TOURING OIL COOLER KIT AND CHROME OIL COOLER COVER
J039572012-11-14
GENERAL
Kit Number
26155-07A
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
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
| 1. | See Figure 1. Remove the spin-on oil filter (2) and oil adapter mounting fitting (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter adapter. NOTE The oil adapter assembly has two flanges protruding from the back. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. | 
Figure 1. Oil Filter and Adapter | ||||||||||
| 2. | See Figure 2. Install the oil adapter gasket (3) onto the oil filter adapter assembly (1).The oil adapter assembly flanges should be aligned so they are installed into the oil adapter gasket cutout as shown. NOTE Due to the locating flanges, the oil cooler adapter assembly and gasket will only install properly in one position on the oil filter mounting surface. | |||||||||||
| 3. | If your kit contains a gasket with a "light-colored backing": See Figure 2. Peel backing off of gasket (4) and apply adhesive side to oil cooler adapter assembly (5). Center the gasket on adapter assembly. Align adapter properly on the mounting surface. Check that the raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 16.3–21.7 N·m (12–16 ft-lbs). | 
Figure 2. Install Oil Adapter | ||||||||||
| 4. | If your kit contains a standard gasket without a "light-colored backing": See Figure 2. Install the oil cooler adapter assembly and gasket onto the oil filter mounting surface of the engine with the mounting fitting (2). Align the adapter properly on the mounting surface. Check the raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 16.3–21.7 N·m (12–16 ft-lbs). | |||||||||||
| 5. | See Figure 3. Disconnect and remove the stator/regulator connector (1) from the bracket on the bottom of the voltage regulator. | |||||||||||
| 6. | Remove voltage regulator mounting nuts, washers and star washers from stud (2) and save for later installation. | |||||||||||
| 7. | Remove wiring bracket from studs. | |||||||||||
| 8. | Pull up to remove voltage regulator from mounting studs. | 
Figure 3. Remove Stator/Regulator Connector | ||||||||||
| 9. | See Figure 4. Do not remove P-clip from the stud. Rotate the P-clip together and the stator wiring (2) on left side of vehicle 180 degrees so the stator wire will be routed to inside of left leg of the regulator. | |||||||||||
| 10. | 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. | |||||||||||
| 11. | 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 (2) with the three washers (3) and three nuts (4). Tighten the nuts to 10.8–13.5 N·m (96–120 in-lbs). | |||||||||||
| 12. | 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. | 
Figure 4. Stator Wiring and P-Clip | ||||||||||
| 13. | See Figure 5. Connect stator (1) and regulator (2) wiring connectors, then position the connector onto the bracket on bottom of the voltage regulator. | |||||||||||
| 14. | Tighten regulator nuts to 9.5–13.6 N·m (84–120 in-lbs). NOTE Position the clamps to avoid interference with oil filter installation. 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. | |||||||||||
| 15. | See Figure 6. Slide two clamps (6) onto each hose (10 and 11) and follow the markings on hoses to connect onto the oil cooler and oil cooler adapter. | |||||||||||
| 16. | Fasten hoses to oil filter adapter and oil cooler with worm drive clamps (6). Tighten clamps to 0.9 N·m (8 in-lbs). NOTE Using an oil filter wrench (HD-44067A) will prevent damage to the crankshaft position sensor. Position the clamps to avoid interference with oil filter installation. Verify the hose routing is clear of the of the oil filter and any sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. | |||||||||||
| 17. | Check that all cables and harnesses are clear of the oil cooler adapter, in order to prevent wear. | |||||||||||
| 18. | Lubricate oil filter seal with new engine oil. Thread filter on until seal touches mounting surface, then turn an additional one-half to three-quarter turn. | |||||||||||
| 19. | Add oil to FILL level on dipstick. | |||||||||||
| 20. | Start the motorcycle and check for oil leaks on and around installed parts. Add oil as needed. | 
Figure 5. Stator and Regulator Wiring |
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)
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, tighten all hose clamps again to 0.9 N·m (8 in-lbs). | |
| 4. | Fill oil to FILL level on dipstick. |
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 | 26154-07A |
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 | O-ring, oil cooler adapter | Not Sold Separately |
9 | Mounting bracket, oil cooler | 62108-03 |
10 | Hose, preformed, short | 62629-05A |
11 | Hose, preformed, long | 62641-05A |
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 (10) | 62658-05 |
15 | Gasket service kit (not shown) - contains gasket (8), gasket (13) and two screws | 12056-05 |