Installation Instructions
CE-73T
The
CE-73T is a three phase charging system designed to fit all 2001-2006 to
upgrade to a 45-amp system.
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 the negative
battery terminal.
2) Drain the primary case oil.
3) Remove the outer primary
cover.
4) Consult an 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 the output shaft
extension. Take note of all shims and spaces between the output shaft extension
and the rotor.
6) Remove the rotor.
7) Unplug the regulator from
the stator and remove the plastic plug receptacle from the stator side. Use a
small needle nose pliers to remove the orange lock clip from inside the plug.
Then use a small screwdriver to release the locking tab and remove each wire
from the plug receptacle one at a time.
8) Remove the 4
stator-mounting screws.
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 the 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 dos not
matter which wire goes in which hole. Push in until 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 5 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
9) Install outer primary and
other parts removed.
Note: Don’t forget to add oil on wet clutch models.
Note: 2000 to 2006 models come stock with a 30 Amp
main breaker. Do not change the stock 30 Amp main breaker to a larger breaker
or switches and wires will not be protected and may burn up.
. We recommend that new
accessories that use a lot of amperage 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) Use a suitable stand or lift to support the motorcycle so the rear wheel is off the ground.
2) Remove the rear wheel.
3) Remove the plastic panel
to expose the main circuit breaker.
4) Remove battery.
5) Hold the new circuit
breaker mounting clip next to the main breaker and mark a spot for the pop
rivet. Drill .192” to .196” hole (#10 drill) and secure the new breaker bracket
with the pop rivet supplied.
6) Insert the new 50 amp
breaker in breaker bracket.
Connect small end of the13”
wire to copper color terminal on circuit breaker. Connect large end to battery
positive terminal.
Note: remove old regulator wire and reconnect new regulator wire before reinstalling plastic panel and rear wheel.
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 the 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 main breaker) to the silver post on
the new 50 amp 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) Reinstall the battery,
plastic panel and rear wheel.
Start the motor and test the voltage at the battery. Voltage should run 14.2 to 14.6 depending on what model you have.
Have A Good Ride!!
Rev.3-11