OIL COOLER KIT FOR TOURING MODELS
J032492013-07-31
GENERAL
Kit Number
26082-05C
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
This kit will not fit models equipped with chrome display stand (99002-97A) or models equipped with a sidecar.
WARNINGRider and passenger safety depend upon the correct installation of this kit. 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. (00308b)
Recommended Special Tools
Oil filter wrench (HD-44067A) is recommended for installation of this kit. It is available for separate purchase from a Harley-Davidson dealer.
INSTALLATION
- See Figure 1. Remove the spin-on filter (1) and oil filter adapter (2) from oil filter mount (3). Discard filter adapter. Clean filter mounting area thoroughly.
NOTICE
Incorrect gasket alignment and installation can cause filtered and unfiltered oil to mix, which can result in engine damage. (00420b)
NOTE
The oil adapter assembly has a flange protruding from the back. This flange must be installed toward the oil filter assembly and through the oil adapter gasket.
Adjust the angle of the adapter assembly to prevent the filter adapter from contacting other vehicle components while the vehicle is running. Incorrect adapter installation can result in damage to the oil filter assembly.
| 1. | See Figure 2. Align flange (3) so it is installed into oil adapter gasket cutout (4). | |
| 2. | See Figure 6. With the oil adapter gasket (8) and oil adapter assembly (1) in place, install the oil adapter fitting (7) through the oil adapter assembly with the coated threads facing inward and internal hex facing outward. Tighten to 16.3–21.7 N·m (12–16 ft-lbs). | |
| 3. | See Figure 3. Remove and disconnect the stator/regulator connector (1) from the bracket on the bottom of the voltage regulator. | |
| 4. | Remove voltage regulator mounting nuts, washers and star washers from stud (2) and save for installation. | |
| 5. | Pull up to remove voltage regulator from mounting studs. |
| 1 | Oil filter |
| 2 | Oil filter mounting adapter |
| 3 | Filter seal surface |
Figure 1. Stock Filter Mounting Bracket
| 1 | Oil adapter gasket |
| 2 | Oil adapter assembly |
| 3 | Oil adapter assembly flange |
| 4 | Oil adapter gasket cutout |
Figure 2. Oil Adapter Assembly Alignment
| 1 | Stator/regulator connector |
| 2 | Voltage regulator mounting stud |
Figure 3. Remove Stator/Regulator Connector
| 1 | Stabilizer link |
| 2 | Stator wiring |
Figure 4. Stator Wiring and P-clip
| 1 | Regulator wiring |
| 2 | Stator wiring |
Figure 5. Stator and Regulator Wiring
NOTE
To route the oil cooler lines correctly, the P-clip together and the stator wiring must be rotated 180 degrees from the original position.
- See Figure 4. Do not remove P-clip from stud. Rotate the P-clip and the stator wire (2) on left side 180 degrees so the stator wire will be routed to inside the left leg of regulator.
| 6. | Verify that the stator wiring is routed under the engine stabilizer link (1). Leave the end of the stator wiring out near the left frame downtube. Be sure the P-clip on the right side is in place, it will not be removed. | |
| 7. | See Figure 6. Install the oil cooler cover (12) over the oil cooler studs, then install the mounting bracket (9) over the studs. Secure the bracket and cover to the oil cooler with the three washers (3) and three nuts (4). Tighten the nuts to 10.8–13.5 N·m (96–120 in-lbs). | |
| 8. | Install the oil cooler mounting bracket onto the regulator mounting studs. Place the wire mounting bracket on top of the oil cooler mounting bracket, then install the voltage regulator on the studs over the oil cooler bracket. Secure the regulator using the hardware previously removed, but do not tighten at this time. | |
| 9. | See Figure 5. Connect stator (2) and regulator (1) wiring connections, then position the connector onto the bracket on bottom of the voltage regulator. |
NOTE
Make sure regulator wires are routed so that they do not pinch or rub against components.
| 10. | Tighten regulator nuts to 9.5–13.6 N·m (84–120 in-lbs). |
| 11. | See Figure 6. Install the long hose (11) and short hose (10) from the kit. Follow the markings on hoses to connect onto the oil cooler and oil cooler adapter. NOTE 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. When performing the following steps, position the worm drive clamps to avoid interference with oil filter installation. | |
| 12. | Fasten hoses to oil filter adapter and oil cooler with worm drive clamp (6). Tighten to 0.9 N·m (8 in-lbs). |
NOTE
Using oil filter wrench (HD-44067A) will prevent damage to the crankshaft position sensor.
- Install oil filter with oil filter wrench (HD-44067A).
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)
NOTE
For 2005 and Later Models: Refer to the owner's manual for oil level cold check instructions.
- Add oil to FILL level on dipstick.
- Start the motorcycle and check for oil leaks on and around installed parts. Add oil as needed.
SYSTEM FLOW TEST - ALL MODELS
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
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 as engine reaches operating temperatures. If the oil cooler remains cool after engine warmup, there may be an oil obstruction. Turn off engine and check system for obstruction. | |
| 3. | After engine has cooled, tighten all hose clamps again to 0.9 N·m (8 in-lbs). |
SERVICE PARTS
Figure 6. Service Parts for Touring Oil Cooler Kit with Chrome Oil Cooler Cover
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Adapter assembly, oil cooler | 26067-05B |
2 | Oil cooler core | 63068-07 |
3 | Washer (3) | 6703 |
4 | Locknut, nylon insert (3) | 7671 |
5 | Flange nut (2) | 7716 |
6 | Clamp, worm drive (4) | 9823 |
7 | Adapter, oil filter | 26041-05A |
8 | Gasket, oil cooler adapter | Not Sold Separately |
9 | Mounting bracket, oil cooler | 62108-03 |
10 | Hose, preformed, short | Not Sold Separately |
11 | Hose, preformed, long | Not Sold Separately |
12 | Cover, oil cooler | 63056-07A |
13 | Gasket | Not Sold Separately |
14 | Rubber oil hose service kit (not shown) - contains four clamps (6), long hose (11) and short hose (12) | 62658-05 |
15 | Gasket service kit (not shown) - contains gasket (8), gasket (13) and two screws | 12056-05 |