Installation Guide. Kennedy Technology Group, Inc.

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Installation Guide Harley-Davidson Amp Module - Base Kit Kennedy Technology Group, Inc. 614 Ridgeway, Rose Hill, Kansas 67133 - USA voice 316.776.1111 fax 316.776.9035 email:kennedy@cellset.com www.

installation Installation of Sub-Modules to the Main bracket Main bracket installation. Device installation and cleanup.

1 Installation Guide Harley-Davidson Amp Module - Base Kit Kennedy Technology Group, Inc. 614 Ridgeway, Rose Hill, Kansas USA voice fax kennedy@cellset.com DO NOT ATTEMPT THIS INSTALLATION IF YOU ARE COLORBLIND! There are four parts to the installation of this audio kit. installation Installation of Sub-Modules to the Main bracket Main bracket installation. Device installation and cleanup. The installation instructions cover both Pre 06, and 2006 and Newer audio systems. PRE INSTALLATION Verify that the bike s audio system is operational. Check audio and radio functions at both the rider and passenger positions. HARNESS INSTALLATIONS Tools Requi #25 Torx nut driver Large Phillips head screwdriver 3/16 wide blade flat screw driver 1/16 wide blade flat screw driver Thin Needle nose pliers or hemostats (prefer) Iso-Tip, Micro heat gun (Kennedy part # 35021) Razor Blade Remove the bike s windscreen and the faring. Disconnect the headlamp from the bike s wiring harness. Pre- 06: Use the 1/4 wide blade flat screw driver to remove Ampseal connector 28B (refer to Photos 1 and 2). Connector 27B Connector 28B B27 B28 Photo 1 - Pre- 06 Radio, Rear View Photo 2 - Pre- 06 Connector Removal continued, next page... 1 of 12

2006 and Newer: Connector location is the same. Use your index finger to lift connector 28B s retaining tab.

Use a 1/16 wide blade flat screw driver to push the Ampseal connector wedge lock tabs away from the wedge lock as shown in Photo 3.

Photo 3 - Connector Disassembly Step 1 Photo 4- Connector Disassembly Step 2 Technique for removal of Ampseal contacts from the connector housing (refer to Photos 5 and

While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed.

2 2006 and Newer: Connector location is the same. Use your index finger to lift connector 28B s retaining tab. Peel back any protective sheathing on the Harley harness so that at least 6 inches of wire are exposed coming out of connector 28B. Use a 1/16 wide blade flat screw driver to push the Ampseal connector wedge lock tabs away from the wedge lock as shown in Photo 3. Pull the wedge lock up as shown in Photo 4. The wedge lock should never be removed from the housing for insertion or removal of the contacts. Photo 3 - Connector Disassembly Step 1 Photo 4- Connector Disassembly Step 2 Technique for removal of Ampseal contacts from the connector housing (refer to Photos 5 and 6): Grab the wire to be removed (shown in the next section) with needle nose pliers or hemostats. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed. Photo 5- Pin Removal, Step 1 Photo 6- Pin Removal, Step 2 End of Removal Technique Installing Kennedy es part #85910 and Locate Kennedy harnesses part #85910 and and 5 pieces of 1/8 diameter x 2 shrink-wrap, from kit part number Refer to Figure 1 (Pre- 06) and Figure 1a (2006 and Newer) on the next page, and make the connections between Ampseal connector 28B and Kennedy harness 85910, and harness 28B and Kennedy of 12

3 KTG gray white green blue violet Connector 28B KTG orange yellow brown gray/yellow (16) gray/orange (17) yellow/ (1) yellow/white (9) Harley 28B yellow/ (2) Figure 1, Pre- 06 Kennedy Amp harness and Connection KTG gray white green blue violet Connector 28B KTG orange yellow brown gray/yellow (28) gray/orange (5) yellow/ (29) yellow/white (6) Harley 28B yellow/ (17) Figure 1a, 2006 and Newer Kennedy Amp harness and Connection 3 of 12

The sequence for installing the harness is: Locate and remove the appropriate contact from the Ampseal connector (refer to Figures 1 and 1a, above) Place a piece of heat shrink over the

Press the mating pin and the Ampseal connector contact together (refer to Photo 7 and 8) until the locking tangs on Kennedy harness mating pin disappear into the Ampseal connector contact.

Estimate the position so that the contacts are cente within the heat shrink (see Photo 9). Apply heat as shown in Photo 10. Let the heat shrink cool completely before moving the connection.

If you purchased a Kennedy Audio Interface Module (part number 95281), perform the Audio Interface installation at this time. Do not yet tie wrap the harness to anything.

4 The sequence for installing the harness is: Locate and remove the appropriate contact from the Ampseal connector (refer to Figures 1 and 1a, above) Place a piece of heat shrink over the corresponding mating pin on Kennedy harness # Press the mating pin and the Ampseal connector contact together (refer to Photo 7 and 8) until the locking tangs on Kennedy harness mating pin disappear into the Ampseal connector contact. Tang Photo 7- Pin and Socket, pre-seated Tang Photo 8- Pin and Socket, Seated Slide the heat shrink tube back over the mating pair. Estimate the position so that the contacts are cente within the heat shrink (see Photo 9). Apply heat as shown in Photo 10. Let the heat shrink cool completely before moving the connection. Connector Pair Photo 9- Heat shrink Position Photo 10- Heat Application Insert the proper Ampseal contact of the Kennedy Amp harness into the empty position just created. If you purchased a Kennedy Audio Interface Module (part number 95281), perform the Audio Interface installation at this time. Do not yet tie wrap the harness to anything. NOTE: If a contact pair is connected in error, carefully cut the heat shrink down its length with the razor blade and pull it off the mated contacts. GO BACK AND REVIEW THE MATING CONTACT WIRE COLORS! Reassemble the Ampseal connector by pressing the wedge lock down until the locking tabs seat. If any Ampseal contact is not seated correctly, the wedge lock will not close. Push any unseated contact further into the connector. 4 of 12

5 Plug Ampseal connector 28B back into the radio. Do not yet tie wrap any Kennedy es to the 28B. This will be done during the device harness installation and clean up, at the end of this installation sheet. Installing Kennedy Amp harness part #85584 Remove Ampseal connector 27B and disassemble the connector as you did to Ampseal Connector 28B (see Photos, previous pages). STOP STOP STOP STOP If you purchased an Unswitched Power harness part # 95296, proceed to B SECTION of this portion of the Amp Module installation. A SECTION: AMP MODULE INSTALLATION, NO UNSWITCHED POWER HARNESS Figure 2, shows the connections to be made between Ampseal connector C27, C27, and Kennedy part # This figure applies to both Pre- 06 and 2006 and Newer Harley audio systems. 5 inches Harley Connector 27B KTG /green (11) orange/blue (12) Harley 27B 2 inches Figure 2, Pre- 06 and 2006 and Newer, Kennedy Amp harness Connection 5 of 12

6 B SECTION: AMP MODULE INSTALLATION, WITH UNSWITCHED POWER HARNESS Figure 3, below shows the connections to be made between Ampseal connector 27B, Kennedy Amp harness #85584, and Kennedy Unswitched Power harness # Before making these connections, remove the Radio Memory fuse from the bike s fuse panel. This figure applies to both Pre- 06 and 2006 and Newer Harley audio systems. Harley Connector 27B KTG KTG /orange /green orange/blue Harley Connector 27B 12 Figure 3, Pre- 06 and 2006 and Newer, Kennedy Amp harnesses & Connection Replace the Radio Memory Fuse. Reassemble the Ampseal connector by pressing the wedge lock down until the locking tabs seat. If any Ampseal contact is not seated correctly, the wedge lock will not close. Push any unseated contact further into the connector. Plug Ampseal connector 27B back into the radio. Do not yet tie wrap any Kennedy es to the 27B. This will be done during the device harness installation and clean up, at the end of this installation sheet. -End of installations- Tools Requi #6 hex nut driver Medium Phillips head screwdriver Diagonal cutters SUB-MODULE TO MAIN BRACKET INSTALLATION Use the Phillips head screwdriver to remove the 4 screws from the Sub-Module(s) bottom panel. 6 of 12

Photo 11 - Sub-Module Internal Connector Refer to the Sub-Module s Installation sheet and perform any Circuit Configuration instructions contained therein.

7 Photo 11 - Sub-Module Internal Connector Refer to the Sub-Module s Installation sheet and perform any Circuit Configuration instructions contained therein. Figu 4 identifies the Amp-Module Flat Cable Connectors referenced in this section of the installation guide. FCP1 FCP2 FCP3 Figure 4, Amp-Module Flat Cable Connectors continued, next page... SUB-MODULE TO MAIN BRACKET INSTALLATION, continued Figure 5, below, identifies the Sub-Module items reference in this portion of the installation guide. Gray plug Gray flat cable Circuit Connector J1 Module Circuit Board Module bottom panel From Amp or previous Module To next Module Figure 5, Sub-Module Items Reference 7 of 12

8 Depending on the number of Sub-Modules you are installing, refer to one of the three figures below. These figures show the appropriate connector to use. Unused connectors are wound around excess cable and inserted into the leftmost Sub-Module. Take the Sub Module s top housing and fit it over the bottom panel so that the gray flat cables exit the slot on the left side of the Sub-Module housing. Gray flat cable FCP3 FCP2 FCP1 From Amp Module 1 of 3 Module 2 of 3 Module 3 of 3 Figure 6, Three Sub-Module Installation FCP3 FCP2 FCP1 From Amp Module 1 of 2 Module 2 of 2 Figure 7, Two Sub-Module Installation SUB-MODULE TO MAIN BRACKET INSTALLATION, continued FCP2 FCP1 FCP2 From Amp Module 1 of 1 Figure 8, One Sub-Module Installation. To insert the Gray flat cable plug into Circuit connector J1, first spread the locking tabs found on both ends of J1. Then push the gray plug down into the circuit connector. These connectors are keyed so that they can not be inserted incorrectly. Press down firmly on the gray plug. The locking ears on the circuit connector J1 should snap back and retain the gray plug. Wind any excess flat cable around unused gray plugs. Using a #6 hex nut driver, remove 2, 4, or 6 (depending on 1, 2, or 3 Sub-Modules to be installed) nuts from the front and back threaded studs attached to the top of the Amp bracket. Refer to Figure 7 for the proper hardware stack. 8 of 12

-End of Sub-Module to Main Bracket installation- MAIN BRACKET INSTALLATION Tools Requi Long shank ball end socket (Snap-on #FABL6E) Long, 3/8 wide blade flat screw driver To better access the the

9 Hex nut Flat washer Sub-Module bottom Flat washer Amp Bracket Gray flat cable Figure 9, Sub-Module Hardware Stack. For multiple Sub-Module installations, route the gray flat cable underneath the Sub-Module. -End of Sub-Module to Main Bracket installation- MAIN BRACKET INSTALLATION Tools Requi Long shank ball end socket (Snap-on #FABL6E) Long, 3/8 wide blade flat screw driver To better access the the radio bracket screws remove any connectors attached to the right fairing radio bracket. Do not remove any OEM modules mounted on top of the 2006 and newer radio. Use a long shank ball end socket (Snap-on #FABL6E) to loosen the left and right side, front and back, bracket screws (see Photo 11). They should be loosened 8 to 10 turns so that their heads are at least 1/2 away from the bike s mounting bracket. Place the 3/8 wide blade flat screw driver between the radio chassis and left mounting bracket. Twist the screwdriver so that the mounting bracket moves away from the radio chassis. Slide the Kennedy Amp bracket into the space between the bracket and radio. Repeat this procedure on the right side of the radio (see Photo 12; For clarity, the Sub-Modules are not included). Push the Main bracket back until its mounting ovals encircle the front, left and right bracket screws. Tighten the four radio mounting bolts. Photo 12- Bracket Installation, Bolt Releasing Photo 13- Bracket Installation, Mount Spreading 9 of 12

Photo 14- Bracket Installation, Final Position Clean the top front of the radio with

10 Photo14 shows the Main bracket in its final position. For clarity, the Sub-Modules are not included. Photo 14- Bracket Installation, Final Position Clean the top front of the radio with isopropyl and attach 2 or 3 adhesive backed wire mounts as shown in the photo below. Optional Placement Photo 15- Cable Mount Position -End of Main Bracket Installation- 10 of 12

11 Tools Requi #25 Torx nut driver Large Phillips head screwdriver Diagonal cutters DEVICE HARNESS INSTALLATION AND CLEANUP. Refer to the Device user sheets to route and connect them to the Kennedy Sub-Modules and bike power. Use the cable ties provided to attach the device cables to the adhesive backed cable mounts. Photo 16- Cable Tie Position Route Kennedy harness along harness 28B and connect it to Kennedy Amp Module plug P2. Route Kennedy harness along harness 28B and connect it to Kennedy Amp Module plug J1. Route Kennedy harness along harness 27B and connect it to its Kennedy Amp Module plug P J P P1 Figure 10, Kennedy Amp Module 11 of 12

Should you need to disconnect these plugs, refer to the Plug Disconnect Hints at the

Refer to the User s guide and test for proper operation Once proper operation is

-End of Device Installation- Plug-set Disconnect Hints Press down on the locking tab.

12 Should you need to disconnect these plugs, refer to the Plug Disconnect Hints at the end of this installation guide. Refer to the User s guide and test for proper operation Once proper operation is verified, reinstall the fairing and windscreen. -End of Device Installation- Plug-set Disconnect Hints Press down on the locking tab. Grip the connectors between mating parts with a pair of needle-nosed pliers. While holding the locking tab down, rock the pliers back... and forth. NEVER, NEVER PULL THE WIRES 12 of 12

Installation Guide. CellSet MC/GPS-Harley. Kennedy Technology Group, Inc.

Installation Guide. CellSet MC/GPS-Harley. Kennedy Technology Group, Inc. Installation Guide CellSet MC/GPS-Harley Kennedy Technology Group, Inc. email:kennedy@cellset.com www.cellset.com DO NOT ATTEMPT THIS INSTALLATION IF YOU ARE COLORBLIND! The installation instructions cover