the outboard wall and e upward in front of the saddlebag lid tether Route connector 42S through the bottom opening 6 of the speaker basket 5 closest to the speaker connector and plug into the speaker connector Get five wire retainers 7 and five cable straps 8 from the kit Remove the liner from the adhesive backing of each wire retainer and affix to the inside walls of the saddlebag about one inch 25 mm above the bottom of the saddlebag as shown Fasten the jumper harness to the wire retainers with the cable straps See Figure 12 Get the rear amplifier 29 bracket 27 T stud anchor 28 screw 30 cover 31 and three push in clips 32 from the kit Remove the liners from the adhesive backing of the amp lifier bracket Carefully position the bracket to the rear inboard corner of the saddlebag in the orientation shown and press firmly into place Hold the bracket in position with steady pressure for a few minutes Position the amplifier onto the bracket with the metal cones on one end fitting firmly into the rubber grommets in the bracket Fasten the amplifier to the bracket with the screw 30 Attach the T stud connector to the amplifier connector Plug saddlebag speaker jumper harness connector 149R into the amplifier connector Attach the anchor to the T stud on the amplifier bracket Place the foam cover over the amplifier and install the cover to the amplifier bracket with t
4. mm long 8 10200012 22 Wire retainer adhesive back 10 69200342 23 Cable strap 10 10065 24 Pad saddlebag latch 4 Not sold separately 25 Plug cover 2 69200329 26 Screw TORX button head 1 4 20 x 0 75 in 19 mm long 4 940 27 Amplifier bracket Not sold separately 28 T stud anchor 73212 07 29 Amplifier 76000141 30 Screw TORX 10 24 x 0 50 in 12 7 mm long 3658 31 Cover amplifier 76000140 32 Clip push in 3 12600068 33 Weather cap kit Not sold separately Items mentioned in text but not included in kit Tweeter 2 part of rear speaker assemblies Large opening in speaker protective basket Saddlebag lid to bottom attaching screw 10 Panel mount connector hole in saddlebag side wall 2 12 way panel mount connector 2 iPod module Part No 72647 11 Bracket iPod module mounting Part No 69200244 Screw TORX 10 24 x 0 50 in 12 7 mm long Part No 3658 Screw TORX pan head self tapping 10 24 x 0 50 in 12 7 mm long 3 Part No 3612 lt x lt Cc wo iPod docking harness Part No 69200157 J05408 14 of 15 SERVICE PARTS 289 Figure 12 Service Parts Boom Audio System Saddlebag Compon
5. to optimize the performance and sound response of the BOOM Audio Custom Touring System RETURN TO SERVICE NOTE To prevent possible damage to the sound system verify that the ignition switch is in the OFF position before attaching the battery cables and installing the main fuse 1 Verify that the ignition switch is in the OFF position AWARNING 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 2 Refer to the service manual and follow the instructions to attach the battery cables positive cable first Apply a light coat of Harley Davidson electrical contact lubricant Part No 99861 02 petroleum jelly or corrosion retardant material to the battery terminals J05408 3 Refer to the service manual and follow the instructions to install the main fuse 4 Test the radio and speaker controls for proper operation 5 Install the outer fairing and windshield Refer to the service manual WENINUE 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 Refer to the service manual and follow the instructions to install the seat BOOM AUDIO SOFTWARE UPGRADE The purchase of this kit entitles yo
6. way female Delphi connector 35FB Item 2 for left fairing speaker e Thirteen inch 33 0 cm long labeled L TWEETER 35T with two way female Delphi connector 35TB Item 4 for left tweeter e Sixteen inch 40 6 cm long labeled L LWR 35L with two way Amp socket housing 35LB Item 6 for left lower speaker Four inch 10 2 cm long labeled AMP 149 with 16 way Molex socket housing 149B Item 8 for front ampli fier e Nine inch 22 9 cm long labeled IPOD 274F with eight way Deutsch socket housing 274F Item 13 for optional iPod module Fifty inch 1 27 M long to rear of vehicle 3 of 15 4 See Figure 3 and Table 2 Plug the two way connector 35FB 2 into the left fairing speaker Plug the two way connector 35TB 4 into the left tweeter 5 Plug the 16 way Molex socket housing 149B 8 into the front amplifier 6 Atthe opposite end of the large conduit plug the 35 way Amp Tyco socket housing 28B Item 9 into the open receptacle on the back of the radio 7 Unplug the 23 way Amp socket housing 27B Item 10 from the back of the radio Open the secondary lock per instructions in the service manual appendix Insert the four terminated wires 11 coming from the large conduit into the empty cavities of the socket housing as follows Light green black wire into cavity 1 e White orange wire into cavity 16 Light green white wire into cavity 17
7. 4 5 5 ate LGN W 7 FA AA Pa rh 8 8 SPL 9 9 9 LGN W 10 10 A wo 11 11 SPL 8 12 12 WO 13 13 14 14 LGN BK ta ig bene WO A 34FB CGN 17 7 BK GN 18 18 19 19 Na nea Nana P 20 20 R LA ARA BK GN 34TB 21 21 LGN BK 22 22 SPL 6 23 23 GY R LGN BK 34LB l l l SPL 5 161514131211109 8 7 6 5 4 3 2 1 149B GY R Figure 3 Wiring Diagram Audio Harness 69200321 J05408 5 of 15 Table 2 Wiring Diagram Audio Harness 69200321 Item Description 1 Six way pin housing 6A to interconnect harness labeled CONNECTOR 6 2 Two way female Delphi connector 35FB to left fairing speaker labeled L FAIRING SPKR 35F 3 Two way female Delphi connector 34FB to right fairing speaker labeled R FAIRING SPKR 34F 4 Two way female Delphi connector 35TB to left tweeter labeled L TWEETER 35T 5 Two way female Delphi connector 34TB to right tweeter labeled R TWEETER 34T 6 Two way Amp socket housing 35LB for left lower speaker labeled L LWR 35L 7 Two way Amp socket housing 34LB for right lower speaker labeled R LWR 34L 8 16 way Molex socket housing 149B for front amplifier labeled AMP 149 9 35 way socket housing 28B to back of radio 10 23 way Amp socket housing 27B to back of radio 11 Four terminated wires from large conduit 12 Twelve way Deutsch socket housing 18
8. 43 Medium Strength Threadlocker and Sealant Blue Part No 99642 97 and RTV sealant are required for proper installation of this kit If the vehicle is CURRENTLY EQUIPPED with fairing lowers two rubber washers Part No 7415A will be needed NOTE The purchase of this kit entitles you to a specially developed sound equalization software that is used in conjunction with the Advanced Audio system This unique equalization was designed to optimize the performance and sound response of the Boom Audio speakers J05408 Even if this kit is not being installed by a Harley Davidson dealer this special equalization software is available without charge from any dealer through Digital Technician II Dealer labor rates may apply for the upgrade procedure 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 In addition a model year 2012 or later FLHXSE service manual supplement is recommended Both are avail able from a Harley Davidson dealer Electrical Overload NOTICE It is pos
9. 5X for XM satellite radio module labeled XM 185X 13 Eight way Deutsch socket housing 274F for iPod module labeled IPOD 274F 14 Red amplifier fuse wire 43B 15 Black ground ring terminal 16 Black green ground ring terminal 17 Four way P amp A accessory connector 4B labeled ACCY CONNECTOR 4 18 B connector labeled B 160 19 Left saddlebag connector 288B labeled LH S BAG 288 20 Right saddlebag connector 289B labeled RH S BAG 289 Modify and Install Vented Fairing Lowers 1 See Figure 10 Disassemble the vented fairing lowers per service manual instructions with the following exceptions a Remove the glove box door and tether F from the lower fairing E per the disassembly instructions in the service manual Keep the screws J b Remove the vent door H from the glove box making note of the order and orientation of the attaching parts c Install the vent door onto the new speaker housing 4 from this kit with the attaching parts in the same order and orientation as just removed Tighten the locknut I per service manual instructions See Figure 4 In the upper part of the fairing 1 measure about 1 0 in 25 mm over 2 and 0 5 in 12 mm up 3 from the lower fairing cap mating flange shaded area and drill a 3 8 in 9 5 mm hole 4 in the glove box inboard side wall See Figure 10 Install a grommet 8 into the hole From the outside route the termina
10. Figure 2 Make note of the location of the black six way Deutsch audio to interconnect harness connector 6 Item 1 before moving the gray Molex 12 way connector 2 Item 2 1 Remove the gray Molex 12 way main to interconnect harness connector 2 from the left side clutch lever side fairing bracket radio support bracket Item 3 J05408 VA S Audio to interconnect harness connector 6 Main to interconnect harness connector 2 Left side fairing bracket Right side fairing bracket Audio or radio harness connector 35 way connector on back of radio Left side front speaker 0 NO OT a Right side front speaker Figure 2 Inner Fairing Connectors FLHX FLHT C U 2 See Figure 11 Get the audio harness 10 from the kit 3 If there is currently a harness connected to the six way vehicle interconnect harness socket housing 6B and the 35 way receptacle 28A on the back of the radio discon nect and remove that harness from the vehicle See Figure 3 and Table 2 Item 1 Plug the black six way audio harness pin housing 6A labeled CONNECTOR 6 from the new audio harness into the vehicle intercon nect harness socket housing 6B NOTE Six additional branches of the audio harness exit from the same end of the large conduit see Figure 11 e Eighteen inch 45 7 cm long labeled L FAIRING SPKR 35F with two
11. Gray red wire into cavity 18 8 Close the secondary lock per instructions in the service manual appendix and plug the socket housing back into the receptacle on the back of the radio NOTE Four additional branches of the audio harness exit from the same end of the large conduit see Figure 11 Eighteen inch 45 7 cm long labeled R FAIRING SPKR 34F with two way female Delphi connector 34FB Item 3 for right fairing speaker Thirteen inch 33 0 cm long labeled R TWEETER 34T with two way female Delphi connector 34TB Item 5 for right tweeter e Sixteen inch 40 6 cm long labeled R LWR 34L with two way Amp socket housing 34LB Item 7 for right lower speaker Eight inch 20 3 cm long labeled XM 185X with twelve way Deutsch socket housing 185X ltem 12 for optional XM satellite radio module 9 Plug the two way connector 34FB 3 into the right fairing speaker Plug the two way connector 34TB 5 into the right tweeter J05408 10 If equipped plug the twelve way Deutsch socket housing 185X Item 12 into the XM satellite radio module NOTE The optional iPod module can be mounted either in the front fairing or right side saddlebag 11 If an iPod module is mounted in the front fairing plug the eight way Deutsch socket housing 274F Item 13 into the iPod module 12 Route the left lower speaker branch of the audio harness 6 with white orange and light gr
12. If no lower gauges Remove the plastic plugs from the lower holes in the inner fairing With lower gauges See Figure 9 Disconnect the oil pressure gauge 113 and lamp 112 connectors Remove two hex nuts D and the back clamp C and remove the gauge B from the right lower opening in the inner fairing Disconnect the air temperature gauge 115 and lamp 114 connectors and remove the gauge A in the same manner 2 ALL versions Disconnect the fuel gauge 117 and lamp 116 connectors Remove two nuts and the back clamp and remove the fuel gauge A from the left upper opening in the inner fairing 3 Install the fuel gauge into the left lower opening Slide the back clamp over the gauge studs Verify that the tab on the back clamp engages the slot at the bottom of the inner fairing bore 4 Loosely install the hex nuts on the studs Verify that the gauge is properly aligned then tighten the nuts to 10 20 in lbs 1 2 2 2 Nm Connect the fuel gauge 117 and lamp 116 connectors 5 Disconnect the voltmeter gauge 111 and lamp 110 connectors 6 and reposition the voltmeter B to the right lower opening in the same manner Install Fairing Tweeters 1 See Figure 9 Get two tweeters 3 from the kit and the two back clamps C and four hex nuts D from the gauges removed from the vehicle For vehicles that only had TWO auxiliary gauges two additional back clamps Part No 67352 96A and four additional hex nut
13. MIDR2 HARLEY DAVIDSON WY J05408 INSTRUCTIONS REV 2011 07 01 BOOM AUDIO CUSTOM TOURING SYSTEM GENERAL Kit Number 76000209 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 NOTE The amplifiers and speakers in this kit are part of a system that has an impedance of one Ohm and are for use ONLY with the Boom Audio Custom Touring System and Harmon Kardon AM FM CD radio on select fitments See the P amp A retail catalog or the Parts and Accessories section of www harley dav idson com English only Using these speakers on 2005 or earlier Harley Davidson audio systems WILL cause permanent damage to those systems Additional Parts and Supplies Required Proper installation of this kit requires separate purchase and installation of Harley Davidson VENTED fairing lowers or replacement if the vehicle currently has NON VENTED lowers See the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only Replacement of saddlebag lids is required See Table 1 These items are available from a Harley Davidson dealer Table 1 Saddlebag Lids With Speaker Mount Part No Description 90200612 Lid kit left unfinished 90200613 Lid kit right unfinished 90200614 Lid kit left Vivid Black 90200615 Lid kit right Vivid Black Loctite 2
14. een white wires down along the left side of the steering head to the left center of the engine guard Route the right lower branch 7 with gray red and light green black wires down along the right side of the steering head to the right center of the engine guard NOTE Position connectors 34LB and 35LB outside the upper fairing to allow easy disconnection when removing fairing lowers 13 Use cable straps from the kit to fasten the upper section of the audio harness to nearby wiring inside the fairing 14 Route the long branch of the audio harness along the clutch lever side of the radio and rearward through the openings in the wire caddy alongside other harnesses down the vehicle backbone Use cable straps to fasten to other harnesses in the caddy 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 Be sure wires do not pull tight when handlebars are turned fully to left or right fork stops 15 Route the harness along the right side of the battery cavity Bring the red fuse holder 43 Item 14 black ground wire 15 and black green ground wire 16 into the front of the battery compartment Position the four way P amp A connector 4B Item 17 and B connector 18 in the area under the seat 16 Route the two long branches rearward to the front of the rear fender Use a cable strap
15. ents FLHX Models 15 of 15 J05408
16. he three push in screws Right Saddlebag Harness 1 Install the remaining saddlebag speaker jumper harness Figure 12 Item 16 in the right side saddlebag in the same manner with the following exception See Figure 8 Route both legs of the harness downward then rearward around to the outboard wall and upward in front of the saddlebag lid tether to the saddlebag lid Route connector 41S Item 13 through the bottom opening 6 of the speaker basket 5 closest to the speaker connector and plug into the speaker connector Affix five wire retainers 7 to the inside walls of the saddlebag about one inch 25 mm above the bottom of the saddlebag as shown Fasten the jumper harness to the wire retainers with cable straps 8 9 of 15 4 See Figure 12 If the iPod module U is being mounted to the saddlebag lid follow the instructions in the iPod module mounting kit 5 Install the saddlebags to the vehicle per service manual instructions 6 See Figure 3 and Table 2 Plug the audio harness con nector 288B into the left side saddlebag harness con nector Plug the audio harness connector 289B into the right side saddlebag harness connector 7 Fasten the saddlebag legs of the audio harness to the upper rear of the saddlebag supports so there is just enough harness loose to comfortably reach the saddle bags 8 Have a Harley Davidson dealer apply the specially developed sound equalization software to the vehicle
17. ker face From the underside of the saddlebag lid insert the screws through the holes in the lid and into the mounting pads in the grille Tighten the screws to 10 15 in lbs 25 4 38 1 Nm 13 Repeat Steps 1 through 12 for the opposite side saddlebag lid 14 Fasten the new lid to the saddlebag latch and bottom with the five screws R removed earlier Tighten to 20 25 in Ibs 2 3 2 8 Nm NOTE See Figure 7 The saddlebag latch hinge is shown with the pins removed for clarity 15 Get two foam pads Figure 12 Item 24 from the kit Cut one piece in half as shown in Figure 7 Remove the liner from the adhesive backing of the uncut pad and affix to the flat side of the latch connector segment Remove the liner from the adhesive backing of one cut pad and affix to the hinge side of the latch connector segment as shown NOTE The remaining foam pad segment can be cut and used as needed to eliminate any saddlebag vibration induced by speaker operation 16 Assemble the remaining saddlebag in the same manner is07029 1 Saddlebag hinge segment 2 Lid hinge segment 3 Hinge connector segment 4 Latch backing plate segment 5 Foam pad 2 Figure 7 Install Foam Pads to Saddlebag Latch Hinge Left Side Shown 8 of 15 SADDLEBAG HARNESS INSTALLATION Left Saddlebag Harness 1 See Figure 12 Get the left side saddlebag the correct saddlebag speaker jumper harness 15 a plug cover 25 and two screws
18. s Part No 67043 96 will be needed 2 Install the tweeters into the left and right upper openings in the inner fairing Slide the back clamp over the tweeter 2 of 15 studs Verify that the tab on the back clamp engages the slot at the bottom of the inner fairing bore 3 Install the hex nuts on the studs and tighten to 10 20 in Ibs 1 2 2 2 Nm Install Fairing Amplifier and Modules NOTES If another module has been installed on top of the radio on the brake lever side relocate that module to the clutch lever side of the radio per the instructions supplied with that module If another module has been installed on top of the radio on the clutch lever side relocate that module per the instructions supplied with that module An iPod module installed on top of the radio on the clutch lever side can be relocated to the right side saddlebag as described later in these instructions is07006 1 Amplifier 2 Radio case screw 3 Rubber grommet 2 Figure 1 Front Amplifier Installation 1 See Figure 1 Remove the screw 2 at the back of the radio 2 Position the amplifier 1 on top of the AM FM radio case with the metal cones on one end fitting firmly into the left most brake lever side rubber grommets 3 at the front of the radio 3 Fasten the amplifier to the radio with the radio case screw 2 Tighten to 35 45 in Ibs 4 0 5 1 Nm Harness Installation and Routing NOTE See
19. sible 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 necessary 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 Boom Audio Custom Touring System requires up to 16 Amps of additional current from the electrical system Kit Contents See Figure 9 Figure 10 Table 3 Figure 11 and Table 4 for front of vehicle components WM See Figure 12 Table 5 and Table 6 for rear of vehicle compon ents 1 of 15 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 A WARNING To prevent spray of fuel purge system of high pressure fuel before supply line is disconnected Gasoline is extremely flammable and highly explosi
20. sure 2 38 in 60 mm down Measure 50 degree angle Measure 2 63 in 67 mm Drill 9 32 in 7 mm hole 2 places Measure 0 50 in 12 7 mm Measure 1 68 in 42 7 mm Measure 1 00 in 25 4 mm PHMNHARYNS 10 0 25 in 6 4 mm radius 4 places Figure 5 Cut Connector Holes in Inboard Saddlebag Wall Left Bag Shown Saddlebag Lid Assembly NOTE Unfinished saddlebag lids must be finish painted before installation 1 See Figure 12 and Table 5 Get the gasket N mounting plate O two wear plates M and the finish painted saddlebag lid L from one of the saddlebag lid kits purchased separately NOTE Ambient temperature should be at least 60 F 16 for proper adhesion of the wear plates and gasket to the saddlebag lid 2 See Figure 6 Remove the liner from the adhesive backing of one of the wear plates 2 Carefully position the wear plate to the saddlebag lid 1 centering it on the tab 3 and press firmly into place Hold the wear plate in position with steady pressure for about a minute Repeat with the second wear plate at the other end of the lid 7 of 15 is06988 Saddlebag lid Wear plate 2 Tab Gasket Adhesive backing mp ON Figure 6 Assemble Wear Plates and Gasket to Saddlebag Lid 3 See Figure 12 Lay the mounting bracket O onto the lid flange lining up the five mounting holes NOTE Orient the gasket with the tall edge toward the o
21. ted wires of a fairing lower speaker harness 6 through the grommet Place the lower fairing per service manual instructions using a new rubber washer K Part No 7415A at the bottom attachment point to the engine guard Position the fairing cap G against the lower fairing align and install the lower fairing per service manual instructions J05408 is07095 Lower fairing left side shown Measure one in 25 mm over Measure 1 2 in 12 mm up Drill 3 8 in 9 5 mm hole o NS Figure 4 Drill Speaker Wire Hole in Lower Fairing Route the speaker harness wires through the large opening in the face of the speaker housing Get a two way pin housing 7 from the kit Insert the red orange wire and terminal into cavity 1 of the pin housing per instructions in the service manual appendix Insert the light green wire and terminal into cavity 2 Plug the pin housing into the back of the speaker Secure the speaker housing to the lower fairing with the three screws J removed earlier with the glove box door 6 of 15 and tether Tighten the screws to 20 25 in Ibs 2 3 2 8 Nm 9 Repeat on the opposite side of the vehicle SADDLEBAG PREPARATION Saddlebag Lid Removal NOTE Remove all items from the saddlebags e The saddlebags do not have to be removed from the vehicle to perform the lid removal procedure Take care to avoid damage to the saddlebag bottom when removing the lid 1 Remove t
22. to fasten both branches to the frame 4 of 15 is07007 1 289B 2 2 YN 3 3 PN 20 4 4H Ahh si YO 6 6 w A AE TIE 9 8 LR wi A Y O LGN BN 10 10 BKGN 1 111 A J D L Ro 12 12 13 13 2 d A pv 4 14 14 YN SPL 2 NN A V GY 3 1 C YN o hh PT A TN R 2 17 l7 SPL 13 AAAA ee A TNBK 1 18 ia A A TN R 19 19 rh 2 Ahhh BK GN 20 29 VOY SPL 14 ne VGY 11 21 21 22 22 10 23 23 9 24 24 L LGN BN A NNN PP p_ E 26 26 AA LGN BN 27 27 6 28 28 DOAN GN 5 0 Ali R A Tanaan aana A Pump Pp WBN 4 31 31 TNBK lan ah N SPL 12 T Ar BN 3 32 32 L TN BK OBE 33 33 1 35 35 C YN YO 288B 6A SS THT Tk 6 28B T Ed M M fT N T tT 7 4 12 STS TTS ran 3 11 10 Pm 4 2 1 PRT TTY SPLAT 8 R O 4B ES 7 O BE 5 O BE D 4 3 3 4 2 i i k KA 43B 185X hhh RJ 5 SPL 4 O R 2 4 6 278 O BE 1 Ph BK GN R A 2 2 LGN BK 3 3 4
23. tom Touring System Front Amplifier and Audio Harness See Figure 11 Item Description Quantity Part Number 9 Amplifier front speaker fairing mounted 76000141 10 Audio harness Not sold separately 11 Cable strap 10 10006 Table 5 Service Parts Touring Model Saddlebag Lids With Speaker Mount See Figure 12 ltem Description Quantity Kit or Part Number Saddlebag Lid Kit Available separately Not part of Custom Touring System Kit 76000209 e Left Unfinished 90200612 e Right Unfinished 90200613 e Left Vivid Black 90200614 e Right Vivid Black 90200615 L lLid cover saddlebag Not sold separately M Wear plate 2 90962 93 N Gasket cover 90675 93A O Mounting bracket 12700035 J05408 13 of 15 SERVICE PARTS Table 6 Service Parts Boom Audio Custom Touring System Saddlebag Components See Figure 12 Item Description Quantity Part Number 12 Basket speaker protective 2 76000182 13 Grille speaker left Not sold separately 14 Grille speaker right Not sold separately 15 Harness saddlebag speaker jumper left 69200159 16 Harness saddlebag speaker jumper right 69200160 17 Saddlebag capacity label 2 14000069 18 Speaker assembly 5x7 2 76000142 19 Screw Hi Lo 8 18 x 1 25 in 31 8 mm long 8 10200095 20 Rubber washer 8 25700117 21 Screw Hi Lo 8 18 x 0 75 in 19 0
24. u to a specially developed sound equalization software that is used in conjunction with the Advanced Audio system This unique equalization was designed to optimize the performance and sound response of the Boom Audio Custom Touring System Even if this kit is not being installed by a Harley Davidson dealer this special equalization software is available without charge from your dealer through Digital Technician II Dealer labor rates may apply for the upgrade procedure IN USE A small amount of water may at times collect in the saddlebag speaker cavities while parked outdoors The saddlebag speakers are weatherproof and the heat from speaker opera tion would soon evaporate the water but there could be a temporary effect on sound quality To promptly empty the speaker cavities lift the saddlebag lids Weather caps see Figure 12 Item 33 are provided to protect the lower fairing and saddlebag connectors on the vehicle when those items are removed for cleaning or servicing 10 of 15 SERVICE PARTS is07003 Figure 9 Service Parts Boom Audio Custom Touring System Upper Fairing Speakers See Table 3 is07026a Figure 10 Service Parts Boom Audio Custom Touring System Lower Fairing Speakers See Table 3 J05408 11 of 15 SERVICE PARTS Table 3 Service Parts Boom Audio Custom Touring System Lower Fairing and Front Speakers See Figures 9 10
25. uter lip of the cover as shown in Figure 6 e Begin gasket installation in the center of the inboard side of the lid opposite the hinge see Figure 8 Item 15 Gasket adhesive will hold the mounting plate in place 4 Gradually remove the liner from the adhesive backing Figure 6 Item 5 of the saddlebag lid gasket 4 as the gasket is pressed into place around the inside perimeter of the lid 1 as shown 5 Set the lid gasket side down on the clean pad or blanket of the work surface 6 See Figure 12 Get a saddlebag speaker assembly 18 speaker basket 12 and four 8 18 x 1 25 in 31 8 mm long screws 19 from the speaker kit 7 From the underside of the saddlebag lid and with the large rectangular opening Q toward the front place the speaker basket under the speaker cavity and snap it into the lid 8 Insert a screw from the top through each mounting hole in the speaker With the tweeter P toward the front of the saddlebag install the speaker into the cavity at the front of the saddlebag lid 9 Align the four screws with the mounting holes in the basket and tighten to 10 15 in Ibs 25 4 38 1 Nm 10 Get the correct speaker grille 13 or 14 four rubber washers 20 and four 8 18 x 0 75 in 19 0 mm long screws 21 from the speaker kit 11 Place a rubber washer into the well surrounding each grille mounting hole in the lid J05408 12 Place the speaker grille into position over the spea
26. ve the cover NOTE Models WITHOUT fairing lowers or models with NON VENTED fairing lowers will require separate purchase of VENTED lowers 8 Models Equipped With Fairing Lowers Remove the lower fairings per service manual instructions Discard the rubber washers at the bottom of the fairings 9 ALL Models Follow service manual instructions to remove the outer fairing and windshield J05408 FAIRING SPEAKER INSTALLATION Remove and Replace Upper Fairing Speakers 1 Remove the original equipment OE speakers from the inner fairing per service manual instructions NOTE Do not connect the vehicle harness to the speaker spade contacts at this time 2 See Figure 9 Follow the service manual and use the new screws 2 from the kit to install the new 5 25 inch 133 mm diameter speakers 1 into the inner fairing Tighten the screws to 16 18 in Ibs 1 8 2 0 Nm Remove and Relocate Auxiliary Gauges NOTES The following sections describe the suggested arrange ment Removal of the air temperature and oil pressure gauges if present from the vehicle relocation of the fuel gauge and volt meter to the lower positions and installa tion of new tweeters in the two upper auxiliary gauge positions However the tweeters and any two of the four gauges can be installed into any position as desired Electrical connectors are identified in the service manual by the numbers and letters shown here within brackets 1
27. ve which could result in death or serious injury 00275a 1 Follow service manual instructions to purge the fuel supply of high pressure gasoline and remove the fuel supply line IWIN NIN To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 2 Refer to the service manual and follow instructions to remove the main fuse 3 Remove the seat Retain all seat mounting hardware AWARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a A 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 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 For ALL models Follow the instructions in the service manual to remove the instrument console if equipped from the fuel tank 6 See the service manual for fuel tank removal instructions 7 Release the catches on the wire trough cover and remo
28. wo screws to release the check strap from the saddlebag lid only 2 Remove five screws to release the lid from the saddlebag latch The latch can remain attached to the saddlebag bottom Retain the screws and backing plate for installation of the new saddlebag lid The removed lid can be dis carded or set aside 3 Repeat for the remaining saddlebag lid Saddlebag Drilling 1 Lay aclean pad or blanket on the work surface to protect the painted surfaces of the saddlebag 2 Remove one saddlebag bottom from the vehicle per ser vice manual instructions Lay it outboard side down on the protected work surface 3 See Figure 5 Lay a strip or strips of masking tape in the approximate area of the holes to be made in the inboard saddlebag wall for the saddlebag jumper harness con nector Very carefully measure and mark the hole locations as shown 4 Mark the centers of the two holes with a center punch Drill two 9 32 in 7 mm diameter holes in the saddlebag wall 5 Carefully cut the rectangular hole for the connector body 6 Remove the tape Lightly sand the hole to remove burrs and sharp edges Clean the saddlebag wall surface of tape residue with a mixture of 50 70 isopropyl alcohol and 30 50 distilled water Allow to dry thoroughly 7 Set the saddlebag aside and repeat Steps 1 6 for the opposite side saddlebag J05408 is07096 Saddlebag rear mounting hole Measure 1 31 in 33 mm rearward Mea
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