Service manual

ELECTRICAL
NOTE: Stored batteries lose their charge at the rate of up
to 1% per day. Recharge to full capacity every 30 to 60
days during a non-use period. If the battery is stored
during the winter months, electrolyte will freeze at higher
temperatures as the battery discharges. The chart below
indicates freezing points by specific gravity.
Electrolyte Freezing Points
Specific Gravity of Electrolyte Freezing Point
1.265
-80℃ (-75° F)
1.225
-37℃ (-35° F)
1.200
-27℃ (-17° F)
1.150
-15℃ (+5° F)
1.100
-8℃ (+18° F)
1.050
-3℃ (+27° F)
SEALED LOW MAINTENANCE BATTERY
CHARGING PROCEDURE
1. Remove the battery from the ATV to prevent damage
from leaking or spilled acid during charging.
2. Charge the battery with a variable rate charging output.
Charge as needed to raise the voltage to
12.8VDC or greater.
3. Install battery in vehicle with positive terminal toward
the front. Coat threads of battery bolt with a corrosion
resistant Grease.
4. Route cables so they are tucked away in front and
behind battery.
5. Connect battery cables.
To avoid the possibility of sparks and explosion, connect
positive (red) cable first and negative (black) cable last.
6. After connecting the battery cables, install the cover on
the battery and attach the hold down strap.
CONVENTIONAL BATTERY ACTIVATION/
SVC
To ensure maximum service life and performance from a
battery, perform the following steps.
NOTE: This section contains information for both
conventional Lead--Acid batteries and Sealed Low
Maintenance batteries. Before service, identify the battery
type in the vehicle. Use the section that applies to the
battery.
Battery electrolyte is poisonous. It contains sulfuric acid.
Serious burns can result from contact with skin, eyes or
clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or vegetable
oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarettes, etc. away. Ventilate when charging or using
in an enclosed space.
Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
The gases given off by a battery are explosive. Any
spark or open flame near a battery can cause an
explosion, which will spray battery acid on anyone close
to it. Should there be contact with battery acid, wash the
affected area with large quantities of cool water and seek
immediate medical attention.
NOTE: New Battery: Battery must be fully charged
before use or battery life will be significantly reduced
10-30% of the battery’s full potential.
To activate a new battery:
1. Remove vent plug from vent fitting. Remove cell caps.
2. Fill battery with electrolyte to upper level marks on
case.
3. Set battery aside to allow for acid absorption and
stabilization for 30 minutes.
4. Add electrolyte to bring level back to upper level mark
on case.
NOTE: This is the last time that electrolyte should be
added. If the level becomes low after this point, add only
distilled water.
5. Charge battery at 1/10 of its amp/hour rating.
Examples: 1/10 of 9 amp battery = .9 amp; 1/10 of 14
amp battery = 1.4 amp; 1/10 of 18 amp battery = 1.8 amp
(recommended charging rates).
9.23