Motorcycle engine cooling and lube systems Harley V-Rod VRSCA (2002-2006)

Oil flow — general
The engine oil serves two purposes. First, the oil lubricates all of the metal to metal parts that are in motion relative to each other. Second, the oil cools the engine, specifically, the pistons. See Figure 3-1. As the oil is warmed to normal...

Oil pressure indicator lamp
See Figure 3-4. The red oil pressure indicator lamp illuminates to indicate improper circulation of the engine oil. The lamp illuminates when the ignition is first turned on (before the engine is started), but should be extinguished once the engine...

Checking oil pressure
PART NO. SPECIALTY TOOL HD-45308 Oil pressure gauge HD-45309 Oil pressure gauge adapter Operating oil pressure is checked as follows: 1. Fill crankcase to proper level. 2. Remove oil pressure switch from crankcase. 3. Attach OIL PRESSURE GAUGE (1)...

Oil pump — replacement
1. See Figure 3-67. With oil pump on engine, loosen bypass fastener and front cover fasteners. Figure 3-67. Oil pump fasteners 2. See Figure 3-68. Remove three fasteners holding oil pump in case. Figure 3-68. Remove oil pump 3. See Figure 3-69....

Oil filter mount — replacement
1. See Figure 3-234. Remove three fasteners and remove oil filter mount. Figure 3-234. Remove oil filter mount fasteners 2. See Figure 3-235. Remove o-ring and discard. Figure 3-235. Replace O-ring 3. Inspect oil passages for debris and dirt. Clean...

Cooling system specifications
Table 6-1. Capacities ITEM LITERS QUARTS Engine coolant 2.4 2.54 Engine oil w/filter 4.3 4.5 Table 6-2. Coolant pressure ITEM KPA PSI Cap lower limit 96 14 Rated cap pressure 110 16 Cap upper limit 124 18 System pressure 103 15 Table 6-3. Coolant...

Coolant flow — general
General The VRSCA engine is cooled by a an ethylene-glycol coolant and the lubricating engine oil. The ethylene-glycol coolant is pressurized and circulated through the engine and a cooling radiator by an impeller type water pump utilizing a...

Cooling system troubleshooting
Warning! The troubleshooting section of this manual is intended solely as a guide to diagnosing problems. Carefully read the appropriate sections of this manual before performing any work. Observe all cautions and warnings. Failure to observe...

Pressure cap description
The pressure cap and radiator filler neck pressurize the coolant system. The pressure cap’s upper spring diaphragm gasket seals to the upper sealing seat in the filler neck. The lower pressure limiting valve in the pressure cap seals to the lower...

Pressure cap test
PART NO. SPECIALTY TOOL HD-45335 Coolant system pressure tester The pressure cap should be tested for the correct operating range every time the antifreeze is changed or any cooling system maintenance performed. Warning! Do not remove the pressure...

Cooling system pressure test
PART NO. SPECIALTY TOOL HD-45335 Coolant system pressure tester The cooling system can be pressure tested to identify a leak and to verify a blown engine gasket. 1. Before troubleshooting cooling system, be sure engine coolant level is at COLD FULL...

Leak detection dye test
PART NO. SPECIALTY TOOL HD-29545-6 Coolant fluorescent leak detection dye HD-35457 Black light leak detector Note. If the coolant overflow bottle is empty when the engine is cold, it is possible that air has been drawn into the coolant system. The...

Tests for blown gasket
PART NO. SPECIALTY TOOL HD-45335 Coolant system pressure tester If a pressure test indicates a leak but there is no visible leak, even after a leak detection dye test, perform the following tests to verify a damaged engine gasket. 1. Start and run...

Engine coolant — replacing
GENUINE HARLEY-DAVIDSON EXTENDED LIFE ANTIFREEZE & COOLANT provides temperature protection to -36.7°C (-34°F). GENUINE HARLEY-DAVIDSON EXTENDED LIFE ANTIFREEZE & COOLANT is pre-diluted and ready to use fullstrength. DO NOT add water. A mixture of...

Thermostat — removal and installation
The thermostat is a valve that remains closed until the engine reaches operating temperature. The thermostat opens allowing engine coolant to flow out of the engine to the radiator when the coolant temperature exceeds 85°C (185°F). The thermostat is...

Water pump — removal and installation
Removal Warning! Do not remove the pressure filler cap when the engine is hot. The cooling system is under pressure and hot coolant and steam may escape causing severe burns. Allow engine to cool before servicing the cooling system. 1. Allow cooling...

Coolant pipes and hoses — removal and installation
Removal 1. Allow cooling system to cool. 2. Remove right side cover and maxi-fuse. See 8.5 Maxi-fuse . Warning! To protect against shock and accident start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety...

Oil line fittings — removal and installation
Removal Warning! Do not remove the filler cap when the engine is hot. The cooling system is under pressure and hot coolant and steam may escape causing severe burns. Allow engine to cool before servicing the cooling system. 1. Allow cooling system...

Radiator — removal and installation
General The heat exchangers, or radiators, for both engine cooling and oil cooling are bolted together in a single radiator/oil cooler assembly. The radiator/oil cooler assembly is fasten to the frame with: Double threaded studs near the steering...

Oil cooler — removal and installation
Removal Warning! Do not remove the filler cap when the engine is hot The cooling system is under pressure and hot coolant and steam may escape causing severe burns. Allow engine to cool before servicing the cooling system. 1. Allow cooling system to...