| PART NUMBER | TOOL NAME |
| HD-46503 | OIL LINE REMOVER, 1/2 INCH |
| FASTENER | TORQUE VALUE | |
| Oil cooler fastener: XR 1200X | 36-60 in·lbs | 4.1-6.8 Nm |
Removal
1. Disconnect the battery. See 1.22 BATTERY MAINTENANCE.
2. Drain oil tank. See 1.6 ENGINE OIL AND FILTER.
3. Using OIL LINE REMOVER, 1/2 INCH (Part # HD-46503), separate oil cooler lines from oil cooler.
4. See Figure 3-37. Remove fasteners (1) securing oil cooler to frame brackets.
Figure 3-37. Oil cooler mounts: 1. Fastener (2); 2. Oil cooler mount (2)
5. Remove oil cooler from motorcycle.
6. If necessary, remove oil cooler rigid lines from gearcase cover. See 3.12 PRECISION COOLING SYSTEM: XR 1200X, Oil Pump Lines.
Installation
Note. Used O-rings can leak. Always install new O-rings when performing repairs.
1. Install new O-rings in quick connect fittings.
2. If removed, install oil cooler rigid lines. See 3.12 PRECISION COOLING SYSTEM: XR 1200X, Oil Pump Lines.
Note. See Figure 3-38. Position oil cooler parallel with down tubes as shown. Do not orient oil cooler forward of down tubes or clutch cable damage will result.
Figure 3-38. Oil cooler orientation: 1. Down tube; 2. Oil cooler
3. See Figure 3-37. Secure oil cooler to frame brackets. Tighten fasteners (1) to 36-60 in·lbs (4.1-6.8 Nm).
Note. Apply a light film of oil to the end of the line before inserting it into the fitting.
4. Connect oil lines to oil cooler fittings. Verify that each is securely held by the retainer clip.
5. Fill the oil tank. See 1.6 ENGINE OIL AND FILTER.
6. Connect the battery. See 1.22 BATTERY MAINTENANCE.