CYCLE ELECTRIC INC
Installation Instructions
CE-32T,
CE-32TL
The CE-32TL is designed for 2000 Softail (The CE-32TL comes with a low
voltage regulator specially tuned for Softails)
These
kits are designed to replace stock charging systems on the models listed. They
reuse the stock plastic stator plug housing. They will fit other Twin Cam
models. If installing on models not listed a stator plug housing will be
needed.
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.
3) Remove outer primary
cover.
Note: If you check the primary chain alignment before disassembling it will be easier to determine what variable thickness shims will be needed for reassembly.
4) Check primary chain
alignment. Place a straight 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= primary
chain alignment.)
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.
8) Unplug regulator from
stator. Remove the stator plug housing. First 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. Than using a small screwdriver release the locking tab and
remove each wires one at a time.
9) Remove 4 stator mounting
screws. Remove 2 stator plug clamp screws. Remove stators.
Alternator Installation
1) Install stator plug and plug
clamp in case. Use lock-tight 222 purple on clamp screws. (Some engine cases
such as S&S do note use a plug clamp.)
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 plug
terminals in to the stator plug housing removed in step 8. Push in until they
click into place. Reinstall blue secondary lock.
4) Install rotor.
Note: Twin Cam models do not use shims under the rotor.
5) Add stock shim removed in
step 6.
6) 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.
7) Install output shaft extension.
8) Install compensator
sprocket with chain adjuster shoe, and clutch if removed.
9) Adjust primary chain.
10) Check primary chain
alignment.
11) 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 the main 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. Be
sure regulator has a good ground connection from the case of regulator to the
motorcycle frame.
2) Route DC+ output wire to
main circuit breaker. Connect wire to silver post of main breaker.
3) Plug stator to regulator.
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 on the very bottom of the 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. 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!!
For complete product listing
and technical information see our web site.