CYCLE ELECTRIC INC
Installation Instructions
CE-22A
These are generalized instructions and are not
intended to be all-inclusive. For more detail on your model see service manual.
Alternator Removal
1) Disconnect negative battery
terminal.
2) Drain primary case oil on
wet clutch models.
3) Remove outer primary
cover.
4) Check primary chain
alignment. Place a strait edge across the gasket surface on the inner primary.
Using a dial caliper, measure the distance from the straight edge to the
primary chain as close to the clutch as possible with the chain pushed all the
way in. Record this measurement as A. Repeat measuring as close to the
compensator sprocket as possible. Label this measurement B. Subtract B from A
and note this C. A-B=C.
C can be a positive or negative number but should not
exceed +/- .030.
5) Consult appropriate
service manual and remove compensator sprocket.
Note: After
several thousand miles it may be possible to remove the compensator sprocket
and chain adjustor shoe without removing the clutch. Caution: Do not put
excessive side force on chain.
6) Remove output shaft
extension. Take note of all shims and spaces between output shaft extension and
rotor.
7) Remove rotor and all
spacers under rotor.
Note: It may be necessary to remove the inner
primary on earlier models.
8) Unplug regulator from
stator
9) Remove 4 stator mounting
screws. Remove 2 stator plug clamp screws. Remove stators.
Alternator Installation
1) Install stator plug and plug
clamp in case. Use lock-tight 222 purple on clamp screws.
2) Mount stator to engine
case with new mounting screws (supplied). Screws have thread-locking compound
already applied. Torque screws to 30-40 in-lbs.
.
Rotor installation for All CE-22A
1- Install small diameter
.095 shim supplied with kit on output shaft before rotor.
2- Install rotor on output
shaft.
3- 1970-1990 Place
large 2.81 O.D. x .219 thick shim (supplied with kit) on output shaft
after rotor.
1991-later FLT and FXR use a
.249 shim (use stock 1.75 OD x.249 thick) or add .030 variable thickness
spacer, after .219 shim supplied with kit.
1991-later Softtail and Dyna models no spacer washers are
used on out side of rotor.
4- All models-add necessary
variable thickness shims to achieve proper primary chain alignment. If
dimension C from step 4 of removal is within +/- .030, reuse the same variable
thickness spacers between the thick shim and output shaft extension.
If dimension C was more than +/- .030, use thicker or
thinner shims as necessary to get C within +/- .030
If C is positive, use thinner shims. If C is negative, use thicker shims.
If C= -.040 and you add .060 C would = +.020
When C=zero compensator
sprocket and clutch sprocket are in line.
6- Install inner primary if
removed.
7- Install compensator
sprocket with chain adjuster shoe, and clutch if removed.
8- Adjust primary chain.
9- Check primary chain alignment.
10- Install outer primary and
other parts removed.
Note: Dont forget to add oil on wet clutch models.
Regulator-Remove Old Regulator
1) Disconnect battery
negative terminal.
2) Disconnect regulator DC
wire from
1970 to early 1984, battery positive terminal or main
breaker battery term.
Late 84-up Acc.side of main breaker (except 84-86
dressers-regulator connects to a terminal stud on the steering head).
Note: if you tie a piece of fishing line to the ring
terminal of old regulator wire before pulling wire out. You can use this cord
to pull the new wire in place.
3) Take note of how old wire
is routed. Cut wire ties and remove wire.
4) Unbolt regulator and
remove.
Install New Regulator
1) If using the same wire
routing as old regulator compare, output wire lengths and cut new regulator
wire to length. Apply ring terminal using proper crimping tool.
Note: Improper crimp on solder-less connectors can
cause charging system problems. That
will leave you on the side of the road. If you do not have a crimping tool,
borrow or buy one. Do not use pliers or rice grips.
2) Mount new regulator. Be
sure regulator has a good ground connection from the case of regulator to the
frame of motorcycle.
3) Route DC+ output wire to
main circuit breaker or fuse. On models with circuit breakers, connect wire to
silver post of main breaker. If using a fuse connect regulator on opposite side
from the battery.
Note: It is our opinion everything connected to a battery
should run through a fuse or circuit breaker except the starter motor if you
have one.
4) Connect AC plug to stator,
on rubber mount models keep wires away from front motor mount. It moves and can
damage wires.
5) Check the routing of all
wires to be sure they are not in a vulnerable position. Keep wires away from
exhaust pipes and moving parts. Be sure wires are not in the very bottom of
lower frame or they will get pinched if you bottom out.
Replace all wire ties previously cut and add new ones where
necessary.
6) Reconnect battery and
start motor. Test battery voltage. All L model regulators should run between
13.7~14.1 Standard models should run 14.2 to 14.6 depending on what model you
have.
Have A Good Ride!!