ELECTRICAL
10.12
BATTERY INSPECTION/REMOVAL
The battery is located under the left rear fender .
Inspect thebatteryfluidlevel. Whenthebatteryfluidnears
thelowerlevel, thebatteryshouldberemovedanddistilled
water should be added to the upper level line. To remove
the battery:
1. Disconnect holder strap and remove cover .
2. Disconnect battery negative (-) (black) cable first,
followed by the positive (+) (red) cable.
CAUTION
Whenever removing or reinstalling the battery, disconnect
the negative (black) cable first and reinstall the negative
cable last!
3. Disconnect the vent hose.
4. Remove the battery.
5. Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Do not
overfill the battery.
To refill use only distilled water . Tap water contains minerals which are harmful to a battery.
Do not allow cleaning solution or tap water to enter the battery. It will shorten the life of the battery.
6. Reinstall the battery caps.
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 will with clean water and dry thoroughly.
2. Reinstallbattery, attachingpositive (+)(red) cablefirstandthenthenegative(-)(black) cable. Coat terminals
and bolt threads with Nyogelt grease PN 2871329.
3. Install clear battery vent tube from vehicle to battery vent. WARNING: Vent tube must be free from
obstructionsandkinksandsecurelyinstalled. Ifnot,batterygasescouldaccumulateandcauseanexplosion.
Vent should be routed away from frame andbody to prevent contact with electrolyte. A voidskin contact with
battery electrolyte, severe burns could result. If electrolyte contacts the vehicle frame, corrosion will occur.
4. Route cables so they are tucked away in front and behind battery.
5. Reinstall battery cover and holder strap.
Do not start the engine with the battery disconnected. V ehicle lamps will burn out if battery is disconnected
during vehicle operation. Also, the reverse speed limiter can be damaged.
BATTERY TESTING
Whenever aservicecomplaintisrelatedtoeitherthestarting orcharging systems,thebatteryshouldbechecked
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.
OCV - OPEN CIRCUIT VOLTAGE TEST
Batteryvoltageshouldbecheckedwithadigitalmultitester. Readingsof12.6orlessrequirefurtherbatterytesting
and charging. See charts and Load Test on page 10.13.
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.
Maintain
between upper
and lower level
marks
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