Oil Cooler and Thermostat Kit
J030272007-02-14
GENERAL
Kit Number
62817-03A, 62895-03A
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com. (English only)
These oil cooler kits feature a thermostat built-in to the oil filter mount.
These kits can also be used as a replacement kit for 2003 FLHRSEI model motorcycles.
These kits cannot be used on models equipped with a sidecar, and are incompatible with Chrome Display Stand 99002-97A.
Additional Parts Required
In addition to the kit components, LOCTITE® Threadlocker 243 (blue) (Harley-Davidson Part Number 99642-97) is also required and can be purchased at any Harley-Davidson dealer.
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 available from a Harley-Davidson Dealer.
Kit Contents
See Table 1.
NOTE
Installing oil cooler system will require adding one-half to one pint of oil. Check oil supply before operating motorcycle. Fill up to, but not above, upper mark on dipstick. Inadequate oil supply can result in loss of oil pressure leading to severe engine damage.
NOTICE
Do not install hoses so they become crimped or oil flow can be restricted. (00380a)
INSTALLATION
| 1. | Run the motorcycle until the engine is at normal operating temperature. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) WARNINGDisconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) | ||
| 2. | Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. |
Remove the Engine Oil and Filter
- Locate the oil filler plug/dipstick on the right side of the vehicle at the top of the transmission case. To remove the oil filler plug, pull steadily while moving back and forth.
- Locate the oil drain plug at the front left side of the oil pan. Place a suitable container under the drain plug. Remove the oil drain plug and allow the oil to drain completely. Inspect the drain plug O-ring for cuts, tears or signs of deterioration, and replace if necessary.
- Position a suitable container under the oil filter.
- Bend a cardboard funnel and fit to the motorcycle to route the draining oil away from the voltage regulator and lower frame carriage into the container.
- Remove the oil filter. Place the jaws of an OIL FILTER WRENCH (HD-42311) over the oil filter with the jaws oriented vertically. Using a 3/8 inch drive with a 4 inch extension, turn the wrench counterclockwise. Do not use an air tool.
NOTE
Dispose of engine oil according to local regulations.
Remove the Voltage Regulator
NOTE
The voltage regulator is being removed only from its mounts. It is not necessary to remove the regulator wiring or cable straps.
- Remove the locknuts securing the voltage regulator to the studs on the lower frame crossmember.
- Carefully pull the voltage regulator away and down from its mounts.
Remove the Existing Engine Oil Filter Mount
| 1. | See Figure 1. Bend the corners of the oil filter lockplate (4) away from the heads of the top and bottom oil filter mount attaching screws (3). Remove and discard the top and bottom screws, lockplate and flat washers (2). | |||||||||||
| 2. | Remove the middle screw and flat washer to free the oil filter mount from the crankcase. Discard the hardware and the oil filter mount. | |||||||||||
| 3. | Thoroughly clean the crankcase mounting surface of oil and debris. | 
Figure 1. Remove Existing Oil Filter Mount |
Install the New Engine Oil Filter Mount
| 1. | See Table 1. Obtain the new oil filter mount (1) and oil filter adapter (25) from the kit. NOTE The new oil filter mount appears slightly different from that shown in Figure 1, but the mounting components are identical. | |||||||||||||||||
| 2. | See Figure 1. Apply LOCTITE 243 (blue) (Harley-Davidson Part Number HD-99642-97) to the threads of the oil filter adapter. Install the adapter to the oil filter mount and tighten to 16–22 N·m (12–16 ft-lbs). | |||||||||||||||||
| 3. | Place a small flat washer (22) from the kit in the recessed bottom mounting hole of the oil filter mount flange. | |||||||||||||||||
| 4. | Align the bottom hole in the lockplate (24) with the hole in the flat washer. | |||||||||||||||||
| 5. | Slide a hex head screw (23) through the lockplate, flat washer and bottom hole of the oil filter mount flange. NOTE The bottom screw cannot be assembled through the oil filter mount flange hole once the return fitting is installed. NOTE See Figure 2. When performing Step 6 and when installing hoses (1) at all clamp (2) locations, note the following: with hose pushed to the bottom of the fitting (3), the clamp must be positioned and crimped onto the hose 1/4 inch (6.36 mm) from end of hose. | 
Figure 2. Installing Hoses and Clamps 
Figure 3. Install Hose Fittings to Oil Filter Mount | ||||||||||||||||
| 6. | Figure 3 and Table 1. With the hardware from Step 5 in place, obtain a hose fitting (26) from the kit. Install the fitting to the rear (return) hole in the oil filter mount. NOTE Dip the end of the hoses into a 50/50 solution of isopropyl alcohol to allow for easier installation. | |||||||||||||||||
| 7. | Obtain the longer return hose (18) and a hose clamp (27) from the kit. Install the return hose to the fitting installed in Step 6, and secure the clamp using HOSE CLAMP PLIERS (HD-41137). | |||||||||||||||||
| 8. | Figure 1. Place a flat washer (22) in the recessed top mounting hole of the oil filter mount flange. | |||||||||||||||||
| 9. | Align the top hole in the lockplate with the hole in the flat washer. | |||||||||||||||||
| 10. | Slide a hex head screw (23) through the lockplate, flat washer and top hole of the oil filter mount flange. NOTE For models with the clutch cable routed to the inside of the downtube (see Figure 6), cut the cable strap for the clutch cable on the frame downtube bracket, and move the cable to the side. This will allow easier access when torquing the new oil filter mount screws. For models with the clutch cable or hydraulic clutch line routed to the outside of the downtube (see Figure 5), no cable straps need to be cut. NOTE To avoid cross threading the tapped holes, use care when starting the screws in the crankcase. | 
Figure 4. Oil Filter Mount torque Sequence | ||||||||||||||||
| 11. | Making sure the O-rings on the oil filter mount remain in place, install the top and bottom screws into the top and bottom holes in the crankcase. Tighten the screws only until snug. | |||||||||||||||||
| 12. | Obtain the remaining flat washer (22) and hex screw from the kit. Place the washer over the screw threads, and install in the middle hole of the oil filter mount flange. | |||||||||||||||||
| 13. | See Figure 4. Starting at the top, alternately tighten the screws to 15–17 N·m (130–150 in-lbs). | |||||||||||||||||
| 14. | Bend the ends of the lockplate to capture the top and bottom screw heads. | |||||||||||||||||
| 15. | Obtain the second hose fitting (26) from the kit. Install the fitting to the front (supply) hole in the oil filter mount. | |||||||||||||||||
| 16. | Obtain the shorter supply hose (19) and a hose clamp (27) from the kit. Install the supply hose to the fitting installed in Step 15, and secure the clamp using HOSE CLAMP PLIERS (HD-41137). |
Install the Radiator Mounting Plate
| 1. | Obtain the radiator mounting plate (21) from the kit. Position the mounting plate over the voltage regulator mounting studs. | |
| 2. | Obtain two flanged lock nuts (15) from the kit. Place the voltage regulator over the mounting plate on the studs, and install the lock nuts. Tighten the nuts to 8–11 N·m (70–100 in-lbs). |
Install the Oil Cooler Radiator
For models with the clutch cable routed to the inside of the downtube: See Figure 6. Use cable straps (28) from the kit to fasten the clutch cable to the frame downtube bracket.
NOTE
It is important to place the cable straps as shown to avoid contact between the oil cooler hoses and the clutch cable.
| 1. | See Figure 5 and Table 1. Obtain a hose clamp (27) from the kit. Locate the longer return hose (18), and install to the lower radiator (oil return) hose fitting. Secure the clamp using HOSE CLAMP PLIERS (HD-41137). | 
Figure 5. Clutch Cable or Hydraulic Line Routed to Outer Side of Downtube 
Figure 6. Oil Cooler Installed | ||||||||||||||||||||||||||
| 2. | Obtain the remaining hose clamp from the kit. Locate the shorter supply hose (19), and install to the upper radiator (oil supply) hose fitting. Secure the clamp using HOSE CLAMP PLIERS (HD-41137). | |||||||||||||||||||||||||||
| 3. | Obtain three larger washers (17) and three lock nuts (16) from the kit. Fasten the radiator to the radiator mounting plate, and tighten to 9–12 N·m (80–110 in-lbs). | |||||||||||||||||||||||||||
| WARNING Failure to provide adequate clearance between stationary and moving parts can cause loss of control, which could result in death or serious injury. (00378a) | ||||||||||||||||||||||||||||
| 4. | Immediately after installing oil cooler, check to be sure there is adequate clearance between oil cooler and hoses and front fender when front suspension is fully compressed. NOTE Installing oil cooler system will require adding one-half to one pint of oil. Check oil supply before operating motorcycle. Fill up to, but not above, upper mark on dipstick. Inadequate oil supply can result in loss of oil pressure leading to severe engine damage. | |||||||||||||||||||||||||||
| 5. | Refer to CHANGING ENGINE OIL AND FILTER in the Service Manual. Install a new oil filter and add the proper amount of oil. | |||||||||||||||||||||||||||
| WARNING Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) | ||||||||||||||||||||||||||||
| 6. | Connect the battery cables, positive cable first. | |||||||||||||||||||||||||||
| WARNING After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) | ||||||||||||||||||||||||||||
| 7. | Refer to the Service Manual, and follow instructions to install the seat. | |||||||||||||||||||||||||||
| 8. | Start the motorcycle and carefully check for system leaks. |
SERVICE PARTS
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
Oil Cooler and Thermostat Kit 62817-03A (Silver) | Parts Common to Both Oil Cooler and Thermostat Kits: | |||||
1 | Oil filter mount kit (silver) (includes items 2, 3, 4 and 7) | 26013-03 | 15 | Nut, flanged lock, 1/4-20 (2) | 7716 | |
2 | Adapter, oil filter | 26352-95A | 16 | Nut, locking, 1/4-20 (3) | 7671 | |
3 | Straight fitting with sealant (2) | 25259-93A | 17 | Washer, flat 0.28 inch ID, 0.63 inch OD (3) | 6703 | |
4 | Oil filter lock tab kit (includes items 5 and 6) | 35071-99A | 18 | Radiator, oil cooler | 62831-03 | |
5 | O-ring (2) | 11293 | 19 | Mounting plate, oil cooler | 62108-03 | |
6 | Flat washer (3) | 6099 | 20 | Washer, flat, 0.26 inch ID, 0.43 inch OD (3) | 6099 | |
7 | Oil filter mount (silver) (includes items 8 and 9) | Not sold separately | 21 | Screw, hex head, locking, 1/4- 20 x 1.0 inch (3) | 4271 | |
8 | O-ring (2) | 11293 | 22 | Lockplate | 35061-99 | |
9 | Oil filter mount, with thermostat (includes items 10 through 14) | Not sold separately | 23 | Adapter, oil filter | 26352-95A | |
10 | O-ring | 11296 | 24 | Fitting, straight with sealant (2) | 25259-93A | |
11 | Gasket, bypass cover | 26021-03 | 25 | Clamp, hose (4) | 10198 | |
12 | Cover, bypass | 26330-03 | 26 | Cable strap (2) | 10006 | |
13 | End cap, oil filter mount | Not sold separately | ||||
14 | Screw, flat head, TORX (2) | 3793A | Service Kit 62899-03A Includes the following items: | |||
Oil Cooler and Thermostat Kit 62895-03A (Chrome) | 27 | Hose, return (bottom, longer) | Not sold separately | |||
1 | Oil filter mount (chrome) (includes items 2, 3, 4 and 7) | 26015-03 | 28 | Hose, supply (top, shorter) | Not sold separately | |
2 | Adapter, oil filter | 26352-95A | ||||
3 | Straight fitting with sealant (2) | 25259-93A | ||||
4 | Oil filter lock tab kit (includes items 5 and 6) | 35071-99A | ||||
5 | O-ring (2) | 11293 | ||||
6 | Flat washer | 6099 | ||||
7 | Oil filter mount (chrome) (includes items 8 and 9) | Not sold separately | ||||
8 | O-ring (2) | 11293 | ||||
9 | OPil filter mount with thermostat (includes items 10 through 14) | Not sold separately | ||||
10 | O-ring | 11296 | ||||
11 | Gasket, bypass cover | 26021-03 | ||||
12 | Cover, bypass | Not sold separately | ||||
13 | End cap, oil filter mount | Not sold separately | ||||
14 | Screw, flat head, TORX (2) | 3793A | ||||