45-Amp Upgrade Alternator Rotor Kit
J020142013-11-01
GENERAL
Kit Number
29999-97B
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
Kit Contents
Table 1. Kit Contents
Quantity
Description
Part Number
1
Rotor assembly
29943-01
1
Gasket, primary cover, FLT's
34901-94A
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNING
Disconnect 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)
EXISTING ROTOR REMOVAL
  1. Remove seat and disconnect battery terminals, negative cable first.
  2. See the Service Manual. Remove the primary chaincase cover. Remove the clutch, primary chain, compensating sprocket and shaft extension as a single assembly.
  3. Remove the alternator rotor spacer, if present.
INSTALLATION
CAUTION
The high-output rotor contains powerful magnets. Exercise caution to prevent possible hand injury during removal and installation. (00558b)
1.
See Figure 1. Verify threads are clean and thread the Shaft Protector and Rotor Remover/Installer, if removed.
NOTE
The Shaft Protector Sleeve not only protects the threads from the splines of the rotor, but acts as a guide to verify that the rotor is properly centered.
2.
Turn thumbscrews of Rotor Remover/Installer into threaded holes in rotor face.
1Engine sprocket shaft
2Make sure threads are clean
3Shaft protector sleeve
4Install shaft protector sleeve
5Thumb screw
6Forcing screw
7Handle
8Install rotor remover/installer
Figure 1. Install Shaft Protector and Rotor Installer
3.
Center ball on forcing screw in recess at end of engine sprocket shaft. Rotate the handle of the tool in a counterclockwise direction to ease rotor into position over stator.
4.
Loosen thumbscrews and remove Rotor Remover/Installer. Remove Shaft Protector Sleeve.
5.
Install the shaft extension on engine sprocket shaft. No alternator rotor spacer is necessary).
6.
Follow instructions in applicable Service Manual and install the clutch assembly, primary chain and shaft extension as a single assembly.
7.
Apply two drops of Red LOCTITE® 262 to threads of clutch nut and engine sprocket nut. Tighten nuts as follows:
a.
Clutch nut-(left hand threads), 70-80 ft-lbs (94.9-105.5 Nm)
b.
Engine sprocket nut- 150-165 ft-lbs (203-223 Nm).
8.
See the Service Manual. Install the Primary Chaincase Cover using new gasket from kit, if necessary.
9.
See the Service Manual. Adjust primary chain tension and clutch freeplay.
10.
Fill primary chaincase with lubricant until level reaches the bottom edge of the clutch plates.
WARNING
Connect positive (+) 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. (00068a)
11.
Connect the battery cables, positive cable first.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
12.
See the Service Manual. Install the seat.
13.
Start engine and perform load test procedure given in Service Manual to verify correct alternator operation.