VRSC RADIATOR KIT
J030212013-08-07
GENERAL
Kit Number
26721-01C
Models
This kit fits all 2002-later VRSC (V-Rod®) models.
Installation Requirements
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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
An OIL LINE REMOVER (HD-46503) is also needed.
Proper installation of this kit requires the addition of engine lubricant and coolant. Genuine Harley-Davidson® H-D® 360 Motorcycle Oil or Syn3® Synthetic Motorcycle Lubricant, and Extended Life Antifreeze and Coolant are available from a Harley-Davidson dealer.
See the service manual for the correct engine lubricant.
INSTALLATION
Radiator Removal
WARNINGDo not loosen or remove pressure cap when cooling system is hot. The cooling system is under pressure and hot coolant and steam can escape from pressure cap, which could cause severe burns. Allow motorcycle to cool before servicing the cooling system. (00091c)
| 1. | See the service manual to open the seat. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||
| 2. | See the service manual to remove the main fuse and disconnect the negative (black) battery cable from the negative battery terminal. NOTE Cover painted parts to protect finish. | |
| 3. | See the service manual to remove the radiator assembly. Air filter or velocity stack removal is not required. See Figure 2. Retain the two grommets (C), washers (D) and nuts (E) for later assembly. | |
| 4. | 2004-later models: Proceed to Radiator Installation, Step 1. The two quick-connect oil fittings (21) and cable strap (26) in the kit can be discarded. 2002-2003 models: See the service manual to remove the "oil in" fitting at the crankcase and the "oil out" fitting at the oil filter. | |
| 5. | Get the two quick-connect oil fittings (21) from the kit. Thread the fittings into the holes in place of the original fittings. Tighten the fittings to 40–44 N·m (29–32 ft-lbs). |
Radiator Installation
| 1. | Hold the new radiator/oil cooler assembly (1) up to the motorcycle frame. | |
| 2. | Line up and fit the radiator inlet and outlet pipes to the engine coolant hoses. | |
| 3. | See Figure 1. While supporting the radiator/oil cooler assembly, push the oil line into the "oil out" fitting on the engine oil filter ( Figure 2 , F) until it clicks into place under the spring clip. NOTE The yellow witness band on the flanged oil line is not visible when the oil line has been correctly snapped into the fitting. | |
| 4. | See Figure 2. Snap a new plastic dust cap (8) over the spring clip groove. NOTE If the oil line is not correctly installed, the dust cap will not snap onto the fitting. |  Figure 1. Flanged Oil Line |
| 5. | Loosely fasten the radiator/oil cooler assembly to the engine mount studs (G) with the new bushings (17) and spacers (18) from the kit, and the grommets (C), washers (D) and nuts (E) removed earlier. NOTE Two more grommets (C) mount the radiator/oil cooler assembly at the crossmember (H). The two new grommets (16) in the kit can be used as necessary to replace grommets that are worn or damaged. If more grommets are required, they are available from a Harley-Davidson dealer. | |
| 6. | Push the remaining oil line into the "oil in" fitting on the crankcase until it clicks in place under the spring clip. Snap a new plastic dust cap (8) over the spring clip groove. | |
| 7. | If the currently installed grommets (C) are worn or damaged, install new grommets (16) into the holes in the radiator/oil cooler crossmember (H). Assemble the crossmember to the mounting pins on the bottom of the oil cooler (9). Install the crossmember to the vehicle frame. | |
| 8. | Lightly tug on the oil lines to verify that they are securely locked to the fittings. | |
| 9. | Tighten the cooling system fasteners: a. Tighten the crossmember fasteners to 20–26 N·m (15–19 ft-lbs). b. Tighten the top mounting nuts (E) to 19–27 N·m (15–20 ft-lbs). c. Tighten the rearmost coolant pipe clamp to 6.5 N·m (57 in-lbs). d. Tighten the forward coolant pipe P-clamp to 6–10 N·m (53–88 in-lbs). e. Tighten the coolant pipe hose clamps at the radiator to 3–4 N·m (27–35 in-lbs). | |
| 10. | 2004-2008 models: Route the drain hose (19) to the coolant bottle. 2009-later models: Remove and discard the drain hose (19) and cable straps (20) from the radiator/oil cooler assembly. | |
| 11. | Secure the voltage regulator connector (I) to the top plate of the radiator. 2002-2003 models: Use the cable strap (26) from the kit. 2004-later models: Use the cable strap already assembled to the connector. The "rosebud" on the strap snaps into the hole in the radiator top plate. | |
| 12. | Install the radiator cover. | |
| 13. | Refer to the wiring diagrams in the service manual, and make the electrical connections: Use a cable strap (not provided) to tie the fan wiring harness to the crankshaft position sensor wiring harness. a. Mate the Crankshaft Position (CKP) Sensor connector [79] halves. b. Mate the top [97T] and bottom [97B] cooling fan connector halves. c. Mate the stator to voltage regulator connector [46] halves. d. Push the top fan connector [97T] into the radiator cover. | |
| 14. | Install the left and right side radiator trim covers. | |
| 15. | Add engine oil to the proper level. See the service manual. | |
| 16. | Remove the radiator pressure cap. Loosen the air bleed plug. Fill the radiator with Genuine Harley-Davidson Extended Life Antifreeze and Coolant through the filler neck. See the service manual. Tighten the air bleed plug to 9–11 N·m (80–97 in-lbs). Install the pressure cap. | |
| 17. | Install the air cleaner cover and the decorative air box cover. See the service manual. | |
NOTICE Do not over-tighten bolts on battery terminals. Use recommended torque values. Over-tightening battery terminal bolts could result in damage to battery terminals. (00216a) | ||
| 18. | Install the negative battery cable. Tighten to 6.8–10.8 N·m (60–96 in-lbs). | |
| 19. | Install main fuse. Install right side cover. |
For 2002-2003 models only:
NOTICE
When closing the seat, make sure the ignition switch is in the FUEL position. If the ignition switch is in any other position when the seat is closed, the seat latch mechanism could be damaged. (00196a)
- ALL models: Close the seat. Start the engine. While the engine is running, inspect the oil fittings for leaks. If leaks are found, turn off the engine and correct. Check coolant level in coolant bottle with coolant cold and motorcycle on jiffy stand. If the coolant level is below the COLD FULL line, remove the cap from the coolant bottle. Add Genuine Harley-Davidson Extended Life Antifreeze and Coolant until the fluid level reaches the COLD FULL line. Continue to run the engine, checking for oil leaks. Watch the coolant level. Add fluid until the level remains at the COLD FULL line with the motorcycle on the jiffy stand. Turn off engine. Check engine oil level. Add oil if necessary.
MAINTENANCE
NOTICE
Clean the inlet surface of the radiator regularly. Leaves and other debris can collect on the radiator surface and degrade radiator performance which could lead to overheating and motorcycle damage. (00197d)
SERVICE PARTS
Figure 2. Service Parts, VRSC Radiator Kit
Table 1. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Radiator/oil cooler assembly (includes items 2-18) | 26721-04C |
2 |
| 26800027 |
3 |
| 26800028 |
4 |
| 26800029 |
5 |
| 5235 |
6 |
| 62940-04A |
7 |
| 62941-04A |
8 |
| 62909-04 |
9 |
| 62700054 |
10 |
| 5237M |
11 |
| 5238M |
12 |
| 5236M |
13 |
| 11101 |
14 |
| 26772-04 |
15 |
| 26724-04 |
16 |
| 26757-01 |
17 |
| 11568 |
18 |
| 26758-01 |
19 | Hose, coolant bottle overflow (for 2008-earlier models) | 62953-08 |
20 | Cable strap (3) (for 2008-earlier models) | 10065 |
21 | Fitting assembly, oil feed/return (2, includes items 22-25) | 63650-04K |
22 |
| Not sold separately |
23 |
| 10994K |
24 |
| 11140 |
25 |
| 11384K |
26 | Cable strap, rosebud mount | 10073 |
Items mentioned in text, but not included in kit: | ||
A | Socket housing, two-way (2), Part No. 73152-96BK (part of fan assembly, Item 15) | |
B | Contact, socket (4), Part No. 73191-96 (part of fan assembly, Item 15) | |
C | Original equipment (OE) radiator mount grommet (2) | |
D | OE washer (2), Part No. 26757-01 | |
E | OE nut (2) | |
F | "Oil out" fitting on engine oil filter | |
G | Engine mount stud (2) | |
H | Radiator/oil cooler crossmember | |
I | Voltage regulator connector | |