New factory stereo in an old bike
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Joined: May 2012
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From: Edmonton AB Canada
New factory stereo in an old bike
I do not have a stereo system on my 05 FLHT it was gutted and wirers hacked to hell when I bought the bike, was told I could put a newer factory model system in it, and found out this was not the case.
Can anyone explain why a new system will not work, is it fit, differnt plugs ect ect
Can anyone explain why a new system will not work, is it fit, differnt plugs ect ect
Seasoned HDF Member
Joined: Jun 2006
Posts: 28,514
Likes: 3,951
From: Vermont
From member "hardy" on another site:
This document will outline the procedure and parts needed to install/retro-fit the newer style Harmon-Kardon radio into pre-2006 Electra Glides. This procedure may/should also work with pre-2006 Road Glides. This will include the intercom set up. The CB and XM module are optional and will briefly be discussed.
Parts needed to install Radio, Intercom, and CB; assuming you have front and/or rear speakers.
76412-06 Harmon-Kardon Advanced Radio
76416-06C CB Radio Module
76440-06 Intercom Kit: This is actually nothing more than the dealer cost to program the radio to work with the intercom. If you get a radio from an Ultra then this should already be enabled.
77173-07 Communications Switch Kit: This is the tank console where the helmet headset plugs into the intercom on the tank console; dash speaker button that allows you to turn off-on the headset and external speakers and left handlebar control switch assembly. If you are upgrading your existing Radio Sound unit then you probably don’t need the speaker switch and handlebar control switch. The tank console is the semi-newer style that has the intercom connection on the left side. The older style had two control buttons on the top, while the newest style has the intercom connection in the center.
70160-06 Ultra Overlay Wire Harness: This is the factory wire harness that makes all the connections possible. You will not be able to retro-fit this and make it work properly. The connectors are different enough that if you are upgrading from the 96-02 style radio/intercom virtually nothing will connect plug-n-play. 03-05 bikes also have a different wire harness that may or may not work. According to the parts manual, there are three different versions of the overlay harness depending on the year model and radio used. Basically every time HD changed radio styles the harness also changed. Rule of thumb: Get the wire harness that works with the radio, so if you have a 06 radio, get the 06 wire harness.
Disclaimer: I am writing these instructions as a general how-to install this radio/intercom/CB set up for a 2001 HD Electra Glide. My bike is a 2001 FLHTPI (EG Police that I have converted into an Ultra minus the cruise control). I will write these instructions with the assumption that the reader has basic mechanical/electrical abilities and owns the proper HD service manual and hand tools. There may be slight differences in year models, but the majority of these instructions will suffice for EG 96 – 05.
I will assume that you already have some sort of radio installed and speakers and are simply upgrading your existing unit or adding an intercom. If you currently have no radio installed as on an EG standard then you will need the speakers for the front. All the other hardware/brackets should be in place. Also, if you are adding rear speakers then you will need the rear speakers and pods. I will briefly discuss these items as well.
The Harmon-Kardon advanced radio as installed on a 96 – 02 model bike will have the following issues: The AVC (automatic volume control) will not function. This is due to the fact that the ECM does not have the serial data bus which sends the signal to the radio to denote speed change.
To save redundant instructions, items such as removal of the tank, removal of the outer fairing, removal of the seat, etc will not be in great detail as you can obtain this information from the service manual.
1. Raise the motorcycle on a lift of some sort. The standard red Sears lift will work perfectly. Don’t forget to properly secure the bike to avoid tip over.
2. Remove the seat and disconnect the battery. You may want to go ahead and remove the battery. Later it will give you added room to install the wire harness.
3. Remove the outer fairing, saddlebags and side shields. Remove the tank console and tank. Remove the ignition switch and dash cap.
4. If you are installing the CB or XM module then attach it to the radio before you install the radio.
5. Install the Harmon-Kardon radio into the existing brackets. You may need to remove the screws that hold the inner fairing to the main fairing brackets. Also remove the smaller brackets that are attached behind the fairing speakers. Once you do that the brackets will slightly spread open which makes it much easier to slide the radio into the fairing. The radio will slide into the radio opening tightly as the rubber weather strip will tend to grip. A squirt of windex to the rubber strip will make this easier.
6. Once you have the radio fully installed, secure the radio with four screws (two on each side). A ball-end T-handle allen wrench is preferred to do this.
7. Secure the fairing brackets and the small speaker brackets.
8. Install the Ultra Overlay wire harness by lying on the frame and running from the frame area to the inside of the fairing. I suggest lying on the left side of the frame as the main wire harness is on the right side. If you are purchasing a new wire harness there will be a area about six inches long that is not covered with conduit. Wrap this with electrical tape. It will not be see as it is under the tank/seat area.
9. Once you have the harness laid out, begin at the rear with the connections to the rear speakers and passenger intercom. The spring that attaches to the passenger intercom plug and the license plate is a bit tricky to get connected.
10. Working from the back of the bike, route the harness along the frame and securely attach with nylon zip ties. You need to make sure the harness is on the side of the frame as it goes under the tank. Also, get it as close/flat to the frame as possible. The service manual shows a picture on how the harness should lay and be installed. Refer to the manual if you have questions. It is very important that the harness is installed properly to avoid possible electrical shorts.
11. Leave the console connector hanging and reinstall the tank but do not secure it to the frame. Consider this a dry-fit. Make sure the tank is in the proper position.
12. Install the intercom console and connect to the tank console with the proper screws.
13. Install the tank console and route the wires, overflow tube back into place. Most of the wire connectors are “idiot proof” and will only go on one way to the mating connector. Make sure you securely connect them all to ensure a water-tight seal.
14. Secure the tank console to the tank and all the other items that goes along with this.
15. Now you should have, what appears to be, quite a bit of excess harness in the fairing. No problem, you need this to avoid pinching. Run the remainder of the harness into the faring area and secure with zip ties where needed. You want a “loop” from the frame to the radio to allow for movement when the handlebar is turned. Make sure once you have the harness tied down that there is free play in the handle bars when turned from side to side.
16. Connect the proper connectors from the harness to the radio/CB/XM unit. Again these are idiot proof and will only connect one way.
17. Locate the fairing cap and install the Speaker button. It goes beside the Spot switch on the left side of the ignition switch. Simply pop out the blank plug and pop in the switch from the underside of the cap. If you purchased the switch kit then this is also plug-n-play.
18. The trailing wire ends from the speaker switch are to be connected to the actual connector. The wires should already have the proper stay-kons crimped to the ends. Refer to the service manual’s wiring diagram to locate the proper placement of the wires into the connector. The diagram will show, for example, red wire goes into pin number 8. The black connector has very small numbers embossed on the outer edge. Once you have identified the proper wire and the proper placement, simply push the wire into the connector. Give it a slight tug to make sure it is seated correctly.
19. Connect the cap harness back to the main wire harness and re-install the cap and ignition switch.
20. Ensure that you have the overlay harness installed properly, and the tank placed properly, re-install the battery.
21. Switch the ignition on. The radio should flash on with the HD logo and such. Manipulate the speaker switch. FYI: speaker switch on (lighted) equal external speakers, off (not lighted) headset speakers.
22. Once you are satisfied with all the connections, and functionality, re-install the tank fasteners, front fairing and seat. You may need to “play” with the controls on the radio to get the features working properly. If you can get your hands on a 06 or newer owners manual, it will list the options and how to enable them properly. A good dealer may make copies for you at no charge.
23. If this is a new radio then once you get it installed the radio will function but the intercom/CB/XM radio will not. You must take it to the dealer to have them flash the ROM and update the ECM to recognize the CB/XM modules. Generally this will cost around 100$. Nothing has to be removed as the dealer will basically plug in to the ECM and add the components. One 96-02 bikes the ECM serial receive bus is virtually non-existent to communicate with the radio. A work-around for this is to have your radio attached to a 06 – newer bike and use that bike’s ECM to program the radio to recognize the components. Then replace the radio to your bike. If you have a good dealer, they may allow you to use a bike that is in their shop for this.
This document will outline the procedure and parts needed to install/retro-fit the newer style Harmon-Kardon radio into pre-2006 Electra Glides. This procedure may/should also work with pre-2006 Road Glides. This will include the intercom set up. The CB and XM module are optional and will briefly be discussed.
Parts needed to install Radio, Intercom, and CB; assuming you have front and/or rear speakers.
76412-06 Harmon-Kardon Advanced Radio
76416-06C CB Radio Module
76440-06 Intercom Kit: This is actually nothing more than the dealer cost to program the radio to work with the intercom. If you get a radio from an Ultra then this should already be enabled.
77173-07 Communications Switch Kit: This is the tank console where the helmet headset plugs into the intercom on the tank console; dash speaker button that allows you to turn off-on the headset and external speakers and left handlebar control switch assembly. If you are upgrading your existing Radio Sound unit then you probably don’t need the speaker switch and handlebar control switch. The tank console is the semi-newer style that has the intercom connection on the left side. The older style had two control buttons on the top, while the newest style has the intercom connection in the center.
70160-06 Ultra Overlay Wire Harness: This is the factory wire harness that makes all the connections possible. You will not be able to retro-fit this and make it work properly. The connectors are different enough that if you are upgrading from the 96-02 style radio/intercom virtually nothing will connect plug-n-play. 03-05 bikes also have a different wire harness that may or may not work. According to the parts manual, there are three different versions of the overlay harness depending on the year model and radio used. Basically every time HD changed radio styles the harness also changed. Rule of thumb: Get the wire harness that works with the radio, so if you have a 06 radio, get the 06 wire harness.
Disclaimer: I am writing these instructions as a general how-to install this radio/intercom/CB set up for a 2001 HD Electra Glide. My bike is a 2001 FLHTPI (EG Police that I have converted into an Ultra minus the cruise control). I will write these instructions with the assumption that the reader has basic mechanical/electrical abilities and owns the proper HD service manual and hand tools. There may be slight differences in year models, but the majority of these instructions will suffice for EG 96 – 05.
I will assume that you already have some sort of radio installed and speakers and are simply upgrading your existing unit or adding an intercom. If you currently have no radio installed as on an EG standard then you will need the speakers for the front. All the other hardware/brackets should be in place. Also, if you are adding rear speakers then you will need the rear speakers and pods. I will briefly discuss these items as well.
The Harmon-Kardon advanced radio as installed on a 96 – 02 model bike will have the following issues: The AVC (automatic volume control) will not function. This is due to the fact that the ECM does not have the serial data bus which sends the signal to the radio to denote speed change.
To save redundant instructions, items such as removal of the tank, removal of the outer fairing, removal of the seat, etc will not be in great detail as you can obtain this information from the service manual.
1. Raise the motorcycle on a lift of some sort. The standard red Sears lift will work perfectly. Don’t forget to properly secure the bike to avoid tip over.
2. Remove the seat and disconnect the battery. You may want to go ahead and remove the battery. Later it will give you added room to install the wire harness.
3. Remove the outer fairing, saddlebags and side shields. Remove the tank console and tank. Remove the ignition switch and dash cap.
4. If you are installing the CB or XM module then attach it to the radio before you install the radio.
5. Install the Harmon-Kardon radio into the existing brackets. You may need to remove the screws that hold the inner fairing to the main fairing brackets. Also remove the smaller brackets that are attached behind the fairing speakers. Once you do that the brackets will slightly spread open which makes it much easier to slide the radio into the fairing. The radio will slide into the radio opening tightly as the rubber weather strip will tend to grip. A squirt of windex to the rubber strip will make this easier.
6. Once you have the radio fully installed, secure the radio with four screws (two on each side). A ball-end T-handle allen wrench is preferred to do this.
7. Secure the fairing brackets and the small speaker brackets.
8. Install the Ultra Overlay wire harness by lying on the frame and running from the frame area to the inside of the fairing. I suggest lying on the left side of the frame as the main wire harness is on the right side. If you are purchasing a new wire harness there will be a area about six inches long that is not covered with conduit. Wrap this with electrical tape. It will not be see as it is under the tank/seat area.
9. Once you have the harness laid out, begin at the rear with the connections to the rear speakers and passenger intercom. The spring that attaches to the passenger intercom plug and the license plate is a bit tricky to get connected.
10. Working from the back of the bike, route the harness along the frame and securely attach with nylon zip ties. You need to make sure the harness is on the side of the frame as it goes under the tank. Also, get it as close/flat to the frame as possible. The service manual shows a picture on how the harness should lay and be installed. Refer to the manual if you have questions. It is very important that the harness is installed properly to avoid possible electrical shorts.
11. Leave the console connector hanging and reinstall the tank but do not secure it to the frame. Consider this a dry-fit. Make sure the tank is in the proper position.
12. Install the intercom console and connect to the tank console with the proper screws.
13. Install the tank console and route the wires, overflow tube back into place. Most of the wire connectors are “idiot proof” and will only go on one way to the mating connector. Make sure you securely connect them all to ensure a water-tight seal.
14. Secure the tank console to the tank and all the other items that goes along with this.
15. Now you should have, what appears to be, quite a bit of excess harness in the fairing. No problem, you need this to avoid pinching. Run the remainder of the harness into the faring area and secure with zip ties where needed. You want a “loop” from the frame to the radio to allow for movement when the handlebar is turned. Make sure once you have the harness tied down that there is free play in the handle bars when turned from side to side.
16. Connect the proper connectors from the harness to the radio/CB/XM unit. Again these are idiot proof and will only connect one way.
17. Locate the fairing cap and install the Speaker button. It goes beside the Spot switch on the left side of the ignition switch. Simply pop out the blank plug and pop in the switch from the underside of the cap. If you purchased the switch kit then this is also plug-n-play.
18. The trailing wire ends from the speaker switch are to be connected to the actual connector. The wires should already have the proper stay-kons crimped to the ends. Refer to the service manual’s wiring diagram to locate the proper placement of the wires into the connector. The diagram will show, for example, red wire goes into pin number 8. The black connector has very small numbers embossed on the outer edge. Once you have identified the proper wire and the proper placement, simply push the wire into the connector. Give it a slight tug to make sure it is seated correctly.
19. Connect the cap harness back to the main wire harness and re-install the cap and ignition switch.
20. Ensure that you have the overlay harness installed properly, and the tank placed properly, re-install the battery.
21. Switch the ignition on. The radio should flash on with the HD logo and such. Manipulate the speaker switch. FYI: speaker switch on (lighted) equal external speakers, off (not lighted) headset speakers.
22. Once you are satisfied with all the connections, and functionality, re-install the tank fasteners, front fairing and seat. You may need to “play” with the controls on the radio to get the features working properly. If you can get your hands on a 06 or newer owners manual, it will list the options and how to enable them properly. A good dealer may make copies for you at no charge.
23. If this is a new radio then once you get it installed the radio will function but the intercom/CB/XM radio will not. You must take it to the dealer to have them flash the ROM and update the ECM to recognize the CB/XM modules. Generally this will cost around 100$. Nothing has to be removed as the dealer will basically plug in to the ECM and add the components. One 96-02 bikes the ECM serial receive bus is virtually non-existent to communicate with the radio. A work-around for this is to have your radio attached to a 06 – newer bike and use that bike’s ECM to program the radio to recognize the components. Then replace the radio to your bike. If you have a good dealer, they may allow you to use a bike that is in their shop for this.
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