-J05211 REV. 2010-05-11

SOFTAIL OIL COOLER

GENERALKit Number

26157-11

Models

For model fitment information, see the P&A Retail Catalog orthe Parts and Accessories section of www.harley-davidson.com(English only).

Additional Parts Required

High Performance Sealant, Gray (P/N 99650-02)

The rider's safety depends upon the correct installationof this kit. Use the appropriate service manual procedures.If the procedure is not within your capabilities or you donot have the correct tools, have a Harley-Davidson dealerperform the installation. Improper installation of this kitcould result in death or serious injury. (00333a)

Kit Contents

See Figure 4 and Table 1.

INSTALLATIONInstall Oil Cooler Cover

1. Thoroughly clean the oil cooler of all dirt, grease and waxwith isopropyl alcohol. Use the alcohol to clean the oilcooler cover as needed. Allow to dry.

2. See Figure 1. Apply a thick bead of High PerformanceSealant-Gray to the left side flat surface of the oil coolerand install the oil cooler cover by pressing it into thesealant.

NOTESBe careful to avoid getting sealant on the oil cooler coolingfins.

Do not install on the motorcycle for 24 hours to allow thesealant to fully cure.

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1. Oil cooler2. Sealant3. Oil cooler cover

Figure 1. Attaching Cover to Oil Cooler

Install Oil Cooler

1. See Figure 2. Install the oil cooler (1) to the left sidedowntube with two clamps (2), two socket head screws(3), four washers (4) and two nuts (5). Orient the clampsflat side outward and position lower bracket 6.00 inchesfrom the bottom of the engine mount bracket (7). Tightenscrews to 96-120 in-lbs (10.2-13.5 Nm).

2. Remove the oil filter and the oil filter adapter. Clean theoil filter area thoroughly. Discard filter and oil filter adapter.

3. See Figure 3. Install oil cooler adapter (2) with gasket (1)and oil filter adapter (3). Tighten oil filter adapter to 12-16ft-lbs (16.3-21.7 Nm).

4. See Figure 4. Install upper hose (3) to barb of oil coolerand tighten with hose clamp (7) to 8.0 in-lbs (0.9 Nm).

5. Install lower hose (2) to lower barb of oil cooler and tightenwith hose clamp (7) to 8.0 in-lbs (0.9 Nm)

6. Install hoses from oil cooler to oil cooler adapter andtighten hose clamps to 8.0 in-lbs (0.9 Nm).

7. Check to make sure the hose routing is clear of the oilfilter, any sharp edges and given proper clearance toengine. The hoses must be free of bends or kinks thatcould obstruct oil flow.

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1. Oil cooler2. Clamp (2)3. Screw (2)4. Washer (4)5. Nut (2)6. Oil cooler cover7. Engine mount bracket

Figure 2. Mounting the Oil Cooler Assembly

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1. Gasket2. Oil cooler adapter assembly3. Oil filter adapter

Figure 3. Install Oil Cooler Adapter Assembly

System Flow Test

Oil level cannot be accurately measured on a cold engine.For pre-ride inspection, with motorcycle leaning on jiffystand on level ground, oil should register on dipstickbetween arrows when engine is cold. Do not add oil tobring the level to the FULL mark on a COLD engine.(00185a)

Do not operate the engine when the oil level is below theadd mark on the dipstick at operating temperature. Enginedamage will result. (00187b)

1. Apply motor oil to the ring of a new oil filter and install.

NOTEAdd only enough oil to bring the level between the two arrows.

2. Start engine. Examine all hose connections for leaks. Ifthere is no leakage, allow engine to warm up.

NOTEPosition the clamps to avoid interference with oil filter installa-tion. Check that hose routing is clear of the oil filter and sharpedges. The hoses must be free of bends or kinks that couldobstruct oil flow.

3. Verify that temperature of oil cooler increases when enginereaches normal operating temperatures. If the oil coolerremains cool after engine has warmed up, there may bean oil obstruction. Turn off engine, allow engine to cooland check system for source of obstruction.

4. Verify that all hose clamps are tightened to 8.0 in-lb (0.9Nm).

5. Fill oil to FILL level on dipstick.

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SERVICE PARTS

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Figure 4. Service Parts: Softail Oil Cooler

Table 1. Service Parts Table

Part NumberDescription (Quantity)Item

26158-11Oil cooler assembly1

26159-11Oil cooler left hose2

26160-11Oil cooler right hose3

26198-09Oil cooler adapter4

69318-02Clamp (2)5

63104-11Oil cooler cover6

9823Worm drive clamp, black, #4 (4)7

26041-05AOil filter adapter8

26115-05Oil cooler adapter gasket9

94026-92TLock nut, nylon insert (2)10

94065-90TFlat washer, chrome (4)11

94312-91TSocket head cap screw (2)12

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