INSTRUCTIONS - Harley
Contents
1. 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 i00858 1 Tag 2 Sealed tube Figure 1 Reminder Tag Sealed Shipping Tube i00859 SSi Figure 2 Vent Tube Clamp only smooth vent elbow requires clamp ADANGER EXPLOSIVE GASES Cigarettes flames or sparks could cause battery to explode Always shield eyes and face from battery Do not charge without proper instruction and training Securely connect cables to the proper terminals Check vent tube to avoid any crimping or obstruction of the tube KEEP FILLING PLUGS TIGHT AND LEVEL POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes and clothing In event of accident flush with water and call a physician immediately KEEP OUT OF REACH OF CHILDREN Figure 3 Battery Warning Label 1of5 Activate Battery 1 Place battery on a level surface CAUTION Do not perform battery activation charging with the battery installed on the motorcycle If electrolyte is accidentally spilled it could severely damage the motorcycle 2 See Figure 1 Remove reminder tag and short sealed tube from battery vent elbow AwarnineG A sealed tube which is left in place could cause a build up of internal gas pressure Internal gas pressure can caus2. 99861 02 to both terminals CAUTION Route battery vent tube on the vehicle side opposite the secondary drive belt chain or tube may be damaged by rubbing against belt chain Route battery vent tube away from ends of mufflers or sparks from mufflers could cause battery to explode which may cause death or serious injury CAUTION Battery vent tube has a small slit near each end of tube The slit near battery vent elbow provides a pressure release for battery gases should bottom of tube become obstructed internal gas pressure can cause a battery to explode You may trim off bottom end of tube after tube is properly routed however always make sure that end with remaining slit is attached to battery vent elbow 5 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 6 Following the Service Manual install motorcycle seat and any other components After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift position during vehicle operation resulting in loss of control of vehicle and death or serious injury 00070a J00597 Store and Maintain Battery Check battery electrolyte level after the first 500 miles Thereafter check battery electrolyte level after every 500 miles or every week on convention
3. 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 9 Disconnect the red charger lead from the terminal of the battery Install all battery filler caps Wash off any acid spillage from battery using water Wipe battery dry 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 motorcycle 3 Follow the Service Manual instructions to secure battery to battery tray using original mounting hardware Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00069a CAUTION Connect cables to correct terminals of battery otherwise serious damage to motorcycle electrical system may occur 4of5 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 terminal connect negative cable to negative battery terminal 6 Apply light coat of Harley Davidson Electrical Contact Lubricant Part No
4. charger ie 2 to 8 amps However over a period of time possi bly 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 remainder of the 12 hours total charge time even though the battery electrolyte has probably attained its proper specific gravi ty This additional charging time is necessary to set the cell plates in a low maintenance battery 3 of 5 Charge Battery Procedure CAUTION Remove battery from motorcycle before charging electrolyte 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 Table 1 Recommended Charging Rates Battery Volt Capacity Bench Charge AMP hr Part No Max Rate 66007 8 esoos 70 12 zs tAMP al a sam Unplug or turn OFF battery charger before connecting charger cables to battery Connecting cables with charger ON can cause a spark and battery explosion resulting in death or serious injury 00066a CAUTION 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 t
5. MTOR HARLEY DAVIDSON AUA J00597 INSTRUCTIONS REV 05 25 2004 Kit Numbers 66006 70 and 66007 84 HARLEY DAVIDSON 12 VOLT BATTERIES General This instruction sheet provides service information for DRY CHARGED batteries There are no Service Parts available with this product WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual proce dures 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 instruc tions A Service Manual for your motorcycle is available from your Harley Davidson dealer WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm 00004b WARNING Do not run motorcycle in a closed garage or confined area Inhaling motorcycle exhaust which contains poi sonous carbon monoxide gas could result in death or serious injury 00005a CAUTION Batteries battery posts terminals and related acces sories contain lead and lead compounds and other chemicals known to the State of California to cause can cer and birth defects or other reproductive harm Wash hands after handling 00019c
6. al 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 motorcycle and charge the battery until the correct specific gravity is obtained Refer to the Service Manual for detailed instructions 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 60 F 16 C charge battery more frequently than once a month Store batteries where they cannot be reached by children to protect children from death or serious injury CAUTION The electrolyte in a discharged battery will freeze if exposed to freezing temperatures Freezing may crack battery case and buckle battery plates Table 2 State of Charge State of Charge Charge Period 100 13 0V 5of5
7. e a battery to explode causing death or serious injury 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 of 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 container to collect any electrolyte which might overflow through vent tube 4 Remove all battery cell filler caps i06385 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 ANTIDOTE EXTERNAL Flush with water INTERNAL Drink large quantities of milk or water followed by milk of magnesia vegetable oil or beaten eggs Call doctor immediately 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 NOTES DO NOT ACTIVATE BATTERY WITH WATER OR ANY LIQUID OTHER THAN DILUTED SULFURIC ACID Electrolyte should be at room approximately 70 F 21 C before filling temperature 6 After 1 2 hour gently tap battery to dislodge air bubbles from cell plates If electrolyte level has fal
8. gassing or spewing of electrolyte occurs turn off the charger temporarily Always turn the charger OFF before removing charger leads from the battery to avoid dangerous sparks Failure to adhere to these precautions could result in death or serious injury 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 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 CAUTION If battery gets hotter than 110 F 43 C during charging discontinue charging and let battery cool If battery releases an excessive amount of gas during charging decrease charging rate J00597 100857 Figure 4 Measuring Specific Gravity of Electrolyte with Hydrometer NOTES 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 The recommended alternative is a variable lapered 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
9. he 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 HD 96910 35 NOTES Cell variance must not exceed 0 010 specific gravity f 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 J00597 Specific gravity changes with temperature differences When the temperature increases specific gravity of a typical fluid decreases and vice versa If electrolyte temperature in battery is not 80 F 27 C use the following formula to compute temperature corrected specific gravity Y For each 10 F 5 5 C above 80 F 27 C add 0 004 to actual specific gravity reading Y 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
10. len during standing refill battery with electrolyte to upper level 7 Install filler caps THIS IS A READY FILLED ACTIVATED SEALED BATTERY NEVER REMOVE STRIP REFER 10 OWNER S MANUAL FOR CHARGING INSTRUCTIONS SS A an SS A oj D O KEEP FLAMES AWAY CONTENTS ARE EXPLOSIVE READ INSTRUCTIONS WEAR SAFETY GLASSES DO NOT ALLOW CHILDREN TO PLAY WITH BATTERY CONTENTS ARE CORROSIVE Figure 3 Battery Warning Label J00597 2of5 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 Always wear proper eye face and hand protection Always charge batteries in a well ventilated area Turn the charger OFF before connecting the leads to the battery to avoid dangerous sparks Never try to charge a visibly damaged or frozen bat tery 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 chas sis ground Be sure that the ignition and all electrical accessories are turned off Make sure that the charger leads to the battery are not broken frayed or loose If the battery becomes hot or if violent
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