Harley speaker pod template

This special equalization software is available without charge from your dealer through Digital Technician II. Dealer labor rates may apply for the upgrade procedure. Open the Tour-Pak lid and remove all items from the Tour-Pak base. Models equipped with mat: Remove the mat. Models equipped with liner: Open the map pocket, and remove the acorn nuts with flat washers. Remove the map pocket and liner. Remove four screws from the left-side speaker grille on the Tour-Pak.

Remove the speaker grille from the speaker pod. Remove the speaker from the speaker pod. Carefully pull the two socket terminals from the speaker spade contacts. Separate the connector halves. See Figure 1. Get the drill template 3 from the kit. If NOT equipped with power port: If equipped with power port: a.

Repeat for the remaining template mounting holes. NOTE Tighten the screws enough to hold the speaker pod in place as the pilot hole is drilled. Remove the screws and speaker pod, and set aside. Turn the template over, and repeat Steps 7 and 8 on the left side of the Tour-Pak. NOTE Hole size will affect the fitment of the ports.

Carefully drill a 51 mm 2 in diameter hole with a sharp hole saw, at the pilot location, through each speaker pod and in both locations on the Tour-Pak wall. Temporarily install the Tour-Pak liner if equipped , and mark the location of the 51 mm 2 in diameter holes on the outside of the liner.

Remove the liner, and carefully cut the two holes in the liner front wall. Get one of the bass boost port gaskets 2 from the kit, and position over the mounting holes on the speaker pod, between the pod and Tour-Pak. Loosely install the original screw and flat washer through the top hole in the Tour-Pak wall and gasket, and into the crimp nut in the speaker pod mounting hole.

If equipped with power port: Place the spacer 4 from the kit behind the power port. Loosely install the new , longer screws 5 and flat washers A through the power port, spacer, and the bottom holes in the Tour-Pak wall and gasket, and into the crimp nuts in the speaker pod mounting holes. If NOT equipped with power port: Loosely install the original screws and flat washers A through the bottom holes. ALL applications: Tighten the screws to 2. Install a rubber grommet 6 into the speaker wire entry hole in the speaker pod wall.

Repeat Steps 12 through 13 on the opposite side of the Tour-Pak. Models equipped with mat: Install the mat. Models equipped with liner: Install the Tour-Pak liner. Open the liner map pocket, and install the acorn nuts with flat washers. Tighten securely. Get the bass boost ports 1 and O-rings 7 from the kit. Temporarily install the bass boost ports by inserting them, from inside the Tour-Pak, into the 51 mm 2 in diameter holes.

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. This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. See Figure 3 and Table 1.

The Tour-Pak does not have to be removed from the vehicle to perform this installation. View interactive image. Fit the notched corner on the left side of the template to the Tour-Pak latch.

Apply tape to the locations indicated on the template to hold the template in place. If the right-side saddlebag has not been removed, cover the top of the saddlebag with clean shop towels to prevent scratching. Damage to the finish could result. Along the left-side and right-side of the Tour-Pak support. Use cable straps from the kit to fasten the branches of the harness to the support.

Continue the branches forward to the front of the fender, then cross the right branch over to the left side of the frame. Use a cable strap to fasten both branches of the harness to the frame. Continue routing the main branch forward, tucking the harness inboard of the frame tube and avoiding the forward saddlebag guard mounting screw head so the harness does not get pinched by the seat. Use four cable straps to fasten the main branch of the harness to the frame tube. Route the harness along the left side of the battery cavity, continuing forward to the harness tray.

Continue along the left side of the harness tray to the rear of the fuel tank. Remove the fuel tank console attaching hardware and lift the console from the tank. Route the rear speaker harness forward under the left rear edge of the console, along the left side of the fuel tank canopy, and out under the left front edge of the console.

Install the console, taking care not to pinch the harness under the console. Route the harness down tight to the fuel tank and use a cable strap to attach the main harness as close to the fuel tank as possible.

Continue the rear speaker harness forward into the fairing, using cable straps to fasten to the main harness. Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. Be sure wires do not pull tight when handlebars are turned fully to left or right fork stops.

To prevent possible damage to the sound system, verify that the ignition switch is in the OFF position before installing the main fuse. 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. Table 1. Service Parts, Rear Speaker Kit. Table 2. Refer to the service manual and follow the instructions given to remove the seat and the left-side saddlebag. The right-side saddlebag does not need to be removed to perform this installation, but removal may prevent cosmetic damage during the installation of this kit.

Follow the instructions in the service manual to remove the main fuse. Open the Tour-Pak lid and remove all items from the Tour-Pak base, including the rubber mat, if equipped. If equipped with a molded liner: Open the map pocket and remove the acorn nuts with flat washers. Remove the map pocket and liner.

View interactive image Figure 1. Template Positioning Right Side Shown. See Figure 1. Position the the right-side template flat Figure 3 , item 4 onto the right front corner of the Tour-Pak.