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[Trigger-Man]

Hey Mac .......finally got around to the BOOM! Audio Stage II install in my newly heated garage ......and after a few mistakes thinking I may have this "wired". It helped that I invested in a 2015 Touring Service Manual and the 2015 FLTRUSE Supplement Manual:

OK, I finally had the time and drive to get this project started.  First, let me say, whatever Harley charges for this install probably is not enough.  This upgrade is NOT for the faint of heart.  I consider myself a pretty good mechanic, but this one is giving me fits.

The instructions SUCK.  The way they state things, is not exactly how it goes.  Too much detail to go into here, just read the instructions for the task you are doing and at least two or three ahead.  They sometimes give details that help. Agreed ....instructions probably written by an engineer who cannot conceptualize the reader doesn't understand what he/she knows LOL.
I have been tinkering for 4-5 hours, and only have the amp mounted, and the rear speakers installed. It really does help to read ALL of the instructions and NOT to assume you've got it. I discovered things like the "A" designation on a connector means "pin" and a "B" designation means "socket". I was also so focused at the wiring at the tourpak/seat screw area where the 69200714 interconnect harness installs that I could not "locate the black, four-way Molex connector [296A] near the back of the underseat area" (per instructions). It took me the next day to realize [296A] was behind the battery area in front of the backrest support bracket !!

Issue 1:  Unpin connector from new harness to install in speaker housing.  OK...but how do you unpin it?  After at least an hour online, I found out it is a 2-pin Delphi Weather Pack connector.  There is a rear clip that must be pried off, then you have to have a tool to unpin it.  What tool?  Good question.  I used one in a huge kit I bought a while back that is for GM, was a two needle like prong one.  Note which one goes in what side, because the striped wire in the left goes in A, and then the stripe goes in B on the right. Don't know why instructions advised unpinning speaker connectors because they fit through the 1" hole we are supposed to drill

Issue 2:  Instruction say to mount the rails on the amplifier before installing.  When done this way, there is no way to maneuver it around the mounting bolts, which you have to remove the tour pack to install. I took off the left bracket, installed the amp using the right, and was able to install the left while the amp was in place on the bike. In fairness, instructions dated 2016-02-06 do warn: "NOTE: If the amplifier is installed before the Tour-Pak is mounted, it is not possible to secure the Tour-Pak"

Issue 3:  Instructions call for you to drill an additional 1 freakin' inch hole in the pods for the new wires.  I did not have a bit that large, so I made a 3/8" hole and used a different grommet.  Way overkill in my opinion. Yeah ......I wondered why such a large hole was spec'd. Only reason I could see was to pass the new speaker connector through .....but then why "de-pin" the connector ?? I purchased a "step drill" ($50) as advised "to prevent damage to the speaker pod covering" .......but that didn't work correctly. I had to use an X-acto blade and 1" diameter template to cut the vinyl hole prior to drilling

Issue 4:  If I ever meet the Harley engineer who designed this, I am going to smack him/her in the mouth.  You have to replace the rubber nutserts in the speaker pods with new ones.  They go in from the rear.  They have a raised edge similar to a grommet, and DO NOT go in all that easy.  So what does any experienced person do, use a little WD-40.  Went in super easy, thus creating another issue.  Because they went in easy, the push back out even easier.  When you are trying to start all four screws, even the slightest off-center touch pushed them back out.  I must have removed the right speaker four times to put ones back in.  No WD-40 used on the left, but my fingers are paying for it. HAHAHA ......I used spit on the more difficult ones and discovered the same thing you did. Then tightening the screws became difficult as the rubber nutserts would spin

Issue 5:  The wiring routing diagram and descriptions are not written for the below average brick like me. I feel the same Mac I finally took a break, and will resume tomorrow.  Will post more then.

Except for running the 69200489 jumper harness to the front fairing and connect to 313, I'm almost done. Aside from trouble understanding the instructions, one of the more difficult tasks was the DATA LINK CONNECTOR (DLC) RELOCATION. This was probably the primary reason for removing the battery and electrical caddy and involved "de-pinning" the original equipment [91A] connector. A word of warning: be certain to record the locations of the wires within the connector so you may replace them in the correct locations when you re-pin later. Two of the wires, W/BK and W/BN, appear to be identical. The BN (brown stripe) is so dark it looked just like the BK (black stripe). The Service Manuals really helped. You'll need a small hook to remove the green pin retainer prior to pulling the pins out to the socket (I used a corkscrew on my Swiss Army knife). Pictures are worth a thousand words .........I'll post a few photos which should help:
UPDATE: See revised Tourpak wiring connection photo posted 2/4/2017

[Trigger-Man]

A photo of the "step drill" bit for the 1" holes in the Tour-Pak speaker boxes.

[Trigger-Man]

Another photo of the step drill bit

[Trigger-Man]

 Does anyone know how to post multiple photos within one response? I'VE REMOVED THE PHOTO PREVIOUSLY HERE AS IT IS NOT CORRECT .

[Trigger-Man]

More photos

[Fired00d]

Does anyone know how to post multiple photos within one response?

You can only attach one file/photo to a post. Those posts that you have seen w/multiple pictures are using the image tag linking to pictures hosted somewhere else on the internet.

 
Ride Safe,
Fired00d
 

[Trigger-Man]

Another photo. Remember to record the serial numbers of your amplifiers. This is required when you take the bike in for flashing.

[Trigger-Man]

Location of [296A]

[Trigger-Man]

[296A] connected to harness [296B]

[Trigger-Man]

Bundle wires carefully

[Trigger-Man]

Thanks Fired00d

[Maczter]

Trigger-man, sent you a PM.

[Trigger-Man]

SUCCESS !! The BOOM! Audio Stage II is correctly installed in my 2015 FLTRUSE and appears to be functioning as advertised. While I haven't experienced it at high speeds yet (still too cold) ........the system sounds wonderfully powerful around town. I completed the installation (in my heated garage ) then brought the bike to Grand Junction H-D to have the radio flashed along with having my 15k service done. As a precaution, I even removed the radio fuse to avoid blown speakers .......HAHAHAHA . Stood there aghast watching the tech connect his Digital Technician laptop, turn the radio on and promptly blow one of the Tourpak speakers !!! Actually we didn't discover the blown speaker until days later because the Digital Technician software wasn't seeing the system correctly and it just wouldn't function.

The next day their Lead Tech came in off vacation and through trial and error discovered I had missed a connection. Per the sometimes vague MOCO instructions, I'd left the 4 pin socket of the Speaker Interconnect Harness (69200714) unconnected. Turns out this 4 pin socket (female) needs to connect to (male) connector #10 [297A] of the Tourpak Amplifier Harness (see photo). In at least one of the MOCO instruction documents this 4 pin socket was referred to as "unused" .......and another document instructs the installer to "cap off this unused 4 pin connector" ! In attempting to find out what was wrong, the tech took everything apart and checked every connection ....fortunately I'd installed everything else correctly. When they reassembled everything they even installed the Rear Speaker Jumper Harness (69200489) neatly inside the wire trough under the gas tank (I'd zip-tied the harness to the outside where it might have gotten pinched by the gas tank)! 

So even though they spent over two days on this ......I was pleased to pay for only 1.5 hours of work ($130) and even though I'd purchased the Stage II equipment elsewhere, they replaced the blown Tourpak speaker under warranty (good thing I'd watched the tech start the radio prior to flashing). Things I've learned:

• NEVER ALLOW THE RADIO TO BE TURNED ON WITH SPEAKERS CONNECTED PRIOR TO FLASHING.
• LOT'S OF MISINFORMATION: I'd heard on a forum that a dealer wouldn't flash with disconnected speakers .......my dealer says it doesn't matter
• RESEARCH EVERYTHING .....DON'T ASSUME. These forums are a mostly wonderful source of information

Hope this information is helpful. C'mon "riding weather"!!!!!!!!!

[Trigger-Man]

This photo corrects a previously posted version......

[OBB]

Thanks for the help guys. I think I'm about a week or two away from ordering these parts. Local dealer is having an 'infotainment' workshop on the 11th and I happen to be off that day. They'll be giving 20% off parts for people that attend.