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Electric Vehicle Battery Testing and Diagnostic Procedures
Polaris Technical Service is frequently asked questions regarding effective ways to properly test deep cycle
batteries on electric vehicles. These questions typically arise out of concern about range and/or run-time of a
vehicle.
The following process document will provide vehicle charging tips, basic battery theory, proper
diagnostic techniques and maintenance tips on maximizing battery life. After reviewing this document, if you
still have questions, please refer to the appropriate service manual, or contact Technical Service.
Worksheets have been included at the end of this document for use during testing for all battery
configurations currently used in Polaris electric vehicles.
WARNING:
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
This battery may emit explosive gases; keep flames, sparks and ignition
sources away.
Protective clothing and safety glasses must be worn when working on or
around batteries.
A: Use the Proper Cord
It is very important to charge the vehicle with the correctly sized power cord. Follow these guidelines when
choosing the right cord:
-
If the cord has 14 gauge wires, use a cord no longer than 25 feet.
-
If the cord has 12 gauge wires, use a cord no longer than 50 feet.
-
If the cord has 10 gauge wires, use a cord no longer than 100 feet.
B: Power and Dedicated Circuit
-
Vehicle should be plugged into a dedicated 120 volts AC outlet with a minimum of a 15 amp
circuit breaker.
-
When using a power cord that has a Ground Fault Interrupter (GFI) on it, do not plug it into a
wall socket with a GFI on it. Only one GFI is recommended.
C: Battery Fluid Level
For vehicles that have flooded batteries, maintenance should be performed on a monthly basis. Vehicles that
are used daily, or in hotter climates, require more frequent battery maintenance.
1. Disconnect battery power.
2. Clean the tops of the batteries, cables, and terminals with a plastic brush, using a baking soda and
water mixture. Rinse thoroughly. Never use a high pressure washer or compressed air for cleaning, as
they could possibly force contaminants into the cells.
3. Remove the caps on all of the battery cells, and check the fluid level.
4. If the fluid level is above the plates in each cell, continue to step 5. If the fluid level is below the plates
in any cell, fill with distilled water until water line is just above the plates.
NOTE: Battery electrolyte levels may vary with manufacturer. Verify manufacturers suggested
fill level before adding fluid.
The information contained within this Team Tip is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Sales Inc. This Team Tip is provided for the sole use of
authorized Polaris dealers and distributors. This Team Tip is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Sales Inc.
© 2012 Polaris Sales Inc. (Page 2 of 13)
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