CYCLE ELECTRIC INC
Installation Instructions
CE-38T CE-48T
The
CE-38T and CE-48T are designed to replace the stock charging system on 1999 –up
FLH-FLT Twin Cam models.
These are generalized instructions and are not
intended to be all-inclusive. For more detail see a service manual on your
model.
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 spacers between output shaft extension
and rotor.
7) 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).
8) Unplug regulator from stator and remove the plastic plug receptacle from stator side. On 1999 to 2001 models, remove the blue secondary lock us a small hook or long #6 wood screw in the small hole in the middle. The blue lock plate will pull out. Using a small screwdriver release the plastic locking tab and remove each wire one at a time. On 2002 and later models remove the terminal position assurance clip on the backside of plug. Each terminal has 2 lock tabs. Using 2 paper clips or #16 gage solid wires. Insert one on each side of a terminal from the front side of the plug receptacle and pull the wire out the backside.
9) Remove 4 stator mounting
screws. Remove 2 stator plug clamp screws. Remove stator.
Alternator Installation
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) Insert stator wire
terminals into plastic plug housing supplied. Push until they click in place.
Install terminal position assurance clip on the backside of plug.
! CAUTION!
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).
4) 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.
Note: no shims are used
under the rotor on Twin Cam models.
5) Install shims removed in
step 6 of removal.
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 rotor 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 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.
Regulator
-Remove Old Regulator
1) Disconnect negative battery terminal
2) Unplug regulator/stator
connectors.
3) Disconnect regulator B+
wire from the main circuit breaker located under the seat.
4) Disconnect regulator GND.
Wire from the ¼’ ground stud located under the seat.
Take note of the wire routing
and cut the necessary wire ties and remove wires.
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.
5) Unbolt regulator and
remove.
Install New Regulator
1) Mount new regulator. Reuse
stock ¼’ nuts to fasten regulator to frame.
2) Rout wire labeled “Silver
post main breaker” to the main circuit breaker under the seat and connect to
the silver post.
3) Rout wire labeled GND. and
connect it to the ¼” ground stud on the frame under the seat.
2) Connect stator/regulator
plug mounted on the regulator. Insert plug until locking tab locks.
3) 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.
4) Reconnect battery and
start motor. Test battery voltage. 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.