BOOM! AUDIO STAGE II TOUR-PAK AMPLIFIER - Harley
Contents
1. Amplifier bracket Not sold separately 5 Capscrew 4 2551W 6 Screw 4 926 7 Grommet round 2 12100073 8 Amplifier bracket Not sold separately 9 Lockwasher 4 7036 10 Cable strap 6 10006 11 Flatwasher 4 6703 12 Nut 4 10100065 13 Capacity label not shown 14001001 Item mentioned in text but not included in kit A Amplifier J05996 4 of 42. Speaker pod Existing hole and grommet speaker pod New hole 1 0 in 25 mm 2 oN Grommet round Figure 1 Grommet Installation is08513a Nut 4 Tour Pak Hex pocket Tour Pak support 4 Tour Pak support Amplifier bracket Screw 4 Flat washer 4 On oO Oe ONS Lockwasher 4 Figure 2 Amplifier Installation AMPLIFIER HARNESS INSTALLATION NOTES These tips help make sure all wiring fits under the seat espe cially in multiple amplifier installations e See Figure 3 Begin routing the amplifier harness from the large 23 way connector 149 1 moving forward on the 2 of 4 vehicle The large connector does not fit through narrower passages e Route the remainder of the harness forward on the vehicle through the space between the Tour Pak support 3 and fender 4 Route all wire harnesses under the frame rail to avoid pinching by cover or seat Connections 36TB right pod speaker and 37TB left pod speaker are connected during installation of the Boom Audio Stage IlI Tour Pak Speaker Kit Part No 76000526 e Take care to route ALL amplifier harness branches away from spark plug wires Close proximity induces spark noise into the audio system When routing wires from right to left sides of the vehicle tuck harnesses under the frame tray behind the battery Keep the battery compartment accessible e Route the six way black pink wired aud
3. ate 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 references service manual information A service manual for this year model motorcycle is required for this installation One is available from a Harley Davidson dealer J05996 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Electrical Overload NOTICE It is possible to overload your vehicle s charging system by adding too many electrical accessories If the combined electrical accessories operating at any one time consume more electrical current than the vehicle s charging system can produce the electrical consumption can discharge the battery and cause damage to the vehicle s electrical system See an authorized Harley Davidson dealer for advice about the amount of current consumed by addi tional electrical accessories or for necessary wiring changes 0021 1c WARNING When installing any electrical accessory be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modi fied Exceeding the maximum amperage can lead to elec trical failures which could result in death or serious injury 00310a The amplifier installed wit
4. cMOTOR HARLEY DAVIDSON WY J05996 INSTRUCTIONS REV 2014 11 14 BOOM AUDIO STAGE II TOUR PAK AMPLIFIER INSTALLATION KIT GENERAL Dealer installation is recommended Radio EQ update using the Digital Technician II diagnostic tool is e Recommended before speaker INSTALLATION e Required before audio system OPERATION e Only available through authorized Harley Davidson dealers Kit Number 76000585 Models For model fitment information see the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only Installation Requirements This kit must be installed e Before installation of the Boom Audio Stage I Tour Pak Speaker Kit Part No 76000526 e After installation of a PRIMARY fairing mounted amplifier The amplifier Part No 76000277A installed with this kit must be purchased separately from a Harley Davidson dealer FLHX FLHXS and FLHXSE models require installation of an original equipment OE rigid Tour Pak Mounting Rack See a Harley Davidson dealer for the correct parts available separ ately Install per the service manual ALL models If installing more than TWO amplifiers an AUDIO IN Three Way Y Connector Part No 69201092 AND a Battery Three Way Y Connector Part No 70270 04A are needed Purchase separately from a Harley Davidson dealer IWIN IN IN The rider s safety depends upon the correct installation of this kit Use the appropri
5. e the revised load limit due to the amplifier installation 2 Install the brackets 4 and 8 to amplifier A with screws 6 Alternately tighten to 84 108 in lbs 9 5 12 2 N m 3 Remove all items from Tour Pak Remove Tour Pak Remove Tour Pak liner if present Place Tour Pak on a protected surface NOTES e Disconnect and remove speakers from speaker pods to avoid damage to wiring inside e Use ofa step drill bit is recommended to prevent damage to the speaker pod covering 4 See Figure 1 Drill a new 1 0 in 25 4 mm hole 3 in each speaker pod 1 away from the existing grommet 2 approximately where shown NOTE These holes are for leads 36TB and 37TB of the amplifier harness Figure 4 Item 3 which are connected during installation of the Boom Audio Stage II Tour Pak Speaker Kit Part No 76000526 5 Lightly sand the speaker housings around the grommet holes NOTE If the amplifier is installed before the Tour Pak is mounted it is not possible to secure the Tour Pak 6 See Figure 2 Place hex nuts 1 into hex pockets 3 on the Tour Pak support 5 7 Install Tour Pak See the service manual Tighten screws to 60 72 in Ibs 6 8 8 1 N m 8 Cover the rear fender with a towel Slide the amplifier with brackets in from the side 9 Install the amplifier Secure with flat washers 7 lock washers 8 and screws 6 Tighten screws to 60 72 in Ibs 6 8 8 1 N m J05996 is08515a
6. h this kit requires up to 8 amps more current from the electrical system Kit Contents See Figure 4 and Table 1 PREPARATION WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b WARNING 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 NOTE WITH security siren With security fob present turn ignition switch ON See the service manual Disarm security system IMMEDIATELY remove the main fuse WITHOUT security siren See the service manual Remove main fuse Turn ignition switch OFF Please dispose of materials responsibly 1 See the service manual to perform the following general ized steps a Remove seat Retain all seat mounting hardware b Remove the ECM caddy from the top of the battery c Disconnect both battery cables negative battery cable first d Remove battery e Remove right side cover f Remove left side cover g Remove the two bolts attaching the electrical caddy under the left side cover AMPLIFIER INSTALLATION 1 Clean the capacity label inside the Tour Pak with a 50 50 mixture of isopropyl alcohol and distilled water See Figure 4 Apply the new capacity label 13 from the kit to cover the original label Not
7. io connectors under the right frame rail into the right side cover Bundle in front of ABS module if present e Route the six way gray DLCs along the left frame rail Bundle the connectors in a pocket in the frame in front of the battery under the wire trough along the frame back bone e Locate the black four way Molex connector 296A near the back of the underseat area FLHX FLTRX models On a jumper harness coming from the fairing FLHTCU FLHTK models On an adapter harness with two 16 way 162C and 162D and two four way 296A and 297B connectors With ONLY ONE Stage Il amplifier installed in the rear Remove the plug in the 296A connector Connect the amplifier harness With TWO or more Stage Il amplifiers installed in the rear Plug the audio input harness Part No 69201092 purchased separately into connector halves 296A and 297B on the interconnect harness 2 Plug amplifier harness 3 connector 296A into the audio input harness Confirm that the amplifier harness connectors and harness routing are clear of all moving parts e Route the battery terminal branch to the battery terminals but DO NOT connect the battery cables now If more than two amplifiers or other accessories already use the ground post of the battery use one of the frame ground studs e If more than two amplifiers are installed on the vehicle a Battery Three Way Y Connector Part No 70270 04A available separa
8. tely is required e Once routing is finalized secure with cable straps 10 and retainers 1 J05996 is08517 1 23 Way connector 149 2 Amplifier harness 3 Tour Pak support 4 Rear fender Figure 3 Harness Routing DATA LINK CONNECTOR DLC RELOCATION 1 Locate the gray six way Data Link Connector DLC 91A in the electrical caddy Cut the tether attaching the rubber plug around the harness 2 Pull connector 91A back through the electrical caddy to a location under the seat behind the caddy 3 See Figure 4 Plug in socket connector 91B on the amplifier harness 6 to connector 91A under the seat NOTE The amplifier harness gray six way pin connector 91A replaces the original equipment OE connector 91A in the electrical caddy 4 Route the new pin connector 91A under the seat and into the electrical caddy 5 Insert the rubber plug removed in Step 1 into the new pin connector 91A Use a cable strap 10 from the kit to attach the tether to the harness COMPLETION NOTE To prevent possible damage to the sound system verify that the ignition switch is OFF before attaching the battery cables WARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 1 Install battery See the service man
9. ual 3 of 4 2 See the service manual Connect the battery terminal branch to the battery terminals red positive cable first a Position the ring terminal onto the positive battery terminal Install the bolt b Position the in line fuse holder in a location that can be easily accessed c Position the ring terminal onto the negative battery terminal Install the bolt d Tighten both bolts to 60 70 in lbs 6 8 7 9 N m 3 Install the electrical caddy under the left side cover with the two bolts removed earlier Tighten both bolts to 72 96 in Ibs 8 1 10 8 N m 4 Install the ECM caddy per the service manual 5 Apply alight coat of petroleum jelly or corrosion retardant material to battery terminals WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 6 See the service manual Install seat 7 See the service manual Install the main fuse SERVICE PARTS is08514 149B 162B 36TB 63 37TB LH Ay ie a 297A Figure 4 Service Parts Amplifier Installation Kit Table 1 Service Parts Item Description Quantity Part Number 1 Bracket wire retainer 4 69200342 2 Wire harness speaker interconnect 69200714 3 Wire harness Tour Pak Amplifier Not sold separately 4
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