Installation Instructions
CE-63T
The
CE-63T is a three phase charging system designed to fit all 2001-2006 Softails
as a direct replacement for stock.
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.
4) 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.
5) Remove output shaft
extension. Take note of all shims and spaces between output shaft extension and
rotor.
6) Remove rotor.
7) Unplug regulator from
stator and remove plastic plug receptacle from stator side. Use a small needle
nose pliers to remove the orange lock clip from inside the plug. Then use a
same small screwdriver to release the locking tab and remove each wire from the
plug receptacle one at a time.
8) Remove 4 stator-mounting
screws. Remove 2 stator plug clamp screws. Remove stators.
Alternator Installation
1) Install the stator wire
through the hole in the case. Pull gently on the wires to seat the case sealing
grommet. On twin cam models the first lip on the grommet well come all the way
through and seat on the out side of the case.
2) Mount the stator to the
engine case with the new mounting screws (supplied). The screws have
thread-locking compound already applied. Torque screws to 30-40 in-lbs.
3) Install the stator wires
into the plug housing. Insert the wires in holes #1 #2 and #3. It dose not
matter which wire goes in which hole. Push in until the terminal snaps in.
after all three wires are fully inserted install the orange locking clip.
4) Install the 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) Reinstall any shims and
spacers removed in step 6 of Alternator Removal.
6) Install compensator
sprocket with chain adjuster
Shoe, and clutch if removed.
7) Adjust primary chain.
8) Check primary chain
alignment. Adjust if necessary
Note: This kit is designed as a direct replace for the stock charging system on 1999 –2003. no primary chain alignment should be necessary
9) Install outer primary and
other parts removed.
Note: Don’t forget to add oil on wet clutch models.
Regulator
-Remove Old Regulator
1) Disconnect battery
negative terminal.
2) Disconnect regulator DC
wires. One connects to the silver post on the main breaker. The other connects
to a grounding stud.
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 two ¼-20 Allen
screws and remove regulator.
Install New Regulator
1) Mount new regulator. Reuse
Allen screws.
2) Route and connect wire
with the yellow label marked (silver post of main breaker) to the silver post
on the main circuit breaker.
3) Rout and connect wire
labeled GND to the grounding stud.
4) Connect AC plug to stator.
5) 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.
6) Reconnect battery and
start motor. Test battery voltage. Voltage should run 14.2 to 14.6 depending on
what model you have.
Have A Good Ride!!
Rev 3-11