INSTRUCTIONS - Harley
Contents
1. leaks Watch the coolant level and add fluid until the level remains at the COLD FULL line with the motorcycle on the jiffy stand Turn off the engine check the oil level and add oil if required Radiator Maintenance CAUTION Carefully clean the front surface of the radiator regularly Leaves and other debris can collect on the radiator sur face and degrade radiator performance This could lead to engine overheating and engine damage 00197a 2 of 3 SMOTOR e Service Parts i02400 Part No Not sold separately Description Quantity Cooling module consists of items 2 22 Radiator Plug Hose ass y oil cooler inlet Hose ass y oil cooler outlet Cap Hose drain Cable strap 3 Oil cooler assembly Screw 8 Nut 4 Screw 2 Bracket O ring 2 26722 04 5235 62940 04 62941 04 62909 04 62953 01 10065 26723 04 5237M 5238M 5236M 26772 04 11101 Item 1 2 3 4 5 6 7 8 9 J03021 Part No 26721 01A VRSC Radiator Kit Voltage regulator connector Item Description Quantity Fan assembly Socket housing 2 place 2 Contact socket 4 Grommet 4 Bushing 2 Spacer 2 Washer front 2 Nut 2 Oil feed return fitting ass y 2 consists of items 24 27 Fitting oil feed return O ring 13 3mm 52 in I D O ring 12 4mm 49 in I D Retainer wire clip Cable strap rosebud mount Date 07 03 Part No 26724 04 73152 96BK 73191 96 26752. 7 01 11568 26758 01 6838M 3725M 63650 04K Not sold separately 10994K 11140 11384K 10073 3 of 3
3. ap Loosen the air bleed plug Fill the radiator with Genuine Harley Davidson Extended Life Antifreeze amp Coolant through the filler neck See ENGINE COOLANT in the Service Manual Tighten the air bleed plug to 9 11 Nm 80 97 in Ibs and reinstall the pressure cap J03021 17 Install the air cleaner cover and the decorative air box cover See AIRBOX AND AIR FILTER in the Service Manual CAUTION Do not over tighten bolts on battery terminals Use rec ommended torque values Over tightening battery termi nal bolts could result in damage to battery terminals 00216a 18 Reinstall the negative battery cable Tighten to 6 8 10 8 Nm 60 96 in Ibs 19 Install the maxi fuse and right side cover CAUTION When closing the seat make sure the ignition switch is in the FUEL position If the ignition switch is in any other position when the seat is closed the seat latch mechanism could be damaged 00196a 20 Close the seat then start the engine While the engine is running inspect the oil fittings for leaks If leaks are found turn off the engine and correct Check the coolant level in the overflow bottle with the coolant cold and the motorcycle on the jiffy stand If the coolant level is below the COLD FULL line remove the cap from the overflow bottle and add Genuine Harley Davidson Extended Life Antifreeze amp Coolant until the fluid level reaches the COLD FULL line Continue to run the engine checking for oil
4. cMOTOR2 HARLEY DAVIDSON WY J03021 INSTRUCTIONS REV 07 03 2003 Kit Number 26721 01A VRSC RADIATOR KIT General This kit fits all 2002 and later VRSC V Rod models See the Service Parts illustration for kit contents NOTE This instruction sheet references Service Manual informa tion A Service Manual for your model motorcycle is required for this installation and is available from any Harley Davidson Dealer Removing the Existing Radiator Assembly WARNING Do not remove radiator filler cap when engine is hot The cooling system is under pressure and hot coolant and steam can escape which could cause severe burns Allow engine to cool before servicing the cooling system 00091a A WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 Refer to BATTERY MAINTENANCE DISCONNEC TION in the Service Manual to disconnect the maxi fuse and negative battery cable 2 Cover the front fender with a shop towel or protective cover 3 Refer to RADIATOR OIL COOLER REMOVAL in the Service Manual to remove the radiator assembly It will not be necessary to remove the air filter or velocity stacks 2004 and Later Models 4 Proceed to Installing the New Radiator Assembly The two quick connect oil fittings 23 and cable strap 28 in the kit can be discarded 2002 2003 Models 4 Refe
5. er Assemble the crossmember to the mounting pins on the bottom of the oil cooler Install the crossmember to the frame 8 Lightly tug on the oil lines to verify that they are securely locked to the fittings 9 Tighten the cooling system fasteners as follows e Cross member fasteners to 20 26 Nm 15 19 ft lbs e Top mounting nuts 22 to 19 27 Nm 15 20 ft lbs e Pipe clamp to 6 5 Nm 57 in Ibs e P clamp to 6 10 Nm 53 88 in Ibs e Hose clamps to 3 4 Nm 27 35 in Ibs 10 Route the drain hose 7 to the overflow bottle 11 Secure the voltage regulator connector to the top plate of the radiator e 2002 2003 Models Use the cable strap 28 from the kit e 2004 and Later Models Use the cable strap already assembled to the connector The rosebud on the strap snaps into the hole in the radiator top plate 12 Install the radiator cover 13 Make the electrical connections as follows e Mate the crank position sensor connector 79 halves e Mate the top 97T and bottom 97B cooling fan connector halves e Mate the stator to voltage regulator connector 46 halves e Push the top fan connector 97T into the radiator cover Use a cable strap not provided to tie the fan wiring harness to the crank position sensor wiring harness 14 Install the left and right side radiator trim covers 15 Fill the engine with oil See ENGINE OIL AND FILTER in the Service Manual 16 Remove the radiator pressure c
6. r to OIL LINE FITTINGS REMOVAL in the Service Manual to remove the oil in fitting at the crankcase and the oil out fitting at the oil filter 5 Obtain the two quick connect oil fittings 23 from the kit Thread the fitings into the holes in place of the original fittings Tighten the fittings to 40 44 Nm 29 32 ft lbs Installing the New Radiator Assembly 1 Hold the new radiator oil cooler assembly up to the motorcycle frame 2 Line up and fit the radiator inlet and outlet pipes to the engine coolant hoses 3 See Figure 1 Supporting the radiator oil cooler assem bly push the oil line into the oil out fitting on the engine oil filter until it clicks in place under the spring clip NOTE The yellow witness band on the flanged oil line will not be vis ible if the oil line has been correctly snapped into the fitting 4 Snap the plastic dust cap over the spring clip groove NOTE The dust cap will not snap onto the fitting if the oil line is not correctly installed on the fitting 5 Thread on but do not tighten the nuts holding the radi ator oil cooler assembly to the engine mount studs 6 Push the remaining oil line into the oil in fitting on the crankcase until it clicks in place under the spring clip Snap the plastic dust cap over the spring clip groove 102401 tif Figure 1 Flanged Oil Line 1 of 3 7 Install the grommets 18 into the holes in the radiator oil cooler crossmemb
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