Instruction Sheet For No.5400, 5401 & 5402
Contents
1. 7 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR No 5400 5401 amp 5402 PREPARATION AND INSTALLATION 1 Remove seat and disconnect negative battery cable per H D Service Manual 2 Remove fuel tank saddlebags and side covers per H D Service Manual 3 Remove horn assembly with attached bracket per H D Service Manual Set aside the horn mounting acorn nut S to use for the cooler installation Leave the rubber isola B tor and top motor mount on the heads in place as shown See Fig 1 4 Remove the top wire harness trough cover to gain access and to place the cooler wiring harness into See Fig 2 5 Next you will need to use a box cutter or knife to cut a notch out of the left side of the plastic harness trough on 2008 and later Touring Models The notch should be positioned directly above the normal horn position When cutting the notch be very careful not to cut any existing wiring Notch should be about a 1 square cutout without any rough edges See Fig 3 6 Locate the main wire harness No 5423 supplied with cooler kit and position it across the top frame rail on top of the existing bike harness You need to lay the cooler harness on the left side of the harness trough so that you have the thermostat with bracket and white con necter at the front end of the bike See Fig 4 On the Softail and Dyna models you need to route the harness next to the wiring harness on the top frame rail To posi tion2. COVER CYLINDER COOLER POLISH SCREEN SCOOP SCREEN FRONT MOUNT LOWER MOTOR HD ZINC STUD CASE 5 16 18 CYLINDER COOLER MOUNT THERMOSTAT PLATE DISC LOGO BACKING PLATE CYLINDER COOLER POLISH MACHINED FAN BLADE 1 SPACER WASHER _ o oo OO WASHER FLAT 5 16 SAE NUT 5 16 18 JAM SPACER 5 16 ID x 1 z o QTY PART NUMBER 5407 2 5411 5412 5413 5414 5434 5426 5406 2 5405 5428 5452 5451 5410 5427 1222 2014 1216 5436 4 5435 BOLT 5 16 18 x 1 1 2 HH 5439 SCREW 6 32 x 3 16 BUTTON HEAD 5440 SCREW 10 32 x 1 2 SHCS 1294 SCREW 3mm x 5 x 10mm SHCS 5421 4 2 WASHER FLAT 1 4 AN 05 07 THICK 5437 SEIS slalSlalalslals lale e s o o s Peiyotmance Fads for tf 555 DAWSON DRIVE CAMARILLO CA 93012 PARTS LIST NO QTY TITLE OR DESCRIPTION PART NUMBER 10 32 x 5 8 SHCS ISOLATOR 1 x 1 2 1 4 20 x 1 2 MOTOR DETMAR Davidson Moiajtes PHONE 805 482 6913 e FAX 805 482 9224 10 FLAT WASHER WASHERS OPTIONAL HORN MOUNT NUT 1 4 20 ON OFF SWITCH PLATE WARRANTY CARD INSTRUCTION SHFFT
3. No 5400 IS REV G 7 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR NoO 5400 5401 amp 5402 The JIMS FORCEFLOW CYLINDER HEAD COOLER is designed for Twin Cam Models 1999 to present Also fits all JIMS Twin Cam Race Engines NOTE These instructions show the installation of this product on a 2012 H D Road Glide This is probably the most difficult model to install on On other H D Twin Cam models you need to follow the same steps for installation There are minor differences on other years or models installation It is highly recommended that NO Acer guard Thom you use the correct H D service manual for reference in B O faa ue wau Ishibit this installation Refer to last page for parts list and for 4 Me AARIS inhibit cooling bubble reference callouts DO NO while in operation OPERATION AND OPTIONS The FORCEFLOW COOLER comes with a thermostat that actuates at 140 degrees along with an on off switch It is the installer s option to use the thermostat system we ve designed and where we recommend you locate it If you choose to relocate the thermostat it is your responsibility to mount properly If you choose not to use the thermostat it is your responsibility to safely disconnect this system Since JIMS hasn t tested this product with optional changes or locations JIMS cannot back any warranty issues in this area IMPORTANT SAFETY ISSUES We have designed the cooler to operate only when the i
4. area behind the cooler assembly and up on the top motor mount to the main loom area To case x Sy LO OY Petfotmance Fads Pt areg Davidsoni eDteta 28 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 4 No 5400 IS REV G 7 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR NoO 5400 5401 amp 5402 Note t is very important and is the installers responsibility to route and anchor harness wiring away from the cylin ders and fan blades If not done correctly it can cause electrical shorts causing fire further damage or bodily harm If you re not sure about this take it to a qualified professional Jims cannot be responsible for your safety or workmanship 17 Do a temporary install of the cooler assembly on the two rubber isolator mounts Hand tighten your stock H D horn mount acorn nut on the top larger rubber isola P yas s tor and a No 5438 acorn nut from kit to secure assem bly 18 Check wiring coming out of the back of cooler housing and take out any slack by lightly pulling on harness going up to the top motor mount area and up to the notched out area of the harness trough Do a visual check inside cooler to see that all wiring has clearance No wiring can come in contact with the fan blade or cylinders Reposition any extra slack in the harness back to the battery area Route wiring over top motor mount to trough area and secure by tie wrappi
5. e adequate clearance when shifting If your shift rod is hit ting on the acorn nut then swap it out for a normal No 1222 nut we ve provided to gain more clearance Check clearance again If that doesn t clear then move the jam nut inward Retighten the outside nut and check shift rod clearance Then re connect shift rod washer and nut Move on to Step 10 Petfotmance Faia fot tlatley Vavitdion Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 Bracket No 5400 IS REV G 7 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR NOoO 5400 5401 amp 5402 JIMS ENGINE RACE CASES For information on installing this Forceflow cooler kit you should have ordered a No 5447 JIMS Engine hardware mounting kit Follow the instructions in that hardware kit to Install the special center case bolt hardware Then proceed back to this 5400 IS cooler instruction sheet and continue on at step No 10 10 Install finger tight for now No 5419 rubber isolator to the lower support bracket with No 5437 AN washer and No 2017 nut as shown See Fig 12 11 Connect the wiring from the cooler housing to the har ness before hanging housing on the motorcycle We suggest you have another person hold the cooler hous ing while you connect to the two original H D horns flag connectors hanging down between the cylinders These are two identical wires coming out of the housing back ing p
6. ers at the front gear shifter lever to get clearance to remove the OEM case bolt White 4 hole T connector P F See Fig 8 I S I Thermostat STOCK H D ENGINE CASES See Fig 9 Refer to call out bubbles in Fig 9 and last instruction page parts list for assembly reference A If your engine cases are factory cases you need to locate the 5 16 18 case stud No 5414 provided _ B Next lightly coat the threads on the end of stud No 5414 without the slot on it with Blue Threadlocker ES C Insert the coated end of stud No 5414 into the center E case bolt hole and tighten stud snug with a flat blade Z lt screwdriver Slide No 2014 flat washer onto the stud D Coat I D of nut No 1222 with Blue Threadlocker and thread on and torque to 15 19 ft lbs using a 1 2 deep socket and torque wrench E Coat I D of jam nut No 5436 with Blue Threadlocker and thread onto the same stud but don t tighten yet F Next install AN washer No 1216 onto No 5414 stud against jam nut and then No 5413 lower mount brack et and another No 1216 AN washer G Install Blue Threadlocker to I D of acorn nut No 5427 and thread onto the stud Before tightening position the lower bracket in the cor rect upright position using a box wrench to hold the jam nut No 5436 Tighten against bracket Now tight en acorn nut No 5327 to 8 9 ft lbs with a 1 2 socket and torque wrench See Fig 11 H Now fit up the shifter rod linkage and see if you hav
7. gle switch to the other position and see if that starts the fan motor Note If you re a Dealer Service Dept installing this prod uct for a customer please forward the JIMS Warranty Card to the customer or end user when completing service and advise to complete and mail in 6 MONTH WARRANTY JIMS will repair or replace at our option any product found to be defective in materials or workmanship for six 6 months from date of purchase This warranty does not cover items damaged by accident misuse or neglect Any implied warranties are expressly excluded and JIMS shall not be liable for any loss of product use or other consequential or incidental costs incurred by the user of our tools FOR WARRANTY Petfotmance Faia fot areg Davidsoni Norowycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 No 5400 IS REV G 7 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR NoO 5400 5401 amp 5402 All returns for warranty must authorized by the sales dept before returning product WARNING REMEMBER TO KEEP HANDS AND ALL OBJECTS CLEAR OF THE SPINNING FAN BLADE WHENEVER FORCEFLOW UNIT IS SWITCHED TO THE ON POSITION DE IN THE Switch 1 OFF y Switch On W Negative eyelet L lt L PTN Potfotmance Fords foe Harley Davidson Merorcyelet SSS DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 7 No 5400 IS PARTS LIST TITLE OR DESCRIPTION
8. gni Fagus LOT tion system is turned on by the operator as a safety factor Install optional washers 5453 if needed DO NOT MODIFY WIRING TO ALLOW COOLER TO OPER SS gt lt ATE WITH THE IGNITION IN THE OFF POSITION CI QZ SS Warning KEEP HANDS AWAY FROM MOVING FAN 7 ara BLADE JIMS R amp D Dept tested the Forceflow cooler with a protective shroud around the fan blade and found that it cooled better without a shroud So with that said do not get your hands etc near the blade when in operation See Fig A Installation of the Forceflow Cooler is not intended to be a fix for a poorly tuned or improperly operating fuel system such as running too lean or rich causing bluing of pipes or engine damage Read the complete instructions before starting the installation of this product JIMS cannot be responsible for the safety or quality of your work If you do not know what you are doing then don t do it Take it to a professional TOOLS AND SUPPLIES RECOMMENDED FOR INSTALLING THE FORCEFLOW COOLER 1 Common box end wrenches ratchet and socket set 2 Quality ft lb torque wrench 3 Box cutter or knife to modify the wiring trough 4 The correct H D Service Manual per year and model you re working on 5 Blue Threadlocker JIMS No 4501 or equivalent 6 Assorted wire tie wraps Petfotmance Fads Pt arkey Davidsoni Nlororcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 1 No 5400 IS REV G
9. it correctly you need to have the thermostat drop down to the old horn position You need to have about a 9 lead hanging out of the harness tough or main wiring harness area as shown to connect horn and cool er wiring Note that the wire harness needs to be rout ed over the top of the top motor mount not under This routing will help keep wiring off cylinders when tie wrapped to motor mount in final running position The other end of the cooler harness with the relay positive wire Deutsch connector amp black negative eyelet should be routed back to the battery area See Fig 5 7 Remove the front cylinder rocker box screw as shown See Fig 6 8 Locate the thermostat with mounting bracket on the harness hanging down between the cylinders Mount the bracket No 5434 with thermostat using No 5439 hex head bolt No 2014 washer and Petfotmance Faia Pt tlatley Vavitdion Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 2 No 5400 IS A Division of Thiessen Products Inc REV G 7 13 INSTRUCTION SHEET FOR NoO 5400 5401 amp 5402 spacer No 5435 to the valve cover as shown Torque to 15 18 ft lbs using Blue Threadlocker JIMS No 4501 At this location the thermostat will activate the fan at 140 degrees with a slight air gap See Fig 5 and Fig 7 9 Remove the center case bolt from the engine case On a H D OEM engine case you will have to remove the shifter rod nut and wash
10. late rubber grommet Fig 13 12 Connect the bikes two existing original horn connectors to the light blue plastic spade connectors from the cool er housing It doesn t matter what blade goes to which wire See Fig 13 Note For added insulation from weather position existing shrink wrap and heat as required before doing the final positioning You may add more shrink wrap if necessary 13 Next locate the cooler assembly backing plate on both the 1 4 and 5 16 rubber isolator studs If the assem bly looks like its centered then you should do the final tightening of the previously finger tightened lower No 2017 nut to the rubber isolator and lower bracket If you cannot align the upper and lower rubber isolator studs to the backing plate tab holes without forcing them then you need to space up the top motor mount bracket You will need to add one thick washer No 5453 to each side of top motor mount Place these washers under the motor mount bracket Try just one pair of washers first If needed stack two on each side of mount as shown See Fig 1 14 Locate the other wire coming out of the housing grommet It has a four pin male white plastic con nector that you connect to the cooler harness hanging down from the motorcycles main harness area See Fig 5 15 Connect the two white plastic connectors together They will only connect when positioned cor rectly See Fig 14 16 Now its time to do the final positioning of the wire loom in the
11. ng for the final operating position Caution Do Not zip tie On Off switch wires too tight They need some slack to move so they don t break at the switch 19 Remove the cooler assembly top and lower mounting nuts to apply Blue Threadlocker to both Install Logo disc No 5426 to the upper isolator mount and then the H D original horn mount acorn and torque to 7 to 9 ft lbs 20 Install the lower washer No 5437 and apply Blue Threadlocker to No 5438 acorn nut and do a final tight ening After the cooler is anchored take your finger and spin the fan blade to check for clearance You should have at least 1 4 between cylinder and fan blade See Fig 15 21 Now tuck the cooler harness into the left side of the motorcycle trough harness Reinstall the wire harness upper trough cover back in its normal position per H D Service Manual On the FXST or FXD models secure the cooler harness wiring with tie wraps 22 The power connector socket is not installed into the Deutsch connector If you are installing the Forceflow on a 1999 and later FLH or 2006 and later Dyna it is recommended to access power via Petfotmance Faia Pt arkey Davidsoni Nlorowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 5 REV G 7 13 No 5400 IS A Division of Thiessen Products Inc INSTRUCTION SHEET FOR NOoO 5400 5401 amp 5402 the accessory plug located under the seat Insert the P socket terminal into posi
12. tion 1 on the Deutsch connec tor install the wedgelock into the connector and plug into the 4 place accessory connector Note On FLH models the accessory switch must be in the on position You can also access power from the Data Link Connector DLC If DLC connector is used for power insert the socket terminal into position 4 on the Deutsch connec tor install wedgelock and connect to the DLC plug See Fig 16 23 Locate the negative battery cable and connect the neg ative wiring eyelet to it Mount negative battery cable to the battery post as shown See Fig 18 Note If your vehicle does not have a Deutsch connector use this wire to tap into any ignition accessory circuit 24 Pull aside the cooler wire harness relay section and install the ECM caddy cover as per H D Service Manual After the caddy cover is in place lay the relay wire har ness section right along the side of the frame as shown You can anchor it if you like See Fig 19 25 Reinstall the fuel tank fuel lines saddlebags and seat per H D Service Manual 26 Now you need to take a test ride and get the motor warmed up Position cooler switch in the on position forward position is OFF and rear is ON See PY FIG 17 The easiest way to check temp is with an infrared thermometer When your engine heats up enough to bring the top rocker box to 140 degrees the cooler should start up If you find your fan motor is not going on turn the tog
Download Pdf Manuals
Related Search