OIL COOLER INSTALLATION GUIDE. Fits Models: RF-1 Touring Models Revised 12.15

Transcription

1 OIL COOLER INSTALLATION GUIDE Fits Models: RF-1 Touring Models 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 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 2 11/16 Open end wrench 7/16 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 forrf 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-107-BK E. Oil Line RFB-106-BK Small Parts Bag F. Indicator Light G. Wiring Harness H. Test Jumper I. Tie Straps J. Thread Locker K. Fitting Wrench L. Adapter Key M. Threaded Adapter ultracoolfl.com Oil Cooler Installation Guide 3

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. Add 3 drops of thread locker to threaded adapter and install to center filter hole. Torque to Ft Lbs, Inch Lbs Step 3 (88 Ci Engine s Only) Adapter Key Installation Older 88 Ci engines need to install the adapter key. To install, remove the 7/8 threaded adapter in oil filter mount. Place key tab in bottom galley. Make sure the key sits against center filter mount. Locate threaded adapter and add 3 drops of thread locker and torque to: 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 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. ultracoolfl.com Oil Cooler Installation Guide 5

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 Step 9 Install Hose RFB-106 to Cooler IMPORTANT: Make sure to OIL all fittings! Locate cooler assembly and remove cover. Locate oil lines and make note of fittings. Locate oil line RFB-106 and hand start straight fitting to LEFT side fitting on cooler core as shown. Now use 11/16 wrench on fitting and one 11/16 Wrench on cooler core as a backup and tighten. Step 10 Install Hose RFB-107 to Cooler Locate oil line RFB-107 and oil fittings. Hand start 45 degree fitting to RIGHT side Fitting on cooler core. Use one 11/16 wrench on fitting one 11/16 wrench on cooler core as a back up wrench. Now tighten. 6 Oil Cooler Installation Guide ultracoolfl.com

7 Step 11 Cooler on Mounting Bracket Place cooler with oil lines attached on mounting bracket. Use one cover bolt to hold cooler to mounting bracket as shown. Connect ground wire from fans to RIGHT Nut on regulator and tighten. Step 12 Oil Line to Adapter # RFB-107 Note: Oil Adapter has a feed and return Locate oil line RFB-107 and run lines behind mounting bracket and come up between engine and frame by shift arm to return fitting on oil adapter. Use fitting tool and start to make small turns. Make sure it goes on nice and easy, then tighten with tools. A Step 13 Oil Line to Adapter# RFB-106 Locate oil line RFB-106 and run line next to other line and up to feed on oil adapter. Hand start to feed fitting, use fitting tool and start to make small turns. Make sure the fitting goes on nice and easy, then tighten with tools. A ultracoolfl.com Oil Cooler Installation Guide 7

8 Step 14 Split Hose Notice in the oil line bag there are 2 pieces of Split rubber hose. Now that your oil lines are attached, look for Rubbing on stator wire or frame. Use a supplied tie strap to hold it in place. This is a must! 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 For more help on LED Installation go to: UltraCoolfl.com Click on FLH Watch our Video Installation Series Installation Steps ultracoolfl.com Oil Cooler Installation Guide 9

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 20 Check List Install Fairing Connect Headlight Check Hose s (tight) Install Oil Filter Clean up any Oil Start Engine and Check Oil You are good to go 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 ultracoolfl.com Oil Cooler Installation Guide 11

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 #