INSTRUCTIONS - Harley
Contents
1. all the seat After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a MOTOR e Service Parts Part No 29982 81 Date 04 03 22 Amp Charging System i00031a eps Part No 2712 9862 9863 10006 29963 99 Description Quantity Screw stator mounting 4 Ring terminal 10 hole Ring terminal 1 4 in dia ID Cable strap 6 Alternator rotor assembly Spacer washer 2 81 in O D 0 219 in thick 29960 85 J00058 Description Quantity Part No Spacer washer 1 75 in O D 0 095 in thick Stator assembly Wireform plug retainer Voltage regulator assembly 29961 85 29965 81B 45095 85 74515 86 2 of 22. cMOTOR2 HARLEY DAVIDSON WY J00058 INSTRUCTIONS REV 04 21 2003 Kit Number 29982 81 22 AMP CHARGING SYSTEM General This kit fits all 1970 through 1988 motorcycles with Big Twin engines See the Service Parts illustration for kit contents A WARNING The rider s safety depends upon the correct installation of this kit Follow the procedures listed in this instruction sheet and in the appropriate Service Manual If the procedures are not within your capabilities or if you do not have the correct tools have your Harley Davidson Dealer perform the installation Failure to follow instructions could result in death or serious injury NOTE This instruction sheet references Service Manual informa tion A Service Manual for your model motorcycle is required for this installation and is available from any Harley Davidson Dealer Installation A WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative battery cable Retain all seat mounting hardware i00031a tif Original Equipment Components 1 Compensating sprocket nut Compensating sprocket cover assembly Sliding cam Compensating sprocket Shaft extension Shim washer s various widths 2 Remove the original alternator and voltage
3. hreads of the compen sating sprocket nut 1 9 Install the nut and tighten to 80 100 ft lbs 109 136 Nm 10 Measure the length of the original voltage regulator out put lead and cut the output lead on the replacement regulator to the same length NOTE The voltage regulator output lead should be connected to the same location as it was originally If the output lead will be connected to the battery positive terminal install the larger ring terminal 3 from the kit If the output lead will be connected to the silver LOAD SIDE terminal of the main circuit breaker install the smaller ring terminal 2 11 Strip 1 4 in 6 4 mm of insulation off the end of the out put lead and install the appropriate ring terminal 12 Install the voltage regulator following Service Manual procedures 13 Depending on the connection location of the original voltage regulator output lead connect the ring terminal of the replacement regulator to either the battery posi tive terminal or the silver LOAD SIDE terminal of the main circuit breaker 14 Secure the regulator wiring using the cable straps 4 from the kit 15 Refer to the Service Manual and follow the instructions given to re attach the negative battery cable 16 Test the vehicle to be sure the charging system is func tioning properly 17 Remove the front crankcase stud and install the wireform plug retainer 9 Tighten the stud to 15 17 ft lbs 20 23 Nm 18 Inst
4. regulator Note the positions of any spacers or shims on the sprocket shaft during disassembly procedures Be sure to remove the original spacer that is positioned inboard of the rotor if so equipped NOTE The alternator rotor should be removed using rotor puller Part No HD 95960 52B 3 See the Service Parts illustration Discard the original stator mounting screws and the mounting screw lock ing plate if so equipped Install the new stator assem bly 8 using the new mounting screws 1 from the kit Tighten the screws to 30 40 in Ibs 3 4 4 5 Nm CAUTION Do not install any combination of new style parts with old style parts Mixing old and new style parts will cause permanent damage to the stator or voltage regulator 4 See Figure 1 Place the smaller spacer washer 9 from the kit over the sprocket shaft CAUTION Do not strike or drop the alternator rotor The magnets could be loosened or damaged which would result in rotor failure 5 Install the new alternator rotor assembly 8 onto the sprocket 6 Place the larger spacer 7 from the kit over the sprock et shaft Place the original shim s 6 over the shaft Kit Components 7 Spacer washer 2 81 in O D x 0 219 in thick 8 Alternator rotor assembly 9 Spacer washer 1 75 in O D x 0 095 in thick Figure 1 Alternator Rotor and Compensating Sprocket Assembly 1of2 7 Check the sprocket alignment 8 Apply Loctite 262 red to the t
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