Undercutting Commutator Mica

After undercutting is completed, again smooth commutator with No. 00 sandpaper. It is also advisable to repeat "growler" check for "short" as there is a possibility of developing a "short" during the turning and undercutting operations. If so, it can very likely be corrected by more thorough cleaning between segments and at ends of commutator.

Reassembling Generator

(To Identify Items, Refer to Illus. 79 or 80)

1. If one or both field coils have to be reassembled, do this first. Remember that field coils (13) and (17) are not alike and must not be interchanged. If one has to be replaced, be sure it is replaced with one of same type.

Thoroughly clean generator frame where pole shoe seats and also clean face of pole shoe that seats against frame. Tighten pole shoe screws (9) and (11) as tight as possible, with a large screwdriver that fits well into screw slot. Unless screws are very tight, there will not be the required clearance (.007" or more) between armature and each pole shoe (this clearance is to be checked later when armature is assembled into frame).

2. Proceed with further assembly of generator.

reversing order of disassembly as outlined under "Disassembling Generator,"

3. If felt oil retaining washer (7), or oil seal explained in paragraph 11, under "Disassembling Generator," , is worn, renew it.

4. Thoroughly wash and closely inspect both the drive end and commutator end bearings, (5) and (42). If either is found worn to any extent, or pitted and rough, renew it. The commutator end bearing particularly should be replaced if it shows any appreciable wear, as a loose bearing allows commutator to run eccentric and chatter, even though commutator itself is perfectly true. Pack both bearings with high melting point grease (Harley-Davidson grade "A" grease).

5. Gauging Armature Pole Shoe Clearance:

Select a sheet of paper .007" thick or use a double sheet totaling this thickness. Cut a piece as wide as length of armature core and long enough to wrap nearly, but not quite, around armature.

Assemble armature in frame with this paper around it, inserting shaft through drive end bearing. If pole shoe clearance is up to the required .007" or more on each side, armature can be inserted and will turn freely. If it binds, pole shoe or shoes removed and replaced must be pulled tighter to frame with pole shoe screws. Possibly parts were not well cledned and there are particles of dirt between shoe and frame, preventing full seating.

Specified pole shoe clearance is necessary to allow for expansion of armature when hot and for play that normally develops due to bearing wear. Taking a chance on less than specified clearance may result in armature striking pole shoe and damaging both the armature and pole shoe. An armature damaged in this manner is usually grounded and must be renewed.

6. Installing Frame End: Generator irame end fits over register in frame and is located by a dowel pin in frame and a corresponding hole in frame end. Frame end must be a snug fit on frame register or a new end must be installed. If frame end is loose on frame, armature-pole shoe clearance is affected and the likely result is a damaged armature. Tighten screws securely.

7. Complete assembly of generator. Be sure pin that secures drive gear, oil centrifuge or spring collar is well riveted at both ends to prevent it from coming out in service and causing serious damage to timing gears and other parts. Side Valve Engine only: Measure the distance from outer face of oil centrifuge on end of armature shaft to end of generator frame (gasket removed). This distance should be 1-53/64" to 1-27/32". Adjust if necessary by removing or adding an armature spacer (18).

Connect field coil wires according to Illus. 96 or 97 and paragraph "2" under "Disassembling Generator,"

Test generator on test stand if this equipment is available. If not, install on engine and test. Generator output can be adjusted as follows: Three brush generator—by moving third brush; two brush generator— by adjusting current and voltage regulator. See "Generator Charging Rate."

Assembling Generator to Engine

Reverse the operations followed in "Removing Generator," also refer to "Installing Gen erator,"

Make sure same number of paper shims are used in reassembling as were found underneath generator when it was removed. After an engine has seen considerable service and gears have worn to some extent, they have possibly developed enough lash or play to permit safely removing one or more of the original shims and thus effecting closer meshing and quieter operation. However, this should not be done unless timing gear case cover is removed so gear mesh and lash can be carefully checked.

Make sure all external wire connections are correct and tight.

Generator Charging Rate

(The following maximum rates specified are battery charge over equipment loads indicated, which do not include sidecar lighting, using test ammeter at battery ground.)

1. Standard Generator:

A maximum charging rate of about 4 amperes with standard equipment tail lamp, speedometer light and headlamp lighted (headlamp on upper light beam) is standard factory setting.

Radio Three Brush Generator:

A maximum charging rate of about 2 amperes with radio and standard equipment tail lamp, speedometer light and headlamp lighted (headlamp on upper light beam) is standard factory setting. If motorcycle is used without radio, remove resistor from generator "relay" and "switch" terminals, and adjust charging rate to a maximum of about 4 to 5 amperes with the above standard equipment lamps lighted.

All Three Brush Generators: Standard factory setting should be sufficient to keep battery in a good state of charge under normal service conditions. At average driving speeds, the charging rate is about the same with lights either "ON" or "OFF" because when lighting switch is "ON" generator output is automatically boosted enough to take care of the standard lighting equipment. The charging rate can be adjusted higher or lower as desired to meet unusual service conditions, but bear in mind that a higher than normal charging rate is likely to overcharge, overheat and damage battery.

When it is found necessary to adjust charging rate, proceed as follows: Remove generator end cover, and loosen screws that hold the regulating brush (small brush) plate assembly to generator frame end. Then shift regulating brush to the right to increase charging rate—to the left, to decrease charging rate. Shift brush only a little at a time, until desired maximum charging rate is obtained (see Illus. 94).

2. Radio Two Brush Generator: A maximum charging rate of 11 to 12 amperes (over ignition only) controlled by current and voltage regulator. When battery voltage is low, regulator will limit generator to about 11 to 12 amperes, and after battery voltage is up to normal, regulator will then limit generator to very low charging rate. If regulator does not control generator within specified limits, see "Current and Voltage Regulator,"

illus. 94

SHIFTING REGULATING (THIRD) BRUSH TO ADJUST CURRENT OUTPUT OF GENERATOR

illus. 94

SHIFTING REGULATING (THIRD) BRUSH TO ADJUST CURRENT OUTPUT OF GENERATOR

Inspecting or Replacing Generator Brushes

Remove the two screws in generator end cover and pull off cover, exposing the commutator and brushes. Brushes can be taken out after unfastening spring retainers. To unfasten small (regulating) brush spring retainer, simply press it downward and outward. Remove fastening screw from each of the larger brush spring retainers.

Brushes are worn out and should be renewed when longest side of brush measures 3/s" or less.

Be sure to insert brushes into holders so that concave face of brush fits curve of commutator.

Cleaning Commutator

Remove footboard, clutch footpedal assembly, and generator end cover. If oil or grease has worked out of bearings and onto commutator, wipe it off first with a rag moistened with gasoline or solvent and then sandpaper until commutator is bright, using No. 00 sandpaper. CAUTION: Never use emery cloth to clean commutator. See "Generator Charging Rate."

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