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How to Mount Harley Oil Coolers

A half dozen independent parts suppliers as well as Harley sell oil coolers for Harley-Davidson motorcycles. The devices help keep the motorcycles air-cooled engine from overheating, especially for bikes that are improperly tuned, ridden long distances or are ridden in very hot climates . All these devices mount on one or both down tubes on the front of the bike. Heat radiates from the oil to the front of an oil cooler where it is dissipated by the wind. Oil coolers add about a quart to the engines oil capacity.

Instructions

1

Drain the oil from the crankcase into a pan as described in the owners manual for the motorcycle. Oil drains from most Harleys through a crankcase plug which you remove with a socket and socket wrench. A few models drain through a hose after loosening a hose clamp with a flat head screwdriver and hand removing a metal plug.

2

Loosen the oil filter using an oil filter wrench. Remove the oil filter by hand and drain the oil in the filter into a pan. Replace the crankcase plug or reseal the drain hose.

3

Clean up all spilled oil with disposable rags. Properly dispose of the used motor oil and filter.

4

Loosen the oil pump hose fitting near the exhaust pipes with a box wrench. Unfasten the oil feed hose from the oil pump by hand. Unscrew the feed hose fitting from the crankcase and discard the hose.

5

Apply Hylomar Gasket and Thread Sealant or equivalent to the two line fitting included with your oil cooler. Hand tighten the fitting to the crankcase and oil pump. Tighten the fitting to 60 inch pounds with a torque wrench.

6

Install the cooler return hose included with your oil cooler to the crankcase fitting by hand. Install the cooler supply hose for your oil cooler to the oil pump fitting by hand.

7

Unclip the clutch cable and wire harness from the left down tube. Remove the clips with pliers and discard. Attach the oil cooler clamps that came with your cooler to approximately the same spot on the down tube.

8

Attach but do not tighten the oil cooler to the cooler clamps with the Allen bolts and nuts in your oil cooler kit. Attach the return line to the right most fitting on the bottom of the oil cooler using a hose clamp and screwdriver.

9

Attach the oil feed line to the left most fitting on the bottom of the cooler using a hose clamp and screwdriver. Tighten both hose clamps.

10

Turn the oil cooler so it faces forward. Check for binds or crimps in the hoses. Tighten the cooler clamps to the down tube to 32 inch pounds of torque.

11

Clip the wiring harness and clutch cable into the oil cooler clamps.

12

Unscrew the cooler supply hose from the oil pump. Screw the return hose to crankcase and tighten to 19 pounds of torque.

13

Screw the cooler supply line to the oil pump and tighten to 19 pounds of torque.

14

Clip the oil cooler lines with the hardware in your oil cooler kit. Hand tighten a new oil filter to the filter mounting stud. Add the factory recommended amount of oil to your oil tank.

15

Examine the dipstick to and add additional small amounts of oil until the dipstick reads full. Start the motorcycle in neutral and check for oil leaks. Turn off the engine when the cooler becomes warm to the touch.

16

Re-tighten all fasteners to the specifications in your oil cleaner kit instructions when the engine has cooled. Reread the dip stick and add oil as indicated.