CYCLE ELECTRIC INC
Installation Instructions
CE-61A
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.
This will help determine what variable thickness shims you will need later.
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 Installations
1) Install stator plug and plug clamp in case. Use
lock-tight 222 purple on clamp screws.
Note: some engine cases do
not use plug clamps.
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 stator wires into plug housing. Insert wire in
hole #1 #2 and #3. Push in until terminal snaps in. after all three wires are
fully inserted install the orange locking clip.
.
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 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 the old
wire is routed. Cut wire ties and remove wire.
4) Unbolt and remove
regulator and bracket.
Regulator Installation
1) Connecting wires to
regulator
Note: When connecting wires, place regulator upside
down with something soft under fins so paint wont be scratched.
A) The Regulator B+ wire is 50 long. One end has a
yellow marker on it. The other end is labeled B+. Connect the end labeled B+ to
the B+ terminal on regulator.
B) This kit comes with two wires labeled GND.
1989 to 92 models use the
shorter 32 wire.
1993 to 98 models use the
longer 48 wire.
Determine which GND wire you
need. Connect the end with the smaller ring terminal labeled GND to the
terminal labeled GND on regulator.
Note: For best appearance, position wires to follow
the contour of the regulator legs.
C) The AC
stator connector has 3 wires labeled AC. Connect one AC wire from the plug to
each AC terminal on regulator. It doesnt matter which one goes where.
2) Mounting Regulator
Set the regulator up onto
frame cross member so it straddles the motor mount. On 1989-94 models use Ό-28x 1Ό bolts (supplied) to mount
regulator. On 1995-98 models slide regulator on Ό -20 studs and use stock nuts.
3) Route the B+ wire the same
way as old regulator wire. Connect yellow end to silver terminal of circuit
breaker.
93-98 route GND wire with B+
wire and connect to the Ό ground stud on the frame.
89-92 Route GND wire along
lower right frame rail. Follow crossover bracket to the left side. Connect to
5/16 bolt where braided ground cable connects. This bolt also connects your
inner primary to frame.
4) Connect AC plug. Rout wires away from motor mount and zip tie to the frame
5) Connect stator to regulator plug.
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!!