CYCLE ELECTRIC INC
The CE-3845-99 is a heavy-duty replacement stator for 1999 to 2001 FLH-FLT models with a 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.
4) 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.
5) Remove output shaft extension. Take note of all shims and spacers between output shaft extension and rotor.
6) 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).
7) Unplug regulator from stator and remove the plastic plug receptacle from stator side. Save this receptacle you will reuse it. On 1999 to 2001 models, remove the blue secondary lock using a small hock or long #6 wood screw in the small hole in the middle. It will pull out. Using a small screwdriver release the plastic locking tab and remove each wire one at a time.
8) 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) Install plastic plug housing removed in step 8 of stator removal. Insert stator wire terminals into plug housing. Push until they click in place. Insert blue secondary lock.
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.
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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