Harley-Davidson 12 Volt Batteries Instruction Sheet
Contents
1. e Ifthe battery becomes hot or if violent gassing or spewing of electrolyte occurs turn off the charger temporarily e Always turn the charger OFF before removing charger leads from the battery to avoid dangerous sparks WARNING Unplug or turn OFF battery charger before connecting charger cables to battery Connecting cables with charger ON can cause a spark and battery explosion which could result in death or serious injury 00066a NOTICE If battery releases an excessive amount of gas during charging decrease the charging rate Overheating can result in plate distortion internal shorting drying out or damage 00413b J00597 is08073 Figure 4 Measuring Specific Gravity of Electrolyte with Hydrometer NOTES e A trickle charger or CHRISTIE charger with a 1 amp charging rate or less may be used However it will take at least 24 hours for the 100 initial charge with these types of chargers e The recommended alternative is a variable tapered rate charger with a maximum charging rate of 2 to 8 amps With this type of charger the initial charging rate should be the maximum charging rate for the particular charger ie 2 to 8 amps However over a period of time possibly as little as 1 to 2 hours the charging rate will taper off to near 0 amps At this point the battery has probably attained a charging voltage of 14 volts or greater Continue charging the battery for at least the rema2. HD 96910 35 NOTES e Cell variance must not exceed 0 010 specific gravity If recommended charging time has elapsed but specific gravity is still below 1 270 at 80 F 27 C continue charging until desired specific gravity is attained When using a syringe hydrometer read electrolyte level at bottom of meniscus curved upper surface of fluid e Specific gravity changes with temperature differences When the temperature increases specific gravity of a typical fluid decreases and vise versa If electrolyte tem perature in battery is not 80 F 27 C use the following formula to compute temperature corrected specific gravity For each 10 F 5 5 C above 80 F 27 C add 0 004 to actual specific gravity reading For each 10 F 5 5 C below 80 F 27 C subtract 0 004 from actual specific gravity reading For example Electrolyte temperature 100 F 38 C Hydrometer reading 1 272 Adjustment for temperature 0 008 Corrected specific gravity 1 280 7 After initial charge gently tap battery to dislodge air bubbles from cell plates NOTE If electrolyte level has fallen refill battery with distilled water to the upper level and charge an additional 1 2 hours 8 After the battery is fully charged disconnect the black lead to the negative terminal of the battery J00597 9 Disconnect the red charger lead from the terminal of the battery 10 Install all battery filler caps 11 Wa
3. 60 F 16 C charge battery more frequently than once a month WARNING Batteries contain sulfuric acid which could cause severe burns to eyes and skin Wear a protective face shield rubberized gloves and protective clothing when working with batteries KEEP BATTERIES AWAY FROM CHILDREN 00063a J00597 WARNING Explosive hydrogen gas which escapes during charging could cause death or serious injury Charge battery in a well ventilated area Keep open flames electrical sparks and smoking materials away from battery at all times KEEP BATTERIES AWAY FROM CHILDREN 00065a ACAUTION Batteries can explode or leak and cause burn injury if recharged disposed of in fire mixed with a different bat tery type inserted backwards or disassembled Replace all used batteries at the same time Do not carry batteries loose in your pocket or purse Do not remove the battery label Keep batteries away from children If swallowed consult a physician at once 00620b NOTICE Do not allow battery to completely discharge The electro lyte in a discharged battery will freeze The more dis charged a battery is the more easily it can freeze and crack the battery case 00218a Table 2 State of Charge State of Charge Voltage Charge Period 100 13 0V None 75 12 8V 3 5 hours 50 12 5V 4 7 hours 25 12 2V 10 hours
4. ABDO A Keep flames away Contents are explosive Read instructions Wear safety glasses Do not allow children to play with battery Contents are corrosive SP APeon gt Figure 3 Battery Warning Label Charge Battery Safety Precautions Never charge a battery without first reviewing the manufacturers instructions for the charger In addition to the manufacturer s instructions follow these safety precautions J00597 20f5 WARNING Explosive hydrogen gas which escapes during charging could cause death or serious injury Charge battery in a well ventilated area Keep open flames electrical sparks and smoking materials away from battery at all times KEEP BATTERIES AWAY FROM CHILDREN 00065a Always wear proper eye face and hand protection e Always charge batteries in a well ventilated area e Turn the charger OFF before connecting the leads to the battery to avoid dangerous sparks e Never try to charge a visibly damaged or frozen battery e Connect the charger leads to the battery red positive lead to the positive terminal and black negative lead to the negative terminal If the battery is still in the vehicle connect the negative lead to the chassis ground Be sure that the ignition and all electrical accessories are turned off e Make sure that the charger leads to the battery are not broken frayed or loose
5. cMOTOR HARLEY DAVIDSON WY J00597 INSTRUCTIONS REV 2013 11 01 HARLEY DAVIDSON 12 VOLT BATTERIES GENERAL Kit Numbers 66006 70 66007 84 Models For model fitment information see the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only This instruction sheet provides service DRYCHARGED batteries There are no Service Parts available with this product information for AWARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer IWAN IN Engine exhaust from this product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm 00004f WARNING Do not run motorcycle in a closed garage or confined area Inhaling motorcycle exhaust which contains poisonous carbon monoxide gas could result in death or serious injury 00005a WARNING Batteries battery posts terminals and related accessories co
6. f battery b On models with a barbed vent elbow install long vent tube over elbow of battery c Place other end of long vent tube in a suitable con tainer to collect any electrolyte which might overflow through vent tube 4 Remove all battery cell filler caps WARNING Never remove warning label attached to top of battery Failure to read and understand all precautions contained in warning could result in death or serious injury 00064a NOTE ANTIDOTE e EXTERNAL Flush with water e INTERNAL Drink large quantities of milk or water followed by milk of magnesia vegetable oil or beaten eggs Call doctor immediately e EYES Flush eyes with water and get immediate medical attention 5 Carefully fill each cell of battery with electrolyte diluted sulfuric acid of 1 265 specific gravity Fill to indicated upper level Let battery stand for 1 2 hour NOTE e DO NOT ACTIVATE BATTERY WITH WATER OR ANY LIQUID OTHER THAN DILUTED SULFURIC ACID e Electrolyte should be at room temperature approximately 70 F 21 C before filling 6 After 1 2 hour gently tap battery to dislodge air bubbles from cell plates If electrolyte level has fallen during standing refill battery with electrolyte to upper level 7 Install filler caps is08072 OOOO ADOBA fi A THIS IS A READY FILLED ACTIVATED SEALED BATTERY NEVER REMOVE STRIP REFER TO OWNER S MANUAL FOR CHARGING INSTRUCTIONS Q
7. inder of the 12 hours total charge time even though the battery electrolyte has probably attained its proper specific gravity This additional charging time is necessary to set the cell plates in a low maintenance battery Charge Battery Procedure NOTICE Remove battery from motorcycle before charging Electro lyte leakage will damage motorcycle parts 00213a 1 Follow instructions in applicable Service Manual to remove the battery from the motorcycle 2 Place the battery on a level service 3 Refer to Table 1 Set battery charger to the recommended charging rate 3 of 5 Table 1 Recommended Charging Rates Battery Part No Volt Capacity AMP Bench Charge hr Max Rate 66006 70 12 7 5 1 AMP 66007 84 12 32 3 AMP WARNING Unplug or turn OFF battery charger before connecting charger cables to battery Connecting cables with charger ON can cause a spark and battery explosion which could result in death or serious injury 00066a NOTICE Do not reverse the charger connections described in the following steps or the charging system of the motorcycle could be damaged 00214a 4 Connect the red battery charger lead to the positive battery terminal 5 Connect the black charger lead to the negative terminal of the battery 6 See Figure 4 Charge battery until specific gravity of electrolyte increases to 1 260 1 270 at 80 F 27 C Measure with HYDROMETER Part No
8. ntain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 00019e J00597 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled WARNING Batteries contain sulfuric acid which could cause severe burns to eyes and skin Wear a protective face shield rubberized gloves and protective clothing when working with batteries KEEP BATTERIES AWAY FROM CHILDREN 00063a is08070 1 Tag 2 Sealed tube Figure 1 Reminder Tag Sealed Shipping Tube is08071 Figure 2 Vent Tube Clamp only smooth vent elbow requires clamp Activate Battery 1 Place battery on a level surface 1of5 Please dispose of materials responsibly NOTICE Remove battery from motorcycle before charging Electro lyte leakage will damage motorcycle parts 00213a 2 See Figure 1 Remove reminder tag and short sealed tube from battery vent elbow IWAN IN A sealed tube which is left in place could cause a buildup of internal gas pressure Internal gas pressure can cause a battery to explode causing death or serious injury 00641c 3 Verify that battery vent elbow is dry and clean and install long vent tube as follows a See Figure 2 On models with a smooth vent elbow clamp long vent tube to elbow of battery Rotate prongs of clamp toward side o
9. rovides a pressure release for battery gases should bottom of tube become obstructed Trim loose end of vent tube as necessary after vent tube is installed and routed 7 Route battery vent tube per Service Manual making sure that it does not become kinked or obstructed that it does not chafe or touch any moving parts and that its outlet is directed away from any metal component 8 Following the Service Manual install motorcycle seat and any other components 4of5 IWAN IN After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b Store and Maintain Battery Check battery electrolyte level after the first 500 miles There after check battery electrolyte level after every 500 miles or every week on conventional batteries and after every 5 000 miles or once a month on low maintenance batteries Check and clean battery terminals each time you check the electrolyte level If motorcycle will not be operated for several months such as during the winter season remove the battery from the motor cycle and charge the battery until the correct specific gravity is obtained Refer to the Service Manual for detailed instruc tions If the battery is stored at temperatures below 60 F 16 C charge the battery every month according to Service Manual instructions If stored in a warm area above
10. sh off any acid spillage from battery using water Wipe battery dry 12 Mark charge date on battery Install Battery 1 Using a wire brush or sandpaper clean battery terminals and cable connectors to remove oxidation 2 Follow instructions in the appropriate Service Manual to install the fully charged battery with vent tube onto motor cycle 3 Follow the Service Manual instructions to secure battery to battery tray using original mounting hardware WARNING Do not allow positive battery cable to contact ground with negative cable connected Resulting sparks can cause a battery explosion which could result in death or serious injury 00069a NOTICE Connect the cables to the correct battery terminals Failure to do so could result in damage to the motorcycle electrical system 00215a 4 Connect positive cable to positive battery terminal NOTE Be sure to install a spacer if required between each cable terminal and battery terminal 5 After positive cable has been connected to positive ter minal connect negative cable to negative battery ter minal 6 Apply light coat of Harley Davidson Electrical Contact Lubricant Part No 99861 02 to both terminals NOTES e Route battery vent tube on the vehicle side opposite the secondary drive belt chain e Route battery vent tube away from muffler ends e Battery vent tube has a small slit near each end of tube The slit near battery vent elbow p
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