OIL COOLER AND THERMOSTAT KIT
J042832006-10-11
GENERAL
Kit Number
62895-03B
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 kits cannot be used on models equipped with a sidecar, and are incompatible with Chrome Display Stand 99002-97A
Additional Parts or Tools Required
Proper installation of this kit also requires the following tools:
- Oil Filter Wrench (H-D 42311)
- 3/8 inch socket drive with 4 inch extension
- Loctite® 243 Threadlocker and Sealant - Blue (H-D 99642-97)
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.
PREPARATION
| 1. | Run the motorcycle until the engine is at normal operation temperature. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||
| 2. | Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. |
REMOVE
Remove the Engine Oil and Filter
| 1. | 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. | |
| 2. | 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. | |
| 3. | Position a suitable container under the oil filter. | |
| 4. | 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. | |
NOTICE Use Harley-Davidson oil filter wrench for filter removal. This tool can prevent damage to crankshaft position sensor and/or sensor cable. (00192b) | ||
| 5. | Remove the oil filter. Place the jaws of the oil filter wrench 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 locking nuts securing the voltage regulator to the studs on the lower frame cross member.
- Carefully pull the voltage regulator away and down from its mounts.
| 1 | O-ring |
| 2 | Flat Washer |
| 3 | Hex Head Screw |
| 4 | Oil Filter Lock Plate |
Figure 1. Remove Existing Oil Filter Mount
Remove the Existing Engine Oil Filter Mount
- See Figure 1. Bend the corners of the oil filter lock tab plate (4) away from the heads of the top and bottom oil filter mount attaching screws (3). Remove and discard the top and bottom screws, lock tab plate and flat washers (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.
- Thoroughly clean the crankcase mounting surface of oil and debris.
INSTALLATION
Install the New Engine Oil Filter Mount
| 1. | See Figure 5. Obtain the new oil filter mount (8) and oil filter adapter (13) from the kit. | |||||||||
| 2. | Apply Loctite 243 (blue) to the threads of the oil filter adapter (13). Install the adapter to the oil filter mount and tighten to 12-16 ft-lbs (16-22 Nm). | |||||||||
| 3. | Place a small flat washer (16) from the kit in the recessed bottom mounting hole of the oil filter mount flange. | |||||||||
| 4. | Align the bottom hole in the lock tab plate (14) with the hole in the flat washer. | |||||||||
| 5. | Slide a hex head screw (15) through the lock tab plate, 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. | |||||||||
| 6. | See Figure 5. With the hardware from Step 5 in place, obtain a hose fitting (2) from the kit. Install the fitting to the rear (return) hole in the oil filter mount. NOTE See Figure 2. When installing hoses at all clamp (2) locations, note the following: with hose pushed to the bottom of the fitting (3), the clamp must be positioned and tightened onto the hose 1/4 in. (6.36mm) from end of hose. NOTE Dip the end of the hoses into a 50/50 solution of water and isopropyl alcohol to allow for easier installation. | 
Figure 2. Installing Hoses and Clamps | ||||||||
| 7. | See Figure 5. Obtain the longer return hose (21) and a hose clamp (25) from the kit. Install the return hose to the fitting installed in Step 6, and tighten clamp to 0.9 N·m (8 in-lbs) | |||||||||
| 8. | Place a flat washer (16) in the recessed top mounting hole of the oil filter mount flange. | |||||||||
| 9. | Align the top hole in the lock tab plate with the hole in the flat washer. | |||||||||
| 10. | Slide a hex head screw (15) through the lock tab plate, 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 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 4 ), no cable straps need to be cut. NOTE Use care when starting the screws in the crankcase to avoid cross threading. |  Figure 3. 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 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 3. Starting at the top, alternately tighten the screws to 15–17 N·m (130–150 in-lbs) | |||||||||
| 14. | Bend the ends of the lock tab plate to capture the top and bottom screw heads. | |||||||||
| 15. | See Figure 5. Obtain the second hose fitting (2) from the kit. Install the fitting to the front (supply) hole in the oil filter mount. | |||||||||
| 16. | Obtain the shorter supply hose (20) and a hose clamp (25) from the kit. Install the supply hose and clamp to the fitting installed in Step 15. Tighten clamp to 0.9 N·m (8 in-lbs) |
Install the Radiator Mounting Bracket
| 1. | See Figure 5. Obtain the radiator mounting bracket (17) from the kit. Position the mounting plate over the voltage regulator mounting studs. | |
| 2. | Obtain two flanged lock nuts (24) 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) |
| 1 | Cable Straps |
Figure 4. Cable Straps on Clutch Cable Inside of Down Tube
Install the Oil Cooler Radiator
For models with the clutch cable routed to the inside of the downtube: See Figure 4. Use cable straps (1) 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 (25) from the kit. Locate the longer return hose (21), and install hose and clamp to the lower radiator (oil return) hose fitting. Tighten clamp to 0.9 N·m (8 in-lbs) | |
| 2. | Obtain the remaining hose clamp from the kit. Locate the shorter supply hose (20), and install hose and clamp to the upper radiator (oil supply) hose fitting. Tighten clamp to 0.9 N·m (8 in-lbs) | |
| 3. | Obtain three larger washers (22) and three lock nuts (23) from the kit. Fasten the radiator to the radiator mounting plate. Tighten lock nuts to 9–12 N·m (80–110 in-lbs) NOTE Position the hose clamps to avoid interference with oil filter installation. Ensure the hose routing is clear of the oil filter and any sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. | |
NOTICE Use Harley-Davidson oil filter wrench for filter removal. This tool can prevent damage to crankshaft position sensor and/or sensor cable. (00192b) | ||
| 4. | Ensure that all cables and harnesses are clear of the cooler adapter to prevent wear. | |
| 5. | Lubricate oil filter with new engine oil. Thread filter on until seal touches mounting surface, then turn an additional 1/2 to 3/4 turn. 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. | |
NOTICE Do NOT operate the engine when the oil level is below the add mark on the dipstick at operating temperature. Engine damage could result. (00493b) | ||
| 6. | Add oil to the "FILL" level on the dipstick. | |
| 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) | ||
| 7. | 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) | ||
| 8. | Refer to the Service Manual, and follow instructions to install the seat. | |
| 9. | Start the motorcycle and carefully check for system leaks. |
System Flow Test
2005 and Later Models or Models with Later Style Dipsticks
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)
2004 and Earlier Models
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. | |
| 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 0.9 N·m (8 in-lbs) | |
| 4. | Fill oil to "FILL" level on dipstick. |
SERVICE PARTS
Figure 5. OIL COOLER AND THERMOSTAT KIT
Table 1. Service Parts Table
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Kit 62895-03B Oil Cooler and Thermostat Kit | 1 | Strap, cable (2) (not shown) | 10006 |
2 | Fitting, straight, with sealant (2) | 25259-93A | |
3 | Mount assembly, oil filter, chrome (includes items 4 and 5) | Not Sold Separately | |
4 |
| 11293 | |
5 |
| Not Sold Separately | |
6 |
| 11296 | |
7 |
| 26021-03 | |
8 |
| Not Sold Separately | |
9 |
| Not Sold Separately | |
10 |
| Not Sold Separately | |
11 |
| Not Sold Separately | |
12 |
| 3793A | |
13 | Adapter, oil filter | 26352-95A | |
14 | Plate, lock tab | Not Sold Separately | |
15 | Screw, hex bolt (3) | 4271 | |
16 | Washer (3) | 6099 | |
17 | Bracket, mounting, oil cooler | 62108-03 | |
18 | Cooler, oil (includes item 19) | 62831-03 | |
19 |
| 62110-03 | |
20 | Hose, front, oil cooler supply (short) | Not Sold Separately | |
21 | Hose, rear, oil cooler return (long) | Not Sold Separately | |
22 | Washer, plain, type A (3) | 6703 | |
23 | Nut, hex lock (3) | 7671 | |
24 | Nut, flange locking (2) (not shown) | 7716 | |
25 | Clamp, worm drive (4) | 9823 | |
Service Kit 62899-03B Oil Cooler Hose Kit | 20 | Hose, front, oil cooler supply (short) | Not Sold Separately |
21 | Hose, rear, oil cooler return (long) | Not Sold Separately |