Installation Guide. Fits Models: RF-2 Touring Models 2009-Present. Revised 12.15

Transcription

1 Oil Cooler Installation Guide Fits Models: RF-2 Touring Models 2009-Present Revised 12.15

2 Welcome To UltraCool Oil Cooling Systems Thank you for making UltraCool your oil cooling system of choice. We hope you will find our installation guide helpful in your installation process. If you need more assistance please call Larry in out Tech Dept at or him at Also visit UltraCoolfl.com/support for more helpful tips on installation. Thank You, UltraCool Tools Required: Before we get started let s go over the tools that You will need to complete this installation. 5/32 Allen wrench 7/16 Open end wrench 2 11/16 Open end wrench Ratchet with 3/8 Drive Extension with 3/8 Drive 1 Socket Oil filter wrench Torque wrench Check your Lbs. Bike lift Nice to have Oil can 7/16 Allen driver (for Step 2) Torx #27 Power drill 5/16 Drill bit Wire strippers Crimper NOTE: Instructions are illustrated and explained from a rider s point of view. 2 Oil Cooler Installation Guide ultracoolfl.com

3 Kit Contents for RF Present B. A. C. D. E. H. F. G. I. J. K. L. M. A. Complete Oil Cooler Assembly B. Complete Oil Adapter C. Mounting Bracket D. Oil Line RFB-206-BK E. Oil Line RFB-207-BK Small Parts Bag F. Indicator Light G. Wiring Harness H. Test Jumper I. Tie Straps J. Thread Locker K. Fitting Wrench L. Threaded Adapter M. Pig Tail Splitter 3 Oil Cooler Installation Guide ultracoolfl.com

4 Step 1 Remove Oil Filter Remove oil filter and clean up any oil and dirt. All surfaces must be oil and dirt free. Step 2 Remove Old Cooler If you have a cooler on your bike you will need to remove it and all parts associated with it. Remove 7/16 Allen adapter in the center of adapter and it will come off. You will need to install a threaded adapter from your parts bag. Step 3 Threaded Adapter Installation Ultracool oil adapters need a threaded adapter installed to mount your oil adapter to (see Step 5). If your bike needs one, locate it in your parts bag and proceed. Add 3 drops of thread locker to threaded adapter and install to center filter hole. Torque to Ft Lbs, Inch Lbs. Step 4 Oil Adapter Installation Locate the oil adapter and take it to a clean Surface. Using a 5/32 Allen driver remove the 6 bolts form the front as shown. Watch out for small washers! Note there are (4) 1 1/8 and (2) ¾ bolts and (6) washers. C B A Threaded Adapter 4 Oil Cooler Installation Guide ultracoolfl.com

5 Step 5 Install Plate C Notice that parts of the adapter are marked A-B-C. Take part C and look on the back, there are two alignment cams. Place part C over the oil filter mount in the 11:00 position. Now take the 1 nut and add a few drops of thread locker to it, and tighten to threaded adapter on oil filter mount. Torque to Ft Lbs, Inch Lbs Step 6 Plate ( A ) and Gasket Install Locate parts A and B of the oil adapter, (2) ¾ bolts and the washers. Screw the bolts in the top as shown. This will hold the gasket in place. Now hand start to Plate (C). Use a 5/32 Allen Wrench for the bottom and hand tighten. Get the (4) 1 1/8 along the bottom and hand tight. *Use Blue Thread Locker on Bolts* Step 7 Torque Oil Adapter Now all of the bolts and washers are installed and hand tight. Use a torque wrench and set it to 5 Ft Lbs or 60 Inch Lbs and tighten in a star pattern as shown. Go to for more installation help. 5 Oil Cooler Installation Guide ultracoolfl.com

6 Step 8 Install Mounting Bracket Locate mounting bracket and remove 2 7/16 nuts from voltage regulator. Lift regulator off of frame, and install Bracket between frame and regulator. Leave the RIGHT NUT LOOSE for ground wire in Step 11. A Step 9 Install oil line RFB-206- BK IMPORTANT: Make sure to OIL all fittings! Locate hose RFB-206-BK and oil fittings. Hand start 45 degree fitting to rear AN-6 fitting on oil adapter. Let line hang down and loose so we can make adjustments later. 45 DEGREE Step 10 Install oil line RFB-207-BK Locate oil line RFB-207-BK and oil fittings. Hand start 90 degree fitting to front AN-6 fitting on oil adapter. Let line hang down and loose so we can make adjustments later. A 90 DEGREE 6 Oil Cooler Installation Guide ultracoolfl.com

7 Step 11 Mount Cooler Assembly Locate cooler assembly and remove cover. Locate cooler assembly on mounting bracket and use 1 cover bolt to hold cooler to bracket as shown. Connect ground wire to right side nut on regulator and tighten regulator nuts. Step 12 Oil Line RFB-207-BK to Cooler Locate oil line RFB-207-BK, take the 45 degree and run it over to the right side AN-6 fitting on cooler core. Oil fitting and hand start it to AN-6 fitting on cooler core. Use a back up wrench 11/16 on the cooler core fitting to prevent damage. Step 13 Oil Line RFB-206-BK to Cooler Locate oil line RFB-206-BK take straight fitting and loop it past left side motor mount. Stay inside the frame fail. Oil fitting and hand start it to AN-6 fitting on cooler core. 7 Oil Cooler Installation Guide ultracoolfl.com

8 Step 14 Tighten all fittings After you have connected all oil lines hand tight locate ratchet, ext and fitting tool to start on the rear fitting on the oil adapter slide fitting tool over black line and slide tool up to fitting. Attach ratchet and extension to fitting tool and start to make small turns, bring up snug and tighten one more flat. Repeat this to all fittings. On cooler core use a 11/16 wrench on core fitting as a back up wrench. NOTE: Notice in the oil line bag there are 2 pieces of Split rubber hose. Now your oil lines are attached and tight. Look for rubbing or chaffing, if you see any, attach a piece of rubber hose with a tie strap to hold it in place. Step 15 Remove Fairing Remove fairing by using a #27 torx. Remove 7 torx as shown and set aside. Step 16 Wiring Harness Locate wiring harness in the parts bag. (A) Plug female spades from harness to male spades on thermal switch, any side as shown below. (B) Plug female bullet from harness to male bullet from fans as shown. (C) Look in headlight wiring harness for a orange/ white wire with a male spade. Connect to female spade (C) on harness. This is your power connection. 8 Oil Cooler Installation Guide ultracoolfl.com

9 Step 17 Secure Harness Secure harness to frame tubes and under fairing with tie straps supplied. Make sure it s a clean job. Step 18 Indicator Light (Optional) The indicator light let s you know when your fans are running Indicator Light Installation Find a good spot on you dash you like. Look on the fairing side and make sure there are no obstructions. Drills 5/16 hole Remove nut from back of light Feed wires thru hole from dash side Replace nut and washer and tighten Red Wire Locate red wire from light Measure red wire to female bullet on harness (D) Cut, strip and attach male bullet to red wire, Connect to female bullet on harness (D) Black Wire Locate black wire from light Measure to ground (around radio) *see shop manual* Cut, Strip and attach ring tongue to black wire Attach to ground Make sure all the wires are secure with tie straps Do a clean job 9 Oil Cooler Installation Guide ultracoolfl.com

10 Step 19 Test Electrical Connections Locate the test jumper in your parts bag. Unplug harness from thermal switch (A). Plug jumper into harness on any side. Turn on bike ignition. Fans and LED should run. Step Present FLH Touring Electrical Connection Remove front fairing and look between your speaker and oil pressure gauge for a 2 pin square female connector Step 2 Plug Ultracool connector into bike connector, then connect the harness. NOTE: If your bike has a power amp you will need to use a connector from H.D. # or use the Road King Set-Up. Road King Electrical Connection Optional for FLH Road King owners need to remove side panel. In the Harley Davidson P&A catalog look for part # See Below. Plug male into female and plug Ultracool connector into HD harness. Connect as shown. Congratulations! Note: Now go for a good ride and warm up your engine and oil to 210 degrees. It takes approximately 10 miles to warm up to that point. Don t let your engine idle in your driveway as this will not get your oil hot. 10 Oil Cooler Installation Guide ultracoolfl.com

11 Notes

12 1851 Airway Drive, Suite C, Hollister, CA TOLL-FREE: Direct: Fax: Web: ultracoolfl.com DISCLAIMER WARNING: Could cause damage when installed on lowered, large front fender and tire, non- maintained or modified suspensions. ULTRACOOL, INC is not liable or responsible whatsoever for any claims for damages or injury subsequent to improper installation or modification of our products. *Intended for stock Motorcycles WARRANTY One year parts only from date of purchase Warranty registration must be completed in full and received within 45 days of purchase to validate warranty Copy of sales receipt must accompany warranty form Warranties are non-transferrable Patent #