Hogtunes REV 200SG KIT-RM User manual

REV 200SG Kit-RM
High Performance Front Speaker Kit with 200 Watt Amplifier
For Use on 1998-2013 Ultra ClassiCs and tri-Glides
installation Manual
REV 200SG Kit-RM
High Performance Front Speaker Kit with 200 Watt Amplifier
For Use on rUshmore Flh models
installation Manual

1
Thank you for choosing the Hogtunes REV 200SG KIT-RM speaker and
amplifier kit for “Rushmore” platform bikes. Since positive word of mouth is the
best way to grow our business, we want your new system to work as well as it
was designed to. If you have any questions or concerns, we are here to help.
The installation will be done in 3 major steps.
Step 1: Changing out the front speakers
Step 2: Installation of the amplifier
Step 3: Routing the power harness
Please follow the installation instructions as provided on the following pages.
Hogtunes Contact Information
Email: [email protected]
Tel: [phone]
A video version of this manual is available at
www.hogtunes.com If you still need
assistance, please consider a professional
installation by your motorcycle dealer.

2
362F-RM FRONT SPEAKER
INSTALLATION INSTRUCTIONS
Step #1: Remove the seat and both wires (+ and -) from the battery. Remove the
outer fairing/headlamp assembly and set aside. Refer to a service
manual if you need help with this. NOTE: Placing a towel on the front
fender can help prevent scratches or “dings” from dropped tools or
fasteners, etc. Expletives will also be kept to a minimum!
Step #2: Speaker Cabinet Removal: On the brake side speaker cabinet,
carefully remove the cable going into the power port/cigarette lighter
assembly. If your bike has the CB module (mounted “sideways” on the
clutch side cabinet) undo the antenna cable and main harness. The
CB Module will stay attached to the clutch side cabinet when removed.
Undo the speaker wire plugs going into each cabinet (pink & pink with
black stripe wires).
The speaker cabinets are vital to the fairings structure.
DO NOT operate the bike without the speaker cabinets installed!
NOTE: We STRONGLY suggest completing the speaker swap on one side and
then moving to other side! Figure 1.1 and 1.2 (below) have arrows that point
to the factory fasteners that will be removed to allow the cabinets to come
out of the bike. Although the Brake Side is shown below, fastener locations
are common for both brake and clutch side cabinets.
Figure 1.1
Side view of brake side cabinet
Figure 1.2
Back view of brake side cabinet

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Step #3: Installing the New Speaker: With the cabinet removed from
bike undo the four screws that hold the factory speaker to the cabinet.
Carefully take off each speaker wire by disconnecting one at a time.
Take a Hogtunes speaker and attach the factory speaker wires, noting
they will only go on one way. The #1 reason for tech related calls
is loose wires at the speaker which is why we designed the
self-locking clips on the speaker frame. Using the factory screws, attach
the Hogtunes 362F-RM speaker to the cabinet noting that there is a
locator “peg” on the cabinet and a hole in the speaker’s frame which
need to line up so the speaker sits flush to the cabinet. Bass response
will be greatly reduced if the speaker is not flush to the
cabinet! The factory speaker grill must be removed and replaced with
the supplied metal mesh grill using the three factory screws on the inside
of the fairing. In the factory grill, you will see two holes and one “key-
hole” where the screws go through and into the fairing. The keyhole on
our grill needs to go in the same spot for proper fitment of the new grill!
With the new grills in place and the speaker properly attached to the
speaker cabinet, the cabinet can be re-installed to the bike. It’s always
a good idea to put the factory fasteners back in to specified torque.
Repeat Step #3 for the second cabinet. Make sure to plug the power
cable back into the power port/cigarette lighter assembly on the brake
side. If your bike has the CB module, make sure to re-install the antenna
cable and main harness.

4
REV 200-RM AMPLIFIER
INSTALLATION INSTRUCTIONS
Step #1: Over top of the radio, pull up to release each wire harness from the
black plate via the factory “Christmas Tree” fasteners. If your bike has
factory GPS, the small square antenna will need to be relocated just
behind the voltmeter as shown in Fig 1.1 below. Remove the four factory
T-20 “Torx” screws that go through the top of the black plate and into
the top of the radio.
Step #2:
Step #3: The amplifier comes pre-mounted to a silver mounting plate. Locate and
remove the four screws (2 per side) that attach the amp to the silver plate.
Put these screws just removed and the amplifier aside for now.
Step #4: Sit the supplied silver plate on top of the radio so it is oriented as shown
in Fig 1.2 on the next page. Put one of the supplied star washers on each
factory screw and re-install through the silver plate, through the factory
black plate and into the top of the radio. Locate the main power harness
and plug it into the matching “pig-tail” on the side of the amp. Locate the
supplied input harness and plug into the “audio input” socket on the side
of the amp. Locate the harness with brown/black and blue/black wires
and plug it into the 4 pin BLACK plug on the “pig-tail” coming out of the
amp. Sit the amp on top of the silver plate so when standing in front of
the bike you can read the Hogtunes logo on top of the amp. Locate the
four short black Phillips head screws and secure the amplifier to the
silver plate.
Figure 1.1 - The white
circle shows the new
location for GPS
Antenna if your bike
came factory equipped
with this feature.

5
Step #4: Figure 1.2
shown here.
Step #5: Also in Fig 1.2 is a white square which shows a smaller black 2 pin fac-
tory plug. The orange wire from the amp has a plug that goes directly
into this factory harness. On the factory plug we are describing, there
may be a factory plug with no wires already installed into it which will
have to be removed. The factory wire colors going into the plug are
purple/blue stripe and black and can be seen under the factory sheath-
ing. The orange wire is the amplifier’s “turn on” lead and tells the amp
to turn on/off with the bikes ignition. The amplifier will not turn on if this
wire is not hooked up to this (or any) switched B+ source!
Step #6: From the amp, take the 2 pin plug with the blue/black wires and install
it into the plug going into the brake side speaker cabinet. Take the 2 pin
plug with the brown/black wires and install it into the plug going into
the clutch side speaker cabinet.
Step #7: From the amp’s input connector, take the 2 pin plug with the green/
black wires an install it into the mating plug on the brake side of the
bike. Also from amp’s input connector, take the 2 pin plug with the
yellow/black wires and install it into the mating plug on the clutch side
of the bike. NOTE: These are the plugs that were originally undone to
allow the speaker cabinet to come out. The plugs will only fit together
one way but, to be absolutely sure, if you look behind the factory wire’s
sheathing, the factory wires are pink and pink/black stripe.
Figure 1.2 - Amplifier and mounting plate
correctly oriented. The plate with four small
holes is for mounting a popular Harley
accessory. The white circles show tabs which
are there for the “Christmas Tree” fasteners to
re-secure the harnesses lifted earlier.

6
ROUTING THE POWER HARNESS
The balance of the main wire harness will pass under the inner fairing where
the main wire harness passes through on the brake side of the bike. Loosen the
tank console and run wires up and over the gas tank, but under the tank console.
There is a provision on the front of the tank console for wires to pass. Secure
the amplifiers harness to the bikes factory harness using zip ties. When
correctly installed, the power and ground wires are the right length to connect
to the battery.
Attach the amp’s red wire to the positive (+) battery terminal and the amp’s
black wire to the negative (-) battery terminal. The factory battery wires are also
re-installed at this point. When attaching the power and ground wires, it is always
a good practice to do the negative first. When the positive connector touches
the battery, some sparking is normal. This is a function of the capacitors in the
amplifier charging up.
IMPORTANT: With all wires secured, turn the front
wheel to each extreme side making sure that any wires
cannot bind or impede the steering of the motorcycle.
Failure to do so can cause an accident resulting
in serious injury or death!
Turn the stereo on and, at low volume, test to make sure the speakers are working.
Now is a good time to “clean up” and secure the wires using the supplied zip ties.
Stock Harness and Amplifier’s
Harnesses Passing From Fairing
To Just In Front Of Tank (Arrow
A) . Cable Tying the Harnesses
To The Main Bike Harness Just
In Front Of The Tank (Arrow
B) Allows The Amp Harnesses
To Go Up Towards The Tanks
Chrome Console Easier And
Makes For a Cleaner Install.
A
BBA

7
adjusting Your sYsteM-Please read!
In order to make your new system perform as good as it was designed,
please take a minute to understand and follow these tips:
1) Set your “Automatic Volume Control” (AVC) to 3 bars. After extensive
on-road testing, we found that this AVC position works and sounds best.
Your new amplifier has been specifically set-up for this radio setting.
2) Your Hogtunes system is designed specifically for a motorcycle at speed.
Exhaust noise and wind noise have been taken into careful consideration
in how your system performs. How your new system sounds in a driveway
or garage is radically different from how it will sound at highway speeds.
Although your system was set-up with a factory radio, with its bass and
treble controls in the middle position, if you feel the need to make
adjustments please do so (carefully) at your normal cruising speed.
technical sPecifications
Hogtunes REV 200SG Kit-RM
Amp’s RMS Power at 2 Ohms: 100 Watts x 2 Channels
Speakers: 125 Watts RMS 200 Peak
Frequency Response: 40hz - 25khz
Fuse at Amp: 15 amp

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Harley-Davidson, Electra Glide, Road Glide, Street Glide, Ultra Classic, Tri Glide, CVO, Screamin
Eagle and Tour-Pak® are Trademarks, and/or Registered Trademarks of Harley-Davidson, Inc.,
Milwaukee, Wisconsin, USA, and if Used or Implied are for Reference Only. There is No Affiliation
Between Harley-Davidson, Inc., and Hogtunes Inc.
WarrantY inforMation
Please Record Your Amplifier’s Serial # Here_________________________
Hogtunes speakers are warranted for a period of 20 years. The REV 200-RM
Amplifier is warranted for 3 years from original purchase date. Proof of purchase
is required for all warranty claims. The warranty applies to the original retail
customer and is not transferable. Please contact Hogtunes for all warranty claims.
Products found to be defective during the warranty period will be repaired or
replaced (with a product deemed to be equivalent) at Hogtunes sole discretion.
Hogtunes complete warranty policy is available on our website at:
www.hogtunes.com/warranty.html
What Is Not Covered:
1) Any expense related to the removal or re-installation of Hogtunes products.
2) Repairs to these products performed by anyone other than Hogtunes.
3) Subsequent damage to any other components.
4) Any product purchased from a non-authorized Hogtunes dealer.
5) Damage to Hogtunes products due to an accident or collision.
6) Hogtunes Amplifiers with broken or removed “warranty void” stickers.
7) Damage due to water from custom installations.
8) Damage from incorrect installation, improper use, abuse or modifications.
9) Damage to inbound product due to improper packing.
IMPORTANT: In the event of a warranty claim, please fill out the
form in the Warranty section of our website, or contact us by
email or by phone. Valid claims will have an Return Authorization
Number (RA#) generated which MUST appear on the outside of
the box when it arrives to our office.
Goods Arriving Without an RA# Will Be Refused!

Any audio system can be a
distraction to the rider
and/or passenger. Please
use caution when
playing your stereo,
ESPECIALLY IN TRAFFIC.
www.hogtunes.com
REV200SGKIT-RM V1.2