Trail Bikes Oil Cooler Kit Installation GuideThe Trail Bikes Oil Cooler Kit is a high quality accessory designed to help your Honda horizontal engine or Honda clone engine keep cooler. Air-cooled engines run hotter when modified or subjected to heavy loads such as racing use.
This kit will help your engine’s durability and reliability by circulating the engine oil through a cooler reducing the engine’s oil temperature. It is highly recommend that you completely read through the installation instructions before you begin.WARNING!!!The installation of aftermarket accessories such as this oil cooler kit may void your manufacturer’s warranty. Trail Bikes is not responsible in any way for such voids.WARNING!!!This guide is for illustration purposes only. All engine work should be performed by a trained professional mechanic and in accordance to factory recommendations.
Improper installation could result in extensive engine damage. Use this guide for reference only.
Any and all instructions provided are suggestions for the professional mechanic.Step 1. Remove oil cooler from box and examine the two mounting brackets included in the kit.
The bracket attached to the cooler is made to slip over your cylinder studs as the illustration shows above.The other bracket is designed to attach to the frame as the illustration shows below. The brackets provided in this kit are designed to work on multiple applications and you will need to determine what works best for your application. If you have the option to use either on your application, we recommend using the frame mounted bracket setup.It is best to locate a spot on the bike that is towards the front of the bike where air will travel across the cooler as the bike is traveling forward. Once a good spot has been located, attach your mounting bracket of choice.
Only hand tighten the cylinder studs or the hose clamp provided for the other mounting bracket. At this time you will “mock up” the installation and make sure that the oil cooler lines will be long enough to reach the cooler and that the lines will not have to make any extreme bends which would restrict oil flow. (Please note that the cooler can be installed upside down if necessary, the oil lines can be at the top or bottom of the cooler)Turn the wheel lock to lock and compress the suspension fully making sure nothing will come in contact with the cooler or the lines.If everything looks like it is going to clear, proceed to step 2.Step 2. Mount the oil cooler in the selected location using the mounting bracket of choice. The illustration above shows the cooler being mounted with the bracket that slips over the cylinder studs. Be sure to re-torque the cylinder studs to your manufactures specification if you choose this method. The torque rating is 8ft lbs for a factory Honda engine.The illustration below shows the oil cooler mounted to the frame using the other bracket provided.
This mounting bracket is attached to the frame using a hose clamp and is the better choice if it can be used on your application. For a stronger and more reliable mount you can also drill and tap a hole in the frame. The bracket has a clearance hole in it already.
This would be the preferred mounting method if applicable.Step 3. Remove the right hand side cylinder head cover (it is the one near the spark plug held in with 3 bolts) The center bolt runs all the way through the head to the other side, hold the cover on the opposite side when removing the long center bolt.Once the head cover is removed, remove the old gasket and clean off any oil from the sealing surface on the head.At this time select the new gasket from the two that are provided in the kit. You need to check the gasket against the head plate to see which one aligns with the holes and passages on your application.Next, prepare the oil cooler taps to be installed into the new head tap plate provided with the kit. You will need to use the Teflon tape provided in the kit on the threads to ensure an oil tight seal as the illustration shows below.
It is not necessary to use Teflon tape on the compression fitting side of the taps. Make sure when wrapping the threads with the Teflon tape that you are applying the tape in the same direction as the taps would thread into the new 5 head tap plate. The tape should cover the threads of the taps but it must not cover the end where oil will flows through.Prepare the new oil cooler head tap plate to replace the right hand side cylinder head cover by installing the oil cooler taps.
Pay close attention to the angle you have installed the taps to ensure they are facing in the direction that you selected when “mocking up” the install in Step 1. Be sure not to over tighten the taps. Make sure that the taps are in such a position that when attaching the oil cooler line that the lines clear the cooling fins on the new head tap plate. Minor adjustments of the taps can be made once everything is in position.Step 4. Ensure that all sealing surfaces are clean and apply the gasket of choice.
Install the head tap plate on the engine and torque the bolts to manufactures specification. The torque rating is 8ft lbs for a factory Honda engine. Once the head tap plate has been installed, proceed to step 5.Step 5. Route oil lines to the oil cooler and head tap plate. At this time only hand tighten the lines and determine what the best routing for your application will be.
You may have to make minor adjustment to the taps to achieve the best routing for you application. It is crucial to ensure that there is no severe bends in the oil lines that could restrict oil flow. The lines must attach to the cooler at a nearly perpendicular angle (90’ angle) or else the banjo fittings will not form a seal. If not installed at a perpendicular angle the end of the line will bottom out on the cooler and not the sealing surface for the banjo fitting. Once you have determined the correct routing for your application then tighten all connections.Step 6. Check over complete installation to ensure that all lines are routed without severe bends and that all connections are tight. Turn the wheel lock to lock and compress the suspension fully making sure nothing will come in contact with the cooler or the lines.
Check the oil dipstick to make sure the oil level is full. You are now ready to start your engine.Start the engine for a few seconds (10 seconds or so) and inspect all connections for any signs of leakage. Shut the engine off after the 10 second interval. Oil pressure should have built up and some of the oil should now be in the cooler causing your crankcase to be low on oil. If it does not appear that the oil level has decreased any there may be an oil flow problem and severe damage could occur if engine is restarted. Recheck all connections and installation if the oil level in the crankcase is not dropping. If the oil level lowered by a few ounces add the necessary oil to bring the crankcase oil level back to full.
Once the oil level is back to full and you have made sure that there are no leaks, start the engine and allow it to run for a little longer and then shut off the motor and verify oil level again. Do this a few times until the oil level stays consistent, resulting in the correct level for the new increased oil capacity with the addition of the new Trail Bikes oil cooler.Step 7. Recheck all oil connections, mounting bracket of choice, cylinder studs should be retorque if you chose this mounting method, re-torque cylinder head cover and check for oil leaks once again. If everything looks good, proceed to start the engine again. After the engine has warmed up you should be able to feel some warmth by touching the oil cooler.
INSTALLATION 1. See Figure 1. Install the oil cooler (2) to the frame with three clamps (4), three socket head screws (1), three nuts (5) and six washers (3) from the kit. Orient the clamps flat side forward and on the forward side of the oil cooler. Tighten the three oil cooler mounting screws to 96-120 in- lbs (10.9-13.5 Nm). See Figure 2.
Remove the spin-on oil filter and oil filter adapter (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter and adapter. 1 3 4 4 4 3 5 2 is03387 1. Socket head screw (3) 2. Oil cooler 3.
Washer (6) 4. Locknut (3) Figure 1. Oil Cooler Clamp Installation NOTE The oil cooler adapter assembly has two flanges protruding out of the back side. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. See Figure 3. From the kit, install the oil cooler adapter gasket (3) onto the oil cooler adapter assembly (1).
The oil cooler adapter assembly flanges should be aligned so it is installed into the oil adapter cooler gasket cutout as shown. NOTE Due to the locating flanges, the oil cooler adapter assembly and gasket will only install properly in one position on the oil filter mounting surface. See Figure 3. Install the oil cooler adapter assembly and gasket onto the oil filter mounting surface of the engine with the mounting fitting (2).
Ensure adapter locates properly in the mounting surface. Ensure the raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 12-16 ft-lbs (16.3-21.7 Nm).NOTE Slide hose clamps from the kit onto the hoses prior to installa- tion. 1 2 is00754 1. Oil filter adapter 2.
Oil filter seal surface Figure 2. Stock Filter Mounting Adapter 1 2 3 is00761 1. Oil cooler adapter assembly 2. Mounting fitting 3. Oil cooler adapter gasket Figure 3. Install Oil Adapter 5. See Figure 5.
Obtain the left side cooler hose (4) and right side cooler hose (5) from kit. Follow the markings on hoses to connect onto the oil cooler and oil cooler adapter, as shown. Fasten hoses to oil cooler adapter and oil cooler with worm drive clamps (6).
Tighten clamps to 8.0 in-lbs (0.9 Nm). Lubricate a new oil filter’s seal with new engine oil. Thread filter on until seal touches mounting surface, then turn an additional 1/2 to 3/4 turn. NOTE Position the clamps to avoid interference with oil filter installation. Check that hose routing is clear of the oil filter and sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. Ensure all cables and harnesses are clear of the oil cooler adapter, in order to prevent wear.
Thoroughly clean the oil cooler of all dirt, grease and wax with isopropyl alcohol. Use the alcohol to clean the chrome oil cooler cover as needed. Allow to dry. Is00745 Figure 4. Apply Sealant Inside Chrome Cover 10.
See Figure 4. Apply sealant to the inside of the chrome cover as shown, at the upper and lower corners. NOTES Be careful to avoid getting sealant on the oil cooler cooling fins. Do not operate the motorcycle for 24 hours to allow the sealant to fully cure. Slip the cover over the oil cooler. Remove any excess sealant from the front and back of the oil cooler. Hold the cover firmly in place for one minute.
System Flow Test 2005 & Later Models or Models with Later Style Dipsticks Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine.
(00185a) 2004 & Earlier Models Incoming search terms:. INSTALLATION: 1. F: Apply a thin film of oil to O-RING (#9) on OIL COOLER MOUNT ADAPTER (#2).
Install the OIL COOLER MOUNT ADAPTER with OIL COOLER SUMP STUD (#6). Note that o-ring on adapter is mounted against oil filter sump. TIP: Only tighten “finger tight” at this point so adapter can move as needed to adjust oil lines. G: Install OIL LINES (#3 & #4) to OIL COOLER and OIL COOLER MOUNT ADAPTER as shown. Do not tighten fittings yet.
NOTE: The shorter 9-3/4″ OIL LINE will be on the TOP fitting on the ADAPTER. H:Install OIL COOLER to frame with the BILLET OIL COOLER CLAMP (#7). Adjust OIL COOLER to desired position and tighten the three 10-24 X 1/2 SOCKET HEAD SCREWS (#8) securely. Rotate the OIL COOLER MOUNT ADAPTER as necessary to align the Oil Lines properly. WARNING: Make sure OIL COOLER is moved outward far enough so that it does not contact the Front Fender when the fender goes through its full range of motion! I & J: Tighten the AN fittings on the OIL COOLER MOUNT ADAPTER as shown with an 11/16″ open end wrench.
Tighten the AN fittings on the OIL COOLER with an 11/16″ open end wrench. TIP: To prevent the OIL COOLER from turning when the fittings are tightened, place a thin screw driver or long allen wrench between the fittings as shown. NOTE: DO NOT USE ANY SEALANT ON AN FITTINGS! K: Tighten OIL COOLER SUMP STUD (#6). Re-install oil filter. Start the engine and check for leaks. Check oil level and top-off as necessary.
Shovelhead Oil Cooler Install
MAINTENANCE: Incoming search terms:. Refer to Owners Manual to drain engine oil and remove oil filter.
See Figure 1. Remove oil feed hose (1) from oil pump. Remove oil feed hose fitting from engine crankcase. Discard oil feed hose. INSTALLATION 1.
See Figure 2 and Table 1. Apply Hylomar Gasket and Thread Sealant to threads of fitting (1) and install fitting to oil pump. Apply Hylomar Gasket and Thread Sealant to threads of fitting (1) and install fitting to crankcase. Tighten fittings to 55-65 in-lbs (6.2-7.4 Nm). 1 2 3 1 is04015 1. Oil Hose Cooler Supply 3. Oil Hose Cooler Return Figure 2.
Oil Hose Cooler Return and Supply Assmeblies 4. Loosely install oil cooler return hose assembly (3) to crankcase fitting.
Loosely install oil cooler supply hose assembly (2) to oil pump fitting. See Figure 3 for proper oil hose routing. The oil supply hose (1) should be the upper hose and the oil return hose (2) the lower hose 1 2 is04018 1.
Oil Supply Hose 2. Oil Return Hose Figure 3. Oil Cooler Hose Routing 7. Remove two existing clips holding the clutch cable and wire harness from the left frame downtube. See Figure 4 and Table 1. Position oil cooler clamps (7) in approximately the same position as the clips that were removed from the frame downtube. Loosely attach oil cooler (4) to the clamps (7) using screws (9) and nuts (8).
Attach oil return hose (3) to the inboard connection of oil cooler (4) with worm clamp (5). INSTALLATION 1. See Figure 1. Remove the spin-on oil filter (2) and oil filter adapter (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter adapter.
NOTE The oil adapter assembly has two flanges protruding out of the back. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. See Figure 2. Install the oil adapter gasket (3) onto the oil filter adapter assembly (1). The oil adapter assembly flanges should be aligned so they are installed into the oil adapter gasket cutout as shown. 1 2 is00602 1. Oil filter adapter 2.
Oil filter Figure 1. Oil Filter and Adapter 1 2 3 5 4 is00761a 1. Oil cooler adapter assembly 2. Mounting fitting 3.
Oil cooler adapter gasket 4. Gasket adhesive side 5. Oil cooler adapter assembly gasket surface Figure 2. Install Oil Adapter Incoming search terms:. INSTALLATION 6 2 1 3 5 4 is04287a 1. Oil Cooler 2.
Stock Washer 4. Mounting Bracket 6. Area to Apply Heat Figure 1. Oil Cooler Preparation Be sure to follow manufacturer’s instructions when using the Robinair Heat Gun or any other radiant heating device.
Failure to follow manufacturer’s instructions can cause a fire, which could result in death or serious injury. See Figure 1. Remove the oil cooler guard (2) from the oil cooler (1) by using the Heat Gun (or equivalent) to apply heat to the top surface. Pull the guard away from the oil cooler and discard. Remove and discard the three locknuts (4) and flat washers (3) fastening the oil cooler to the mounting bracket (5). Raise the oil cooler slightly to separate the studs on the underside of the oil cooler from the mounting bracket.
See Figure 2. Place the oil cooler cover (1) onto the oil cooler studs, between the oil cooler and the mounting bracket. Lower the oil cooler and cover into the holes in the mounting bracket.
Place a new flat washer and locknut from the kit onto each stud. Line the oil cooler cover up squarely against the oil cooler, and tighten the locknuts to 80-100 in-lbs (9.1-12.4 Nm). SERVICE PARTS. LCD DIPSTICK INSTALLATION 1. Remove the original equipment (OE) dipstick from the filler neck.
Non-threaded Dipsticks: Lightly oil the O-ring on the new LCD dipstick. Orient the dipstick so that the display window is horizontal and readable from left to right, with the Bar and Shield logo to the left (towards the rear of the motorcycle). Push the dipstick straight into the filler neck until it seats. For threaded dipsticks: Lightly oil O-ring and screw into the transmission like OE dipstick. If the orientation of the display is unsatisfactory when fully seated, refer to Adjusting the Display Angle later in these instructions. NOTE To be sure of correct readings, the dipstick MUST seat firmly against the flange.
LCD DIPSTICK USE AND CARE Removing the Dipstick The dipstick assembly must be removed from the filler neck to add oil or to service the internal battery. Displaying the Oil Temperature and Level See Figure 1. Press and release the rubber button on the front face to display the temperature of the oil in the oil tank in degrees Fahrenheit (°F), and the oil level. The display will automatically shut off after approximately ten seconds. Do not overfill oil tank.
Doing so can result in oil carryover to the air cleaner leading to equipment damage and/or equipment malfunction. (00190a) NOTES Oil level cannot be accurately measured:.
on a cold engine. with the motorcycle upright. with the engine running NOTE Oil level on 2000 through 2004 Softail models with the original dipstick is checked with the motorcycle standing upright (not leaning on the jiffy stand). THIS IS NOT THE CASE with the LCD oil temperature/level dipstick. For all 2000 and later Softail models, oil level inspection must be done with the motorcycle LEANING ON the jiffy stand, on level ground. For pre-ride oil level inspection: With the motorcycle on level ground, RESTING ON the jiffy stand:.The oil level should be as indicated in Figure 1, display 4 through 8 (bars showing oil level, and “COLD OIL” message followed by flashing oil temperature) when the engine is cold. DO NOT ADD OIL to bring the level to the FULL mark on the dipstick of a COLD engine.If the oil level indicates as in display 9 (animated level bars, followed by an “888 NO SENSOR” code), the wires inside the dipstick may be disconnected or damaged.
Refer to Replacing the Battery later in these instructions to separate the dipstick upper and lower assemblies. If the small plug next to the battery has become dislodged from the receptacle, plug it in.
If a visible wire is damaged, a repair can be attempted. If no damage is visible, the dipstick is damaged internally and should be replaced. For oil level inspection at operating temperature: Ride the motorcycle until the engine is at normal operating temperature.
Idle for 1-2 minutes with the motorcycle on level ground, RESTING ON the jiffy stand (except Softails), turn the engine OFF. Incoming search terms:. 2000 cH ROME 99 – 07 SOFTAIL MODELS #2001 CHROME 99 – 07 DYNA MODELS #2002 CHROME 99 – 07 FLT MODELS, flht, flhr, fltr #2005 black CHROME 99 – 07 SOFTAIL MODELS #2006 BLACK CHROME 99 – 07 DYNA MODELS #2007 black CHROME 99 – 07 FLT MODELS, flht, flhr, fltr #2020 REPLACEMENT OIL FILTER #’S: 2000, 2001, 2002, 2005, 2006, 2007 1. See Figure 1 to verify all Feuling components and the proper mounting bracket for your model 2.
Wash, clean and inspect all new Feuling hardware, Including – off-set sandwich oil filter adapter, filter cooler housing and oil lines, use compressed air to blow dry the oil lines, fittings, threads and bolt holes. Use a tap and die if needed to clean threads. (On installation use lubrication on all fasteners and fittings) 3. Refer to the proper service manual for your model motorcycle & engine, for removal of engine oil and spin-on oil filter. Dispose of these items properly. Clean engine case oil filter spigot and sealing surface thoroughly.
Install the clean Feuling off set oil filter sandwich adapter; both O-ring and gasket need to be assembled dry. First install the inside half of the off-set oil filter adapter, O-ring side towards engine case filter mount. We recommend using a dab loctite on the 1″ lock nut. (See figure 2) It is recommend to mock up the sandwich adapter before torquing nuts and bolts to obtain desired orientation and proper clearance to engine case and frame rails.
Install the fittings and oil lines onto the outer half of sandwich adapter torque fittings to proper specs using thread sealant on the 1/8 NPT threads and engine oil on the -4 AN oil line fittings. Complete installation of sandwich adapter, including the inner gasket. Finger tight the allen head bolts in an alternating sequence on both sides before final torque. Re-Torque the allen head bolts after the first heat cycle after installation and during every oil change. Engine Oil Replacement. Replace the engine oil after the first 50 miles or 1 hour with 5w50, 10w50 or 15W50 synthetic engine oil.
Then replace again every 1,500 miles or 1 each year. Check oil level every 500 miles, add oil if needed. Changing the Engine Oil (1).Warm up the engine for a few minutes. (2).Stop the engine. Place scooter on center stand.
(4).Place an oil pan under the engine and remove the dipstick. (5).Remove the drain plug and drain the oil. Reach in drain hole, pull out filter clean and reinstall, after all oil drains out. (6).Reinstall drain plug. Fill the engine with oil until the level is in the designated area on the dipstick. (8).Start the engine and check for oil leaks.
If a leak is found stop the engine immediately and look for cause. Rear Wheel Oil Replacement. Replace the gear oil after the first 500 miles with 5W/50 synthetic engine oil. Replace the gear oil again every 4 months or every 2000 miles. Replacing the Gear Oil (1).Put the scooter on the center stand (please see photo below).
(2).Place an oil pan under the gear case (please see photo below). (3).Remove the oil filler bolt and the drain plug to drain the oil (please see photo below). (4).Reinstall and tighten the drain plug. (5).Fill the gear case with oil (please see photo below). (6).Reinstall the oil filler bolt.
(7).Check for oil leakage. Cleaning Air Cleaner Be sure to check the air cleaner regularly. (1).Place the scooter on the center stand.
(2).Unscrew and remove the left side panel. (3).Remove the air cleaner cover by removing the screws. (4).Take out the air cleaner by removing the screws.
(5).Remove the air cleaner element and wash it gently, but thoroughly in solvent. Replace if damaged. (6).Squeeze out the excess solvent and dry it. (7).Apply oil to the entire surface of the air cleaner and squeeze out the excess oil. It should be damp but not dripping.
(8).Install the air cleaner, cleaner cover, and left side panel. Center stand 1 oil pan 2 3 oil drain plug oil pan 5 Main Switches On Position:. Electrical circuits are switched on. The engine can be started and the key can not be removed. The Norton filter adapter is then bolted to the rear piece, oil hoses are added, an oil filter is screwed into place, and the assembly is offered to the bike. With the bike supported by straps up on a lift, it will be easy to loosely mount the front clamp section in place and slide the whole assembly up the frame tube.
In order to miss the center stand, the filter will need to be as high as possible without the grease nipple striking the top of the adapter. As it ends up, there is “sweet spot” where both the nipple and the stand miss the oil filter by about an 1/8 inch. Tighten the mount down when you find that place. I found that the Norton filter adapter is best plumbed using 5/16 ID black neoprene fuel hose. The spigots on the adapter are 3/8 inch, but it is better to stretch the hose over these that to use easier fitting 3/8 ID hose and then try to shrink it onto the Triumph’s smaller metal oil lines. There will simply be fewer oil leaks using the smaller hose.
Be sure that you plumb the filter into the oil line that returns engine oil back to the oil tank. The Triumph oil pump cannot be counted on to create enough vacuum to suction highly viscous motor oil through a very fine filter during cool temperatures. Trying to place the filter on the oil line feeding the engine will quickly result in massive engine damage. It is always better to have the oil pump pushing oil through the filter, and the only way to have RF Whatley, Suwanee, GA 5 Jan 2008 that is to use the return oil line.
On all “unit-construction” Triumph engines, the rear-most oil port is the engine oil return. Other Notes. It is generally considered that adding an oil filter will at least quadruple the life of a British motorcycle engine. These motors, which were for the most part perfected in the 1950′s, were designed to run on the older non-detergent oils.
In the original design, the oil tank was the oil filter since all particulate debris in the oil settled to the bottom of the oil tank as sediment. All modern engine oils are high-detergent and tend to inhibit the formation of sediment.
Therefore most of the fine abrasive in the engine oil continues to circulate unless a filter is added. Incoming search terms:.