TOURING OIL COOLER KIT AND CHROME OIL COOLER COVER
J047392008-03-11
GENERAL
Kit Number
26155-09
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).
- This kit does not fit with Definitive5™ Filtration System Kits (63800-07, 63801-07 or 63802-07).
- This kit does not fit motorcycles equipped with a sidecar.
Additional Parts Required
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)
INSTALLATION
| 1. | See Figure 1. Remove the spin-on oil filter (2) and oil filter adapter (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 out of the back. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. | |||||||||||||||||||||||
| 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. | 
Figure 1. Oil Filter and Adapter 
Figure 2. Install Oil Adapter 
Figure 3. Voltage Regulator and Connectors | ||||||||||||||||||||||
| 3. | See Figure 2. If your kit contains a gasket with a "light-colored backing": Peel backing off of gasket (4) and apply adhesive side to oil cooler adapter gasket surface (5). Verify that gasket is centered on adapter assembly. Verify that adapter locates properly in the mounting surface. Verify that raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 16.3–21.7 N·m (12–16 ft-lbs). See Figure 2. If your kit contains a standard gasket without a "light-colored backing": Install the oil cooler adapter assembly and gasket onto the oil filter mounting surface of the engine with the mounting fitting (2). Verify that adapter locates properly in the mounting surface. Verify that raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 16.3–21.7 N·m (12–16 ft-lbs). | |||||||||||||||||||||||
| 4. | See Figure 3. Release locking latches from connectors and disconnect the stator connector (4) and voltage regulator connector (3) from the voltage regulator (1). | |||||||||||||||||||||||
| 5. | Remove voltage regulator mounting nuts. | |||||||||||||||||||||||
| 6. | Lift voltage regulator (1) to remove it from mounting studs (2). | |||||||||||||||||||||||
| 7. | See Figure 4. Install the oil cooler cover (12) over the oil cooler (2) 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 locknuts (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 two flange nuts (Item 5, Figure 4 ), but do not tighten at this time. | |||||||||||||||||||||||
| 9. | See Figure 3. Connect stator connector (4) and voltage regulator connector (3) to the voltage regulator (1). Secure connectors with latches. | |||||||||||||||||||||||
| 10. | Tighten regulator nuts to 84-120 in-lbs (9.5-13.6 Nm). | |||||||||||||||||||||||
| 11. | See Figure 4. Slide two clamps onto the left hose (11) and the right hose (10) and connect the hoses onto the oil cooler (2) and oil cooler adapter (1). | |||||||||||||||||||||||
| 12. | 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. Ensure 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. | |||||||||||||||||||||||
| 13. | Ensure that all cables and harnesses are clear of the oil cooler adapter, in order to prevent wear. | |||||||||||||||||||||||
| 14. | Lubricate oil filter seal with new engine oil. Thread filter on until seal touches mounting surface, then turn an additional 1/2 to 3/4 turn. | |||||||||||||||||||||||
| 15. | Add oil to FILL level on dipstick. | |||||||||||||||||||||||
| 16. | Start the motorcycle and check for oil leaks on and around installed parts. Add oil as needed. |
System Flow Test
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. 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. | |
| 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, allow engine to cool and check system for source of obstruction. | |
| 3. | Verify that all hose clamps are tightened to 0.9 N·m (8 in-lbs). | |
| 4. | Fill oil to FILL level on dipstick. |
SERVICE PARTS
Figure 4. 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 | 26198-09 |
2 | Oil cooler core | 63068-09 |
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 | 62108-09 |
10 | Hose, preformed, right | 62629-09 |
11 | Hose, preformed, left | 62641-09 |
12 | Cover, oil cooler | 63056-07A |
13 | Gasket | Not Sold Separately |
14 | Gasket service kit (not shown) - contains gasket (8), gasket (13) and two screws | 12056-05 |