Alternator Rotor Kit
J000572013-11-01
GENERAL
Kit Number
29957-81B
Models
This Alternator Rotor Kit is designed for installation on all 1981 and Later 1340 cc Big Twin models. Read all instructions carefully before proceeding with the installation.
INSTALLATION
WARNINGObjects in mirrors are closer than they appear. Use caution when judging distance of objects in mirrors. Failure to judge correct distances could result in death or serious injury. (00033a)
WARNINGDisconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
NOTE
If a 32-Amp High-Output Alternator Kit has been previously installed on a 1981 to 1988 vehicle, then the spacer washers and shim washers should have been properly positioned on the sprocket shaft at the time that kit was installed. The spacer washers prevent the rotor from contacting either the primary chain or the stator. Reuse the washers from that 32-Amp Alternator Kit. Install them in the same place from which they were removed when you are installing the new rotor from this kit and discard the two washers from this kit. The positioning of the spacer/shim washers, on a vehicle in which a 32-Amp Alternator Kit has previously been installed, may be different from that specified in this Instruction Sheet.
A vehicle in which a 32-Amp Alternator Kit has been installed may be identified by a longer female connector plug on the stator. With the regulator male plug disconnected, the 32-Amp stator female plug protrudes above the left crankcase outer surface. On a standard 22-Amp stator the female plug is slightly recessed below the left crankcase outer surface.
| 1. | See the appropriate service manual to remove original alternator rotor. Note positions of any spacer washers or shim washers on sprocket shaft during disassembly procedures. Be sure to remove original spacer washer, if equipped, which is positioned inboard of rotor. NOTE Alternator rotor should be removed using rotor puller (Harley- Davidson® Part No. HD-95960-52B). | |
| 2. | Wipe the stator clean using a clean cloth. | |
| 3. | See Figure 2 , Figure 3 and Figure 4. On all models (except those with a 32-Amp Alternator Kit installed; see NOTE before Step 1), place small spacer washer (1.75 in. O.D. x 0.095 in. thickness) from kit over sprocket shaft. | |
| 4. | Install new alternator rotor assembly onto sprocket shaft. | |
| 5. | Depending on model application, perform one of the following procedures: a. On 1981 to 1990 models only (except those 1981 to 1988 models with a 32-Amp Alternator Kit installed; see NOTE before Step 1), place large spacer washer (2.81 in. O.D. x 0.219 in. thickness) from kit and original shim washer(s) (in that order) over sprocket shaft. b. On 1991 and Later FLT / FXR models only, discard large spacer washer (2.81 in. O.D. x 0.219 in. thickness) from kit. Place original thick spacer washer (1.75 in. O.D. x 0.249 in. thickness) and original shim washer(s) (in that order) over sprocket shaft. c. On 1991 and Later Softail and Dyna Glide models only, discard large spacer washer (2.81-in. O.D. x 0.219 in. thickness) from kit. Place original shim washer(s) over sprocket shaft. Original thick spacer washer (1.75 in. O.D. x 0.249 in. thickness) will be installed later (see Step 6). |  Figure 1. Service Parts |
| 6. | See the appropriate service manual and the following special instructions, to complete the installation. a. On all models, check sprocket alignment. b. On 1991 and Later Softail and Dyna Glide models only, place original thick spacer washer (1.75 in. O.D. x 0.249 in. thickness) between compensating sprocket cover assembly and compensating sprocket nut. c. On all models, apply LOCTITE® Threadlocker 262 (red) to threads of compensating sprocket nut. d. Depending on model application, tighten compensating sprocket nut to 108.4–135.5 N·m (80–100 ft-lbs) torque (1981 to 1990 models) or to 203.3–223.7 N·m (150–165 ft-lbs) torque (1991 and later models) | |
| 7. | Connect battery cables (positive cable first). |
Table 1. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Rotor assembly, alternator | Not sold separately |
2 | Spacer (2.81 in. O.D. x 0.219 in. thickness) | 29960-85 |
3 | Spacer (1.75 in. O.D. x 0.095 in. thickness) | 29961-85 |
Figure 2. 1981 to 1990 Models
Figure 3. 1991 and Later FLT/FXR Models
Figure 4. 1991 and Later Softail, Dyna Glide Models
Table 2. Alternator Rotor and Compensating Sprocket Assembly Components
Quantity | Description |
|---|---|
1 | Compensating sprocket nut |
2 | Compensating sprocket cover assy |
3 | Sliding cam |
4 | Compensating sprocket |
5 | Shaft extension |
6 | Shim washer(s) (variable thickness) |
7 | Spacer washer (1.75 in. O.D. x 0.249 in. thickness) |
8 | Spacer washer (2.81 in. O.D. x 0.219 in. thickness) (Part of Kit) |
9 | Alternator rotor assembly (Part of Kit) |
10 | Spacer washer (1.75 in. O.D. x 0.095 in. thickness) (Part of Kit) |