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 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 precautions could result in death or serious injury.
3. Remove negative battery cable.
4. Remove the radiator/oil cooler assembly. See 6.8 Radiator/oil cooler.
5. See Figure 6-20. With assembly on bench and holding a cup under each line, loosen two sleeves (18) that connect oil pipes (16, 19) to oil cooler (17).
6. If replacing oil pipes:
- a. Remove oil line bracket fastener (13) and bracket (12) with spacers (5) bushings (6), grommets (8) and washers (9).
- b. Cut cable wraps (3) to drain hose and oil lines.
- c. Remove drain hose (4) and oil cooler outlet and inlet pipes (16, 19).
7. Cut cable wrap (3) holding expansion bottle drain hose to oil cooler.
8. Remove fasteners (15) holding oil cooler (17) to engine coolant radiator (20). Remove oil cooler.
Installation
1. See Figure 6-20. Install oil cooler (17) to engine coolant radiator (20). Tighten fasteners (7) to 9-11 Nm (80-97 in·lbs).
2. If installing oil pipes:
- a. Route oil pipes (16, 19) in front and over top of engine coolant radiator (20).
- b. Install bracket (12) over the oil lines and tighten fastener (13) to 15 Nm (11 ft·lbs).
- c. See Figure 6-22.Cable wrap oil pipes and drain hose to coolant radiator at upper and lower points on straight portion prior to bend in pipes.
- d. See Figure 6-20. Install spacer (5), bushings (6), grommet (8), and washers (9) to mounting bracket.
Figure 6-22. Lower oil pipes to drain hose cable wrap
3. Install sleeves (17) of the oil pipes (14, 18) to oil cooler.
4. See Figure 6-23. Support oil cooler fitting with a wrench and tighten sleeves to 50-55 Nm (37-40 ft·lbs).
Figure 6-23. Support wrench on oil cooler (radiator/oil cooler installed)
5. See Figure 6-22. Cable wrap (3) drain hose (4) at bottom of oil cooler.
6. Replace the radiator/oil cooler assembly. See 6.8 Radiator/oil cooler.
Caution! Attach the cables to the correct battery terminals using the proper torque. Overtightening bolts can damage battery terminals and incorrect connections may damage the motorcycle's electrical system.
Warning! Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion that could result in death or serious injury.
7. Replace the negative battery cable. Tighten to 6.8-10.8 Nm (60-96 in·lbs).
8. Install maxi-fuse and right side cover.
9. After running engine:
- a. Inspect oil sleeves and fittings for oil leaks.
- b. Check oil level and add oil if required.
- c. Check coolant level in overflow bottle with coolant cold and motorcycle on jiffy stand and add coolant if required.