CYCLE ELECTRIC INC
Installation Instructions
CE-3845-02 Stator
The
CE-3845-02 is a heavy-duty replacement stator for 2002-2005 FLH-FLT models with
38 or 48 amp charging systems.
These are generalized instructions and are not
intended to be all-inclusive. For more detail see a service manual on your
model.
Stator Removal
1) Disconnect negative
battery terminal.
2) Drain primary case oil.
3) Remove outer primary
cover.
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 spacers between output shaft extension
and rotor.
7) Remove the
rotor.
Note: the magnets in the 48 amp rotors are
significantly stronger than normal rotors. It is recommended that you use a
special rotor remover/installer tool such as (HD-441771).
8)
Unplug regulator from stator and remove the plastic plug receptacle from stator
side. Save this receptacle, you will reuse it. Remove the terminal position
assurance clip on the backside of plug. Each terminal has 2 lock tabs. Using 2
paper clips or #16 gage solid wires. Insert one on each side of a terminal from
the front side of the plug receptacle and pull the wire out the backside.
9) Remove 4 stator mounting
screws. Remove 2 stator plug clamp screws. Remove stator.
Stator 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.
3) Insert stator wire
terminals into plastic plug housing supplied. Push until they click in place.
Install terminal position assurance clip on the backside of plug.
4) Connect stator plug to
regulator.
! CAUTION!
When installing the rotor, keep fingers away from
edge. The magnetic force may cause rotor to suddenly be drawn inward and could
pinch fingers if in the way.
Note: the
magnets in the CE-9700 rotors are significantly stronger than normal rotors. It
is recommended that you use a special rotor remover/installer tool such as
(HD-441771).
5) Install rotor slowly. Take
care not to let the magnets hit the stator. Do not let the rotor snap in to
place or magnet damage may occur.
Note: no shims are used
under the rotor on Twin Cam models.
6) Install shims removed in
step 6 of removal.
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.
11) Add oil to primary case.
Have A Good Ride!!
For complete product listing
and technical information see our web site.