CYCLE ELECTRIC INC
Installation Instructions
CE-62A
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.
Note: step 4 will help
determine what variable thickness shims will be necessary to achieve proper
primary chain alignment
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 old stators.
Alternator Installations
1) Install new 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.
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 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 circuit breaker
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) Mount new regulator. This
kit is designed to fit on models that the regulator mounts between the front
down tubes on the frame. The new regulator should bolt to the stock mount.
2) Route the DC+ output wire
to the main circuit breaker and Connect it to the silver post.
3) Connect AC plug to stator,
on rubber mount models keep wires away from front motor mount. It moves and can
damage wires.
4) 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.
5) Reconnect battery and
start motor. Test battery voltage. Voltage should run 14.2 to 14.6.
Have A Good Ride!!