INSTRUCTIONS - Harley
Contents
1. 20 0 0 OL dl N TT 1 OL 8 aa LHM 34O 40103 YOlY INGOW 010 OL 1 OL Ads LYE JAI NOTLINSI JAZZI TWNIIS Y N Y N 87H LHI 440 N0 REF 87H 1H918 NOWWOJ EHE 1 133 8 034 NYI 1 3510 1437 8 7H 1337 NOWNOD 8 TYNIIS 40103 1 NId NId 9 8 MEE 1HM7340 034 8 Q34 NUL 1 NJ973118 Y JGAEI 831188 NOTLINSI JGAel 440 NO 1 9510 Y 11130 6 8 8 6 1103419 duo 3SN4 amp V83TONSH 1918 NId 2 gig 8 OL CELI 311384917 01 1 1 6 1437 1 OL 18 a 130 5 6 1 gaa 8 440 NO 52217155 4 106 INITUIM Y Y 56 8 80702 15 8 Yves 00 081 SSE 1113 8 aad NYL 6 n7a NYL gt 8 T 80702 84 1 HVA3TONHH 918 OL OWT 2810 NOWHOS 5 s31H9IT 311384917 OL Ts 1 1431 OL2. CD play starts when the disc number and track number indicators light on main unit NOTE When the CD Magazine is initially installed into the changer the changer will cycle through the stack until the first disc is recognized Once the changer recognizes a slot without a CD the changer will not cycle through that slot until the magazine is ejected and re installed TUNE THE FM RECEIVER TO PRE SET FREQUENCY For Domestic Models this will be 88 1 MHz If an FM station happens to be broadcasting at this frequency refer to Changing the RF Level Output and Frequency under General Information and Specifications ADJUSTING THE VOLUME Adjust the volume of the bikes receiver radio with the Audio Control Switch on the left handlebar switch assembly Push the Audio Control Switch UP to raise the volume DOWN to lower the volume Volume level will be displayed on the receiver display If the volume when playing CD s is different than the volume when playing the radio with the CD off refer to Changing the RF Level Output and Frequency under General Information and Specification TO STOP CD PLAYBACK Press the right handlebar ON OFF switch J01422 Do not try to insert CD s without first pulling out the disc tray from the magazine Never place CD s directly into the magazine Do not disassemble the magazine Take care not to drop or hit the magazines Do not apply excessive pressure to the disc t
3. 2A Is continuity present System OK Install original Modu lator Replace Controller Check for continuity to Locate and ground on connector repair open on 2A pin 3 Blk Red wire Is continuity present YES Replace Modulator Locate and repair open ground circuit Use Harness Connector Test Kit HD 41404 Black Pin Probes and Patch Cords Use Harness Connector Test Kit 41404 Black Socket Probes and Patch Cords J01422 16 of 20 i03949 Power Switch Won t Turn Changer Off SETUP Radio ON Tuned to CD Frequency CD Audio Present Can Disc Track be advanced using Controller in Tour Pak Remove Seat Disconnect connector 1A Check for continuity Disconnect connector as follows 1A Check for continuity While holding H B control in desired position to ground for connector 1B pins 4 and 5 Power ON OFF Continuity present From Connector Terminal To Connector Terminal 1A 4 BLK 1A 5 Red Continuity present Locate and repair short to Check for voltage on con ground Can Disc track nector 1B pins 4 and 5 be advanced after repair Voltage present YES Replace Controller 2 Disconnect connector 4A System OK Replace Controller Locate and repair short Replace Controller aE to voltage Can Disc heck Check continuity at connector Track be advanced after 4B pins 1 and 2 Power ir While holding handlebar con repair trol in desired position
4. REV 7 13 2004 Kit Number 77184 01A INSTRUCTIONS HARLEY DAVIDSON J01422 CD CHANGER KIT 1 Remove seat 2 Disconnect battery cables negative cable first Mount CD Changer in Tour Pak 3 Remove the Tour Pak liner or rubber mat Refer to instruc tions in applicable Service Manual and remove the Tour Pak Save all mounting hardware 4 Lay the Tour Pak on a bench or other suitable surface and open the lid Remove the antenna ground wire screw and ground near the center of the plate Save hardware Remove two screws securing small leather pouch and remove pouch Re install pouch hardware 5 FLHTCUI models Holding Phillips screw inside Tour Pak right rear corner remove flange nut at bottom to release CB loading coil bracket Remove Phillips screw with exter nal tooth lockwasher Save hardware 6 Close Tour Pak Turn Tour Pak over and remove the seven flange nuts remaining six if FLHTCUI at the bot tom Save nuts 7 Place Tour Pak topside up and open lid Reach inside and remove the metal plate pulling threaded studs from holes in bottom Mark the plate with an arrow signifying the front as installed 8 Obtain the template provided with this Instruction Sheet 92099 04 Secure the metal plate in a vice or other suit able holding device Place template over the metal plate noting the following a Orient template so existing rigid Tour Pak rack mounting holes are aligned with those marked in
5. i03796 eps
6. Gather excess cabling and wiring together and position at corner of rear left side of Tour Pak Use cable ties and bundle the cables wires as small as possible into rear left corner of Tour Pak b Position Tour Pak Liner in Tour Pak and align corners and sides as close to original installation as possible Push liner down and work cutout in around CD changer c Press edges of liner against original Velcro on sides to secure in place d Obtain the Tour Pak leather pouch removed in earlier Step Attach the second Velcro Strip to pouch and to back wall of Tour Pak liner if applicable Install leather pouch 30f20 22 See Service Parts Page Illustration and Figure 4 Disconnect the antenna lead from the antenna base if not already disconnected Obtain new lead 18 from kit Attach female end of new antenna lead to male end of lead exiting modulator box Attach threaded large coax end of new lead to original antenna lead coming from radio NOTE On models in which Antenna Relocation Kit has been installed it may be possible to attach coax from new lead directly to coax adapter installed to left rear fender support 3 Antenna Coax Male End of Modulator Lead Female End of New Lead Figure 4 Attach Radio Antenna and Modulator Leads 23 See Figure 5 Obtain new Antenna Lead 19 from kit Attach Female end of antenna lead from Modulator Box to Male end of new lead Connect opposite end with nut of new lead d
7. CN Figure 12 2004 and Later Power B Connector and Ground Wire location 41 See Figure 13 Continue routing harness up under fuel tank toward forks ACD Changer amp Harnes 5 of 20 Route and Connect Wiring Harness 33 Follow instructions in applicable Service Manual and par tially remove fuel tank to gain access to main harness 34 Follow instructions in applicable Service Manual and remove battery 35 See Service Parts Page Illustration Obtain Wiring Harness 2 from kit Locate the end with 3 Pin and 6 Pin Deutsch connectors installed Locate the bikes main har ness running along the upper right frame tube 36 See Figure 10 At area under the seat connect the con troller 6 Pin and Modulator 3 Pin connectors to the new wiring harness supplied with kit Connectors installed in Steps 31 and 32 for locating purposes Lay the CD Changer new harness against the frame following upper right frame tube Modular 3 Pin Connector To Tour Pak New Wiring Harness from Kit Controller 6 Pin Connector Figure 10 Connect New Wiring Harness Under Seat As observed from Left Side of Bike 37 See Figure 11 2003 and Earlier Looking toward the front and left of battery box locate the circuit breaker Obtain the RED power lead with in line fuse from the CD har ness cut off terminal and crimp on ring terminal Remove nut from SILVER terminal post and connect RED power ring terminal lead to circ
8. Figure 2 Remove CD Changer From Brackets J01422 1 CD Changer 2 Changer Input 4 Controller Input Figure 6 Connect Modulator to CD Changer 25 If Tour Pak is equipped with liner perform the following a Obtain Liner Template from kit Note Liner Template is part of Bracket Template used to mark holes for CD Changer Bracket and marked with non continuous lines b Using a sharp knife cut opening for CD changer ESD Safety Precautions for CD Changer Control Unit Controller Static Discharge Procedure Prior to removing the controller from the static bag hold the bag in one hand barehanded while touching a grounding point on the motorcycle with your other hand Use any of the follow ing ground points negative battery post brake disc grounding plate in Tour Pak or main ground stud on frame This will eliminate any charge that you or the bag may have developed Be sure to ground yourself again prior to pinning out the con troller connector 26 Refer to Figure 6 and Service Parts Page Illustration Obtain the Tour Pak Liner Cut in Step 25 if applicable the Unit Controller 21 and Changer Cover 20 Route the unit controller cables through cover and liner and con nect the Male plug Controller to Female connector marked Controller Input on modulator box 27 Route Controller 6 Pin Harness down through grommet and out of Tour Pak 28 Prepare and Install Tour Pak liner by performing the fol lowing a
9. is con tinuity present System OK Replace Controller Locate and repair open Inspect left HB switch in main harness wiring for damage Damage present YES Locate and repair open Replace CD Track Disc or damaged wiring selector switch Refer to procedures for CB push to transmit switch Ultra models Use Harness Connector Test Kit HD 41404 Black Pin Probes and Patch Cords Use Harness Connector Test Kit 41404 Black Socket Probes and Patch Cords J01422 17 of 20 i03950 Disc Track Won t Advance SETUP Radio ON Tuned to CD Frequency CD Audio Present Can Disc Track be advanced using Controller in Tour Pak Remove Seat Disconnect connector 1A Check for continuity Disconnect connector as follows 1A Check for continuity While holding H B control in desired position to ground for connector 1B pins 1 2 3 TRACK Continuity present From Connector Terminal To Connector Terminal 1A 3 TN R 1A 1 BLK GN DISC From Connector Terminal To inal 9 Connector Terminal Locate and repair short to Check for voltage on con 1A 2 TN BLU 1A 1 BLK GN ground Can Disc track nector 1B pins 1 2 3 be advanced after repair Voltage present Continuity present YES 2 Disconnect connector 3A Locate and repair short Replace Controller Check continuity at connector to voltage Can Disc 3B pins 1 and 8 Track or Track og advanced a
10. template b Be sure to correctly identify and mark the template drill holes specified for your Tour Pak i e King vs Shorty Tour Pak c Use a punch and indent the center of the cross hairs then use a 1 8 inch bit to drill guide holes 9 Using a 5 16 inch bit drill four CD bracket mounting holes marked and punched in previous step NOTE Make mark and indent hole for drilling but do not drill antenna ground hole at this time NOTE Be sure to perform Step 10 prior to installing CD changer You will not be able to access the Front Tour Pak mounting holes once changer has been installed 10 Obtain two of the mounting screws removed in Step 3 and install into Front Tour Pak Mounting Holes in plate 1 of 20 General This kit is designed for installation on 2000 and later FLHT FLHTC FLHTCI FLHTCUI FLTR FLTRI and FLTRSEI Models equipped with rigid or detachable Tour Pak Racks Tour Paks with 5 mounting bolts NOTE Will not fit Chopped Tour Paks equipped with Light Kit Part Number 54302 98 See Service Parts Page Illustration for kit contents NOTE FLTR l models require a Tour Pak and one of the following Rigid Tour Pak Rack kit Part Number 53118 98 with Antenna Relocation Kit Part Number 76329 98 Detachable Tour Pack Rack Kit Part Number 53107 96 with Antenna Relocation Kit Part Number 76326 00 FLHT models equipped with Detachable Tour Pak Rack Kit Part Number 53107 96 require Antenna Relocation Kit
11. 1 See Figure 3 and Service Parts Illustration Locate the punch out circle near the right front of the Tour Pak Using a 3 4 inch bit drill a hole to be used for wire harness routing Lightly sand to remove burrs or sharp edges Obtain grommet 25 from kit and install to hole Route modulator harness down through grommet and out of Tour Pak 1 Modulator Harness 2 Drill 3 4 inch hole and install rubber grommet Figure 3 Drill Harness Routing Hole 2 of 20 Changer mounting bracket Modulator Cable ground clamp Nut Figure 1 CD Changer Installed to Plate See Figure 1 Position the CD changer with bracket on the plate with modulator facing toward rear and CD con nector sockets oriented to the right side of Tour Pak See Service Parts Page Illustration Obtain four screws 17 and locknuts 16 from kit Align the brackets over the holes just drilled and install four screws from back of metal plate through changer mounting brackets Install locknuts and tighten to 96 144 in Ibs 11 16 Nm See Figure 2 Disconnect and remove the Jumper from the modulator Changer Input to the CD Changer Remove the three buttonhead screws and lockwashers on each bracket securing CD changer to left and right chang er brackets Pull the changer up and out of the brackets Save hardware for re installation On all except FLTR and FLTR l proceed to Step 16 11 12 13 14 15 1 Jumper CD unit to modulator
12. Figure 1 Compulsory Eject Hole TROUBLESHOOTING CHARTS The following pages consist of troubleshooting charts designed to assist in diagnosing CD Changer operation problems CD Inoperative Power Switch Won t Turn Changer Off Disc Track Won t Advance Forced Manual Eject Procedures 15 of 20 CD CHANGER RESET BUTTON You may need to reset the CD changer when power is interrupted from the CD Changer i e Battery removal disconnection from motorcycle or the CD changer is functioning erratically Press the reset Button on the CD changer with the Ignition Light Key Switch in the IGNITION or ACCESS position and the CD changer ON When the display show R 1 to R 8 confirm that the cord is connected correctly and press the microcomputer reset button of the controller and CD changer When the display shows R 8 confirm that the unit is connected to the CD automatic changer MAGAZINE CANNOT BE EJECTED 1 When the magazine cannot be ejected push in the maga zine and play the 12th compact disc once more 2 When play has ended remove the CD Changer access toward the right to expose the EJECT button If the above procedures fail to work see Figure 1 and perform the following a Peel off the protective seal over the compulsory eject hole b Put a blunt instrument i e screwdriver into the hole to release magazine c If you are still unable to eject magazine replace the protective seal and consu
13. GENERAL INFORMATION AND SPECIFICATIONS Handlebar Controls Allows rider input to the Controller for CD ON OFF and Track and Disc advance DIN Cable Short cable between the CD changer and Modulator that transfers power serial data and audio Controller Converts signal from handlebar control to serial data for controlling Track Disc and Power Displays Disc and Track Information as well as other CD functions only executable from the the controller FM Modulator The modulator converts the line out from the CD changer to FM signals The FM signals supplied to the receiver s antenna are received and CD sound is reproduced Selectable Output Frequency 88 1 MHz 89 9 MHz Frequency changed in 0 2 MHz intervals Frequencies Domestic 88 1 107 9 The RF output frequency of the FM modulator box is set to 88 1 MHz at the factory NOTE If an FM station happens to be broadcasting at the same frequency follow the steps below to change the RF output HDI 87 5 108 Japan 76 1 89 9 CHANGING THE RF LEVEL OUTPUT AND FREQUENCY In areas where the RF output frequency will need to be changed perform the following steps Be sure to turn the main unit ON Press both the microcomputer reset button of the CD changer and that of the main unit to reset the microcomputer NOTE If the reset button is pressed after RF and frequency has been adjusted the level and frequency will return to the preset level of L5 and frequency of 88 1
14. MHz a Press the RPT F SEL button on the controller for more than 2 seconds b With the gt gt I button or the l lt lt 4 button set to a frequency where no signal is being broadcast The frequency will be changed in 0 2 MHz intervals and is setable between 88 1 and 89 9MHz c Press the RPT F SEL button to return to the original display NOTE If the sound of the FM receiver is distorted or different than CD playback perform the following 1 Press the BBE button for more than two seconds 2 Adjust the RF output level by pressing the gt gt l l lt lt V button on the controller 14 of 20 ELECTRICAL REQUIREMENTS This unit is designed to operate with 12 volts DC negative ground electrical system PRECAUTIONS Always disconnect the negative battery cable prior to making connections to prevent short circuits from occurring FUNCTIONS CD Changer The CD Changer accepts serial data from the CD Controller via the RF Modulator to execute the changer functions which include Track Disc and Power The CD Changer is a player changer that holds the CD Magazine The magazine capacity is 12 CD s The EJECT button will eject the CD magazine from the changer The CD Changer outputs a low level audio that is routed via the RF Modulator to the radio for amplification The CD Changer also contains the low level audio buffer that helps the CD player to avoid skipping Full Floating Isolation The CD Change
15. NT button two times to enter normal mode Disc Scan Disc number blinks Only the first tracks on all discs in the magazine are intro scanned When the required disc is located press the INT button once to enter normal play mode BBE Press the BBE button to turn BBE circuit ON OFF Refer to BBE Circuit under General Information and Specifications for more information RANDOM PLAYBACK Each time the RND button is pressed the mode is changed from the RND mode to the RND mode to the clear mode in this order RND Plays all tunes on the disc currently being played back in random order RND Randomly play all the tunes on all the discs in the magazine 12 of 20 TO START CD PLAYBACK NOTE Refer to the Illustrations on the following page WARNING Do not attempt to operate the CD controller or remove the CD Magazine from CD changer both located in Tour Pak while riding Attempting to operate either the CD controller or removing the CD magazine while riding can lead to loss of control of vehicle resulting in death or serious injury NOTE Refer to Premium Sound System or Operators Manual for Radio Operation TURN THE MAIN UNIT in Tour Pak POWER ON PRESS THE RIGHT HANDLEBAR OR CONTROLLER in Tour Pak ON OFF SWITCH TO ON The display window lights on controller NOTE The CD changer will select the first tray in the magazine which contains a disc and start playing after approximately 10 15 seconds
16. Part Number 76326 00 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 per form the installation Improper installation of this kit could result in death or serious injury 00333a NOTE A Service Manual for your motorcycle is available from any Harley Davidson dealer WARNING prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables nega tive cable first before proceeding 00307a PING 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 Installation Installation of this kit involves performing the following steps Mount CD Changer in Tour Pak Route and Connect CD Changer Wiring Harness Assemble Left and Right Switches Route and Connect Handlebar Switches Install Antenna Relocation Kit FLTR FLTRI Only If this kit is being installed to FLTR FLTRI at this point you will want to relocate the antenna These models require that existing antenna be removed from left rear fender mount and mounted to back of Tour Pak Depending on whether you have a rigid or de
17. Screw TRACK and DISC Advance Switch Figure 19 Install Left Switch Assembly 7 of 20 Remove Left Handlebar Clamp 54 Using a T27 TORX drive head remove the two screws with flat washers securing the left handlebar clamp to the clutch lever bracket and remove the clamp Discard the clamp and two screws but save the flatwashers for re installation Leave the clutch lever bracket in place on han dlebar for now Install Right Handlebar Switch Housing 55 See Parts Illustration Obtain the right switch assembly marked ON OFF chrome housing clamp 3 and two 1 5 8 inch long button head screws 17 from kit Also obtain the flatwasher saved from Step 53 CAUTION Do not remove the switch housing assembly without first placing a 5 32 inch 4 mm thick cardboard insert between the brake lever and lever bracket Removing the assembly without the insert in place may result in damage to the rubber boot and plunger of the front stoplight switch 56 See Figure 16 Position the brake lever master cylinder assembly inboard of the switch housing assembly engag ing the tab on the lower switch housing in the groove at the top of the brake lever bracket 1 Switch 50 Assembly 3 Tab 2 Brake Lever Bracket 4 Groove Figure 16 Fit Brake Lever Master Cylinder to Right Handlebar Switch Housings 57 See Figure 17 Align the holes in the switch housing clamp with those in the master cylinder housing and start the two screws w
18. anger will search all twelve trays starting with 1 for a tray containing a disc If a disc is found in a tray the CD changer will play the disc and remember which numbered tray the disc is in When the disc is finished playing or the CD button is pushed on the left handlebar the CD changer will then search for the next tray containing a disc after a slight pause on trays not containing discs Upon finding a disc in a tray the CD changer will play and again remember the tray This process will continue until all twelve trays are searched After the CD changer searches the twelfth tray for a disc or the compact disc in the twelfth tray has finished playing the CD changer returns to the beginning of the magazine and starts playing the first CD disc remembered from the first pass through the trays containing discs NOTE The CD changer will remember trays which contain discs even when the IGNITION switch or CD controller has been turned OFF When the magazine is removed the CD changer memory is lost When the magazine is re installed the first pass search for trays with discs will be repeated The CD changer will remember which trays have discs and which trays are empty and will only access those with discs in them 11 of 20 TO LOAD MAGAZINE CD Magazine holds twelve 5 inch 12 cm CD discs 1 See Figure 1 Slide the disc tray partly out from the magazine until it stops 2 Place a CD on the d
19. d 7 Slide wire seal up to connector and press into connector creating a seal around wiring and connector Awarnine 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 61 Reconnect battery positive cable first 62 Install seat Awarnine After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a 63 See Service Parts Illustration Obtain remaining wire ties 22 from kit Following complete path of CD changer har ness install tie straps to cleanly secure harness to frame Install tie straps to secure switch wires routed along han dlebars 64 Follow instructions in applicable Service Manual and re install outer fairing 65 Follow instructions in applicable Service Manual and re install fuel tank Installing Handlebar Switch Connectors Install Two Place Connector ON OFF Switch 1 See Service Parts Illustration Obtain the 2 Place Receptacle 9 and Wedge Lock 12 from kit Locate CD ON OFF Switch wires with pins Wire colors will be Black and Red N oo See Figure 23 Remove the rubber wire seal from the con nector 12 m 5 or 3 4 Black to Socket 1 5 R
20. e Connector pins with the holes and press each pin inward until a click is heard 31 See Figure 8 Install 3 Place Connector to 3 Pin Modulator f Orient the locking wedge and press until it clicks into Harness wiring by performing the following place Look down into connector to verify wedge is seated properly a See Service Parts Page Illustration Obtain 3 Place Receptacle 8 and Wedge Lock 11 from kit g Slide wire seal up to connector and press into i A connector creating a seal around wiring and connector b Locate the three wires with pin terminals on harness exiting the Tour Pak from Modulator The wires will be h Install dummy plug 14 into remaining pin receptacle Orange White Red and Black hole Socket 6 c See Figure 8 If installed remove the rubber wire seal from the connector i03644 d Orient the connector with external latch facing to the right as shown and install the wire terminal pins oriented as shown through the wire seal e Install the terminal pins into the connector aligning the pins with the holes and press each pin inward until a click is heard f Orient the locking wedge and press until it clicks into place Look down into connector to verify wedge is seated properly g Slide wire seal up to connector and press into connector creating a seal around wiring and connector Install Controller Harness Wiring to 6 Place Connector 32 See Figure 9 I
21. ed to Socket 2 1 Locking Wedge 2 Terminal Latch 3 Wire Seal Figure 23 Install 2 Pin ON OFF Switch Connector IMPORTANT PRIOR TO OPERATING THE UNIT CAREFULLY READ THE SECTIONS COVERING BASIC OPERATION AND GENERAL INFORMATION AND SPECIFICATIONS 9 of 20 Part No 77184 01 Date 7 04 Service Parts CD Changer Kit i03645a 26 SS 9 E 2 12 0 A y Description Part Number Item Description Part Number Changer assy and modulator See NOTE 14 Plug receptacle dummy 74195 98 brackets 6 screws and jumper not sold 15 Bolt hex head 1 4 20x1 inch 4 3483 Harness cd w in line fuse 77012 04 16 Nut lock hex 1 4 20 4 7686 Housing switch chrome 2 45048 95 17 Screw TORX 1 4 20x5 8 inch 4 4033 Assy switch 2 way left 77185 01 18 Cable female end coax end 77006 01 Assy switch 1 way right 77186 01 19 Cable antenna pin end ant plug 77005 01 Decal load capacity 90001 01 20 Assy sleeve cd changer 77187 01 Terminal pin 74190 98 21 Controller assembly cd changer 1 Connector receptacle 3 pin 2 74103 98BK 22 Tie wire 10 10065 Connector receptacle 2 pin 74102 98BK 23 Screw changer sleeve 2 77011 01 Connector receptacle 6 pin 74106 98BK 24 Screw self tapping ground 3529 Wedge lock 3 pin 2 74143 98 25 Grommet 11507 Wedge lock 2 pin 74142 98 26 Clamp cable ground 77014 01 Wedge lock 6 pin 74146 98 Velcro 3 3 4 width 2 not shown Template n
22. ff Switch Wire Routing Two Wires Bezel Screw Location CD Changer Harness Figure 20 FLTR Wire Routing J01422 4 Orient the connector with external latch facing upward as shown and install the pin terminals oriented as shown through the wire seal 5 Install the pins into the connector aligning the pins with holes and press each until a click is heard 6 Orient the locking wedge and press until it clicks inside connector 7 Slide wire seal up to connector and press into connector creating a seal around wiring and connector Install Three Place Connector TRACK DISC Switch 1 See Service Parts Page Illustration Obtain the 3 Place Receptacle 8 and Wedge Lock 11 from kit 2 Locate the Track and Disc Advance Switch wires three with pins Wire colors will be Blk Grn Tan Blu and Tan Red 3 See Figure 24 Remove the rubber wire seal from the con nector 4 Orient the connector with external latch facing upward as shown and install the pin terminals oriented as shown through the wire seal 103643 Tan Blue to Socket Locking Wedge Black Green to 2 Socket 1 Tan Red to Socket Stock Parts 3 Figure 24 Install 3 Pin TRACK DISC Advance Connector 5 Install the pins into the connector aligning the pins with the holes and press each until a click is heard 6 Orient the locking wedge and press until it click into place Look down into connector to verify wedge is seate
23. he orange white wire in the following steps fol low the main harness as closely as possible and use the exist ing harness wire ties and frame clamps slip orange white wire through wherever possible to secure next to harness conduit 44 Route the orange white wire along main harness and On FLTR models continue through fairing mounting bracket tunnel and around to cigarette lighter On FLHT models continue under inner fairing behind instruments and around to cigarette lighter 45 Connect the orange white wire socket terminal to the ciga rette lighter spade contact Connect the original orange cigarette lighter socket terminal to the piggyback spade terminal attached to red wire terminal Assemble Left and Right Switches NOTE Keep in mind during the following Steps that the switch con sisting of two leads is for controlling the Power ON OFF and will be attached to the right handlebar The switch consisting of three leads is used for controlling the CD Track and Disc Advance and will be installed to the left handlebar 46 See Figure 14 and Service Parts Page Illustration Obtain one of the Switch Assembly Packages and one of the han dlebar clamps 3 from kit 47 Insert switch 4 or 5 into handlebar clamp with tabbed side oriented as shown 48 See Figure 14 Insert the escutcheon into the handlebar clamp lining it up with the switch Push inward while hold ing switch in place until tabs snap cleanly
24. irectly to threaded antenna connector and tight en nut Re install antenna ground to metal plate with screw and lockwasher Antenna Connector Antenna Ground Male End of New Lead Female End of Modulator Lead Figure 5 Attach Antenna and Modulator Leads 24 See Figure 6 Install Jumper connecting CD Changer to Modulator Removed in Step 14 Connect one end of jumper to female plug in marked Changer Input on mod ulator box Connect other end to Female connector on lower left side of CD changer J01422 29 See Figure 7 Slide cover over changer and align screw holes in changer cover with holes in changer brackets Obtain screws 23 from kit and secure changer cover to changer brackets Tighten carefully 30 Remove Velcro Strip and adhesive protector attached to controller Install one of the Velcro strips to secure con troller in recessed area of cover sleeve as shown Controller External Latch 4 Wire Seal Locking Wedge 5 Red to Socket 2 Orange White to 6 Black to Socket 3 Socket 1 Figure 8 Install 3 Place Modulator Connector c See Figure 9 If installed remove the rubber wire seal from the connector d Orient the connector with external latch facing to the right as shown and install the wire terminal pins Figure 7 Install CD Changer Cover oriented as shown through the wire seal Install Modulator Harness Wiring to 3 Place e Install the terminal pins into the connector aligning th
25. isc tray with the label side UP NOTE Don t touch the recorded surface of the CD shiny side opposite to the label when handling CD s 3 Align the disc tray with the grooves in the magazine and push the disc tray all the way in until the tray clicks Repeat Steps 1 through 3 for the remaining 11 disc trays NOTE Check that disc tray is securely inserted into the magazine the CD becomes disengaged from the disc tray reposition it on the tray NOTE When there is no disc in the disc magazine of the CD auto matic changer or when the disc is inserted into the tray upside down NO DISC will be shown in controller display In such case remove the disc magazine from the CD chang er and reload the discs correctly TO INSERT MAGAZINE 1 Slide the CD Changer cover toward the left side of the motorcycle to open 2 See Figure 1 Insert the CD Magazine into the CD Changer loading slot with the disc tray tabs facing the right side of the motorcycle and the Turquoise Arrowhead on the CD Magazine facing DOWN toward bottom of Tour Pak and forward 3 Slide the CD Changer access cover toward the right side of the motorcycle to close NOTE The CD Changer access door covering the loading slot must be kept closed except when changing the magazine Magazine Turquoise Arrowhead Figure 1 Loading Magazine J01422 SELECT TRACK OR DISC NOTE When all tunes on the first disc have been played
26. ith flatwashers Beginning with top screw tight en the screws to 60 80 7 9 Nm using a T27 TORX drive head J01422 Route Connect Handlebar Switch Wiring NOTE Wire Routing and connection is different for FLTR models than FLHT Follow instructions for your particular model 60 Route and connect switch wiring as follows FLTR Models a See Figure 20 Using a T25 TORX drive head remove the screws on left and right of side of instrument bezel b Use thumbs to push tab at rear of bezel from slot above ignition switch Gently raise free side of bezel until tabs at front of instrument nacelle become disengaged from slot at front of bezel concealed behind decorative adhesive strip i i au 6 instrument cluster and temporarily lay to the Wiring not yet secured with wire ties 2 Follow existing Wiring through hole d Route the ON OFF switch down along right handlebar and up to instrument area Figure 21 FLHT Wire Routing e Locate and pull up the changer harness wiring routed in earlier step through the fairing mounting bracket tunnel FLHT Models f See Service Parts Illustration Follow instructions under a See Figure 21 Route the ON OFF switch wiring Installing 2 Place Switch Deutsch Connector on the following right handlebar existing switch wiring and following page and install the 2 ON OFF switch wire brake line down through hole near fork tube then out pins to the male connector 9 Instal
27. l Wedgelock 12 through front of inner fairing g Repeat Steps a through f for the Track and Disc b From front of fairing locate changer harness routed Advance Switch and three pin connector 8 Install under fairing in earlier Step WR EU See Fi 22 Follow instructi der Installing 3 c See Figure 22 Follow instructions under Installing 3 h Connect the male and female halves of the ON OFF Place Switch Deutsch Connector on the following page and install the TRACK DISC switch 3 wire pins to the connector 9 Install Wedgelock 12 d Repeat Steps a through c for the Track and Disc Advance Switch and three pin connector 8 Install wedge lock 11 e See Figure 22 Connect the male and female halves of the ON OFF and Track and Disc Advance connectors Use wire ties 22 to secure wires in place and tuck in around instrument wiring i03640 tif Inner Fairing From Handlebar Switch From CD Changer Harness Figure 22 Connect Switch to Harness 8 of 20 and Track and Disc Advance connectors and tuck wiring up under instruments Use wire ties 22 to secure wiring in place Insert tab at rear of bezel into slot of instrument nacelle Holding left and right sides of nacelle together place bezel over instrument nacelle flange When properly mated tabs at front of instrument nacelle engage lip in slot at front of bezel behind decorative adhesive strip Install two bezel screws and tighten securely or On O
28. lt your Harley Davidson Dealer FLOATING ISOLATOR SELECTOR See Figure 1 The CD changer is mounted to absorb normal vibration when riding There are two floating isolation selectors at each end of the CD changer and are factory set Both selector switches should be set to the 12 o clock position as shown J01422 08 CD Inoperative SETUP Bike ON Radio ON Tuned to CD Frequency Volume set to Nominal Level Does CD Controller in Tour Pak display disc and track information Press POWER button on Controller Does CD display turn ON Controller display information Is Cigarette Lighter Is system functional Accessory Fuse OK CD fuse OK 0 Replace fuse See Pwr Switch Won t Will CD magazine EJECT Replace fuse Turn CD ON OFF Refer to Installation Instructions Procedure and Verify all Tour Pak Cables are connected properly 1 CD to Modulator Cable 2 Antenna Cables Are They Connected Properly Remove Outer Fairing Discon Disconnect 3 Pin connector 2A nect Cigarette Lighter O W under seat Check for power Check for continuity from lighter between Pin 2 Red and Pin 3 wire O W to Connector 2A Pin 1 BK Is voltage present OM Is continuity present Replace Reinstall Modulator YES Replace Modulator Repair open See Forced Ejection 4 Check for continuity between Does system work on O W wire Procedure Silver Circuit Breaker Post and Pin 2 Red of Connector
29. lter pins 1 and 2 Disc While repair holding handlebar control in desired position is continuity present System OK Replace Controller Locate and repair open in Tour Pak accessory harness Locate and repair open Inspect left HB switch in main harness wiring for damage Damage present YES Locate and repair open Replace CD Track Disc or damaged wiring selector switch Refer to procedures for CB push to transmit switch Ultra models Use Harness Connector Test Kit HD 41404 Black Pin Probes and Patch Cords Use Harness Connector Test Kit 41404 Black Socket Probes and Patch Cords J01422 18 of 20 19 of 20 See Figure 1 Peel off the sticker on the left side of the unit in the notch of the mounting bracket Insert a small screwdriver and press the internal lever to manually eject the magazine Manual Eject Procedures Magazine Won t Eject RESET Press Eject for 3 Seconds Are all Trays Stored in the Magazine Check Visually Call Radio Sound Inc Customer Service for Assistance 1 800 367 4506 CAUTION DO NOT Pry a Screwdriver under the Eject Button Located on the Top of the CD Changer Under the Sliding door This Will Result in Damage To the Unit J01422
30. nstall 6 Place Connectors to 6 Pin Controller Harness wiring by performing the following Locking Wedge Tan Blue to a See Service Parts Page Illustration Obtain the 6 Place External Latch Socket 2 Receptacle 10 Wedge Lock 13 and Dummy Plug Wire Seal Black Green to 14 from kit Tan Red to Socket 1 Socket 3 Dummy Plug to Black to 4 Socket 6 Red to 5 b Locate the five wires with pin terminals on harness exiting Tour Pak from CD Controller Wires will be Tan Red Black Red Black Green and Tan Blue Figure 9 Install 6 Place Controller Connector J01422 4 of 20 38 Locate the ground post on the right side and remove nut Connect the Black wire ring terminal from CD harness to ground post Re install nut 39 See Figure 12 2004 and Later Looking toward right front and right of battery box locate B connector Obtain the RED power lead with fuse in line from the CD harness attach the electrical terminal and crimp to end of Red power lead Insert terminal end into blank B connector end 40 Locate the ground post on the right side in front of battery Look thru square hole in frame backbone and remove ground post nut Connect the Black wire ring terminal from CD harness to ground post Re install nut Ground Post WARNING DISCONNECT BATTERY NEGATIVE TERMINAL FIRST BEFORE PERFORMING ANY MECHANICAL SERVICE ACCIDENTAL STARTER OPERATION COULD CAUSE INJURY Bt Connector Blank End
31. ot shown 92099 04 7 8 9 1 a A 4 14 4 NOTE Service to Changer and or Modulator must be performed by RSI Radio Sound Inc 1713 Cobalt Drive Louisville Kentucky 40299 Phone 502 267 6768 or 800 367 4506 Fax 502 267 6794 J01422 10 of 20 BASIC OPERATION MAGAZINE REMOVAL 1 Open the Tour Pak lid 2 Slide the CD Changer cover toward the left side of the motorcycle to expose the EJECT pushbutton 3 Push the EJECT button and the magazine ejects from the loading slot Remove the CD Magazine NOTE Holding in the EJECT button for a few seconds will reset the CD changer Memory Program This is generally not desired ACAUTION The CD changer uses invisible laser radiation and is equipped with safety switches which prevent laser radiation emission when unloading the CD magazine and the safety interlocks have failed or are defeated Avoid direct exposure to the laser beam Do not open the top cover to the CD changer There are no user Service able parts inside Have the CD changer serviced by a qualified technician Failure to have the CD changer serviced by a qualified service technician could result in death or serious injury DISC SELECTION TO CD CHANGER MEMORY There are openings in the bottom of the disc trays through which the CD changer senses if a disc is in a particular way When the magazine has been inserted into the CD changer the CD memory will be erased The CD ch
32. r is mounted to absorb normal vibration when riding Mistracking may occur when riding on an extremely rough road The CD Changer will not be damaged by mistracking however since it is offensive to the ear stop playback and restart the CD Changer when you reach a road in good condition Auto CD Acknowledge When the CD Magazine is initially installed into the changer the changer will cycle through the stack until the first CD disc is recognized Once the changer recognizes a slot without a CD the changer will not cycle through that slot until the magazine is ejected and reinstalled BBE Circuit Press the BBE button to turn BBE circuit ON OFF The BBE system restores the brilliance and clarity of the original live sound in recordings broadcasts etc When a speaker reproduces sound it introduces frequency dependent phase shifting causing high frequency sounds to take longer to reach the ear that low frequency sounds The BBE circuit adjusts the phase relationship between the low mid and high frequencies so they reach the listener s ears at the proper time In addition using dynamic program driven augmentation the BBE circuit boosts low and high frequencies which loudspeakers tend to be less efficient in reproducing When combined with the phase compensation feature the resulting sound has cleaner more finely detailed live presence J01422 TROUBLESHOOTING PROCEDURES Protective Seal Over Access Hole DA
33. rays which have been removed from the magazines Never apply solvents such as benzene or thinner to the magazine or trays These solvents may erode their surfaces CD Storage Make sure to keep CD s in their cases Do not put CD s where they will be exposed to sunlight or in a place subject to high temperatures and humidity Avoid leaving CD s in your motorcycle o0219xox tif BBE Level Display Window Microprocessor Interrupt 00222x0x TO LISTEN TO THE RADIO OR TAPE AFTER PLAYING COMPACT DISC Press the ON OFF button on the right handlebar to switch the power OFF Tune to the desired radio station or play cassette tape NOTE Lower the volume level before stopping disc playback other wise noise may be generated Magazine and Disc Handling Do not carry the magazine with its inserting slot facing down The CD s can drop out and be damaged Always keep the twelve disc trays loaded in the magazine When sliding the disc trays out or in to place CD s hold the magazine horizontally so as not to drop the CD s CD CONTROLLER Skip Search Level Frequency DISC RPT F SEL Repeat Playback Random Playback CD CONTROLLER DISPLAY Disc Number Indicator 1 12 Track Number Indicator 1 99 tot BBE Indicator mc RND RPT RND Random Playback Indicator NODISC TRACK TRACK Indicator DISC Indicator 13 of 20 RPT Repeat Indicator J01422
34. tachable Tour Pak the purchase of one of the following kits will be necessary Antenna Relocation Kit Part Number 76329 98 for Rigid Tour Pak Mounting Antenna Relocation Kit Part Number 76326 00 for Detachable Tour Pak Mounting FLTR and FLTR l Models Follow directions on Instruction Sheet packaged with Antenna Relocation Kit and relocate antenna Proceed to Step 16 16 Place metal plate in Tour Pak Re install the seven flange nuts six if FLHTCUI securing the metal plate to the Tour Pak Re install CB loading coil if present using screw and lockwasher Follow instructions in applicable Service Manual and re install Tour Pak to Tour Pak mount 17 Obtain a 29 136 inch bit Note antenna hole location marked but not drilled in earlier Step Drill hole for anten na ground wire NOTE You will need to drill through both the plate and Tour Pak 18 Position the changer within the mounting brackets and re install the six buttonhead screws with lockwashers 3 per side removed in Step 14 Tighten securely 19 Refer to Figure 1 Align cable ground clamp with shielded area of antenna cable and install self tapping screw 26 from kit to secure ground to plate Tighten securely 20 Follow instructions in applicable Service Manual under Deutsch Connectors Removing Installing Pin Terminals and remove the three pin terminals from the Modulator Wiring Harness Connector Save connector components for reinstallation 2
35. the sec ond disc starts automatically from the first tuned During playback press the TRK select button on the left handlebar down to advance to the next track During playback press the DSC select button on the left handlebar up to advance to the next available disc During disc selection the disc number and track number indicators blink on the controller unit REPEAT PLAYBACK NOTE To set changer for Repeat Playback Random Playback Intro scan or to turn the BBE on off the controller must be accessed Press the RPT button before playback It is possible to perform the repeat playback of single tune or all tunes of one disc in the magazine Each time the RPT button is pressed the repeat mode changes as follows Single tune repeat The current or specified tune will be played back repeatedly All turn repeat All tunes on the current or specified CD will be played back repeatedly INTRO SCAN OPERATIONS Use these functions to play back the first 15 seconds of tracks With intro scan operations either the first 15 seconds of all tracks of all discs in the magazine are intro scanned or just the first track of all discs in the magazine Each time the INT button is pressed the mode changes from TRACK scan for all tracks to DISC scan for the first tracks of each disc to clear Track Scan Track number blinks All tracks on all discs in the magazine are intro scanned When the required track is located press the I
36. to switch secur ing switch in place 49 Install speednut center tabs facing upward over switch pin collar and simultaneously press on ears until the speednut seats over switch pin collar 50 See Figure 14 Position actuator so it will read correctly when installed Align the two small pins on the actuator with the two small holes in actuator tabs and gently press until the actuator snaps into place 51 Perform Steps 46 through 50 for the opposite switch assembly NOTE In Steps 52 through 59 you will be removing the left and right handlebar clamps and replacing them with the new Switch Assemblies J01422 i03636 ON OFF Switch Figure 17 Install Right Switch Assembly Install Left Handlebar Switch Housing 58 See Figure 18 On the left side position the clutch hand lever assembly inboard of the switch housing assembly engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket Clutch Lever Bracket 2 Groove 3 Tab 4 Switch Hsg Assembly Figure 18 Fit Clutch Lever Bracket to Left Handlebar Switch Housings 59 See Figure 19 and Service Parts Illustration Obtain chrome housing clamp 3 screws 17 and flatwasher saved in Step 54 Align holes in switch housing clamp with those in the clutch lever bracket and start the two screws with flatwashers Beginning with the upper screw tighten the screws to 60 80 in lbs 7 9 Nm using a 7 TORX drive head i03637 Upper
37. uit breaker to SILVER terminal post Re install nut E Circuit Breaker Silver Post 2 Battery Cable 3 Ground Post 4 inline Fuse 5 To Front of Bike Figure 11 2003 and Earlier Connect Power and Ground Wiring J01422 i03635 Actuator Tab Speednut Switch Escutcheon Tabs Actuator Handlebar Clamp Tabs Wire End Switch Pin Collar Figure 14 Switch Assembly Components Remove Right Handlebar Clamp CAUTION Do not remove the switch housing assembly without first placing a 5 32 inch 4 mm thick cardboard insert between the brake lever and lever bracket Removing the assembly without the insert in place may result in damage to the rubber boot and plunger of the front stoplight switch 52 See Figure 15 Place the cardboard insert between the brake lever and brake lever bracket 03710 Cardboard Insert Figure 15 Install Cardboard Insert 53 Using a T27 TORX drive head remove the two screws with flat washers securing the handlebar clamp to the master cylinder housing and remove the clamp Discard the clamp and two screws but save the flatwashers for re installation Leave master cylinder housing in place on handlebar for now 6 of 20 42 Follow instructions in applicable Service Manual and remove the outer fairing 43 Locate the cigarette lighter and disconnect the orange white wire socket terminal from the spade contact on the lighter NOTE When routing t
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