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Old 12-26-2004, 06:28 PM   #1
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Talking New tech article : BATTERY REPLACEMENT

OK, this is a pretty simple operation, that just about anyone can do themselves if you are careful.

The 11 degree nights around here have taken their toll on my poor battery so I needed a new one.

Most bikes have the battery under the seat, some Ducs, the suzuki TLR, they have the battery in tight spots and you have to remove body panels to get to them, this bike is under the seat so thats what Im going to show.

First off, make sure you have all the supplies needed, battery, a low amp charger (2 amp), gloves, safety goggles, and any tools you need to get to the battery.


Last edited by engineboy; 12-27-2004 at 07:47 AM..
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Old 12-26-2004, 06:29 PM   #2
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Remove the battery from the box and make sure its all in one piece, also make sure the acid pack is full.....you might want to use gloves, unless you like the itch that battery acid leaves you with

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Old 12-26-2004, 06:32 PM   #3
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You need to remove the paper thats accross the top of the battery and remove the caps on the electrolyte (save the caps, you will need them later.

Carefully set the acid pack on the top of the battery, making sure all the holes line up.

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Old 12-26-2004, 06:33 PM   #4
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Now push steady till the acid pack "snaps" down on the battery puncturing the foil and letting the acid fill the battery.

Leave it like this for about 15 minutes.

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Old 12-26-2004, 06:35 PM   #5
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Now is a good time to go remove the old battery from the bike, after finding it and getting to it, you always want to remove the negative side cable first.

I use a 10mm socket, and a small ratchet.

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Old 12-26-2004, 06:37 PM   #6
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Now remove the positive cable and remove the old battery.

By this time, all the acid should be into the new battery, so carefully remove the acid pack from the top of the battery and install the caps.


Last edited by engineboy; 12-26-2004 at 06:40 PM..
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Old 12-26-2004, 06:40 PM   #7
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Now you want to install an initial charge on the battery.

Make sure the charger is off and install the clamps, remember, red is always positive and black is always negative. Now turn on the charger.

Notice the charger needle is in the red, showing a load on the charger.

Charge at 2 amps for at least 2 hours if you are going to ride afterwards, I went 5 since Im not going anywhere tonight

Ive heard people say leave it overnight, but you really dont want to charge a battery un-attended all night....5 hours is plenty, just dont throw it on the charger for 15 minutes and expect the battery to last, yes it will start the bike, but its not good for the battery.


Last edited by engineboy; 12-26-2004 at 07:00 PM..
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Old 12-26-2004, 06:42 PM   #8
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While the new battery is charging, its a good idea to take a wire brush, sandpaper, whatever you have and clean the cable terminals real good, make them bling bling.

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Old 12-26-2004, 06:44 PM   #9
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Fast forward 5 hours.....notice the needle on the charger has come down into the green..shes done

Turn off the charger first, then remove the clamps.


Last edited by engineboy; 12-26-2004 at 06:52 PM..
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Old 12-26-2004, 06:45 PM   #10
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Next you want to install the nuts into there respective place, they will drop right in and stay there as long as you dont go throwing the battery around.

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Old 12-26-2004, 06:47 PM   #11
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Drop the new battery in and install the positive cable first, reverse of removal.

Tighten just enough to hold it there. They dont need to be cranked down.


Last edited by engineboy; 12-26-2004 at 06:52 PM..
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Old 12-26-2004, 06:48 PM   #12
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Install the negative cable and thats it, installed.

Try to start the bike up before you close it all up, just in case you have a loose connection.

Wash your hands before you rub your eyes and you are ready to ride

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Old 12-27-2004, 04:56 AM   #13
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You might want to let eveyone know to use glasses while filling the battery with the acid. One time I got a drop of acid in my eye and it'll be the last time I don't wear glasses while I fill a battery. It's also a good idea to leave the caps off while the battery is charging. Otherwise the battery will puke acid out the vent hole onto your bench.....

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Old 12-27-2004, 07:43 AM   #14
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Quote:
Originally posted by Sunshine
You might want to let eveyone know to use glasses while filling the battery with the acid. One time I got a drop of acid in my eye and it'll be the last time I don't wear glasses while I fill a battery. It's also a good idea to leave the caps off while the battery is charging. Otherwise the battery will puke acid out the vent hole onto your bench.....

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The glasses are a good idea Thanks.

On a low amp charge, the battery shouldnt perk. If you are boiling the battery to the point of it coming out the vent holes, you are charging it at too high an amp rate or the battery is overfull with acid.

I did mine for 5 hours and no acid came out anywhere.
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Replace Your Battery!

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Last edited by engineboy; 12-27-2004 at 08:54 PM..
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Old 12-27-2004, 08:38 PM   #15
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Nice write up! A simple job, but you touched on a lot of small but important details that people may skip. Thanks!
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