How to Replace an Oil Cooler on a Harley Davidson Motorcycle

The job of an oil cooler is to dissipate engine heat. If your
present oil cooler is not working well, it will not dissipate heat as
it should. Heat puts stain on an engine. By dissipating extra
engine-generated heat, a new oil cooler can help reduce strain on the
motor and give it extra life and power.

Items You’ll Require

• oil filter wrench (sometimes called a strap wrench)
• 3/8-inch drive ratchet
• 7/8-inch socket
• 7/16-inch socket
• 7/16-inch Allen wrench
• six-inch, 3/8-inch drive extension
• torque wrench (optional)
• flat head screwdriver
• a pair of side cutters
• oil (your choice of weight and brand [H.D. recommends 20w50])
• silicone or WD-40 lubricating spray
• zip or wire ties
• recommended oil filter
• oil cooler kit
• hose clamps if not included in the kit
• Teflon tape

Procedure

1) Drain the oil from the vehicle. (The best time to change the oil cooler is at the time of your next oil change.)

2) Remove and properly dispose of the oil filter. Using the 7/8-inch
socket, gently loosen the oil filter adaptor and remove it from the
motor. Use a rag and some brake cleaner to clean the assembly.

3) Install the new gasket onto the new oil filter adaptor assembly.
Be certain the gasket fits snugly. Also, make sure there are no dents
or burrs on the plate where you will install the oil filter.

4) Using the 7/8-inch socket, mount the new oil filter adaptor
assembly onto the bike. Place some Teflon tape on the threads. This
will insure there are no leaks and help you remove the assembly more
easily. If you have a torque wrench, use it to torque down the fitting
to 160 inch pounds. Do not over tighten.  

5) Inspect the gasket on the oil filter adaptor assembly to make sure it is not bulging out anywhere.

6) Move any wire harnesses out of the way. The instructions that
came with your oil cooler will help here, especially if they are
model-specific.

7) Refer to the instructions to help locate the oil cooler on your
vehicle. It may be necessary to reposition some equipment. It may also
be necessary to reposition some wires; use wire ties to secure them
afterward.

8) Examine all parts. Make sure they sit solidly on the brackets and studs. Tighten down fasteners.

9) Use your finger to lubricate the gasket on the new oil filter.
Install the filter and hand-tighten one-quarter turn beyond snug.

10) Install the hoses that lead from the oil cooler to the oil
filter adaptor. Slide your hose clamps onto the hoses. Lubricate the
inside of each hose with silicone lubricant. Slide the hoses onto the
appropriate nipples and tighten them.

11) Fill the vehicle with oil (refer to owner’s manual).

12) Start the engine and allow it to run until it’s warm. The oil
cooler will warm up, too. If it doesn’t, disassemble the cooler and
hoses and check for blockages.

13) Turn off the engine and check the oil level. If it is low, top
it off. Check oil cooler fittings after a couple hundred miles to make
sure they are tight.