CYCLE ELECTRIC INC
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.
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.
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.
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!!
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