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ELECTRICAL
7.12
BATTERY TESTING
Whenever a service complaint is related to either the
starting or charging systems, the battery should be
checked first.
Following are tests which can easily be made on a
maintenence--free battery to determine its condition:
The OCV Test and Load Test.
OCV - OPEN CIRCUIT
VO LTAGE
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.
To perform an open circuit voltage test, set the digital
meter to DC volts and place the tester leads on each
battery terminal. Minimum voltage should be 12.4 to
12.7 VDC for a known good battery.
OPEN CIRCUIT VOLTAGE
State of
charge
Maintenance Free
100% Charged
75% Charged
50% Charged
25% Charged
0% Charged
12.6V
12.4V
12.1V
11.9V
less than 11.9V
Self Discharge vs. Temperature
Temerature Days to 0% charged
104 F
77 F
32 F
300
600
950
LOAD TEST
CAUTION: To prevent shock or component
damage, remove spark plug high tension leads
and connect securely to engine ground before
proceeding.
NOTE: This test can only be performed on machines
with electric starters. This test cannot be performed
with an engine or starting system that is not working
properly.
A battery may indicate a full charge condition in the OCV
test and the specific gravity test, but still may not have
the storage capacity necessary to properly function in
the electrical system. For this reason, a battery capacity
or load test should be conducted whenever poor battery
performance is encountered. To perform this test, hook
a multitester to the battery in the same manner as was
done in the OCV test. The reading should be 12.6 volts
or greater. Engage the starter and observe the battery
voltage while cranking the engine. Continue the test for
15 seconds. During cranking the observed voltage
should not drop below 9.5 volts. If the beginning voltage
is 12.6 volts or higher and the cranking voltage drops
below 9.5 volts during the test, replace the battery and
re--test. Continued low cranking voltage with a known
good battery may indicate excess current draw from one
or more of the starting components.
OFF SEASON STORAGE
To prevent battery damage during extended periods
of non-use, the following basic battery maintenance
items must be performed:
G Remove the battery from the
machine and wash the case and
battery tray with a mild solution of
baking soda and water. Rinse with
lots of fresh water after cleaning.
NOTE: Do not get any of the baking
soda into the battery or the acid will
be neutralized.
G Using a wire brush or knife, remove
any corrosion from the cables and
terminals.
G Never add water to a sealed
maintenance free battery.
G Charge at a rate no greater than 1/10
of the battery’s amp/hr capacity until
the open circuit voltage is 12.9V or
greater.
G Store the battery either in the machine
with the cables disconnected, or store
in a cool place.
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 charging output no
larger than 1/10 of the battery’s amp/hr rating.
Charge as needed to raise the open circuit
voltage to 12.9V or greater.
3. Install battery in vehicle with positive terminal
toward the front. Coat threads of battery bolt with
a corrosion resistant dielectric grease.
Dielectric Grease
(PN 2871329)
4. Connect the battery cables.
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