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ELECTRICAL
Battery Service
Battery Inspection/Removal
The battery is located under the left rear fender.
Inspect the battery fluid level. When the battery fluid nears
the lower level, the battery should be removed and distilled
water should be added to the upper level line. 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!
3.
Disconnect the vent hose.
4.
Remove the battery.
Maintain
between upper
and lower level
marks
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.....,.
.
.-.-".
.".
...
."
........
........
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.....
5.
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.
&.
Do not allow cleaning solution or tap water to enter the battery. It will shorten the life of the battery.
6.
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 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 Polaris dielectric grease PN
2871027.
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.
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 start the engine with the battery disconnected. Vehicle lamps will burn out if battery is disconnected
during vehicle operation. Also, the reverse speed limiter can be 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: OCV Test, Specific
Gravity Test and Load Test.
OCV .. Open Circuit Voltage Test
Battery voltage should be checked with a digital multitester. Readings of
12.6
or less require further battery testing
and charging. See charts and Load Test on page
10.22.
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 on the plates, reducing the efficiency and service life of the
b~e~
-
Polaris Industries Inc.
10.21
7/96
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Troubleshooting
