XL Premium Oil Cooler Kit Instruction Sheet - Harley
Contents
1. Item Description Quantity Part Number Cooler oil 63094 07 2 Right angle connector and wire 72405 98GN 3 Oil cooler cover kit 62500024 4 Hose oil cooler supply Not Sold Separately 5 Screw 2 3540 6 Screw 2 4359 7 Washers 3 6330 8 Clamp worm drive 4 3 9823 9 P clamp 10076 10 Cable strap 2 10246 11 Fitting 63091 07 12 Fitting 63533 41A 13 Sealed splice connector 18 22 AWG 70585 93 14 Grommet brake line Not Sold Separately 15 Hose oil cooler return Not Sold Separately 16 Fitting elbow 90 degree 62700080 17 Clamp oil cooler 2 62800016 J05661 5of6 Table 1 Service Parts Table ltem Description Quantity Part Number 18 Mounting bar oil cooler Not Sold Separately 19 Conduit high temperature Not Sold Separately 20 Nut hex 4 7748W 21 Service kit oil hose Includes items 4 15 and 8 62700078 J05661 6 of 62. Drain engine oil See the service manual Remove the oil filter See the service manual Remove exhaust system See the service manual Remove oil pressure switch See Figure 1 Remove oil feed hose 1 from oil pump Pap woN Remove and discard the oil pump hose fitting 2 from the oil pump 7 ABS Models See Figure 5 Remove the upper ABS brake line clamp 22 from the left down tube 8 Remove two clips securing the clutch cable and wiring harness to the downtube INSTALLATION 1 See the service manual Install oil pressure switch in the same manner as indicated but in the location indicated below a Apply Loctite 565 High Performance Pipe Sealant with Teflon to oil pressure switch b See Figure 2 Install oil pressure switch 3 to crank case where the feed hose was connected c Tighten to 50 70 in Ibs 5 6 7 9 Nm 1 of 6 Please dispose of materials responsibly 2 Install jumper wire assembly item 2 Figure 6 to oil pressure switch lead a Cut the existing oil pressure connector off the wiring harness Cut close to the connector b Measure the amount of wire necessary for the con nector of the wire assembly to reach the oil pressure switch Cut the wire to length c Strip 3 8 in 10 mm of insulation from the lead d Measure the amount of conduit item 19 Figure 6 necessary to cover the wire assembly Cut the conduit to length e Install conduit over the wire assembly f See th
3. TICE 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 Inspect hoses for kinks or twists Adjustment hoses as necessary to remove kinks or twists 2 Start engine Inspect all hose connections for leaks If there is no leakage allow engine to warm up 3 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 4 After engine has cooled retighten all fittings and clamps to the required torque specifications 5 Fill oil to Full level on dipstick if necessary 3 of 6 is07527 Grommet 2 Oil cooler clamp 2 Screw 2 Nut 2 Screw 2 Flat washer 2 Mounting bar Oil cooler supply hose Nut 2 10 Oil cooler 11 Oil cooler cover OON OUR O N 12 Screw 2 13 Spacer tube 14 Oil cooler return hose 15 Worm clamp 3 16 Hose fitting 17 Elbow fitting 18 Line fitting 19 P clamp 20 Cable strap 21 Bend in ABS brake lines 22 ABS brake line clamp J05661 Figure 5 Oil Cooler Installation 4of6 SERVICE PARTS is07517 Figure 6 Service Parts XL Premium Oil Cooler Kit Table 1 Service Parts Table
4. cMOTOR HARLEY DAVIDSON WY J05661 INSTRUCTIONS REV 2013 04 20 XL PREMIUM OIL COOLER KIT REMOVE i ee j GENERAL Kit Number 62700082 Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required Proper installation of this kit requires the following items e Hylomar Gasket and Thread Sealant e Loctite 243 Threadlocker and Sealant Part No 99642 97 e Oil Filter Wrench Part No 42311 or Part No 44067 A e Loctite 565 High Performance Pipe Sealant with Teflon AWARNING The rider s safety depends 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 00333a 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 Kit Contents See Figure 6 and Table 1 J05661 1 Oil Pump Feed Hose 2 Oil Pump Hose Fitting amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Figure 1 Oil Pump Feed Hose 1 See the service manual
5. e service manual sealed splice connector installation instructions Install the new oil pressure switch connector to the harness lead with the sealed splice connector item 13 Figure 6 3 Connect oil pressure switch connector to the oil pressure switch 4 See Figure 2 Apply Hylomar Gasket and Thread Sealant to fitting item 11 Figure 6 Install fitting to oil pump Tighten fitting to 55 65 in Ibs 6 2 7 4 Nm 5 Loosely install oil cooler supply hose assembly 2 to oil pump fitting 6 Apply Hylomar Gasket and Thread Sealant to fitting item 16 Figure 6 Install fitting to original oil pressure switch mounting location Tighten finger tight then turn 2 3 times more Orient the fitting opening to be in line with the oil filter housing 7 Apply Hylomar Gasket and Thread Sealant to fitting item 12 Figure 6 Install fitting to the elbow fitting Tighten finger tight then turn 2 3 times more Orient the fitting to be in line with the oil filter housing 1 Oil supply hose 2 Oil cooler return hose 3 Clutch cable Fitting Oil cooler supply hose Oil pressure switch Pena Oil pressure switch connector Figure 2 Oil Supply Line and Oil Pressure Switch J05661 Figure 3 Oil Cooler Hose Routing 8 See Figure 5 Install the brake line grommets 1 onto the ABS brake lines along the downtube 9 Install the oil cooler clamps 2 over the brake line grom mets Adjust the locatio
6. ns as necessary to match the oil cooler mounting tab spacing and desired oil cooler mounting location Locate top clamp below the bend in the ABS brake lines 21 10 See Figure 5 Orient mounting bar 7 as shown with the rounded end up and the first and third holes outboard Install mounting bar 7 to oil cooler clamps and secure with screw 3 and nut 4 Do not tighten fasteners Repeat for other oil cooler clamp NOTE See Figure 3 When installing the oil cooler and connecting the oil lines make sure that the clutch is routed properly 11 Install P clamp 19 over the clutch cable and wiring har ness 12 Loosely attach oil cooler 10 to the mounting bar 7 upper hole using screw 5 washer 6 P clamp 19 and nut 4 13 Loosely attach oil cooler 10 to the mounting bar 7 lower hole using screw 5 washers 6 and nut 4 14 Connect oil return hose 14 to the inboard connection of oil cooler 10 with worm clamp 15 15 Connect oil return hose 14 to hose fitting 16 with worm clamp 15 16 Connect oil cooler supply hose 8 to the outboard connec tion of oil cooler 10 with worm clamp 15 Orient hose to allow clearance between oil pressure switch and oil cooler return hose 17 Tighten worm clamps to 8 0 in Ibs 0 9 Nm 2of6 18 Adjust oil cooler a Adjust oil cooler as necessary to have it facing for ward b Adjust oil cooler height if necessary so there is no tension on the
7. oil cooler hoses c Remove screws one at a time to maintain clamp location Apply Loctite 243 Threadlocker and sealant blue to threads Install screws to clamps clamps 19 Tighten oil cooler clamp screws to 96 120 in lbs 10 2 13 5 Nm NOTE See Figure 4 Make sure that oil cooler supply hose 2 does not rub against the oil pressure switch 1 20 Tighten oil cooler supply hose at oil pump fitting to 18 20 ft lbs 24 4 27 1 Nm Hold the tube in place while tight ening 21 See Figure 5 Install cable strap 20 around frame and wire harness in area shown Tighten cable strap so all wires are pulled toward the outside of the frame rail 22 Install previously removed ABS brake line clamps 23 Inspect oil lines and hoses Makes sure that there is no contact with the wiring harness or cables NOTE Make sure no part of the cooler cover contacts the wiring har ness or cables 24 See the instructions included with the oil cooler cover Install oil cooler cover onto the oil cooler 25 After tightening the oil cooler clamp screws inspect to make sure that there is enough clearance between the oil cooler cover and the wiring harness to prevent rubbing or chafing 26 See the service manual Install exhaust system 27 See the service manual Install oil filter and add oil J05661 is07558 1 Oil pressure switch 2 Oil hose Figure 4 Oil Pressure Switch and Oil Hose SYSTEM FLOW TEST NO
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