Revision 1.

0 6/2013

Installation Guide
FITS DYNA FRAME FROM 1993 - 2013
This is a step by step guide to installing a Reefer oil cooling system on a Dyna

see a full step by step video at www.ultracool .com/support

Fan Assisted Oil Coolers

Patent #6955150

Welcome to UltraCool
We would like to thank you for making UltraCool your system of choice. We hope these instructions are helpful in assisting you with your installation. If you have any further questions regarding the installation process, please feel free to call us.

Important please read first

Please read through this entire installation process before you decide if you are capable of the installation. If you feel you are not , please call (831)630-1322 for a dealer in your area that can assist you. Lets Get Started Below you will find a list of parts required for installation. Please inventory all parts are in this kit before you start the installation process. Also listed is a tools required list for installation. Please make sure these are available to you.

Tools Required
5/32 Allen wrench 5/16 Allen wrench 11/16 Open end wrench 3/8 Ratchet 3/8 Extention 1 socket Power Drill 5/16 Drill bit Wire strippers Oil filter wrench Torque wrench (optional) Bike Lift (optional) 7/8 socket 7/16 Hex driver (for HD Cooler Removal) Phillips screwdriver

DYNA REPLACEMENT PARTS ITEM # RF-103 DY-108 DYB-105 DYB-107 RF-109 RF-110 RF-138 RF-118 RF-122 RF-126 RF-128 RF-129 RF-131 RF-GC RF-CF RF-205 RF-106 RF-208 RF-124 ITEM DESCRIPTION AN-6 Male Fitting Mounting Bracket Hose A - (2) 90 Hose B - (2) 45 Fitting Tool Oil Adapter - Complete Thermal Switch Threaded Pipe Adapter Adapter - Center Gasket Dual Fan Set Grill for Cover O-ring Gasket - Rubber Chrome Cover Glossy Black Cover Flat Black Cover 45 Fitting 90 Fitting Straight Fitting Heat Exchanger - Cooler PRICE $ 2.75 $ 10.00 $ 25.00 $ 25.00 $ 5.00 $ 155.00 $ 21.00 $ $ $ $ 5.00 3.00 9.00 5.00

$ 72.00

Installation Parts
Complete Fan assembly (2) Braided oil lines Steel mounting bracket Aluminum oil adapter unit Small Parts bag

$ 35.00 $ 40.00 $ 40.00 $ $ $ 9.00 9.00 7.00

Small Parts Bag

LED kit Fuse Holder Fitting Wrench Spade Connector Butt Connector Tie Straps Thread locker Blue wire tap Threaded adapter (for HD Cooler only)

$ 75.00
Prices are subject to change

Right

Front

Rear

Left

NOTE: Installation instructions are explained and illustrated from the riders point of view.

Step 1: Remove oil filter

FOR MORE HELP visit ultracool .com/support

Remove the oil filter ., the mating surface needs to be clean and oil free before you move on to step 3.

Getting started

Before we get started with the installation, make sure you follow the instructions carefully and double check your work using our checklist at the end of this installation guide.

Oil Filter Mount

Step 2: Old cooler

Step 3: Threaded adapter

If you have a stock cooler on your bike now, you will need to remove it by taking out the allen bolt in the center of the adapter as shown below.

After you have removed the old adapter, locate the threaded adapter and add 2-3 drops of thread locker and install in center of filter mount as shown below and tighten.

7/16

7/8

This is an important part of the installation, please take your time. Tools required: Rachet // 1 Socket // Extension and thread locker Step 4b Step 4a
Remove the 6 bolts from the oil adapter.

B B A

Make sure the oil filter mount is clean and dry before you proceed. Notice in instructions parts are marked A, B, C. Take part C and the 1 nut, and add 3 drops of thread locker to nut, then thread it onto the oil filter mount. Angle part C with down tubes as shown in Fig. B and tighten nut to 20 ft. lbs.

C C

3/4 3/4

1
Step 5: Oil adapter installation Fig. B

Take the other half of the adapter and assemble it with the gasket and the top (2) 3/4 hex bolts. This will hold the gasket in place. Hand start the (2) 3/4 bolts to the adapter on the bike, just hand tight. Start the (4) 1 bolts along the bottom of the adapter. You MUST tighten all (6) hex bolts in an even star pattern. This is important. You can also use thread locker on these. Check these bolts after first ride to make sure that they are snug.

3/4 3/4

Step 6: Installing Mounting Bracket

a) Remove top bolt b) Loosen bottom bolt 1/4 c) Slide bracket behind loose bolt and washer c) Replace top bolt d) Torque bolts 25-35 ft/lbs

Step 7: Installing cooler assembly

Set cooler assembly on top of mounting bracket. Use (2) -20 x bolts and tighten, just hand tight for now.

Step 8: Oil line installation

Locate HOSE A with (2) 90 degree fittings. Pull nut up flush with inside flare and add three drops of oil to inside threads and three drops to back of nut. Hand start fitting on oil adapter marked C . Hand tight for now (do not tighten). Repeat process for fitting marked B on oil cooler. Repeat process for HOSE B .

Step 9: Tighten oil lines

Locate the fitting wrench in parts bag. You will need a ratchet and an extension. Slide fitting wrench over oil line and up to nut. Now tighten the nut up snug, and back it off. Repeat this process twice, and the last time tighten the nut 2-3 flats. This process will shape the AN-6 cone fitting and you should have a leak proof seal.
C

HOSE A
B

HOSE B
A A D
D

Step 10: Fitting cover

After you have installed your oil lines, you can remove the 2 bolts holding on the fan bracket and slide the cover in place. Make adjustments to cover and bracket and tighten bolts. Plug red female connector to one side of thermal switch (refer to this as the FAN SIDE for LED installation in the instructions.)

Step 11: Connecting to power

Locate 48 PVC wiring harness and connect red female connector to the remaining pin on the thermal switch. Run the harness under the engine along the right side of frame rail and secure to frame using tie straps.

Step 12: Connecting to power

Remove seat by removing bolt at rear of seat and set aside. Bring PVC harness up center frame tube to battery box.

FOR MORE HELP visit ultracool .com/support

Step 13: Connecting to power

Locate large 8 pin connector and look for orange and white wire. Pull back covering and attach wire tap onto orange and white wire and close tight.

Step 14: Connection

Locate red wire in PVC tube from thermal switch F and strip end of red wire. Locate fuse holder and cut wire in half, strip both ends using a blue butt connector E connect red fan wire and red fuse wire. Connect blue spade connector to other end of red wire from fuse holder C and insert into blue wire tap B secure fuse holder using tie straps. Check connection with a meter if available.

Rear fender connector

orange and white wire

blue wire tap

A B C E D F

A) Orange/white wire B) Blue wire tap C) Fuse holder

D) Red wire E) Butt connector F) Red wire from thermal switch

Step 15: Installing LED light

Sit on bike and look for a good location on the dash for the LED light. Remove bolts holding dash to gas tank. After finding a good location check under dash that nothing is in the way, then drill a 5/16 hole. Remove nut from back of LED light and feed black and red wires thru 5/16 hole from the top. Now secure LED with nut from the back. Look for a good ground point under the dash. Measure black LED wire and cut, strip and attach red ring tongue connector to end of black wire, then secure it to the ground point.
Suggested locations

Step 16: Wiring up LED light

Take remaining red wire from LED and run it down the front down tube towards the oil adapter. Measure the red wire to the fan side of the thermal switch, strip the red wire and attach a blue piggyback connector to the end. Now put the piggyback on the fan side pin of the thermal switch. Next, connect the red female connector from the fan to the piggyback. Secure wire to front down tube with tie straps supplied.

PVC tubing

Red LED wire

C F

A Red wire from fans B Red connector to piggy back C Fan side pin connector D Red wire from LED light E F

Piggy back connector Battery side

Checklist

Congratulations! you have completed your installation. Now lets go back and double check our work.

Install oil filter, and do not over tighten! Check oil level and top off. Oil lines are not touching any electrical lines or cables. Oil lines are tight. Cooler cover is installed and tight. All PVC tubing is secure. Dash bolts are installed and tight. Seat is replaced and bolt is tight. Engine bolts are tight. Any extra parts? What are they for? Clean up any oil on the engine. All electrical connections are checked. Keep 5/32 allen driver handy.
Now start up the bike and let it idle for a few minutes. Turn off engine And check oil level. Go for a 2-3 mile ride and get the engine hot. Come back and check 4 bolts along bottom of oil adapter. This is a Important step because our gasket is silicone coated and some shrinkage Is possible. Checking is a good idea.

Post a picture of your bike for the world to see!

Warranty

If you want to upload a picture of your bike to our website, go to http://ultracool .com/submit-testimonial

UltraCool warrants that this product be free from manufacturing and material defects for a period of 1 year from the date of purchase to the original purchaser. In the event you experience a problem within this period, please e-mail or call us at

Disclaimer
UltraCool or any of its agents shale not be held liable for injury that results from the missuse or improper installation from their products.

UltraCool Oil Coolers 1851 Airway Drive Unit C, Hollister, CA 95023

Phone: (831)630-1322 | Fax: (831)630-1322 | Order Line: 888-630-1322 http://www.ultracoolfl.com Email: Robert Clink: Earl Sutton: Larry Steed: [email protected] [email protected] [email protected] President General Sales Tech Support General Mailbox: [email protected]

OIL COOLING SYSTEMS

Revision 1.00 6/2013