Battery Installation - Polaris SPORTSMAN 400 2003 Service Manual

ELECTRICAL
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. Remove the battery.
4. Remove the filler caps and add distilled water
only as needed to bring each cell to the proper
level. Do not overfill the battery.
Refill using only distilled water.
contains minerals which are harmful to a battery.
Do not allow cleaning solution or tap water inside
the battery. Battery life may be reduced.
5. 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 well with clean water and dry
thoroughly.
2. Reinstall battery, attaching positive (+) (red) cable
first and then the negative (-) (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 obstructions and kinks and securely
installed. If not, battery gases could accumulate
and cause an explosion. The vent tube should be
routed away from frame and body to prevent
contact with electrolyte. Avoid skin contact with
electrolyte, as severe burns could result.
electrolyte contacts the vehicle frame, corrosion
will occur.
4. Route the cables correctly.
5. Reinstall the holder strap.
BATTERY TESTING
Whenever a service complaint is related to either the
starting or charging systems, the battery should be
checked first.
Following are three tests which can easily be made on
a battery to determine its condition:
Specific Gravity Test and Load Test.
10.18
OCV - OPEN CIRCUIT
VOLTAGE 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 on below.
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
Tap water
on the plates, reducing the efficiency and service life
of the battery.
SPECIFIC GRAVITY TEST
A tool such as a Battery Hydrometer (PN 2870836)
can be used to measure electrolyte strength or
specific gravity. As the battery goes through the
charge/discharge cycle, the electrolyte goes from a
heavy (more acidic) state at full charge to a light (more
water) state when discharged. The hydrometer can
measure state of charge and differences between
cells in a multi-cell battery. Readings of 1.270 or
greater should be observed in a fully charged battery.
Differences of more than .025 between the lowest and
highest cell readings indicate a need to replace the
battery.
If
State of
charge
100%
Charged
75% Charged
50% Charged
OCV Test,
25% Charged
0% Charged
Contiued on next page
Battery Hydrometer (PN 2870836)
1.10
1.15
Detail A
1.20
1.25
1.30
OPEN CIRCUIT VOLTAGE
Conventional
Lead-acid
12.60V
12.40V
12.10V
11.90V
less than
11.80V
YuMicront
Type
12.70V
12.50V
12.20V
12.0V
less than 11.9V