INSTRUCTIONS - Harley
Contents
1. HARLEY DAVIDSON J0291 1 INSTRUCTIONS REV 5 22 03 Kit Numbers 76330 03A Domestic and 76339 03A HDI FLHT 1998 AND LATER MODELS RADIO CD KIT General This radio kit fits 1998 and later FLHT models NOTE 1998 to 2003 FLHT models require addtional setup proce dures for Automatic Volume Control to function Setup pro cedures are included in these instructions See the Service Parts illustration for kit contents This kit requires installing Antenna Part Number 76306 98 sold separately and available from your Harley Davidson dealer Installation Outer Fairing Removal 1 Remove the seat according to the applicable service manual instructions 2 Disconnect the battery negative cable first WARNING To protect against shock and accidental start up of vehi cle disconnect the battery cables negative cable first before proceeding Inadequate safety precautions could result in death or serious injury WARNING Always disconnect the negative battery cable first If the positive battery cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or seri ous injury 3 See Figure 1 Remove the outer fairing and windshield a Remove the TORX screws 1 2 3 from the outer fairing to remove the windshield b Remove the TORX screws 4 5 6 7 from the inner fairing Turn the handlebar to acces2. al injury 3 Install the seat Warranty Information To activate the warranty for this kit 1 Complete the Premium Sound System Warranty Registration Card The radio serial number is located on a label on top of the radio chassis 2 Send the registration card to Radio Sound Inc 3 Complete the Premium Sound System Warranty Owner Record 4 Keep the Premium Sound System Warranty Owner Record and dated bill of sale for your warranty records 5 of 6 SMOTORZ Service Parts i04642 sg gt Stock screw 4 Item Description Part No 1 Radio kit 76330 03A Domestic 76164 04 Radio kit 76339 03A HDI 76178 04 2 Antenna base assembly 76335 87 Includes items 3 and 4 3 Nut 1 2 20 76259 86 4 Lockwasher internal tooth 7129 5 Antenna base assembly Tour Pak 76252 86 Includes items 3 and 4 6 Ground cable 70465 86A 7 Antenna mounting bracket 76153 95 8 Lockwasher 5 16 inch 2 7041 9 Hex head screw 5 16 18X5 8 inch 2 2882W 10 Hex head screw 5 16 18X7 8 inch 3991 J02911 Part No 76330 03A 76339 03A 19 Date 5 03 1998 and Later FLHT Radio CD Kit Antenna sold separately Stock cable located inside fairing plugs into back of radio Item Description Cable strap 10 Antenna base gasket Reinforcement plate Lockwasher 10 internal tooth Screw 10 32 x 3 4 in Antenna cable grommet Adapter speaker 2 Speaker 2
3. Screw 10 16X2 inch 4 Screw 10 16X 1 1 4 inch 2 Warranty sound system not shown Warranty card not shown Sound System Manual not shown Part No 10006 76255 86 76253 86 7118 2576 11486 77047 98 77029 01 2965 3639 93745 02 99471 02 Stock cable located under vehicle left sidecover 99464 03A 6 of 6
4. cable Install the Antenna on Vehicles Equipped with a Tour Pak Preparation NOTE Install the antenna where indicated to avoid antenna interfer ence when opening and closing the Tour Pak lid Install the antenna base in the upper left corner of the Tour Pak out side rear wall J02911 NOTE The measurements in this procedure refer and apply to the lower half of the Tour Pak only and do not involve or include measurements from or on the Tour Pak lid 1 See Figure 6 Measure the width to find the center of the Tour Pak outside rear wall 2 Fasten a 2 inch wide strip of masking tape vertically from top to bottom on the outside back center of the Tour Pak 3 Repeat Step 1 to mark the Tour Pak vertical center on the top and bottom of the tape strip 4 Draw a vertical line on the tape from the top mark to the bottom mark 5 From the drawn center line measure 9 1 4 inch to the left 6 At the 9 1 4 inch measurement fasten a 2 inch wide strip of masking tape vertically from the Tour Pak top edge to the horizontal middle of the Tour Pak wall 7 Repeat Step 5 to mark a vertical line on the masking tape from Step 6 8 Across the vertical line on the left tape strip draw a short horizontal line a 1 1 4 inch down from the Tour Pak top edge and b 1 1 2 inch down from the horizontal line drawn in step 8a 2 3 4 inch from the Tour Pak top edge 9 Mark the center of the crossed lines with a center punch and dr
5. inner fairing while lowering the back of the radio Check that the nose seal is not distorted compressed or pinched 3 Fasten the radio to the inner fairing brackets using the four screws and washers from Step 4 in Outer Fairing Removal Torque the screws to 45 60 in Ibs 5 0 6 7 Nm 4 See Figure 2 Plug the radio antenna cable connector into the back of the radio Tuck excess cable under the right corner of the radio 5 Plug the 23 place connector 27 from the wiring har ness into the connector on the back of the radio 1 of 6 03414 Radio connector 27 23 place Antenna cable connection socket Install the Speakers 1 Remove the three screws fastening the right side speaker adapter and grill to the fairing Discard the screws and adapter 2 See the Service Parts illustration Align the holes in the speaker with those in the new adapter Position the speaker spade contacts at the top of the adapter the top being the thickest edge Snap the speaker into the adapter 3 See Figure 3 Install two 2 inch screws at the top of the speaker to fasten the speaker adapter assembly to the inner fairing Torque the screws to 22 28 in Ibs 2 5 3 2 Nm 4 Fasten the bottom of the speaker and the fairing sup port brace using one 1 1 8 inch screw in the speaker s lower outboard mounting hole Torque the screw to 35 50 in Ibs 4 0 5 7 Nm NOTE The
6. side of the Tour Pak support Install a grommet in the 5 8 inch hole at the bottom front left side of the Tour Pak Test the Sound System NOTE Before installing the outer fairing test the radio CD anten na and speakers 1 Turn the ignition to the OFF position Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in death or serious injury 2 Connect the battery cables to the battery positive cable first Refer to the SOUND SYSTEM manual in this kit to test the sound system operation Troubleshoot the radio CD speaker and antenna func tions as needed Otherwise install the Tour Pak liner and continue to the next section 4 of 6 1998 to 2003 AVC Setup Procedures NOTE This setup is not required for 2004 and later FLHT Models 1998 to 2003 models require this procedure for the Automatic Volume Control to function 1 Press and hold any two preset buttons on the front panel while turning the ignition light switch from OFF to IGNITION or ACCESS 2 Diagnostic Group 1 d1 the first of several diagnostic screens will appear in the LCD Press the local distant LO DX button to cycle through the diagnostic screens 3 Stop at the screen Press 1 for bikes before MY2004 for 1998 to 2003 models Press 2 for is your bike is MY2004 or later 4 Press Preset 1 bu
7. ill 1 8 inch pilot holes in the Tour Pak wall at the marked points 10 From the outside of the Tour Pak drill the pilot holes from Step 9 to a e 17 32 inch hole through the TOP pilot hole e 1 4 inch hole through the BOTTOM pilot hole 11 Remove the tape from the Tour Pak NOTE Some Tour Paks are equipped with a 5 8 inch hole in the bottom at the front left side This hole is for antenna cable routing If your Tour Pak does not have this hole complete Step 12 Otherwise continue to the next section 12 Drill an antenna cable access hole a Remove the Tour Pak liner b See Figure 1 Locate the pattern of eight 0 31 inch diameter holes in the metal plate on the inside bottom of the Tour Pak c From the front left hand hole measure forward 1 inch and left outboard 4 inch Mark this location d Drill a small pilot hole at the marked location e From the underside of the Tour Pak drill a 5 8 inch hole from outside the Tour Pak to the inside Antenna Installation 1 See the Service Parts Illustration Place the gasket 12 on the antenna base assembly 5 3 of 6 i01002a 1 1 4 inch Center line 7 PA 1 1 2 inch 9 1 4 inch AZ j L F 17 32 inch hole 5 8 inch hole Figure 6 Drilling the Tour Pak for Radio Antenna Installation 2 Place the base assembly with the antenna mast stud facing upward into the drilled holes on the back of the Tour Pak 3 Place the reinforcement plate 13 on
8. o the base 5 Bracket 6 Antenna cable 7 Lockwasher 2 8 Screws 2 2 Antenna base assy 3 Nut 1 2 20 4 Lockwasher int tooth Figure 4 Antenna Mounting 2 of 6 a Figure 5 Cable Strap Locations NOTE Tighten the set screw holding the antenna mast to the antenna base assembly The antenna set screws have met ric threads M4 0 7 x 3 mm and require a 2 0 mm Allen wrench 2 Thread one of the large nuts 3 onto the antenna base assembly 3 Insert the antenna base through the large internal tooth lockwasher 4 and hole in the antenna mounting brack et 5 4 Fasten the other large nut 3 to the antenna base to secure the base to the bracket With a wrench on the upper nut tighten the lower nut to 40 in Ibs 4 5 Nm Connect the Antenna Cable 1 Remove the left sidecover from the vehicle to reveal the antenna cable 2 Cut the cable strap fastening the antenna cable to the frame 3 Route the antenna cable to the right side of the vehicle and foward of the luggage rack mount 4 See Figure 4 Plug the antenna cable connector into the antenna base 5 Tighten the knurled nut on the antenna cable connector to secure the connector to the antenna base 6 See Figures 4 and 5 Secure the antenna cable to the vehicle using cable straps at the locations shown 7 Install additional cable straps on the left side of the front luggage rack mount and as required to secure the antenna
9. s screws 6 and 7 c Tilt the outer fairing toward the front then squeeze the two external tabs to remove the wire connector from the back of the headlamp assembly d HDI models only Remove the black and orange white wires from the stake on connectors near the bottom of the headlight e Lift the fairing and headlamp assembly from the motorcycle 4 Remove the four screws fastening the sides of the stor age box to the inner fairing brackets Save the screws for installation Install the Radio CD Player NOTE Copy the serial number from the label located on top of the radio chassis before installing the radio The serial number must be included on the warranty form 103413 T27 TORX screws upper fairing 2 OI LA N T25 TORX screws lower fairing Figure 1 Removing Outer Fairing Fasteners NOTE Connector numbers in brackets for example 27 corre spond to the connector numbers in the service manual wiring diagrams A service manual is available from your Harley Davidson dealer 1 Hold the radio between the support brackets with the radio nose seal in position over the hole in the fairing NOTE To assist installation apply soapy water to the nose seal then gently rock the radio back and forth while inserting the radio into the fairing 2 Tilt the back of the radio up 45 degrees Gradually push the radio nose seal into the hole in the
10. speaker mounting hole on the lower inboard side of either speaker is not used 5 Connect the speaker wires to their respective size spade connectors e Right side speaker Connect the grey red and light green black wires from the right side of the fairing to the right speaker spade connectors e Left side speaker Connect the white orange and light green white wires from the left side of the fairing to the left speaker spade connectors 6 Repeat steps 1 through 5 to install the left speaker J02911 i04641 The lower inboard mounting hole for each speaker is not used 1 Screw 2 in 2 3 1 1 8 in screw 1 left 2 Spade connectors speaker 4 1 1 8 in screw 1 right speaker Figure 3 Speaker Installation Install the Antenna on Vehicles without a Tour Pak Install the Antenna Bracket 1 See Figure 4 Remove the right side saddlebag 2 Fasten the antenna bracket 5 to the right fender sup port bracket using two 5 16 18 X 5 8 inch screws 9 and lockwashers 8 from the kit NOTE If a saddlebag guard or rail is mounted at the lower hole in the support bracket use the 5 16 18 X 7 8 inch screw 10 to fasten the antenna bracket and saddlebag guard to the support bracket 3 Tighten the mounting screws to 19 ft lbs 26 Nm Fasten the Antenna to the Antenna Base 1 See Figure 4 Screw the antenna sold separately onto the antenna base assembly 2 and tighten the set screw in the antenna to secure it t
11. the antenna base assembly studs inside the Tour Pak 4 Place the ground cable 6 on the antenna base assem bly antenna stud 5 Fasten the antenna base assembly reinforcement plate and ground stud to the Tour Pak using a lock washer 4 and nut 3 6 Attach the other end of the ground cable to a mounting bolt on the inside bottom of the Tour Pak 7 Install the screw 15 and small lockwasher 14 in the bottom hole of the antenna base and from inside the Tour Pak 8 Screw the antenna sold separately onto the antenna base assembly 2 and tighten the set screw in the antenna to secure it to the base NOTE Tighten the set screw holding the antenna mast to the antenna base assembly The antenna set screws have met ric threads M4 0 7 x 3 mm and require a 2 0 mm Allen wrench 9 Remove the left sidecover from the vehicle to reveal the antenna cable 10 Cut the cable strap fastening the antenna cable to the frame 11 Route antenna cable along the Tour Pak left side sup port rack and up through the 5 8 inch hole in the bot tom front left side of the Tour Pak J02911 12 13 14 15 Plug the antenna cable connector into the antenna base Allow enough cable that when connected the cable rests flat on the inside bottom of the Tour Pak Tighten the knurled nut on the antenna cable connector to secure the connector to the antenna base Use cable straps to secure the antenna cable to the left
12. tton 5 After selecting the correct model year repeatedly press the LO DX button until the receiver reverts back to nor mal radio operation Install the Outer Fairing 1 See Figure 1 Place the windshield in position on the inner fairing Align the slots in the windshield with the threaded inserts 2 Install the outer fairing a Place the fairing and headlamp assembly on the motorcycle b Fasten the wire connector to the back of the headlamp assembly c HDI models only Fasten the black and orange white wires to the stake on connectors near the bottom of the headlamp assembly d On the outer fairing loosely fasten three screws below the windshield e On the inner fairing start the two fairing screws just above the wind deflectors on both the left and right side f Turn the handlebar to the left and start the next fairing screw below the fairing cap g Turn the handlebar to the right and start the fairing screw on the opposite side h Alternately tighten the four fairing screws on the inner fairing side to 45 55 in Ibs 5 6 2 Nm i On the front of the vehicle tighten the outer fairing screws below the windshield to 10 13 in Ibs 1 1 1 4 Nm J02911 WARNING After installing the seat pull upward on the front of the seat to be sure it is locked in position If the seat is loose it could shift position during vehicle operation and startle the rider causing loss of control and person
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