54 AMP HIGH-OUTPUT CHARGING SYSTEM UPGRADE KIT
J057872014-03-04
GENERAL
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
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)
NOTE
A Service Manual for your motorcycle is available at your Harley-Davidson Dealer.
Kit Contents
See Figure 7 and Table 1.
INSTALLATION
Prepare Motorcycle for Kit Installation
1.
All models: See Figure 1. Position the bracket (3) onto the voltage regulator (4) and install the washer (2) and bolt (1). Tighten the bolts to 11.3–13.6 N·m (100–120 in-lbs).
2.
See the service manual. Disconnect negative battery cable.
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)
3.
See the service manual. Remove the Voltage Regulator.
4.
Replace oil cooler hose (air cooled models):
a.
Place a drain pan under motorcycle. Remove oil cooler.
b.
See Figure 2. Cut the hose clamp (1) and disconnect the oil cooler hose (2) from the oil cooler (3).
c.
See Figure 3. Release the hose clamp (1) and remove the oil cooler hose (3) from the oil filter adapter (2).
d.
Position the original hose clamp on the upper end of the new oil cooler hose supplied with the kit.
e.
Position the new clamp on the lower end of the hose.
f.
Install the new oil cooler hose. Position and install the clamps.
1Bolt
2Washer
3Bracket
4Voltage regulator
Figure 1. Voltage Regulator Bracket
1Hose clamp
2Oil cooler hose
3Oil cooler
Figure 2. Oil Cooler Hose (Lower)
1Hose clamp
2Oil filter adapter
3Oil cooler hose
Figure 3. Oil Cooler Hose (Upper)
Replace the Stock Alternator (all models)
1.
All models: See the service manual. Remove the seat, starter, primary chaincase cover, primary chaincase housing, primary chain, clutch, compensating wheel, left footboard and bracket, jiffy stand alternator assembly and rotor assembly.
NOTE
Stator TORX screws and compensator screw are not reusable and must be replaced.
NOTE
Contact cleaner, alcohol or glass cleaner sprayed on rubber grommet will provide lubrication when pulling grommet through crankcase hole.
2.
See the service manual. Using the new rotor assembly and stator assembly included in the kit install the alternator assembly.
3.
See the service manual. Install the starter, primary chaincase cover, primary chaincase housing, primary chain, clutch, compensating wheel, left footboard and bracket, and the jiffy stand.
4.
See Figure 4. Connect the stator connector [46]. Secure with the latch.
5.
Connect the voltage regulator connector [77]. Secure with the latch.
6.
See Figure 4. Position the voltage regulator assembly (6) and install the two new voltage regulator locknuts (1). Tighten the nuts to 7.9–11.3 N·m (70–100 in-lbs).
NOTE
Make sure that new oil cooler hose does not contact frame or regulator bracket.
7.
Twin-Cooled:
a.
Remove the downtube screws.
b.
Position the coolant down tubes.
c.
See Figure 5. Position the voltage regulator assembly (2) and install the downtube screws (1). Tighten the screws to 11.3–13.6 N·m (100–120 in-lbs). On MY13 and earlier Touring models, it will be necessary to install two new nuts (17) and washers (18) supplied in the kit. Tighten the screws to 11.3–13.6 N·m (100–120 in-lbs). Trike Models require separate purchase of (2) screws Part No. 3909.
1Lock nut
2Stator connector latch
3Stator connector [46]
4Voltage regulator connector [77]
5Voltage regulator connector latch
6Voltage regulator assembly
Figure 4. Voltage Regulator Assembly
1Down tube screws
2Voltage regulator assembly
3Down tubes
Figure 5. Down Tube Screws
8.
Air cooled: Install screw, washer and locknuts in upper bracket holes.
9.
See Figure 6. Secure cooler to frame with screws. Tighten to 27.1–29.8 N·m (20–22 ft-lbs).
10.
Secure stator wire to frame using barbed cable strap.
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.
Start the engine and check voltage across the battery terminals. Voltage measured must be 13-15 VDC.
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.
Install seat.
Figure 6. Lower Oil Cooler Screws
SERVICE PARTS
Figure 7. 54 Amp Charging System Upgrade Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Oil cooler hose
62700085
2
Cable straps (2)
10065
3
3-Phase 54 AMP stator assembly
29900029
4
Charging rotor assembly
29900033
5
Clamp spring, black
10354
6
54 AMP voltage regulator assembly
74700021
7
Washer (4)
6771A
8
Hex cap screw SAE grade 8 (4)
4751
9
Lock Nut (4)
7716
10
Voltage regulator bracket
12700087
11
Washer (2)
6119
12
Screw (2)
4741A
13*
Primary cover housing gasket
34934-06
14*
Primary cover gasket
34901-07
15*
Screws (4)
3050
16*
Bushings (2)
42642-00A
17*
Screw
10500031
18*
Screws (5)
786A
19*
Barbed cable strap (not included in kit)
10177
*All item numbers in the BOM with an asterisk are not shown on the drawing.