9.20
ELECTRICAL
CONVENTIONAL BATTERY
INSPECTION/REMOVAL
The battery is located in the front rack storage compartment.
Inspect the battery fluid level. When the battery fluid nears the
lower level, remove the battery and fill with distilled water only
to the upper level line. To remove the battery:
1. Disconnect holder strap and remove covers.
2. Disconnect battery negative (-) (black) cable first, followed
by the positive (+) (red) cable.
3. Remove the battery.
4. Remove the filler caps and add distilled water only as
needed to bring each cell to the proper level. Do not overfill
the battery.
Refill using only distilled water. Tap water contains minerals
which are harmful to a battery.
Do not allow cleaning solution or tap water inside the battery.
Battery life may be reduced.Reinstall the battery caps.
5. Reinstall the battery caps.
CONVENTIONAL BATTERY
INSTALLATION
1. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup water
and one tablespoon baking soda. Rinse well with clean
water and dry thoroughly.
2. Route the cables correctly.
3. Reinstall battery, attaching positive (+) (red) cable first and
then the negative (-) (black) cable. Coat terminals and bolt
threads with Nyogel™ Grease (PN 2871329).
4. Install clear battery vent tube from vehicle to battery vent.
WARNING: Vent tube must be free from obstructions and
kinks and securely installed. If not, battery gases could
accumulate and cause an explosion. The vent tube should
be routed away from frame and body to prevent contact
with electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts the vehicle
frame, corrosion will occur.
5. Reinstall the holder strap.
CONVENTIONAL BATTERY
TESTING
Whenever a service complaint is related to either the starting or
charging systems, the battery should be checked first.
Following are three tests which can easily be made on a battery
to determine its condition: OCV Test, Specific Gravity Test and
Load Test.
CONVENTIONAL BATTERY OCV
- OPEN CIRCUIT VOLTAGE TEST
Battery voltage should be checked with a digital multitester.
Readings of 12.6 volts or less require further battery testing and
charging. See charts and Load Test on below.
NOTE: Lead-acid batteries should be kept at or near a
full charge as possible. Electrolyte level should be kept
between the low and full marks. If the battery is stored or
used in a partially charged condition, or with low
electrolyte levels, hard crystal sulfation will form on the
plates, reducing the efficiency and service life of the
battery.
CAUTION
Whenever removing or reinstalling the battery, dis-
connect the negative (black) cable first and reinstall
the negative cable last!
Maintain
between upper
and lower level
marks
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