Vixen 21 Oil Cooler Replacement Repair Guide

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Oil Cooler
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Step 1

              Oil Cooler

After removing the side panel, it’s clear that my oil cooler has been leaking for a while. Fortunately, AFAB sells a complete replacement kit including a new oil cooler and new hoses!

After removing the side panel, it’s clear that my oil cooler has been leaking for a while. Fortunately, AFAB sells a complete replacement kit including a new oil cooler and new hoses!

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Step 2

The tail light covers come off easy enough with 10 screws and a single connector.
The white housing beneath comes off with a bolt on the left and a screw on the right.

The tail light covers come off easy enough with 10 screws and a single connector.

The white housing beneath comes off with a bolt on the left and a screw on the right.

Step 3

On my Vixen there was a hex head bolt on the top right, and a on-its-way-to-being-stripped Phillips head bolt on the top left.

On my Vixen there was a hex head bolt on the top right, and a on-its-way-to-being-stripped Phillips head bolt on the top left.

Step 4

There were two Phillips screws in the bottom of the panel, but these weren’t actually attached to anything.
My new side-routed exhaust definitely made it harder to get this panel out.

There were two Phillips screws in the bottom of the panel, but these weren’t actually attached to anything.

My new side-routed exhaust definitely made it harder to get this panel out.

Step 5

There’s one electrical plug and 4 obvious hex bolts to remove the condenser fan.

There’s one electrical plug and 4 obvious hex bolts to remove the condenser fan.

Step 6

Once the condenser fan is removed we can get a good look at the oil cooler. The fittings are certainly leaking, but the cooler itself might actually be fine.
The Vixen bleeds black and I bleed red, whoops!

Once the condenser fan is removed we can get a good look at the oil cooler. The fittings are certainly leaking, but the cooler itself might actually be fine.

The Vixen bleeds black and I bleed red, whoops!

Step 7

Here’s all the shiny new replacement parts. You can buy the oil cooler kit from AFAB.
I made a mess of the threads putting one of the blue aluminum fittings in to the top of the new oil cooler. Thanks to a 1/2" NPT tap and die from Harbor Freight and a friend’s help I was able to salvage it and I don’t think it leaks, but time will tell…

Here’s all the shiny new replacement parts. You can buy the oil cooler kit from AFAB.

I made a mess of the threads putting one of the blue aluminum fittings in to the top of the new oil cooler. Thanks to a 1/2" NPT tap and die from Harbor Freight and a friend’s help I was able to salvage it and I don’t think it leaks, but time will tell…

Step 8

On a closer inspection, all my existing fittings are leaking, which at this point I suppose is a good sign.

On a closer inspection, all my existing fittings are leaking, which at this point I suppose is a good sign.

Step 9

Getting the oil cooler off the condenser was easy, there’s just two bolts. But it’s still attached to the engine…

Getting the oil cooler off the condenser was easy, there’s just two bolts. But it’s still attached to the engine…

Step 10

It was easy enough to loosen the hose clamps and pop the hoses off.
This made a mess, because not surprisingly, there’s oil in the lines.

It was easy enough to loosen the hose clamps and pop the hoses off.

This made a mess, because not surprisingly, there’s oil in the lines.

Step 11

The old oil cooler is out!

The old oil cooler is out!

Step 12

There was a lot of oil/dust sludge beneath the oil cooler, requiring a rather dirty cleanup.

There was a lot of oil/dust sludge beneath the oil cooler, requiring a rather dirty cleanup.

Step 13

Removing the remaining couplers was quite challenging.
I was able to borrow some large metric wrenches (24 mm and 27 mm) from a friend to help with this step.

Removing the remaining couplers was quite challenging.

I was able to borrow some large metric wrenches (24 mm and 27 mm) from a friend to help with this step.

Step 14

After the first fitting was off, I was able to get a 24 mm socket over the second one to remove the fitting.

After the first fitting was off, I was able to get a 24 mm socket over the second one to remove the fitting.

Step 15

I routed the new lines the same as the old ones.
The plastic lining the hole the hoses go through is definitely decaying, but seems like it’ll still protect the hoses ok.

I routed the new lines the same as the old ones.

The plastic lining the hole the hoses go through is definitely decaying, but seems like it’ll still protect the hoses ok.

Step 16

The lines are just barely long enough, but it reaches!

The lines are just barely long enough, but it reaches!

Step 17

Mounting to the condenser is straightforward.

Mounting to the condenser is straightforward.

Step 18

Everything’s in place!
I spent some more time cleaning the dirty panel below. Thus far I have no leaks from the new oil cooler!

Everything’s in place!

I spent some more time cleaning the dirty panel below. Thus far I have no leaks from the new oil cooler!

To reassemble your device, follow these instructions in reverse order.

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                    Luke Soules

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