Coolant Pump Replacement Kit
J067002018-10-25
GENERAL
Kit Number
26800107
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
- To reach difficult spring clamps use 24 INCH HOSE CLAMP TOOL (Part Number:HD-52004).
- Crimping the clamps (Part No. 10344) HOSE CLAMP PLIERS (Part Number:HD-41137) are needed.
- Harley-Davidson recommends using MATCO COOLING SYSTEM FILLER (Part Number:MCR102A) and COOLING SYSTEM ADAPTER (Part Number:MPT10128) or equivalent to vacuum test and fill the coolant system.
Kit Contents
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 this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
PREPARE
| CAUTION Cooling fans operate automatically, even when the ignition switch is off. Keep hands away from fan blades. Contact with a rotating fan blade can result in minor or moderate injury. (00093a) | ||
| 1. | NOTE See the service manual of the year and model vehicle that the service is being preformed on for the following steps. | |
| 2. | Drain cooling system. | |
| 3. | Remove both fairing lowers. | |
| 4. | Remove coolant pump and thermostat. | |
| 5. | See Figure 1. Remove clamps (2) and hoses (1, 3, 5, 6). | |
| 6. | Remove bracket (4). |
| 1 | Hose, right downtube to thermostat |
| 2 | Hose clamps, crimp type (2) |
| 3 | Hose, pump to left downtube |
| 4 | Bracket |
| 5 | Hose, left radiator to thermostat |
| 6 | Hose, right radiator to thermostat |
Figure 1. Coolant Hoses and Bracket
INSTALLATION
Sub-Assemble New Pump Components
| 1. | Remove shipping plugs from coolant pump. | |
| 2. | See Figure 2. Install new grommet (2) in new bracket (9) . |
| 1 | Bracket |
| 2 | Grommet |
Figure 2. Grommets
| 3. | See Figure 3. With the pump [235A] (3) oriented to the top, position the new pump (4) on the bracket (1). | |
| 4. | Align and fully seat boss on rubber pump isolator band (5) to rest between the upper tab (2) and lower tab (6) on the bracket. |
| 1 | Bracket |
| 2 | Upper tab |
| 3 | Pump [235A] |
| 4 | Pump |
| 5 | Isolator band |
| 6 | Lower tab |
Figure 3. Pump and Bracket
| 5. | See Figure 4. Slide the "T" portion of the new strap assembly bracket (3) into the upper tap (2) of the new bracket (1). | |
| 6. | Install new pump on bracket. |
| 1 | Bracket |
| 2 | Upper tab |
| 3 | Bracket, strap assembly |
Figure 4. Top Bracket Strap
| 7. | See Figure 5. Fully seat the strap assembly bracket (1) into the isolator band. Rotate the clamp screw (3) behind the lower tab (2). Tighten. Torque: 5.4–6.78 N·m (48–60 in-lbs) NOTE If needed, loosen clamp screw fully but do not remove. |
| 1 | Bracket, strap assembly |
| 2 | Lower tab |
| 3 | Clamp screw |
Figure 5. Bottom Bracket Strap
| 8. | See Figure 19. Locate pump to engine hose (8) and clamp (1). | |
| 9. | See Figure 6. Install pump to engine hose (1) on pump outlet (3). a. Locate pump outlet (3) which is marked by an arrow facing (4) upward. b. Position pump to engine hose and clamp above pump outlet. c. Slide both pump to engine hose and clamp to outlet base. |
| 1 | Pump to engine hose |
| 2 | Clamp (part no. 10344) |
| 3 | Pump outlet |
| 4 | Arrow (facing up) |
Figure 6. Pump to Engine Hose
| 10. | See Figure 7. Align pump to engine hose. | |
| 11. | Using clamp pliers tool, secure hose to pump outlet. Special Tool: HOSE CLAMP PLIERS (HD-41137) |
| 1 | Bracket |
| 2 | Right side of pump |
Figure 7. Orientation of Pump to Engine Hose
| 12. | See Figure 8. Install new pump assembly on left downtube (2). a. Position new hose clamp (1) on left coolant downtube. b. Lifting the pump assembly (4) into place. Guide pump to engine hose into place on left downtube. NOTE Verify that clamp (1) does not contact frame downtube. |
| 1 | Hose clamp |
| 2 | Left coolant downtube |
| 3 | Pump to engine hose |
| 4 | Pump assembly |
Figure 8. Pump Assembly to Left Coolant Down Tube
| 13. | See Figure 9. Install the pump assembly to frame (3). a. Install new screw (4). Tighten. Torque: 27.1–29.8 N·m (20–22 ft-lbs) b. Using the clamp tool, locate the clamp (2) on the pump to engine hose. Position clamp about 6.4 mm (0.25 in) from the end to hose. Special Tool: 24 INCH HOSE CLAMP TOOL (HD-52004) |
| 1 | Pump to engine hose |
| 2 | Clamp |
| 3 | Frame |
| 4 | Screw - buttonhead (2) |
Figure 9. Installing Pump Assembly to Frame
| 14. | See Figure 10. Install new harness (2). a. Connect coolant pump [235] b. Route excess wire to right side of coolant pump and leave loose. |
| 1 | Coolant pump [235B] |
| 2 | Harness |
| 3 | Coolant pump [235A] |
| 4 | Coolant pump [232A] |
Figure 10. New Coolant Pump Harness
Sub-Assemble to Left Lower Fairing
| 15. | Install engine to left radiator hose. a. See Figure 19. Locate engine to left radiator hose (7), hose clamp (4) and hose clamp (1). b. See Figure 11. Position hose clamp (3) on left lower radiator outlet. c. Install the left side of engine to left radiator hose onto the left lower radiator outlet. d. Position hose clamp (5) on right downtube (1). e. Install the right side of engine to left radiator hose onto the right downtube. f. See Figure 12. Position engine to left radiator hose (3) to have the hose position between the lower tab (1) and bracket (2). g. See Figure 11. Using the clamp tool, locate the clamp (5) on the engine to left radiator hose. Position clamp about 6.4 mm (0.25 in) from the end to hose. NOTE Verify that clamp (5) does not contact frame downtube. h. Using the clamp pliers tool, locate the clamp (3) on the engine to left radiator hose. Position clamp about 6.4 mm (0.25 in) from the end to hose and crimp clamp. |
| 1 | Right downtube |
| 2 | Left Lower radiator outlet |
| 3 | Clamp (part no. 10344) |
| 4 | Engine to left radiator hose |
| 5 | Hose clamp (part no. 10800052) |
Figure 11. Engine to Left Radiator Hose
| 1 | Lower tab |
| 2 | Bracket |
| 3 | Engine to left radiator hose |
Figure 12. Positioning of Engine to Left Radiator Hose
| 16. | Refer to Table 1. Locate cable strap (13). | |
| 17. | See Figure 13. Secure radiator fan wiring and Engine Coolant Temperature (ECT) sensor wiring to coolant hose. Place cable straps in the three positions. |
| 1 | Radiator fan wiring |
| 2 | ECT sensor wiring |
| 3 | Cable strap (3) |
Figure 13. Securing Left Fan/ECT Sensor Wiring to Hose
Sub-Assemble to Right Lower Fairing
| 18. | See Figure 19. Locate right radiator to pump inlet hose (6), clamp (1) and hose clamp (4). | |
| 19. | See Figure 14. Install the right radiator to pump inlet hose. a. Position the hose clamp (2) on the coolant pump inlet. b. Install the right radiator to pump inlet hose on coolant pump inlet. |
| 1 | Coolant pump inlet |
| 2 | Hose clamp (part no.. 10800052) |
| 3 | Right radiator to pump inlet hose |
Figure 14. Coolant Pump Inlet Hose
| 20. | See Figure 15. Position the right radiator to pump inlet hose (1) behind the left bracket grommet (2) and behind the engine to left radiator hose (4). |
| 1 | Right radiator to pump inlet hose |
| 2 | Left bracket grommet |
| 3 | Lower tab |
| 4 | Engine to left radiator hose |
| 5 | Cable strap, x-mas tree mount |
Figure 15. Routing of Right Radiator to Pump Inlet Hose
| 21. | Install right radiator to pump inlet hose on the outlet tube. a. See Figure 16. Position the clamp (2) on the right radiator outlet tube (1). b. Install right radiator to pump inlet hose on the outlet tube. | |
| 22. | Install the clamps on right radiator to pump inlet hose. a. See Figure 15. Verify hose is positioned correctly. b. See Figure 14. Using the clamp tool, locate the clamp (2) on the right radiator to pump inlet hose. Position clamp about 6.4 mm (0.25 in) from the end to hose. c. See Figure 16. Using the clamp pliers tool, locate the clamp (2) on the right radiator to pump inlet hose. Position clamp about 6.4 mm (0.25 in) from the end to hose and crimp clamp. |
| 1 | Right radiator outlet tube |
| 2 | Clamp (part no. 10344) |
| 3 | Right radiator to pump inlet hose |
Figure 16. Right Radiator Hose
| 23. | See Figure 17. Secure radiator fan wiring (1) and overflow vent hose (2) to coolant hose (3). Place cable straps (4) in the three positions. NOTE When installing the cable straps (4), verify the overflow vent hose does not collapse under the pressure of the cable straps. |
| 1 | Radiator fan wiring |
| 2 | Overflow vent hose |
| 3 | Right radiator to pump inlet hose |
| 4 | Cable strap (3) |
| 5 | Right radiator outlet tube |
Figure 17. Securing Right Fan Wiring and Overflow Vent to Hose
COMPLETE
| 1. | NOTE See the service manual of the year and model vehicle that the service is being preformed on for the following steps. a. See Figure 18. Verify water pump harness is correctly routed. | |
| 2. | See Figure 15. Secure pump harness with cable strap (5). | |
| 3. | Install pump cover. | |
| 4. | Install both fairing lowers. | |
| 5. | Install main fuse. | |
| 6. | Fill cooling system. | |
| 7. | Take motorcycle for test drive. | |
| 8. | Check for leaks. |
| 1 | Coolant pump harness |
| 2 | Left radiator fan/sensor harness |
Figure 18. Water Pump Harness Routing
SERVICE PARTS
Figure 19. Service Parts: Coolant Pump System Kit
Table 1. Service Parts: Coolant Pump System Kit
Item | Qty | Description | Part No. |
|---|---|---|---|
1 | 3 | Hose clamp - black | 10344 |
2 | 2 | Grommet | 11692 |
3 | 2 | Screw - buttonhead | 4266A |
4 | 3 | Hose clamp | 10800052 |
5 | 1 | Coolant pump | 26600050 |
6 | 1 | Coolant hose - right radiator to pump inlet | 26900131 |
7 | 1 | Coolant hose - engine to left radiator | 26900132 |
8 | 1 | Coolant hose - pump to engine | 26900146 |
9 | 1 | Bracket - coolant pump | 62800032 |
10 | 1 | Bracket - strap assembly | 62800041 |
11 | 1 | Harness - coolant pump | 69201960 |
12 | 2 | Washer - rubber (Not shown) | 7415A |
13 | 8 | Cable strap (Not shown) | 10006 |
14 | 1 | Cable strap - x-mas tree mount (not shown) | 10177 |