DYNA OIL COOLER KIT
J035952005-04-13
GENERAL
Kit Number
26110-05
Models
This kit fits 2006 Dyna model motorcycles with the following exceptions:
- This kit does not fit California motorcycles equipped with an evaporative emissions cannister.
- This kit does not fit motorcycles equipped with an engine guard.
- This kit does not fit motorcycles equipped with a chin spoiler.
NOTE
Chrome Oil Cooler Cover (63040-05) will fit with this kit and is available from a Harley-Davidson Dealer.
Additional Parts Required
WARNINGRider and passenger safety depend upon the correct installation of this kit. 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. (00333b)
NOTE
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.
INSTALLATION
| 1. | Remove two socket head screws and voltage regulator. Discard screws. | |||||||||||
| 2. | Remove electrical caddy from regulator bracket of frame. | |||||||||||
| 3. | See Figure 1. Remove the spin-on oil filter (2) and oil adapter mounting fitting (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter adapter. | 
Figure 1. Oil Filter and Adapter 
Figure 2. Oil Cooler | ||||||||||
| 4. | See Figure 3. Install electrical caddy (9) to the regulator relocation bracket (11). | |||||||||||
| 5. | See Figure 3. Install the regulator relocation bracket (11) to the frame using hex screw (1), two washers (2) and hex nut (3) from the kit. Tighten screw to 6.8–9 N·m (60–80 in-lbs). NOTE Prior to removing the front isolator hardware, the vehicle must be in an upright and level position. When raising the jack, be sure jack does not contact or pinch the clutch cable. | |||||||||||
| 6. | Support front of engine with a piece of soft wood and lifting jack. | |||||||||||
| 7. | With motorcycle upright and level and the engine supported by a suitable jack, remove the front isolator bolts, lock washers and washers. Discard isolator bolts, and retain washers and lock washers for reuse. | |||||||||||
| 8. | See Figure 2. Install the oil cooler (5) to the frame using two socket head cap screws (6), two washers and lock washers (removed in previous step) and two spacers (4) from the kit. Tighten to 28–36 N·m (21–27 ft-lbs). |
| 1 | Hex screw |
| 2 | Flat washer (2) |
| 3 | Nut |
| 4 | Thin spacer (2) |
| 5 | Oil cooler |
| 6 | Socket head screw (2) |
| 7 | Socket head screw (2) |
| 8 | Voltage regulator |
| 9 | Electric caddy |
| 10 | Thick spacer (2) |
| 11 | Regulator relocation bracket |
| 12 | Stator connector |
Figure 3. Regulator Relocation Bracket and electrical caddy installation
| 9. | Install the voltage regulator (8) to the regulator relocation bracket (11) and frame using two socket head screws (7) and two thick spacers (10) from the kit. Tighten screws to 6.8–9 N·m (60–80 in-lbs). | |||||||
| 10. | Secure excess cable/wire harness length to the right side down tube, if necessary. NOTE The oil adapter assembly has a flange protruding out of the back side. The flange must be installed toward the oil filter mounting location and through the oil adapter gasket. | |||||||
| 11. | See Figure 4. From the kit, install the oil adapter gasket (3) onto the oil filter adapter assembly (1).The oil adapter assembly flange should be aligned so it is installed into the oil adapter gasket cutout as shown. NOTE Position the stator and regulator cables to avoid interference with oil adapter assembly. | |||||||
| 12. | See Figure 4. Install the oil adapter assembly and gasket onto the oil filter mounting surface of the engine with the mounting fitting (2). Ensure adapter locates properly in the mounting surface. Ensure the raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 16.3–21.7 N·m (12–16 ft-lbs). | 
Figure 4. Install Oil Adapter | ||||||
| 13. | See Figure 5. Obtain the bottom hose (11) and top hose (10) from kit. Follow the markings on hoses to connect onto the oil cooler and oil cooler adapter. | |||||||
| 14. | Fasten hoses to oil filter adapter and oil cooler with worm drive clamps (7). Tighten clamps to 0.9 N·m (8 in-lbs). | |||||||
| 15. | Lubricate oil filter seal with new engine oil. Use Oil Filter Wrench (HD-44067A) to install oil filter. Thread filter on until seal touches mounting surface, then turn an additional 1/2 to 3/4 turn. NOTE Position the clamps to avoid interference with oil-filter installation. Check that hose routing is clear of the oil filter and sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. | |||||||
| 16. | Using a wire tie secure the clutch cable to the left frame down tube and away from both oil cooler hoses. | |||||||
| 17. | Ensure all cables and harnesses are clear of the oil adapter, in order to prevent wear. | |||||||
| 18. | Fill oil to FILL level on dipstick. |
System Flow Test
NOTICE
Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine. (00185a)
NOTICE
Oil level cannot be accurately measured on a cold engine. For pre-ride inspection with the motorcycle upright (not leaning on jiffy stand) on level ground, the oil should register approximately at the midpoint of the cross-hatch area on the dipstick when the engine is cold. Do not add oil to bring the level to the full mark on a cold engine. (00186b)
NOTICE
Do not operate the engine when the oil level is below the add mark on the dipstick at operating temperature. Engine damage will result. (00187b)
| 1. | Start engine. Examine all hose connections for leaks. If there is no leakage, allow engine to warm up. NOTE Position the clamps to avoid interference with oil filter installation. Check that hose routing is clear of the oil filter and sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. | |
| 2. | Verify that temperature of oil cooler increases when engine reaches normal operating temperatures. If the oil cooler remains cool after engine has warmed up, there may be an oil obstruction. Turn off engine and check system for source of obstruction. | |
| 3. | After engine has cooled, re-tighten all hose clamps to 0.68 N·m (6 in-lbs). |
SERVICE PARTS
Figure 5. Service Parts for Dyna Oil Cooler Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Screw, hex socket (2) | 4820A |
2 | Spacer (2) | 5695 |
3 | Nut | 7688 |
4 | Washer (2) | 6703 |
5 | Screw, hex cap | 3767B |
6 | Oil cooler, Dyna, black | 62657-05 |
7 | Screw, socket head cap (2) | 4311 |
8 | Spacer | 5694 |
9 | Hose clamp (4) | Not Sold Separately |
10 | Hose, oil, top | Not Sold Separately |
11 | Hose, oil, bottom | Not Sold Separately |
12 | Oil adapter assembly | 26111-05 |
13 | Fitting, oil adapter mounting | 26041-05A |
14 | Gasket, oil adapter | Not Sold Separately |
15 | Bracket, regulator relocation | Not Sold Separately |
16 | Gasket | Not Sold Separately |
17 | Rubber oil hose service kit (not shown) - contains four clamps (9), short hose (10) and long hose (11) | 62622-03A |
18 | Gasket service kit (not shown) - contains gasket (14), gasket (16) and two screws | 12056-05 |