Greasing Commutator End Armature Bearing

Lubricating Commutator End Armature Bearing

(To Identify Items, Refer to Illus. 79 or 80— Also Refer to Illus. 98)

To lubricate bearing (42) it is necessary to first remove end cover (54). Then bearing can be oiled through hole in outer grease retainer (52) or outer grease retainer can be shifted to expose bearing and permit greasing as follows:

Take out two of the three outer grease retainer screws (53) and loosen the third screw slightly to permit shifting outer grease retainer to one side. Pack bearing with high melting point grease (Har-ley-Davidson grade "A" grease). After greasing, replace outer grease retainer. CAUTION: If outer grease retainer is completely removed or two of the screws are removed and the third screw is made very loose, regulating brush holder (50) is free to move and thus change charging rate. Therefore, before retightening outer grease retainer screws be sure that regulating brush holder has remained in its original position.

If not convenient to grease bearing at specified interval, at least lubricate with a few drops of engine oil. Be careful that this bearing is not over-lubricated, as excess oil will very likely work out of bearing and some may get onto commutator and brushes.

Generator drive gear end bearing requires no attention as it is lubricated by the oil that circulates through engine.

Cut-Out Relay

(Refer to Illus. 99)

Adjusting Points and Air Gap

The cut-out relay is provided with an additional contact for the normally open position to control the generator signal light in instrument panel. When the generator voltage exceeds battery voltage (between 6.3 and 6.8 volts) the relay closes the battery-generator circuit. At this time, the upper contact points break and the instrument panel indicator light goes off, indicating that .generator is charging the battery. This occurs at approximately 20 miles per hour in high gear.

The relay contact points must be correctly adjusted and the armature must have correct spacing above magnet core for sensitive and correct cut-in and cutout operation.

Armature and core air gap: The space (air gap) between the armature and magnet core end should be .015" when the two upper points are in contact. Bend upper contact point support and adjust armature to obtain this gap.

Main contact point gap: After armature and magnet core end air gap have been adjusted, gauge the main contact point gap. It should be .020" and can be obtained by bending the lower point support up or down as may be necessary.

Signal light point gap: Press the armature down until the lower main points are in contact and gauge the upper contact point gap. It should be .020" and can be obtained by bending the upper point support up or down as necessary.

Adjusting armature spring tension: The relay main lower points should close at 6.3 to 6.8 volts (connect voltmeter to relay terminal marked "GEN" and to the relay base), and can be adjusted by decreasing or increasing the armature spring tension. Increasing spring tension increases the closing voltage—decreasing spring tension reduces closing voltage. The armature spring tension is altered by bending the spring stop, mounted on top of magnet, up or down.

Testing Cut-Out Relay

If it has been determined that point setting and air gap are correct and relay does not function, test as follows:

With relay removed from motorcycle, and using a 110 volt test lamp, place one test point on "GEN" terminal of relay and other test point on relay base. If lamp does not light, it indicates an open circuit in shunt (voltage) coil which will prevent contact points from closing.

armature generator signal light contact points upper contact point support spring tension adjustment generator-battery circuit points (0.020 in.)

lower point support armature generator signal light contact points lower point support

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