Cycle Electric Catalogue

Generators Pages 4-5 Regulators Regulators for generators Pages 2-3 Rectifying regulators Pages 6-7 Stators Pages 8-9 Alternator Kits Pages 10-13

PHONE 800-523-2645 FAX 937-884-5542 www.cycleelectricinc.com dealerorders@cycleelectricinc.com

Charging Systems for American V-Twins Top Quality Made In U.S.A

Cycle Electric Inc is the leading manufacturer of high quality American made charging systems for use on Harley Davidson® and other American made V Twin motorcycles. We manufacture all of our generators, regulators, rectifying regulators and stators in our Brookville Ohio factory. This is the only way to control quality. We purchase our rotors from Harley Davidson®. We offer 46 complete changing systems to cover from 1936 to present day. Cycle Electric Inc. components are designed to deliver better-output and increased durability. Mission statement Cycle Electric Inc. is dedicated to producing the highest quality longest lasting electrical charging systems and components for America made V Twin motorcycles. Our first priority is quality. Our second priority is customer service. All Cycle Electric Inc. regulators are built to last. We start with a rugged design capable of handling overloads and continuous operation. Then we use only top quality materials and military spec. assembly procedures to ensure a low failure rate and long service life. REGULATORS FOR GENERATORS

CE-100 Series Regulators For use on 6 and 12 volt generators

The CE-100 series regulators accurately control voltage and current. Accurate voltage control is necessary to maintain proper battery charging rate. Accurate current control is very impor- tant to get maximum power without causing generator damage. CE-500 Series Regulators

The CE-500, CE-500L and CE-506 are designed as part of the DGV-5000, DGV- 5000L and DGV-5006 generators with built in regulator (see page 4). The “A” and “F” wires connect internally. The CE-500 series regulators are sold as a re- placement part for the DGV-5000 series generators. Thay are not designed to go on other generators.

CE-540 Series Regulators The CE-540 and CE-540L are designed to fit Model 65A 12-volt generators. The CE-546 is designed to fit Model 61 6-volt generators. These regulators replace the end bell and become a structural part of the generator. The “A” and “F” wires connect externally to the existing generator terminals. The current limiting cir- cuit senses armature temperature and adjusts available out put to allow maximum amperes without over heating the armature. This gives you more power for faster battery recharging and cooler operation for longer generator life.

2

Regulators for Generators The model 65A 12 volt generator is rated at 10 amps. It is capable of producing 25 to 30 amps; however, if you draw 20 amps out of a 10 amp generator it will burn up within 20 minutes. It is the regulator’s job to limit the amps from the generator to 10 amps. We recommend testing your regulator when installing a new generator. Some regulators do not regulate amps. DO NOT USE THESE. To insure proper regulation we recommend using a Cycle Electric Regulator.

A

B

C

M

L Series Regulators “L” = Low Voltage Regulator

All Cycle Electric, Inc. regulators have battery saving features built into them. On models with horse shoe oil tanks we take this one step further. Horse shoe oil tanks heat up your battery. As battery temperature increases the chemical reaction between lead and acid speeds up. Therefore the battery will draw more amps with the same voltage applied. To prevent over charging (battery boil out) it is necessary to reduce charging voltage. Full amperes are still available for accessories. The “L” Series Regulators are a low voltage unit for use with the battery in the oil tank.

3

Manufacturers of The Original Model 65A Generator

Cycle Electric Inc. manufactures the model 65A CE part # DGV-2569 12 volt and model 61 CE part # DGV-2578 6-volt generators to Harley-Davidson specifications for restoration purposes. The Cycle Electric Inc. DGV-2569 generator is covered by a 1-year warranty on workmanship and material defect. For a full 2-year warranty use the Cycle Electric Inc. DGV-5000 generator with built in regulator.

DGV-2569 (Model 65A)

The DGV-5000 is a complete charging system for generator bikes. It features simplified wiring, higher output, longer service life and a two year warranty. After two years Cycle Electric Inc. offers repair service. This is the last generator you will have to buy for your bike. Works with or without battery.

DGV-5000 Cycle Electric Inc. makes generators to fit Indian Chiefs and Scouts. 4 models are available in 6 and 12 volt with and without built in regulator. They fit in the stock mounting clamp and use the stock 1 / 2 ” straight bore pulley. These generators offer increased output compared to stock. INDIAN GENERATORS

IN-5000

Cycle Electric Part No.

H-D Part No.

Description/Application 12 Volt high output charging system. Use on all 1965-1984 generator models (see note 1) 12 Volt charging system. Use on (1936-1964 see notes 2 & 3) 6 Volt conversion When using small 12 volt battery in 6 volt oil tank small battery kick only. 6 Volt charging system use on 1936-1964 (see notes 2 & 3) Generator - 12 Volt OEM stock 1965-1981 will fit 1936-1984 (see note 1 & 2) Generator - 6 Volt OEM stock 1958-1964 (model 61) will fit 1936-1964 (see note 2) Connector use with DGV-5000 on 1978-1981 Sportster to retain stock wiring Connector use with DGV-5000 on 1982-1984 Sportster to retain stock wiring

DGV-5000 DGV-5000L DGV-5006 DGV-2569 DGV-2578

29975-65A 29975-61

CE-571 CE-572 IN-2578 IN-2569 IN-5006 IN-5000

6 Volt Generator Indian Chief. For Scouts add CCW to part # 12 Volt Generator Indian Chief. For Scouts add CCW to part #

6 Volt Generator with Built-In Regulator for Indian Chief. For Scouts add CCW to part # 12 Volt Generator with Built-In Regulator for Indian Chief. For Scouts add CCW to part #

Notes: 1. When replacing 65B Generator (82-84 Hitichi) add H.D. #31035-58 Oil Deflector. Use same gear. 2. 1936-1957 when replacing 3 brush generators use #31035-58 oil deflector, discard spring and old deflector. 3. Check for clearance on foot clutch models. Over all length of DGV-5000 is 7.58 inches form gasket surface to fins. L=low voltage M=machined outside diameter H=1/4-24 heli coil (Add letter to end of part #. See website for more info.)

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Cycle Electric Inc. Original Equipment Replacement Generator Parts

Cycle Electric Part No.

Cycle Electric Part No.

Index No.

H-D Part No. 30851-65A 30851-61 30201-65 30201-58 603

Index No.

1 1004 30012-58 30095-61 30132-61A 30145-46A 30276-58 30280-58 30350-66 30421-58A 30426-58 30453-58 30475-66 31096-58 31097-58 31098-58 30014-80 30373-58 30392-58 30393-58 31035-58 H-D Part No.

Description/Application

Retaining Ring Frame Screw (Set) End Plate with Bearing End Cover with Bearing Oil Seal Pole Shoes (Set) Screw Pole Shoe Brush Holder with Brush Wire Positive Lead Brush Set Description/Application

CV-2570 CG-7721 CP-13831 CP-13869 CK-30715 CK-30710 CK-30709-7 CK-30584 CK-30596 AN-960-10-L CK-30593 CK-30598 MS-35338-44 MS-35338-43 AN-936-B-10 CK-30592 CP-13841-2 CG-7707-2

12 Volt Armature 6 Volt Armature 12 Volt Field Coil 6 Volt Field Coil Roll Pin Screw Brush Cover Screw Brush Plate Screw Terminal Insulating Bushing Washer Brush Plate Washer Terminal Washer Brush Plate

CK-30604 CK-30605 CG-8101 CG-8102 CK-30622 CP-13833 CK-30608 CP-13835 CK-30612 CK-30613 CK-30614 CP-13838 CP-13840 CK-30620 CK-30621 CP-14665 CK-30609 CK-30610 CK-30611

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

1374 2587 2690W 5911 6165W

Spring Brush Brush Cover Clip

6189 6193 7036 7069 7220 7634 7638 7676 7683 8331 9007 9088

Lockwasher Brush Cover Lockwasher Brush Plate Lockwasher Terminal Nut Terminal Nut Brush Plate Nut Brush Cover Locknut Frame Screw Rivet Ball Bearing Needle Bearing

Insulator Insulator Tolerance Ring Insulator Brush Plate Shim Brush Plate Insulating Bushing Oil Deflector Repair Kit

CK-30594 CK-30600 CK-30601 CK-30602

ALL 5000 SERIES GENERATORS WORK WITH OR WITHOUT A BATTERY - OPERATION WITHOUT BATTERY REQUIRES MAGNETO.

If it does not say Cycle Electric Inc. on it we did not make it!

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Top Quality Made in U.S.A Rectifying Regulators CE-200 and CE-300 Rectifying Regulators The CE-200 series rectifying regulators are designed for use with 18 and 22 amp alternators. The CE-300 series rectifying regulators are designed for use with 32 amp alternators. All models have wire harnesses to match the stock connectors on the motorcycle they are designed to go on. Available with high- lighted fins or all black finish. For all black add the letter B on the end of the part #.

CE-601 Three Phase Rectifying Regulators The CE-601 is designed for use on 2001 to 2006 Softail® models. The CE-601-07 is designed for use on 2007 Softail® models. The CE-601-08 is designed for use on 2008 to 2015 Softail® models.

The CE-602 is designed for use on 2004 to 2005 Dyna® models. The CE-602-06 is designed for use on 2006 to 2007 Dyna® models. The CE-602-08 is designed for use on 2008 to 2015 Dyna® models. CE-602 Three Phase Rectifying Regulators

CE-604 Three Phase Rectifying Regulators The CE-604 is designed for use in three phase kits for Dyna® and Softail® models when upgrading from a single phase system. The CE-604NB is for use without a battery. (Use with NBC-180 capacitor)

The standard CE-445 has threaded stud terminals for versatile wiring. The CE-445-97 comes with a wire harness to fit 1997 to 2001 FLH and FLT. The CE-445-02 and CE-445-04 have permanently attached wires and a bracket to hold the stock stator plug on 2002-2005 FLH/FLT models. The CE-603 is used in three phase kits for FLH-FLT models. It has threaded stud termi- nals for versatile wiring. See page 13 for available wire harnesses. The CE-606 is designed for use on 2006 to 2008 FLH-FLT models. CE-603 and CE-606 Three Phase Regulators CE-445 38,45 and 48 Amp Single Phase Regulators

CE-607 Three Phase Regulator The CE-607 is designed for use on 2009 to 2011 FLH-FLT with out an oil cooler. The lower mounting profile gives a clean custom look. Does not fit with low mount oil cooler

CE-608 Three Phase Regulator The CE-608 is designed for use on 2009 to 2013 FLH-FLT with a low mount oil cooler. The regulator mounts high to keep it away from the oil cooler.

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Rectifying Regulators for Alternators

Plug CE#

HD#

Description

D

CE-203

74512-79A 1976-1980 All Big Twins

E CE-204 E CE-204L N CE-204P

74516-86

1981-1988 All Big Twins 1984-1988 All Softail®

Softail

Replacement regulator for CE-22AP Kit

For use with No Battery & 22 amp stator (battery Eliminator needed)

E

CE-204NB

H CE-205 H CE-206

74523-84A Late 1984-1990 All XL Models

74523-91

1991 All XL Models

I J

CE-207 CE-208

74523-92A 1992-1993 All XL Models 74523-94A 1994-2003 All XL Models

K CE-210 T CE-211 T CE-212 G CE-320 G CE-320L N CE-320P N CE-320LP L CE-324 L CE-325L M CE-445 L CE-445-97 N CE-445-02 Q CE-445-04

74523-04 745464-07 74711-08 74519-88

2004-2006 All XL Models 2007-2008 All XL Models

2008 XR1200 Models, 2009-2013 All Sportster Models

1989-1996 All FL (Except fuel injected) Models 1989-1998 All FXR & FXD Models

Softail

1989-1999 All Softail® Models

Replacement regulator for CE-32AP Kit Replacement regulator for CE-32ALP Kit

74518-99A 1999-2003 All Dyna® Models

74512-00 74505-95 74505-97 74505-02 74505-04 74540-01 74540-07 74540-08 74631-04 74631-06 74631-08

2000 All Softail® Models

1995-1996 FLHTCUI, FLHTCI, FLCUI Models

1997-2001 All FLH, FLT Models (Not recommended with low mount oil cooler see p.14) 2002-2003 All FLH, FLT Models (Not recommended with low mount oil cooler see p.14) 2004-2005 All FLH, FLT Models (Not recommended with low mount oil cooler see p.14)

P CE-601

2001-2006 All Softail® Models

R CE-601-07 T CE-601-08

2007 All Softail® Models

2008-2015 All Softail® Models 2004-2005 All Dyna® Models 2006-2007 All Dyna® Models 2008-2015 All Dyna® Models

S CE-602

O CE-602-06 T CE-602-08

M CE-603 P CE-604

Replacement regulator for CE-61A & CE-81A Kit

Replacement regulator for CE-62A Kit

For use with No Battery & three phase stator (battery Eliminator needed)

P CE-604NB

T CE-606 T CE-607 T CE-608 O IN-320

74505-06

2006-2008 All FLH, FLT Models (Not recommended with low mount oil cooler see p.14)

2009-2011 All FLH, FLT Models With out low mount oil cooler only 2009-2013 All FLH, FLT Models Will fit with low mount oil cooler

2002-UP Gilroy Power Plus Indian Chiefs. For use with with stock stator or IN-32A Kit

J

D

E

G

H

I

K

L

M

N

O

P

Q

S

T

R

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Stators

The unique design of Cycle Electric Inc. stators offer •Insulation able to withstand temperatures of 600° F to eliminate stator burn out •Better low speed output to reduce battery discharge at an idle .•Lower operating temperature for longer service life •Improved plugs that will not swell or separate

It has taken us years of constant upgrading to develop our current line of stators. We start with a higher temperature insulation system capable of withstanding temperatures in excess of 600° F. Others fail at 425° F. This insulation is thinner which allows better heat transfer and better magnetic coupling. We then wind each stator using our precision needle winder. This improves consistency, heat transfer, and magnetic coupling. Better heat transfer means cooler operating temperatures. Better magnetic coupling yields improved output over the entire R.P.M. range. When combined with our top quality plug materials you will not find a stator that can outperform or outlast a Cycle Electric Inc stator. Stator Pin Housings Stators without molded rubber regulator plugs use reusable plug pin housings. These pin housings are not supplied with new replacment stator. On new builds or when changing to a different plug style the pin housing will need to be purchased separately.

CEP-81 used with CE-8188P stator CEP-89 used with CE-8999P stator CEP-02 used with CE-3845-02 stator CEP-60 used with CE-6010/CE-6011/CE-6012/CE-6014/CE-7010/CE-8010-07 CEP-81/CEP-89

CEP-02

CEP-60

Stator Plugs

1

2

3

4

5

6

7

8

9

10

11

12

13

14

8

Stator Applications Chart .

Note: Stators are listed as used in stock applications. If the charging system has been upgraded the stock stator will not mach the rest of the system. Look at the plug style to determine what system you have

Plug # Cycle Electric Part #

H-D Part #

Used On

Lamination Stack

Rated Amps

Usable DCAmps @1000 RPM @2500RPM

Sportsters

1 2

CE-8590 CE-9100 CE-0732 CE-6012 CE-6014

29967-84 29967-89 29997-07

84-90 Sportster 91-06 Sportster 07-15 Sportster

1/2” 1/2”

18 22 32 38 38 18 22 22 32 32 32 38 38 45 45 47 47 50 50 50

18 20 27 38 38 19 22 22 29 29 29 48 38 38 50 50 50 50 54 54 54

14 15 17 12

13 14 14

5/8

CE-69S/CE-69S-04/CE69S-07

5/8” 1/2”

Buel Three phase stator

Big Twins

3 4

CE-7680 CE-8188 CE-8188P CE-8999 CE-8999P CE-9902 CE-3845 CE-3845-97 CE-3845-99 CE-3845-02

29965-75 29965-81A

76-80 All Big Twins 81-88 All Big Twins

1/2” 1/2” 1/2” 5/8” 5/8” 5/8” 7/8” 7/8” 7/8” 7/8” 5/8” 5/8” 3/4” 3/4”

11.5

14 14 14 14 14 32

12

CE-22AP Kit

5

29970-88 89-99 Big Twins with 32 amp alt.

12

CE-32AP Kit

8 6 7 8 9

29951-99

99-03 Dyna/00Softail CE-38A/CE-45A Kits

38/48 38/48 38/48 38/48

29987-97 29987-99 29987-02 30017-01

97-98 FLH-FLT 99-01 FLH-FLT 02-05 FLH-FLT

18/32 18/32 18/32 17/20 17/20

38/48 38/48 38/48

10 11 10 10 10 13

CE-6010 CE-6011 CE-7010 CE-7011

01-06 Softail/04-06 Dyna CE-60A/CE61A/CE-62A Kits

CE-73T/CE-74T Kits

25 25 33 33 35 35 35

CE-71A Kits

CE-8010-07 CE-8010-08

30017-07 30017-08

07-Softail/ Dyna 08-15 Dyna/ Softail

15/16” 15/16”

6

CE-8011 CE-8012 CE-8014

CE-81A Kit

1” 1” 1”

13

29987-06A

06-15 FLH-FLT

CE-84T-99/CE-84T-04 Kits

CE-8120 Shim Kit For putting 32 amp stator on 1970-1988 models

On 1989 and later big twins the case is machined deeper to make room for the thicker 32 amp stator. The CE-8120 shim kit replaces the stock rotor shims when installing a 32-amp stator on 1970-1988 big twins. This provides proper rotor to stator alignment while keep- ing the primary chain alignment the same.

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Alternator Kit Application Chart

Amps 1000 2500 RPM RPM

Kit #

Models These Kits Will Fit

Stator

Rotor Regulator

Sportster

CE-8590 CE-8400 CE-205 CE-9100 CE-9200 CE-207 CE-9100 CE-9200 CE-208 CE-9100 CE-0200 CE-210 CE-9100 CE-0400 CE-210 CE-0732 CE-0200 CE-211 CE-0732 CE-0400 CE-211 CE-0732 CE-0200 CE-212 CE-0732 CE-0400 CE-212 CE-6012 CE-9210 CE-609 CE-6012 CE-0410 CE-609 CE-6012 No Rotor CE-609

CE-19S CE-20S CE-21S

Late 84-90 Sportster ® 91-93 Sportster ® 94-03 Sportster ® 04-06 883 Sportster ® 04-061200 Sportster ® 07-08 883 Sportster ® 07-08 XL1200 Sportster ® 09-13 883 Sportster ® 91-03 Sportster ® 04-06 1200 Sportster ® 07-08 Sportster ®

19

14 20 14 20 14 20 14 20 15 27 15 27 15 27 15 27 18 38 18 38 18 38

CE-23S-04 CE-24S-04 CE-23S-07 CE-24S-07 CE-23S-09 CE-24S-09 CE-69S CE-69S-04 CE-69S-07 CE-22A CE-22AP CE-22ANB CE-32A CE-32AP CE-32AL CE-32ALP

08-12 XR 1200 / 09-13 all1200 Sportster ®

Big Twins 1970-1998 Shovel Head & Evo

CE-8188 CE-8100 CE-204

14 20

70-98 all Big Twins

CE-8188P CE-8100 CE-204P 14 20 CE-8188 CE-8100 CE-204NB 14 20 CE-8999P CE-8100 CE-320P 14 29 CE-8999 CE-8100 CE-320L 14 29 CE-8999P CE-8100 CE-320LP 14 29 CE-8999 CE-8100 CE-320 14 29

70-98 all Evo Big Twins with no battery 89-98 Big Twins (70-88with shim kit)

89-99 Softail ® (70-88 with shim kit)

Three Phase Upgrade Kits for Shovel Head & Evo

CE-60A CE-61A CE-62A

1970-1984 All 4 speed solid mount 80-88 FLH/FLT/FXR With 5 speed rubber mount 91-98 all Dyna ® 84-99 all Softail ®

CE-6011 CE-8100 CE-605

18 38

CE-6011 CE-8100 CE-603-642 18 38

CE-6011 CE-8100 CE-604 18 38 CE-62ANB 91-98 all Dyna ® 84-99 all Softail ® with no battery CE-6011 CE-8100 CE-604NB 18 38 CE-71A 80-88 FLH/FLT/FXR With 5 speed rubber mount CE-7011 CE-0600 CE-603-643 25 50 CE-81A 89-98 FLH-FLT-FXR (Note 2) CE-8011 CE-0600 CE-603-643 35 54 CE-81A-97 97-98 FLH-FLT (Note 2) CE-8011 CE-0600 CE-603-643 35 54 Softail Twin Cam 2000 & Later CE-32TL 2000 all Softail ® CE-9902 CE-8100 CE-325L 14 29 CE-63T 01-06 all Softail ® CE-6010 CE-9500 CE-601 20 38 CE-68T 2000 all Softail ® upgrade to 38 Amp Three phase CE-6010 CE-8100 CE-601 18 38 CE-73T 01-06 all Softial ® upgrade to 45 Amp Three phase CE-7010 CE-0600 CE-601 25 50 CE-83T 07 all Softail ® (Note 1) CE-8010-07 CE-0700 CE-601-07 33 50 CE-86T 08-11 all Softail ® (Note 1) CE-8010-08 CE-0700 CE-601-08 33 50 CE-88T 12-15 all Softail ® CE-8010-08 CE-0800 CE-601-08 33 50 Dyna Twin Cams 1999 & Later CE-32T 99-03 all Dyna CE-9902 CE-8100 CE-324 14 29 CE-67T 99-03 all Dyna ® upgrade to 38 Amp Three phase CE-6010 CE-8100 CE-604 18 38 CE-74T 99-03 all Dyna ® upgrade to 45 AmpThree phase CE-7010 CE-0600 CE-604 25 50 CE-64T 04-05 all Dyna ® CE-6010 CE-9500 CE-602 20 38 CE-82T 06-07 all Dyna ® (Note 1) CE-8010-07 CE-0700 CE-602-06 33 50 CE-85T 08-11all Dyna ® (Note 1) CE-8010-08 CE-0700 CE-602-08 33 50 CE-87T 12-15 all Dyna ® CE-8010-08 CE-0800 CE-602-08 33 50 FLH-FLT Twin Cam Touring Models CE-84T-99 99-03 FLH-FLT (Note 2) CE-8014 CE-0600 CE-603-644 35 54 CE-84T-04 04-05 FLH-FLT (Note 2) CE-8014 CE-0600 CE-603-645 35 54 CE-84T-06 06 FLH-FLT (Note 2) CE-8012 CE-0600 CE-606 35 54 CE-84T-07 07-08 FLH-FLT (Note 1&2) CE-8012 CE-0700 CE-606 35 54 CE-84T-09 09-10 FLH-FLT with out oil cooler (Note 1&3) CE-8012 CE-0700 CE-607 35 54 CE-84T-10 09-10 FLH-FLT with oil Cooler CE-8012 CE-0700 CE-608 35 54 CE-84T-12 11-13 All FLH-FLT CE-8012 CE-0800 CE-608 35 54 Indian Cheif With Gilroy Powerplus100 IN-32A 32 amp single phase CE-8999 CE-8100 IN-320 14 29 IN-62A 38 amp three phase CE-6011 CE-8100 IN-602 17 38 See notes on page 15. Some kits contain parts not listed in this chart.

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Top Quality Made in U.S.A

Alternator Kits Cycle Electric Inc. Alternator kits combine our state of the art stators with our legendary bullet proof rectifying regulators and a stock H.D. Rotor. They offer better low speed output and a smoother charge to the battery. You will not find a more durable, longer lasting charging system. They are 100%American made. See the applications chart on page 10 for the proper year fitment. The CE-22A is a 22 amp kit that will fit any Shovel Head or Evo. Ideal for the lightly accessorized bike that normally uses 15 amps or less. The CE-22ANB is a 22 amp kit with a special regulator and battery eliminator capacitor for use without a battery. Note: Must use a magneto for ignition.

The CE-32A is a 32 amp kit for 1989-98. It will fit 1970-88 with the CE-8120 shim kit. The CE-32AL is for Softail® and custom bikes with the battery in a horseshoe oil tank. It comes with a “L” regulator specially tuned for the higher battery temperature.

The CE-22AP, CE-32AP and CE-32ALP kits use a new style wire harness on the stator and regulators. The stator wires have a rubber grommet to seal where they come through the case. They extend 9 inches from the case with a plug on the end. The regulator also has 9 inches of wire with a mating plug. The regulator can mount in the original location or be relocated, which makes them a good choice for customs. Extra wire can be run under the frame and zip tied out of the way.

The CE-32T is a 32-amp kit for twin cam models. It will fit any twin cam motor. The CE-32TL comes with a low voltage regulator for bikes with a horseshoe oil tank. Recommended for bikes that normally use up to 24 amps. No Picture Shown.

CE-38A, CE-38T, CE-45A, CE-48T

Cycle Electric Inc. has discontinued the 38,45 and 48 amp single-phase kits. All parts for these systems will still be sold separately. We feel our 80 series 50-amp three phase kits provide a much better value. They give better output and durability and cost less. Indian Chief Alternator Kits The IN-32A is a 32-amp single-phase system designed to replace the stock system on Gilroy Powerplus Indian Chiefs. It includes the stock connecter to plug in to the factory wire harness The IN-62A is designed to upgrade Gilroy Powerplus Indian Chiefs to the 38 amp three-phase system. It is similar to the CE-62A kit and includes a connecter on the output wires to plug into the factory Indian wire harness.

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Cycle Electric Inc Three Phase Charging Kits 38 Amp 45Amp and 50 Amp Kits Available

60 Series 38 Amp Three Phase Kits The 60 series kits produce 17 or 20 amps @ 1000 RPM (depending on the rotor used) and 38 amps @2500 RPM. Due to the compact size of the stator these kits are available to cover 1970 and later big twins and 1991 and later Sportsters without changing rotor shimming. See descriptions below and the applications chart on page 10 Cycle Electric Inc. three phase charging kits are an excellent choice to upgrade your old charging system. You get in- creased output over the entire rpm range and a smoother charge to the battery. That means more power for accessories like lights, electronics and heated clothing. The increased low speed output is a must for fuel-injected models. Cycle Electric Inc. offers the 60 series, 70 series and 80 series three-phase systems. Each series has several different kits to fit specific models and years.

The CE-60A is a three-phase kit for 1970-1984 rigid mount 4 speed big twins with the stock regulator bracket mounted to the kickstand bracket. (No picture shown) The CE-61A will fit 1980-88 rubber mount 5 speed FLH-FLT & FXR. (Also see CE-71A kit) (For 89-98 FLH-FLT see CE-81A) The CE-62A will upgrade 1991-98 all Dyna® & 1984-99 all Softail®

CE-61A

The CE-62ANB is a three phase kit with a special regulator and battery eliminator capaci- tor for use without a battery. The ultra smooth three phase output makes this system a good choice for no battery operation. Note: Must use a magneto for ignition. Also see CE-22ANB The CE-63T is a direct replacement for the stock system on 2001-06 Softail®. The CE-64T is a direct replacement for the stock system on 2004-05 Dyna®.

CE-62A

The CE-67T will upgrade 1999-03 Dyna® to three phase. It is the same as the CE- 62A but has a twin cam stator. The CE-68T will upgrade 2000 Softail® to three phase. The CE-69S will fit 1991-03 Sportsters® The CE-69S-04 will fit 2004-06 1200 Sportsters® The CE-69S-07 will fit 2007-12 Sportsters® ( Stator and regulator only) This kit uses the stock rotor. It will fit 883 & 1200. The 70 series kits produce 25 amps @ 1000 RPM and 50 amps @2500 RPM. The stator in the 70 series is a slimmed down version of the larger 80 series. This allows maximum power on models where the full size stator will not fit. They are ideal for running extra lights and heated clothing. The CE-71A will fit 1984-88 rubber mount 5 speed FLH-FLT & FXR. Highly recommended for dressers to keep them charging at an idle. This will stop the voltmeter from taking a dive and keep the blinkers flashing at idle. (For 89-98 FLH-FLT see CE-81A) The CE-73T will upgrade 2001-06 Softail® models from a 38 to a 45 amp system. The CE-74T will upgrade 99-03 Dyna® models from a 38 to a 45 amp system. 70 Series 45 Amp Three Phase Kits

CE-69S/CE-69S-04

CE-74T

12

80 Series 50 Amp Three Phase Kits The 80 series kits produce 50 amps @ 2500 RPM and 32 amps @ 1000 RPM. They are available to cover 1989 to present Big twins. These kits give an incredible increase in charging power when upgrading from a 32 or 38-amp system. They also offer better durability and dependability than the stock 48-amp single-phase system. The larger three-phase stator delivers a smoother charge and has the ability to produce maximum power with out over heating.

See descriptions below and applications chart on page 10

The CE-81A will fit all 1989-96 Evo FLH-FLT & FXR models. (Will fit 97-98, See CE-81A-97) The CE-81A-97 will fit 97-98 FLH/FLT. This is the same as the CE-81A without the spacer collar and 50-amp breaker that come stock on the 97-98 models.(See note 2) The CE-82T is a replacement for the stock system on 2007 Dyna models. It will upgrade the 2006 Dyna models. (See note 1) The CE-83T is a replacement for the stock system on 2007 Softail models. (See note 1) The CE-84T-99 is a recommended upgrade for all 1999-2003 FLH-FLT.(See note 2) The CE-84T-04 is a recommended upgrade for all 2004-2005 FLH-FLT.(See note 2) The CE-84T-06 is a replacement for the stock system on 2006 FLH-FLT models.(See note 2) The CE-84T-07 is a replacement for the stock system on 2007-2008 FLH-FLT models.(See notes 1&2) The CE-84T-09 fits 2009-2010 FLH-FLT models without oil cooler. The low mount regulator give a clean custom look. (See note 1) The CE-84T-10 fits 2009-2010 FLH-FLT models with oil cooler. The regulator mounts high to keep it away from the oil cooler. The CE-84T-12 fits all 2011-2013 FLH-FLT models. The regulator mounts high to keep it away from the hot oil cooler. The CE-85T is a replacement for the stock system on 2008-2011 Dyna models. (See note 1) The CE-86T is a replacement for the stock system on 2008-2011 Softail models. (See note 1) CE-81A

The CE-87T is a replacement for the stock system on 2012-2015 Dyna models. The CE-88T is a replacement for the stock system on 2012-2015 Softail models.

CE-84T-04

Wire Harness for Kits

CE-437 CE-642 CE-643 CE-644 CE-645

Replacment Wire Harness for CE-445-97 regulator

Replacment Wire Harness for CE-61A, CE-71A, Kits ( used with CE-603 regulator) Replacment Wire Harness for CE-81A Kits ( used with CE-603 regulator) Replacment Wire Harness for CE-84T-99 Kits ( used with CE-603 regulator) Replacment Wire Harness for CE-84T-04 Kits ( used with CE-603 regulator)

See notes on the top of page 15

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Testing for an overloaded charging system If the electrical system uses more amps then your charging system can put out, voltage will drop causing battery discharge. When this happens it appears that the charging system has failed when in reality it may just be overloaded. Testing System Voltage The easiest and fastest way to determine if a charging system is operating satisfactorily is with a voltmeter. Connect the voltmeter across the battery before starting the bike. A fully charged battery should read 12.7 volts at 72° F. Anything less indicates a battery that needs to be charged or has other problems. Start the bike. If an electric starter was used run the mo- tor at a high idle for a minute or two to recharge the battery after starting. (Caution: take care not to blue the pipes). Turn on accessories used in normal operation (not turn signals or horn). If the voltage at the battery is between 13.8 and 14.8 VDC (depending on model) you can assume the charging system is keeping up. If the voltage is too low, do a system amperage output test and an amperage usage test. If the output is low repair the charging system. If the output is normal and usage exceeds output install a larger charging system or reduce the load. Determining Usable DC Amps (System Output Test) We define usable amps as the amount of DC amps the charging system can deliver while maintaining an acceptable volt- age. If voltage drops below 13.8 the battery will not fully charge. By the time voltage drops to 12.7, you are drawing amps out of the battery, so any increase in ampere output after voltage drops below 13.8 will be considered unusable amps. To test system output, you will need a voltmeter and an amp meter rated for higher amps then the system rated output, and a load dump. (i.e. carbon pile resistor or other variable load) Connect the voltmeter across the battery. Connect the amp meter in series with regulator output (measure amps in the wire from the regulator to the battery). Start the motor and allow it to warm-up enough to obtain a steady idle (1000 RPM). Connect load across the battery. (Add light bulbs, resistors or whatever your using for a load dump) until the voltmeter reads between 13.8 and 13.5. Read amp meter. This will be usable low speed amps. Now increase RPM to normal cruising speed (2500 RPM) add load until volts drop to 13.8. Read amp meter. This will be usable high-speed amps. On some systems maximum amps will come at 4500 RPM or higher. Unless you cruise at 95+ do not consider this as usable. Usable DC amps should be at least 1or 2 amps higher then system load. Determining Amperage Usage 1) Disconnect your charging system. Put a battery charger on the battery to keep system voltage up. 2) Use a clamp on inductive amp meter on battery negative cable. 3) Start the engine and turn on all normal electrical accessories. Read the amp meter. Add 2 amps for battery draw. This is normal amperage usage. 4) Turn on all accessories. Read meter. Add 2 amps for battery draw. This is maximum usage. Note: Amperage usage should be at least 2 amps lower then charging system output. Low Mount Oil Coolers Cycle Electric Inc. does not recommend installing an oil cooler in front of any regulator. Regulators are solid-state electronic devices that produce heat. They need a flow of cooler air to dissipate this heat. As the temperature of a solid- state device is increased, the probability of failure is increased. If the regulator gets hot enough it will fail. An oil cooler placed in front of the regulator will put the heat from the motor into the regulator. This is not a good idea. Lithium Ion Batterys Lithium Ion Batteries are quickly becoming popular. There are several versions of them made out of different com- pounds available. Each has its own charging characteristics. Contact your battery manufacturer to find out what the optimum charging voltage is for that battery. The most popular lithium ion compound used for motorcycle batteries is lithium iron phosphate. They like a charging voltage between 13.4 and 14.4 VDC. A lead acid batteries optimal charging voltage runs between 13.8 and 14.8. Cycle Electric Inc. standard regulators charge between 14.2 and 14.6 volts DC depending on model, All Cycle Electric Inc. low volt regulators charge between 13.7-13.9 volts DC. All Cycle Electric Inc. regulators are compatible with lithium ion batteries designed for use on 12 volt motorcycle systems but we recommend using “L” models for added over charging protection. Warning: disconnecting the battery with the motor running can cause damage to electronic components. Do not discon- nect your battery with the motor running. We do not recommend the use of batteries that have a self-disconnect feature. For more information on diagnosing charging problems go to our web site www.cycleelectricinc.com

14

Notes

Terms 1) Dealers Only 2) All orders will be shipped U.P.S., C.O.D. or prepaid 3) Shipping will be paid on orders over $600.00 within the continental U.S.A. (This does not cover any C.O.D. fees) 4) There will be a $25.00 charge on all returned checks. Warranty All Cycle Electric Inc. products are warranted for two years. Any Cycle Electric Inc. product found to be defective within two years of the origi- nal purchase date should be returned freight paid to 8734 Dayton Greenville Pike, Brookville OH 45309. We will repair or replace it. Exclusions Cycle Electric Inc. will not be found responsible for damage due to physical impact, internal tampering or faulty regulation from regulators not manufactured by Cycle Electric Inc. Cycle Electric Inc 8734 Dayton Greenville Pike Brookville OH 45309 Note 2: Not recommended for use with oil coolers that mount in front of the regulator. Cycle Electric Inc. does not recommend installing an oil cooler in front of any regula- tor. See low mount oil cooler on page 14. Note 3: Will not fit with low mount oil cooler. Note 1: 06-11Dyna, 07-11 Softail & 07-10 FLH-FLT Models came stock with the compensator spring cup built in to the alternator rotor. If the compensator has been up- graded on these models they will use a rotor without the spring cup. Add “UC” on the end of the kit part number if you need the rotor without a spring cup.

PHONE 800-523-2645 / 937-884-7300 FAX 937-884-5542 EMAIL dealerorders@cycleelectricinc.com This email address is for dealer orders only. Please include the shop name and your Dealer ID #.

For the most up to date info see our website www.cycleelectricinc.com

15

Charging Systems for American V-Twins Top Quality Made In U.S.A

50 Amp 80 Series Kits

The Cycle Electric Inc. 80 series kits produce 50 amps @ 2500 RPM and 32 amps @ 1000 RPM. We offer 22 different kits to fit 1989 to 2014 FLH-FLT, Twin Cam Dyna ® and Softail ® . These kits offer an incredible increase in charging power when upgrading from a 32 or 38 amp system and better durability than the stock 48-amp system. All Cycle Electric Inc. products are made in the U.S.A. and come with a two-year warranty.

DGV-5000 The DGV-5000 is a complete charging system for generator bikes. It features simplified wiring, higher output, longer service life and a two-year guarantee. After two years Cycle Electric Inc. offers repair service. This is the last generator you will have to buy for your bike.

· Complete Charging System

· Two Year Guarantee

· Higher Output

· Made in USA

· Last Generator You’ll Need To Buy

· Longer Service Life

www.cycleelectricinc.com