Battery Installation - Polaris Trail Boss 330 2003 Service Manual

ELECTRICAL
To remove the battery:
1. Disconnect holder strap and remove cover.
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!
To activate a NEW conventional lead/acid battery:
1. Remove vent plug and battery cell caps.
2. Fill battery with electrolyte to upper level marks on
case.
3. Set battery aside and allow it to cool and stabilize
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.
Example: 1/10 of 14 amp battery = 1.4 amp
To charge an existing conventional lead/acid
battery:
1. Disconnect the vent hose.
2. Remove the battery.
3. Remove the filler caps and add distilled water only
as needed to bring each cell to the proper level.
Do not overfill the battery.
To refill use only distilled water. Tap water
contains minerals which are harmful to a battery.
4. Reinstall the battery caps.
5. Charge battery at 1/10 of its amp/hour rating.
Example: 1/10 of 14 amp battery = 1.4 amp
6. Reinstall the battery after testing.

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 will 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 Dielectric Grease
(PN 2871329).
3. (Conventional Lead/Acid Batteries Only) 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. Vent should be routed away from frame
and body to prevent contact with electrolyte. Avoid
skin contact with battery electrolyte, severe burns
could result. If electrolyte contacts the vehicle
frame, corrosion will occur.
4. Route cables so they are tucked away in front and
behind battery.
5. Reinstall battery cover and holder strap.
Do not run the engine with the battery
disconnected. Electrical components can become
damaged.
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 (Conventional Lead--acid
batteries only) and Load Test.
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 Page 10.16.
NOTE: Lead-acid battery electrolyte levels 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, crystal sulfation will form on the
plates, reducing the efficiency and service life of the
battery.
OCV Test,
10.15