CYCLE ELECTRIC INC.
45 AMP THREE PHASE CHARGING KIT
These are generalized
instructions and are not intended to be all-inclusive. For more detail on your
model see service manual.
1 Retainer clamp
1 .271 spacer
1 Wire kit
1 50 Amp Breaker
1 Circuit Breaker Clamp
4 Stator Mounting Screws
2 ¼ -28 x 1¼ Bolts
2 ¼ -28 Locknuts
2 ¼ Flat washers
6 Wire Ties.
Things Needed Not Included In Kit
1. Primary gasket for your
2. Additional variable
thickness shims may be required to obtain proper primary chain alignment.
1) Disconnect negative
2) Consult appropriate
service manual and the remove outer primary cover.
3) Consult appropriate
service manual and remove the compensator sprocket.
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.
4) Remove output shaft
extension. Take note of all shims and spaces between output shaft extension and
rotor. There should be a .219 shim and a thin shim. ******
5) Remove the rotor and all
spacers under the rotor.
6) Unplug the regulator from
7) Remove the stator mounting
bolts. Remove the wire clamp screws and remove the stator
1) Install new stator. Feed the wires through the hole in the
crankcase. Use a dull flat blade screwdriver and push on the flat surface of
the grommet while gently pulling on the wires until the grommet slides into
position. The wire clamp area should line up.
Do not slide the grommet too far because it may not
slide back without causing grommet damage.
Note: the retaining clamp aria on the CE-8011 stator has been enlarged and requires a modified clamp. Use the clamp supplied in this kit.
5) Install the grommet
retainer clamp. Use lock-tight 222 (purple) on retainer screws.
Note: If your cases do not
have wire clamp screw holes, use high temp silicone sealer (preferably black)
to hold grommet in place. When using
sealer the grommet will slide in the hole very easy. Do not let first lip on grommet to come out the top of case hole.
6) Install four new stator-mounting
screws (supplied). Torque to 30-40 In-Lb.
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.
7) Install the .271 spacer supplied in this kit on the out put shaft
8) Install rotor.
9) Install variable thickness
shims removed in step 4 of alternator removal. This shim is usually between
.020 and .060 thick. (DO NOT USE .219 SPACER.)
10) Install output shaft
11) Install compensator
sprocket adjuster shoe and clutch if removed. Check the primary chain
alignment. Adjust as necessary.
12) After confirming that the
primary chain is properly aligned, apply red lock-tight #262 to threads on
output shaft and torque to 150 to 165 ft/lb.
If clutch was removed, use lock-tight number 262 and
torque to 70-80 ft-lb (left-hand thread).
12) Adjust primary chain.
13) Assemble primary cover
and all other components previously removed.
14) Fill primary with oil.
Oil should be level with the bottom edge of clutch plates.
1) Disconnect battery
2) Remove old regulator.
A- Disconnect regulator B+ wire from the main circuit
breaker (See chart for location).
2) Disconnect regulator DC
wire from Acc. side of main breaker (except 84-86 dressers the regulator
connects to a terminal stud on the steering head).
Take note of how the
regulator wire is routed and cut the necessary wire ties and remove the wire.
Note: If you tie a piece of nylon cord or fishing line
to the ring terminal before pulling wire out, you can use this cord to pull new
wire in place.
3) Remove the regulator with
the steal bracket from lower frame cross member.
Note: 1985-1988 models came stock with a 30 Amp main
breaker. Do not change to a larger breaker or switches and wires will not be
properly protected and may burn up. Add the 50A auxiliary breaker supplied in
this kit. We recommend that new accessories that use a lot of amps be connected
to the silver terminate on the new 50A breaker. If you want these accessories
to activate from your ignition switch, use a relay.
1) Mount the breaker bracket
on the front side of the battery tray. Remove the battery. Drill a .192
to .196 hole (#10 drill) and secure the new breaker bracket with the pop rivet
2) Insert the new 50A breaker
in the new breaker bracket.
3) Connect the small end of
the 13 wire to copper color terminal on the new circuit breaker. Connect large
end to the positive terminal on the battery.
Note: The bottom
of the feet on the regulator is cut at an angle to lean the regulator away from
the oil filter. Be sure to mount the regulator so it leans forward away from
the oil filter.
1) Connecting wires to the
Note: When connecting
wires, place the regulator upside down with something soft under fins so the
paint wont be scratched.
A- The Regulator B+ wire is
50 long. One end has yellow marker on it. Connect end labeled B+ to B+
terminal on regulator.
B- The regulator ground wire is 32 and is labeled GND. Connect the end with the smaller ring terminal to the GND terminal on the regulator.
Note: For best appearance, position wires to follow
the contour of the regulator legs.
C- To connect
the AC wires place the regulator upside-down on suitable stand in front of
front motor mount. The regulator-shipping box should work. Connect one AC wire from stator to each AC
terminal on the regulator. It doesnt matter which one goes where.
2) Mounting Regulator
Flip regulator up onto frame cross member so it straddles
the motor mount. use ¼-28x 1¼ bolts
(supplied) to mount regulator.
3) Rout the B+ wire and
connect the yellow end to silver terminal of new 50-amp breaker.
Route GND wire along lower right frame rail. Follow
crossover bracket to the left side. Connect to the 5/16 bolt where the braided
ground cable connects. This bolt also connects your inner primary to frame.
4) Check all wires to be sure they are not in a vulnerable
position. Keep wires away from front motor mount and exhaust pipes. Do not run
wires on the bottom of frame rail where they will get pinched if you bottom
Replace all wire ties previously cut and add new where
Reconnect battery and start motor.
Check voltage at the battery
With a good battery you
should get 14.3 to 14.6 VDC.
Have A Good