ULTRACOOL, INC 68 South Rainbow Drive Bldg #10 Dayton, NV 89403 OIL COOLER Touring INSTALLATION GUIDE Models 1994-2008 2.0 Version - Includes Trikes 'Call for fitment on earlier models Direct: (775)-241-9155 Fax: 775-241-9158 Email:info@ultracoolfl.com Web: www.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 claim Warranties are non-transferrable Patent# 6955150
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 our Tech Dept at (775) 241-9155 or email him at Info@ulmlcoolfl.com Front Accessory Page 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 Provides additional cooling and consistent filtering across the entire surface and a high flow rate nearly 7 times greater than paper filters. Unaffected by water, heat or pressure. Built in hex nut for easy removal of the filter. It's cleanable and reusable. Available in polished aluminum or black The UltraCool cooler cover is made of marine grade vinyl and is used when riding in cold weather. Disconnect the fans when using cover. NOTE: Instructions are illustrated and explained from a rider's point of view. 21 Oil Cooler Installation Guide I ultracoolfl.com This (1" Handlebar) clamp is a new addition and will hold the Reefer or Softail L.E.D. Light allowing you to see exactly when the oil cooler system is active. Available in chrome, black, and black chrome. ultracoolfl.com I Oil Cooler Installation Guide 111
Step 18 Test Electrical Connections Locate the test jumper in your parts bag. Unplug harness from thermal switch (A). Plug jumper into harness. Turn on bike ignition. Fans and LED should run. Kit Contents for 'RF-11999-2008 B. C. Step 19 Check List D Check Hose's (tight) D Install Oil Filter and Clean up any Oil D Install Cooler Cover D Start Engine and Check Oil D 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. 0 I. J. o ) K. L. A. Complete Oil Cooler Assembly B. Complete Oil Adapter with Wire 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 H. M. K. Fitting Wrench L. Adapter Key M. Threaded Bushing 10 I Oil Cooler Installation Guide I ultracoolfl.com ultracoolfl.com I Oil Cooler Installation Guide I 3
Step1 Remove Oil Filter Remove oil filter and clean up any oil and dirt. All surfaces must be oil and dirt free. Step2 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 our threaded bushing provided in your parts bag. Step17 Installing LED (Optional) 3 Options: 1) In the fairing: Requires a 5/16 hole to be drilled. (See drawing) 2) We have a handle bar clamp Part #AC-20 in Chrome, Black or Black Chrome. Fits only 1" handlebars. 3) We have a small tab mount that fits under a screw on your handle bar controls. Step 3 Threaded Bushing Installation All 88 ci engines need to install the adapter key. To install, remove the 7 /8" threaded bushing in oil filter mount and discard. Locate the new threaded bushing in your parts bag. Place key tab in bottom galley. Make sure the key sits against center filter mount. Add red or blue thread locker to short end and torque to 18-22Ft-Lbs. 96ci motors do not require adapter key. Adapter Key for 88ci Engines --REMOVE--.. 'S\ 7/16r(j Step4 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. For all options, connect push pinned wires into connector and lock with orange retainer. Does not matter which wire goes where. Run wire on down tube to connector on harness. Orange Wire Option A: This works with the accessory switch located on the fairing, and will disable the fans with the switch off. Orange Wire Option B: This option will turn the fans on and off with the accessory switch located on the fairing. Connect test jumper to the thermal switch connector. Now the switch will control the fans. Threaded Bushing U 7/8" 41 Oil Cooler Installation Guide I ultracoolfl.com --THERMAL SWITCH-- ultracoolfl.com I Oil Cooler Installation Guide I 9
Step 14 Tighten all Fittings and Install Split Hose Adjust hoses and tighten 1 flat. Notice in the oil line bag there are 2 pieces of Split rubber hose for rub spots. 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! Use the straps on all hoses to keep tight and from chaffing. Step5 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 blue thread locker to it, and tighten to threaded adapter on oil filter mount. Torque to 18-22 Ft Lbs, 216-26 4 Inch Lbs Step6 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 15 (1994-2008) Installing Relay Harness with Gray 4 Pin Connector Remove left saddle bag, left side cover and seat. Remove main power fuse. Connect black ring connector to battery negative side. Connect red ring connector to battery positive side. Connect blue wire to blue wire on gray connector. (Orange wire can be used in Option A or B. See page 9). Plug gray connector into black P-A connector. (This is under the seat). The 2 prong white connector will go to the wiring harness in step 16. Secure harness with zip ties provided. Relay Harness 1)Black Ring Connector-Battery Negative. 2)Red Ring Connector-Battery Positive. 3)White Power Connector to Harness. 4)Blue Trigger Wire 5)Black with Logo is Relay 0 of Jo 0 il) Step7 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. --THERMAL SWITCH-- ', ', ',, 3/4" 1-1/8" Step 16 Installing Wiring Harness The black connector is for the thermal switch. The gray connectors are for the fans and LED. (Does not matter which one). The LED is optional. From the adapter run and attach harness down left frame rail, up along side of electrical fuse box and connect white connectors. Secure harness with zip ties provided. Wiring Harness 1)White Power Connector 2)Grey Connectors to Fan and LED Light (Interchangeable) 3)Black Connector to Thermal Switch Go to www.ultracoolfl.com for Installation Videos ultracoolfl.com I Oil Cooler Installation Guide I 5
Step8 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. Tighten nuts. (For models 1994-1998 requires spacing the regulator up 1/2"-3/4"). Step11 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. RIGHT SIDE LEFT SIDE Step9 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-1O6 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-1O7 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. Step12 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. RIGHT SIDE Step13 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. LEFT SIDE 6 I Oil Cooler Installation Guide I ultracoolfl.com ultracoolfl.com I Oil Cooler Installation Guide 17