COMPU-FIRE 55560 - User Manual

024-55560
1
INSTALLATION INSTRUCTIONS
COMPU-FIRE® 3 PHASE CHARGING SYSTEMS
(Evo Big Twin Engines)
Part # 55560 Evo Big Twin with wet primary. Inc. vented rotor.
Part # 55570 Evo Big Twin w/ open primary. Inc. rotor w/o vents.
READ THESE INSTRUCTIONS COMPLETELY BEFORE BEGINNING
INSTALLATION!
NOTE: REFER TO THE FACTORY SHOP MANUAL ELECTRICAL SECTION FOR SAFETY
INSTRUCTIONS PRIOR TO PERFORMING ANY ELECTRICAL SYSTEM REPAIRS OR
MODIFICATIONS!
CAUTION! ALWAYS DISCONNECT THE BATTERY CABLES BEFORE PERFORMING ANY
ELECTRICAL SYSTEM REPAIRS OR MODIFICATIONS.THIS WILL PREVENT DAMAGE TO
THE ELECTRICAL SYSTEM OR COMPONENTS IN CASE OF AN ELECTRICAL ARC
CAUSED BY SHORTING THE BATTERY POWER TO GROUND.
WARNING! SEVERE DAMAGE TO THE ELECTRICAL SYSTEM OR PERSONAL INJURY
MAY OCCUR BY NOT FOLLOWING THE ABOVE SAFETY INSTRUCTIONS.
CAUTION! The installation of the Compu-Fire 3-Phase Charging System requires factory Harley
Davidson® service tools in the disassembly of the clutch and primary chain sprocket. If you are
not familiar with the disassembly of the primary drive assembly, or do not have the proper tools,
Compu-Fire recommends the installation be performed by a trained Harley Davidson®
technician.
1. Disconnect the cables at the battery. Remove the ground (-) cable first and then the
positive (+) cable.
2. Drain the oil in the primary chain case and remove the outer primary cover,
compensating sprocket, primary drive and clutch as described in the factory manual.
3. Remove the alternator rotor using Harley Davidson® puller part no. 95960-52B. Note
the location of the washers. Discard the washer on the inside of the rotor.
4. Remove the stator plug retainer and the four Torx head screws attaching the stator.
5. Remove the sprocket shaft seal and spacer following the factory service manual
instructions.

Summary

INSTALLATION INSTRUCTIONS

Product Overview and Identification

Details Compu-Fire 3 Phase Charging Systems for Evo Big Twin engines and specific part numbers.

Critical Safety and Handling Warnings

Highlights essential cautions and warnings for safe installation and system protection.

Installation - Initial Preparation and Disassembly

Covers disconnecting the battery, draining oil, and removing the primary cover and rotor.

Installation - Component Replacement and Mounting

Details installing the new sprocket shaft seal, stator, and rotor with specific tools.

Installation - Final Assembly and Wiring

Covers re-installing the primary drive, attaching the voltage regulator, and connecting the battery.

TROUBLESHOOTING TIPS

Stator Troubleshooting

Provides continuity and output tests for the stator.

Regulator Troubleshooting

Outlines voltage checks for the regulator at battery terminals.

Overview

1. Compu-Fire 3-Phase Charging Systems
   1. Function Description
   2. Important Technical Specifications
   3. Usage Features
   4. Maintenance Features

Compu-Fire 3-Phase Charging Systems

The Compu-Fire 3-Phase Charging System is an aftermarket electrical component designed for Harley-Davidson Evo Big Twin Engines. It provides a robust and efficient charging solution for motorcycles, replacing the stock charging system. The system is available in two main configurations: Part # 55560 for Evo Big Twin with a wet primary and a vented rotor, and Part # 55570 for Evo Big Twin with an open primary and a rotor without vents.

Function Description

The primary function of the Compu-Fire 3-Phase Charging System is to generate and regulate electrical power to charge the motorcycle's battery and supply power to the electrical system. It consists of a 3-phase stator, an alternating rotor, and a voltage regulator.

• Stator: The stator is a stationary component with windings that generate alternating current (AC) when the rotor spins within it. The 3-phase design ensures a more consistent and powerful output compared to single-phase systems.
• Rotor: The rotor is a rotating component attached to the crankshaft. It contains strong magnets that induce current in the stator windings as it spins. The design of the rotor varies based on the primary system (wet or open), with vented rotors for wet primaries to aid in cooling the stator.
• Voltage Regulator: The voltage regulator converts the AC output from the stator into direct current (DC) suitable for charging the battery and powering the motorcycle's electrical components. It also maintains a stable voltage output, preventing overcharging or undercharging of the battery. The Compu-Fire regulator utilizes high-efficiency series-type circuitry, which differs from original equipment (OE) designs.

Important Technical Specifications

• Engine Compatibility: Designed specifically for Harley-Davidson Evo Big Twin Engines.
• Primary System Compatibility:
  • Part # 55560: Wet primary, includes a vented rotor for enhanced stator cooling.
  • Part # 55570: Open primary, includes a non-vented rotor.
• Stator Output: Each phase (AB, AC, BC) of the 3-phase stator should produce approximately 14 volts AC per 1,000 RPM.
• Fuse Requirement: The system requires a 40 amp fuse for protection.
• Voltage Regulator Type: High-efficiency series-type circuitry.
• Rotor Magnets: The rotor incorporates extremely strong magnets, which contribute to its powerful output but also necessitate careful handling during installation.
• Installation Tools: Requires specific Harley-Davidson service tools for disassembly and installation, including pullers (e.g., H-D part no. 95960-52B) and rotor installation tools (e.g., H-D tool P/N 41771 or Jim's tool P/N 758-147).
• Seal Spacer: Includes a large flanged seal spacer.
• Spacer Washer: Includes a spacer washer (2.81 in. O.D. x .219 in. thick) for most models, with exceptions for Softail/Dyna.

Usage Features

• Enhanced Charging Performance: The 3-phase design generally offers superior charging efficiency and output compared to stock single-phase systems, which can be beneficial for motorcycles with increased electrical demands.
• System Integration: Designed to integrate with the existing motorcycle electrical system, connecting to the battery and utilizing the factory primary drive assembly.
• Rotor Ventilation (Wet Primary): The vented rotor for wet primary systems helps dissipate heat from the stator, contributing to the longevity and performance of the charging system.
• Robust Design: The components are manufactured and inspected under strict quality assurance procedures to ensure durability and reliability.

Maintenance Features

• Installation Precautions:
  • Always disconnect battery cables (ground first, then positive) before any electrical work to prevent damage from electrical arcs.
  • Requires draining primary chain case oil and removing the outer primary cover, compensating sprocket, primary drive, and clutch.
  • Use Loctite 262 (red) on the threads of the compensating nut during reassembly.
  • Ensure the stator cable is routed correctly to prevent pinching or rubbing by the rotor.
  • The voltage regulator must be mounted in an area with good airflow for optimal cooling.
  • Secure all wires with supplied wire ties to prevent contact with the exhaust system or moving parts.
  • Do not shorten the (+) wire from the voltage regulator or alter its factory-crimped terminal; coil and secure excess cable if necessary.
• Troubleshooting Guidelines:
  • Stator:
    • Each of the three pins should have continuity to each other, but no continuity to ground.
    • Each phase (AB, AC, BC) should output approximately 14 volts AC per 1,000 RPM.
  • Regulator:
    • With the ignition off, battery voltage should be 12-13 volts DC.
    • With the engine running at 1500 RPM, the battery voltage should increase by 1/2 to 1 volt, indicating proper charging.
  • Important Note: Do not use standard H-D factory shop manual test procedures for the Compu-Fire regulator, as its series-type circuitry is different and may lead to inconclusive results.
• Handling Precautions: Due to the extremely strong magnets in the rotor, avoid placing it near metal parts, tools, or hardware in the work area to prevent damage to the magnets. Exercise extreme caution during installation to prevent fingers from being pinched between the rotor and the engine case or stator.
• Warranty: PerTronix, LLC. provides a limited warranty of 12 months from the date of purchase, covering defects in material and workmanship for the module, trigger rotor, and wiring components.
• Technical Support: Technical assistance is available by calling 909/547-9058.
• Rotor Damage: Compu-Fire will not accept rotors returned with chipped or broken magnets, as such damage is attributed to careless handling or improper installation techniques.

COMPU-FIRE 55560 Specifications

General

Brand	COMPU-FIRE
Model	55560
Category	Battery Charger
Language	English