Harley Davidson Electra Glide. Service manual (1959 to 1969) — page 12

A generator that is put Into service with the wrong polarity may result in burned relay points, a dead battery and damage to the generator.

Polarize the generator by momentarily connecting the "BAT" and "GEN” terminals with a jumper wire.

GENERATOR CHARGING RATE

After a generator has been repaired, assembled, installed on motorcycle, connected and polarized, it may be checked for maximum output. That is, the maximum, uncontrolled amperage output range may be checked to determine the success of the repair work. This test is described in previous paragraph "TESTING GENERATOR OUTPUT". This test will not, however, indicate if the battery and generator are being protected by proper regulator function. See "Voltage Regulator," Section 51, for correct Delco Remy Bulletin giving checks that can be made to determine if the regulator is functioning normally.

DISASSEMBLING GENERATOR (Fig. 5E-1)

Remove generator from engine gearcase as described in "Removing Generator."

Remove gasket (1). Remove gear shaft nut (2) and washer (3). Remove generator drive gear (4 or 4A) using Gear Puller, Part No. 95715-19A or All Purpose Claw Puller, Part No. 95635-46, and Wedge Attachment, Part No. 95637-46. Slip drive end oil deflector (5) off armature shaft.

Remove brush cover strap (6). Turn off commutator end cover nuts (7) and remove washers (8). Pull frame screws and washers (9) out of frame. Tap commutator end cover (10) gently with small mallet and remove. Remove nuts (11) and washers (12) to free positive brush cable and brush leads. Remove brush holder mounting plate (13).

Press armature (14) out of bearing on arbor press or by clamping generator frame between copper jaws in vise and tapping gear drive shaft end with rawhide mallet.
Remove terminal screw nuts (15), lock washers (16) and insulating washers (17). Remove terminal screws (22 and 24) from inside generator frame and remove from them terminal insulator (18), terminal bolt clip (19), terminal screw bushings (20), bracket insulator (21) and positive brush cable (23).
Tap drive end plate (28) off frame and remove bearing retainer (25) using needle nose pliers. Press armature bearing (26) out of drive end plate using arbor press and appropriate drift pin. Remove bearing retainer (27). Press armature oil seal (29) out of drive end plate from drive gear side.

Remove two pole shoe screws (30). Use large, heavy, screwdriver. Screws are turned extremely tight. Remove pole shoes (31) and field coils (32) from frame (33). Do not remove pole shoe screws, pole shoes and field coils unless necessary to replace faulty parts.

CLEANING, INSPECTION AND REPAIR (Fig. 5E-1)

Clean all parts except gasket, armature, field coils and brushes in cleaning solvent and blow dry with compressed air. Wipe rest of parts clean with cloth dampened in white gas and blow dry with compressed air.
Examine all parts carefully for wear. Give close attention to condition of insulators, armature windings, field coil wrapping and surfaces of pole shoes nearest armature. If armature had oily appearance before cleaning, replace oil seal. Replace any part of brush holder mounting assembly that is bent. Disassemble parts as far as necessary in order of numbers shown in Fig. 5E-1, lowest number first.
Check play in armature ball bearing. If any play can be detected, replace part.

Check fit of armature shaft in end cover bushing or roller bearing (44, 44A). If fit is obviously too loose, replace as follows:

BUSHING REMOVAL

Clamp 9/16 in. - 24 plug tap in vise and turn end cover onto tap by hand until bushing is removed. Assemble generator parts 7, 8, 9, 10, 28 and 33. Place hew bushing on end of arbor in special Harley-Davidson Generator Bushing Tool, Part No.97250-58, and insert arbor through generator from drive gear end. Place pilot tool over arbor and seat in bearing recess in generator drive end plate. Drive bushing into end cover until it seats firmly. Remove arbor by twisting. Insert screwdriver or rod in hole in arbor to assist in twisting if necessary. Disassemble generator parts.

ROLLER BEARING REMOVAL

Press out worn bearing. Support end cover and press on closed end of new bearing until it is flush with surface of end cover.

ASSEMBLING GENERATOR (Fig. 5E-1)

Assemble all parts to the brush holder mounting plate (13).

Position pole shoes (31) in field coils (32) and insert in frame. Turn in pole shoe screws until snug. Place frame in vise and use very large