Braided Stainless Coolant Hose Kit
J016692013-11-01
GENERAL
Kit Numbers
26792-01
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
WARNING
Rider 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.
INSTALLATION
1.
Wait for cooling system to completely cool down.
2.
See the Service Manual. Remove outer (cosmetic) airbox cover and remove upper and lower halves of air filter housing. Save components for installation.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNING
Disconnect negative (-) 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. (00049a)
3.
Disconnect the battery cables, negative cable first.
NOTE
It is not necessary to drain the cooling system however, a small amount of coolant will escape when removing hoses. After installing new braided hoses, top off the cooling system using specifications from applicable Service Manual.
4.
See Figure 1. Remove the clamp screw securing the cooling lines to the engine (near the battery) and remove the clamp. Save screw and clamp for installation.
1Clamp screw
2Clamp
3Coolant lines to/from radiator
Figure 1. Remove Cooling Line Clamp and Screw
5.
See Figure 2. Loosen the lower worm drive screw and remove the lower coolant hose clamp. Save clamp for installation.
NOTE
When performing the following step, the decorative (chrome) coolant hose cover will be removed with the hose clamp.
6.
Loosen the worm drive screw and remove the upper hose clamp and decorative cover. Save for installation.
1Upper hose clamp
2Decorative cover
3Outer hose
4Lower hose clamp
Figure 2. Remove Cooling Line Clamp and Screw
7.
See Figure 3. Using a knife, cut a slit down the upper plastic shrink tube and remove the shrink sleeve. Using a twisting motion (cut hose, if necessary), remove the hose ends from line tubes. Discard hose.
Figure 3. Cut and Remove Shrink Sleeve
8.
See Figure 4. Loosen worm drive screws and remove upper and lower clamps from inner (short) hose. Use knife and cut hose in half to remove. Discard hose.
1Upper hose clamp
2Lower hose clamp
Figure 4. Remove Inner Hose Upper and Lower Clamps
9.
See Figure 7. Obtain new worm drive Clamp (3) and Decorative Cover (4) from kit. Tighten clamp to decrease diameter until clamp will fit into decorative cover as shown. Loosen clamp until clamps rounds out fully on inside of cover as shown. (with clamp adjuster extending from cut-out). Perform the same procedure for the remaining cover and clamp.
10.
Obtain new Inner Hose (2) from kit. Slide the decorative cover (with clamp) over one end of hose until hose butts up against end of cover.
NOTE
When performing the next few steps, it will be necessary to relocate (move) the coolant (metal) lines away from the inlet/outlet tubes to provide room for installing hose. Be extremely careful not to bend or kink metal coolant lines when relocating.
11.
See Figure 5. Orient hose with decorative cover at bottom. Use coolant to lubricate end and install hose onto inlet tube. Twist while pushing downward until hose slides as far down onto tube as possible. At the top of frame, lightly lubricate hose with coolant and install the coolant line tube into top of hose. Twist hose assembly while pushing tube into hose as far as down as possible.
NOTE
One stainless clamp (removed in Step 5) and two black clamps (removed in Step 8) are left from removing the original hoses. It is up to you which of the clamps you prefer to use to secure upper portion of the inner braided hose.
12.
Install one of the saved hose clamps so that clamp is even with top of hose to secure the hose to the coolant line tube (coming from radiator).
13.
Rotate decorative cover on bottom and hose clamp on top so that clamps are positioned on inner side of braided line (least visible).
14.
Tighten upper and lower hose clamps securely.
15.
See Figure 5 and Figure 7. Obtain longer braided hose (1) and remaining Worm Drive Clamp (3) and Decorative Cover (4) assembled during Step 9.
1Upper hose clamp even with top of hose
2Short braided stainless coolant hose
3Lower decorative cover and hose clamp
4Lower decorative cover and hose clamp
5Long braided stainless coolant hose
Figure 5. Install Braided Hoses and Clamps
16.
Slide the decorative cover onto one end of the hose until the hose butts up completely against the end of the cover.
17.
Refer to Figure 5. Use coolant and lightly lubricate the inside of the end of hose. Orient hose with decorative cover at bottom as shown and install hose onto inlet tube. Twist while pushing downward until hose slides as far down onto tube as possible. Do not tighten worm drive clamp.
18.
Use coolant and lightly lubricate the opposite end of hose and install the coolant line tube into top of hose. Twist hose assembly while pushing tube into hose as far as down as possible.
19.
Orient lower decorative cover and hose clamp so clamp is on inner side of hose (least visible).
20.
See Figure 6. Install upper hose clamp with decorative cover (removed in Step 2) and align so cover is straight. Tighten hose clamp securely.
Figure 6. Install Upper Clamp and Cover
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)
21.
Install the battery cables, positive cable first.
22.
See the Service Manual. Install upper and lower halves of air filter housing.
23.
See the Service Manual. Top off the cooling system according to specifications.
24.
See the Service Manual. Install outer (cosmetic) airbox cover.
Figure 7. Service Parts
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Hose, inlet (braided stainless)
26793-01
2
Hose, outlet (braided stainless)
26794-01
3
Clamp, cosmetic hose (2)
26795-01
4
Sleeve, decorative clamp (2)
26796-01