Adding an oil cooler to a Harley-Davidson motorcycle is a common upgrade for riders seeking enhanced performance and reliability, especially in high-temperature conditions or heavy traffic. The oil cooler helps regulate engine temperature, reducing the risk of overheating and extending engine life. This guide compiles detailed installation instructions and insights from multiple verified sources, focusing on models such as the 96" and various Touring models. The process involves removing the existing oil cooler cover, installing a new oil cooler unit, and securing it properly with the appropriate hardware and tools.
The instructions cover both the Oil Cooler SPLITSCREEN and the OIL BUD models, with emphasis on proper alignment, secure mounting, and the use of specific tools like a 7/16" Allen key. The article also includes insights from user reports on potential concerns such as debris accumulation and durability in off-road conditions.
Installation Overview and Preparation
Before beginning the installation process, it is important to gather the necessary tools and materials. The sources indicate that a 7/16" Allen key is required for tightening bolts during installation. Additionally, a new gasket, hose clamps, and the oil cooler unit itself are needed. Some installations may also require a voltage regulator, dielectric grease, and a new oil filter.
The oil cooler is typically mounted near the engine or along the frame rails. The SPLITSCREEN model is affixed using 3M double-sided adhesive tape, while the OIL BUD requires a mounting bracket and bolts. In both cases, the installation involves careful alignment to ensure that the cooler's slots and openings match with the existing engine components and rubber grommets.
For the SPLITSCREEN model, the first step is to remove the oil cooler cover by rotating the pins away from the rubber grommets. After cleaning the area thoroughly, the 3M tape is applied, and the SPLITSCREEN is carefully placed into position. Reinstallation of the cover is the reverse of the removal process.
The OIL BUD, on the other hand, involves more mechanical steps. The support bracket is attached to the voltage regulator mounts, and the oil cooler is placed onto the bracket. The oil filter threaded bolt is then inserted and tightened. Oil cooler lines are routed to the adapter, and hose clamps are secured once the lines are in place.
Detailed Installation Steps
Step 1: Removing the Oil Cooler Cover and Components
For the SPLITSCREEN model, the installation process begins with the removal of the oil cooler cover. According to the provided documentation, the cover is removed by rotating the pins away from the rubber grommets. This allows access to the oil cooler itself. Once removed, the area is cleaned to prepare for the adhesive tape.
For the OIL BUD model, the process involves removing the oil filter and the voltage regulator. The voltage regulator is temporarily removed to make space for the oil cooler support bracket. The bracket is then placed onto the voltage regulator mounts, and the oil filter threaded bolt is removed for later reinstallation.
Step 2: Preparing the Oil Cooler Unit
Before mounting the oil cooler unit, it is important to ensure that all necessary components are in place. For the SPLITSCREEN model, the 3M double-sided adhesive tape is pre-installed on the back of the screen. The user is advised to perform a "practice placement" to ensure proper alignment before removing the protective film from the tape and attaching the SPLITSCREEN to the oil cooler. Special attention is given to aligning the screen slots with the cooler tabs and rubber grommets.
For the OIL BUD model, the oil cooler adapter is prepared by placing the supplied gasket onto the back of the adapter. The gasket is designed with a sticky backing that requires the user to remove a protective paper layer before applying it. Once the gasket is in place, the oil cooler bracket is mounted onto the engine, and the oil filter threaded bolt is reinstalled using the 7/16" Allen key.
Step 3: Mounting the Oil Cooler
After the preparation steps, the oil cooler is mounted onto the support bracket. In the case of the SPLITSCREEN, the oil cooler cover is reinstalled by hanging the slots onto the cooler tabs and rotating the pins back into the rubber grommets. This ensures a secure fit and proper alignment.
For the OIL BUD, the oil cooler is placed onto the support bracket, but it is not secured at this stage. The voltage regulator is then reinstalled, and dielectric grease is applied to the electrical plugs to prevent corrosion. The oil cooler supply lines are routed to the adapter, and hose clamps are tightened to secure the connections.
Once the lines are in place, the oil filter is installed. For the SPLITSCREEN model, a chrome cover can be slid over the oil cooler before securing it with the provided washers and nuts. Loose ends are then secured to complete the installation.
Step 4: Final Adjustments and Testing
After all components are installed, it is important to double-check the alignment and tighten all bolts in an X pattern to ensure even pressure distribution. In the case of the OIL BUD, the user is advised to check clearances and ensure that the cooler is not obstructed by other components. The two halves of the cooler are connected, and the bolt securing the front section is tightened.
Once the installation is complete, the motorcycle is tested to ensure that the oil cooler functions as intended. Users are advised to monitor oil temperature and check for any leaks or unusual behavior. If the cooler is mounted near the front tire, as in some custom installations, users are encouraged to consider potential exposure to debris and take preventive measures such as using a protective cover or adjusting the mounting position.
Oil Cooler Models and User Considerations
Different oil cooler models offer varying levels of performance and aesthetics. The SPLITSCREEN is a minimalist design that integrates with the existing oil cooler cover, while the OIL BUD is a more discreet option mounted under the engine. Both models are designed to improve cooling efficiency, but they differ in terms of visibility and ease of installation.
Users considering an oil cooler upgrade should evaluate their riding conditions and preferences. For example, the SPLITSCREEN model is recommended for riders who prioritize a clean, stock appearance, while the OIL BUD is ideal for those seeking a more hidden installation. However, the OIL BUD's lower position may make it more susceptible to debris and potential damage from off-road conditions.
In response to a user's concern about debris accumulation and durability, one source mentions that while the OIL BUD is mounted closer to the road, it has not required cleaning in regular use. However, if the rider frequently travels on muddy or gravel roads, periodic cleaning may be necessary to maintain optimal performance.
Tools and Accessories
The installation of an oil cooler requires specific tools and accessories. The most commonly mentioned tool is the 7/16" Allen key, which is used to tighten bolts during the installation process. Some users report that this tool was not readily available at local hardware stores and had to be purchased as part of a kit or special order.
Other necessary components include a new gasket, hose clamps, and an oil filter. The OIL BUD also comes with a mounting bracket, washers, nuts, and a protective sleeve for the wiring. In some cases, a voltage regulator may need to be temporarily removed to make space for the oil cooler.
Users are encouraged to prepare all necessary tools and materials before beginning the installation to avoid delays or additional trips to the store. The process is generally considered straightforward, but attention to detail is important to ensure a secure and functional installation.
Conclusion
Installing an oil cooler on a Harley-Davidson motorcycle is a valuable upgrade that can improve engine performance and longevity. The detailed steps outlined in this guide provide a comprehensive overview of the installation process for both the SPLITSCREEN and OIL BUD models. Users should ensure they have the correct tools, including a 7/16" Allen key, and follow the manufacturer's instructions carefully to achieve a secure and functional installation.
For riders who frequently ride in high-temperature conditions or heavy traffic, an oil cooler can make a significant difference in maintaining optimal engine temperature. Additionally, users who ride off-road or on gravel roads should consider the potential for debris accumulation and take preventive measures to protect the oil cooler.
Ultimately, the installation of an oil cooler is a rewarding project that can enhance the performance and reliability of a Harley-Davidson motorcycle. By following the steps outlined in this guide, users can ensure a successful installation and enjoy the benefits of improved cooling efficiency.