Ultra Cool - Reefer Install Manual Dyna

7/27/2019 Ultra Cool - Reefer Install Manual Dyna

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Installation Guide

Patent #6955150

FITS DYNA FRAME FROM 1993 - 2013

Revision 1.0 6/2

see a full step by step video

www.ultracool.com/suppo This is a step by step guide to installing

a Reefer oil cooling system on a Dyna

Fan Assisted Oil Coolers



Front Rear

Right

Left NOTE: Installation instructionsare explained and illustrated

from the rider’s point of view.

2

Welcome to UltraCool

We would like to thank you for making UltraCool your system of choice. We hope these instructions arehelpful in assisting you with your installation. If you have any further questions regarding the installationprocess, 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 installa-

tion. If you feel you are not , please call (831)630-1322 for a dealer in your area that can assist you.

Lets Get StartedBelow you will find a list of parts required for installation. Please inventory all parts are in this kit beforeyou 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 wrench5/16” Allen wrench11/16” Open end wrench

3/8” Ratchet3/8” Extention1” socket

Power Drill

5/16” Drill bitWire strippers

Oil filter wrenchTorque wrench (optional)Bike Lift (optional)

7/8” socket7/16” Hex driver

(for HD Cooler Removal)Phillips screwdriver

Installation Parts

Complete Fan assembly

(2) Braided oil linesSteel mounting bracketAluminum oil adapter unitSmall Parts bag

Small Parts Bag

LED kit

Fuse HolderFitting WrenchSpade Connector

Butt ConnectorTie Straps

Thread locker

Blue wire tapThreaded adapter(for HD Cooler only)

ITEM # ITEM DESCRIPTION PRICE

RF-103 AN-6 Male Fitting $ 2.75

DY-108 Mounting Bracket $ 10.00

DYB-105 Hose A - (2) 90º $ 25.00

DYB-107 Hose B - (2) 45º $ 25.00

RF-109 Fitting Tool $ 5.00

RF-110 Oil Adapter - Complete $ 155.00

RF-138 Thermal Switch $ 21.00

RF-118 Threaded Pipe Adapter $ 5.00

RF-122 Adapter - Center Gasket $ 3.00

RF-126 Dual Fan Set $ 72.00

RF-128 Grill for Cover $ 9.00

RF-129 O-ring Gasket - Rubber $ 5.00

RF-131 Chrome Cover $ 35.00

RF-GC Glossy Black Cover $ 40.00

RF-CF Flat Black Cover $ 40.00

RF-205 45º Fitting $ 9.00

RF-106 90º Fitting $ 9.00

RF-208 Straight Fitting $ 7.00

RF-124 Heat Exchanger - Cooler $ 75.00

DYNA REPLACEMENT PARTS

Prices are subject to change



Step 2: Old coolerIf 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.

Step 3: Threaded adapterAfter 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.

Step 1: Remove oil filterRemove the oil filter., the mating surface needs to be

clean and oil free before you move on to step 3.

Oil

Filter

Mount

7/16”7/8”

3

Getting startedBefore 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.

FOR MORE HELPvisit ultracool.com/support



4

Step 4aStep 4b

Remove the 6 bolts from the oil adapter.Make sure the oil filter mount is clean and dry before

you proceed. Notice in instructions parts are markedA, B, C. Take part “C” and the 1” nut, and add 3 drops of

thread locker to nut, then thread it onto the oil filtermount. Angle part C with down tubes as shown in

Fig. B and tighten nut to 20 ft. lbs.

3/4”

3/4”

1”

Step 5: Oil adapter installationTake the other half of the adapter and assemble it with

the gasket and the top (2) 3/4” hex bolts. This will holdthe gasket in place. Hand start the (2) 3/4” bolts to the

adapter on the bike, just hand tight. Start the (4) 1” boltsalong 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 boltsafter first ride to make sure that they are snug.

3/4”

3/4”

1”

This is an important part of the installation, please take your time.

Tools required:Rachet // 1” Socket // Extension and thread locker

Fig. B

B

A

C

A

B

C



Step 6: Installing Mounting Bracket

Step 8: Oil line installation

a) Remove top bolt

b) Loosen bottom bolt 1/4”c) Slide bracket behind loose bolt and washerc) Replace top bolt

d) Torque bolts 25-35 ft/lbs

5

B

C

D

C

D

Locate HOSE A with (2) 90 degree fittings. Pull nut upflush with inside flare and add three drops of oil to

inside threads and three drops to back of nut. Handstart fitting on oil adapter marked C . Hand tight for

now (do not tighten). Repeat process for fittingmarked B on oil cooler. Repeat process for HOSE B .

Step 9: Tighten oil lines

Locate the fitting wrench in parts bag. You will need aratchet and an extension. Slide fitting wrench over oil

line and up to nut. Now tighten the nut up snug, andback it off. Repeat this process twice, and the last time

tighten the nut 2-3 flats. This process will shape theAN-6 cone fitting and you should have a leak proof seal

Step 7: Installing cooler assemblySet cooler assembly on top of mounting bracket.

Use (2) ¼”-20 x ¾” bolts and tighten, just handtight for now.

B

A

A

HOSE A

HOSE B



6

Step 10: Fitting coverAfter you have installed your oil lines, you canremove the 2 bolts holding on the fan bracket

and slide the cover in place. Make adjustmentsto cover and bracket and tighten bolts. Plugred female connector to one side of thermalswitch (refer to this as the FAN SIDE for LED

installation in the instructions.)

Step 13: Connecting to powerLocate large 8 pin connector and look fororange and white wire. Pull back coveringand attach wire tap onto orange and whitewire and close tight.

Step 14: ConnectionLocate red wire in PVC tube from thermal switch Fand strip end of red wire. Locate fuse holder andcut wire in half, strip both ends using a blue buttconnector E connect red fan wire and red fuse wire.

Connect blue spade connector to other end of redwire from fuse holder C and insert into blue wire tapB secure fuse holder using tie straps. Checkconnection with a meter if available.

Step 11: Connecting to powerLocate 48” PVC wiring harness and connect redfemale connector to the remaining pin on the

thermal switch. Run the harness under the enginealong the right side of frame rail and secure to frameusing tie straps.

Step 12: Connecting to powerRemove seat by removing bolt at rear of seat and

set aside. Bring PVC harness up center frame tubeto battery box.

Rear fender

connector

orange and white wire

blue wire tap

AB C

D

E

F

A) Orange/white wire

B) Blue wire tap

C) Fuse holder

D) Red wire

E) Butt connector

F) Red wire from thermal switch

FOR MORE HELPvisit ultracool.com/support



Step 15: Installing LED lightSit on bike and look for a good location on the

dash for the LED light. Remove bolts holdingdash to gas tank. After finding a good locationcheck under dash that nothing is in the way,then drill a 5/16” hole. Remove nut from backof LED light and feed black and red wiresthru 5/16” hole from the top. Now secure LEDwith nut from the back. Look for a good ground

point under the dash. Measure black LED wireand cut, strip and attach red ring tongueconnector to end of black wire, then secure it tothe ground point.

Step 16: Wiring up LED lightTake 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 thermalswitch, strip the red wire and attach a blue piggybackconnector to the end. Now put the piggyback on thefan side pin of the thermal switch. Next, connect thered female connector from the fan to the piggyback.Secure wire to front down tube with tie straps supplied.

Suggestedlocations PVC

tubing

Red LEDwire

A

B

E

D

F

CRed wire from fans

Red connector to piggy back

Fan side pin connectorRed wire from LED light

Piggy back connector

Battery side

A

B

C

D

E

F

7



Checklist

Congratulations! you have completed your installation. Now let’s 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 andget the engine hot.

8O I L C O O L I N G S Y S T E M S Revision 1.00 6/2013

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

Warranty

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

DisclaimerUltraCool 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:

General Mailbox:

Earl Sutton:

Larry Steed:

[email protected]

[email protected]

[email protected]

[email protected]

President

General

Sales

Tech Support

Documents

Ultra Cool - Reefer Install Manual Dyna