Speedo Seats & Luggage- racks Frame Chassis Suspension Forktubes Wheels Brake Fenders Gastanks Motorparts Gaskets Intake Transmission & Driveline Exhaust Electrical & Lights Handlebars, Cables & Mirrors Oil tanks Oil & Chemicals Fasteners Windshields Forward controls, Footpegs Miscellaneous ELECTRICAL - IGNITION, WIRING, STARTERS, REGULATORS & BATTERIES 15 1259 AFTERMARKET PARTS & ACCESSORIES FOR CUSTOM MOTORCYCLES / MOTORCYCLESTOREHOUSE.COM CHARGING KITS ACCEL, LECTRIC CHARGING KITS High quality components to replace stock parts. Rotor, stator & regulator/rectifier kit comes as a complete kit with Accel's Heavy Duty rotor, alternator stator and chrome plated regulator. The rotor is made with a special stainless steel alloy enclosure, on 91-99 models, to protect magnets from coming loose or damage. Extra wide splines. Compatible with the stock charging system. Nothing else needed to solve your charging issues. 516237 91-99 B.T. (excl. Twin Cam). 32Amp. 516241 01-06 Softail; 04-05 Dyna. 38Amp. 516237 516241 32 AMP CHARGING KITS Complete charging kit for 70-99 Big Twin models (excl. TC). Includes a voltage regulator/rectifier, alternator stator and an alternator rotor. Everything you need to set-up a complete new charging system. This kit will convert 70-88 Big Twin models to the late, and more potent, 89-99 B.T. style charging system. Spyke Import 908061 577800 Kit with black regulator 908062 577801 Kit with chrome regulator 908062 577800 STANDARD CO, CHARGING KIT Includes altenator stator, rotor and spacer kit. 908081 89-99 B.T. (excl. TC). 32Amp. 908079 01-06 Softail; 04-05 Dyna. 38Amp 908079 Tech-tip 95 Charge under control 45/48 Amp 1-phase vs 50 Amp 3-phase 45 Amp power In 1995 Harley Davidson introduced its first production fuel injected motorcycle, a larger charging system was required to run the electric fuel pump. A 38-amp single-phase system was developed. It was a dependable system that delivers 16 amps at 1000 rpm and 38 amps at 2500 RPM. Some riders required more electrical power on their full dressed fuel injected models. On the new system Harley bumped-up the output of the 38-amp system by increasing the strength of the magnets, by using rare earth magnets, on the rotor and it was called a 45-amp system. To make an analogy it is like taking a stock motor, boring and stroking it, then adding the most radical cam you can find. It really puts out but hits hard in current spikes. Extra power but more stress on down stream components, which can shorten the life span of some parts. There was no alternative at the time. 48 Amp heat In 1999, with the introduction of the Twin Cam, the 45 became a 48-amp system. The 45 and 48 amp systems are basically the same but the 48-amp is the first system that can actually produce more amperage then it is rated for. This system puts out 30 amps at 1000 RPM and about 54-amps maximum. When drawing over 45-amps out of this system, the stator cools insufficiently, the temperature will rise and if the draw continuous it will eventually melt the insulation, resulting in a short out and it's over. Molding insulation used on non-Cycle Electric stators starts melting at 425 F°, by 450 F° they're toast. Cycle Electric developed a stator insulation material that withstands peaks of 600 F°. Simply drawing full power out of the 48-amp system (54-amps) results in temperatures this high. Currently all Cycle Electric stators receive the better insurance of this high-temp insulation material. Still, continuous operation at very high temperature will shorten any stator's life span. 1-phase 48-amp Alternators all produce alternating current, commonly referred to as AC (Alternating Current). If you make a graph plotting AC voltage against time it would make a reciprocating wave. Ideally it would make what is known as a sine wave, which has rounded almost semi-circle shape to it. Using the stronger rare earth magnets in the OEM system produce a more square waveform, which indicates a quick change in voltage which leads to current spikes which produce heat and go harder on both regulator and battery, a downside of 48-amp single-phase system. The more commonly used ceramic magnet rotors produce a wave that rise and drop that is more gradually, but are not powerful enough for some applications. 3-phase 50-amp At the time no other charging systems were available to replace the 48-amp single phase system power house. The introduction of the 50-amp 3-phase system gives useful benefits with similar charging capacity. The three main advantages are better durability due to smoother charging, lower heat and lower cost by using ceramic magnets. The larger 3-phase stator used in the 50-amp system has 18 polls (120° offset) to do the same work of the 12 polls on the single-phase stator. This spreads the load out over a larger area and smaller coils produce more but smaller waves delivering a smoother charge and more charge with lower RPM's. On top of that each poll has only two layers of wire compared to four layers on the old stator, which leads to better heat dissipation and overall lower operating temperature. Excessive heat remains the leading cause of stator failure. Stock replacement? Cycle Electric Inc. does no longer offer the 45/48 amp single-phase systems in kits, but single replacement will remain available. However, Cycle Electric does recommend upgrading to a 3-phase system, especially in the high output 48-amp charging systems. The 50-amp upgrade kits are available for 1998-up models. Information provided by Cycle Electric Inc.
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