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Yuasa SmartShot 900 Automatic 12V 900mA

1. 12 Activating Standard Pa bag ede xa eben 12 SECTION THREE Inspecting Testing and Charging The Discharge Charge t veles 654 6 45 IEEE bd 13 Reasons for Self discharge 14 15 Ampere Hour and Cold Cranking 16 Mpeg a Baley 16 17 Battery Devices NEWER rr 17 pane R ee eee eed A 18 Chargers dnd 19 20 Charging a New Standard oS 5545445909004 E E ERO TT ETT T TOIT TT TET TETTE 20 21 Charges 2 SECTION FOUR Maintenance and Storage Monthly Maintenance for Conventional and YuMicron Types 22 slo P rr 22 Sullaliom and oo rett 40 45 55544464 ES vdd dd qu RI E 22 23 SECTION FIVE Sealed VRLA Batteries New Generation Battery 1 24 Sealed VRLA Battery Construction 1 24 pou 24 25 How a Sealed VRLA Battery Differs from Conventional 25
2. 16 50 Approximate Charge Times Hours Using a Trickle 0 25 Amp Charger 75 13 15 18 23 24 25 50 25 30 35 45 48 50 25 38 45 53 68 71 75 096 50 60 70 90 95 100 Approximate Charge Times Hours Using a 1 Amp Taper Charger 75 6 7 8 10 10 11 50 1 13 14 18 19 20 25 15 18 20 26 27 28 0 20 23 27 34 35 37 Approximate Charge Times Hours Using a 1 Amp Constant Current Charger 75 3 4 4 6 6 6 50 6 8 9 11 12 13 25 9 1 13 17 18 19 0 13 15 18 23 24 25 new battery after activation is approximately 80 charged 7 Initial charging is always recommended NEVER quick charge Charge a new battery at a rate equal to 1 10 of its rated capacity Maintenance and Storage SECTION Monthly Maintenance for Conventional and YuMicron Types Batteries don t demand a lot of attention But not giving your battery the attention it needs can leave you stranded or poorer by the cost of a new battery How often should you maintain a battery About monthly under usual conditions However recharging is necessary when lights get dim when the starter sounds weak or when the battery isn t used for more than two weeks Important as it is there s really not much to battery maintenance Basically just follow the procedure out lined in the section Inspecting a Battery That means Check electrolyte level Keep the top free of grime Check cables clamps and case for obvious damage or loose con
3. YUASA BATTERY CHARGERS Yuasa SmartShot Automatic 12V 1 5 Amp 5 Stage Battery Charger Part No 1201501 Yuasa s Automatic 12V 1 5 Amp battery charger incorporates superior 5 stage charging technology This high power unit provides error proof operation to fully charge sealed maintenance free and conventional lead acid batteries e Provides up to 16 volts to enable recovery of sulfated batteries during pre qualification stage e 28 day Charge Recycle re evaluates battery status for long term storage e Designed to prevent overcharging e AC power LED indicator e Charging and float mode LED display e Reverse polarity protection e Sparktree operation e Battery accessory leads and fused ring connectors included e Steel construction for durability e 3 year limited warranty Yuasa SmartShot 900 Automatic 12V 900mA Battery Charger Part No YUA 120090 Yuasa s Automatic 900mA 12V battery charger is the industry s most powerful plug in wall charger Combining the latest technology and a host of usertriendly features this compact high power unit provides optimum amperage return and is designed to fully charge and maintain conventional and sealed maintenance free batteries e Fully automatic three level charge cycle for effective charging e Reaches 14 4 volts peak then automatically switches to float e Designed to prevent overcharging e AC power LED indicator e Charging and float mode LED display e Reverse polari
4. Pasted Plates Specified Thickness Ensures vibration resistance through precise compression amp proper service life through specified active material balance amp Weight Dried Charged Tank Formed amp Properly dried plates in a sealed battery Plates Dried Plates i imi ave a virtually limitless shelf life while still retaining 70 80 state of charge when illed with aci Shorter current path for increased electrical conductivity amp higher starting currents heavier parts for maximum durability Case Cover Thermal Bonded Plastic Air tight seal to prevent air ingress Seal amp acid seepage Terminal Cover Patented Poly Seal Eliminates acid seepage reduces Seal Terminal corrosion amp extends battery life Case amp Cover Polypropylene Superior resistance to gasoline amp oil impact resistant in extreme weather conditions Additive Sulfate Stop Sulfate stop added to reduce the solubility Some models of lead into the acid which then reduces battery sulfation potential Separator Leaf Separator Polyethylene leaf with glass mat sheet Top Lead Through Partition Construction Connections Large Straps onded for compression to withstand severe vibration conditions Separator Absorbed Glass Mat Absorbs acid while creating cell compression for extreme vibration resistance Top Lead Alloy Calcium Alloy Increased weld strength amp severe vibration resistance Valve amp Flame Arrestor Valve relieves excess pressure to
5. reduction or drop of gravity of the electrolyte from cell discharge Grid A metallic framework used in a battery for conducting electric current and supporting the active material Group One or more plates of one type positive or negative burned to a post or strap H5SO Sulfuric Acid High Rate On charge any rate higher than the normal finishing rate Hydration Lead Reaction between water and lead or lead com ounds Gravities lower than those bond in discharged cells are apt to produce hydration which appears as a white coating on plate groups and separators in a cell GLOSSARY Hydrometer device used to mea sure density or specific gravity of elec trolyte solutions Hydroset Curing process for lin that oxidizes the lead paste reducing free lead to a few percent of total Initial Voltage The closed circuit voltage at the beginning of a dis charge t is usually measured after current has flowed for a period suffi cient for the voltage rate of change to become practically constant Insert A bushing of lead or lead alloy molded or sealed into cell covers and to which the post is burned to create a creep resistant cover to post seal Intercell Connector Conductor of lead or lead alloy used to connect two battery cells Internal Resistance Resistance within a cell or battery to the flow of electric current measured by the ratio of the change in voltage to a specified change in curr
6. Alloy Ambient Temperature The sur rounding temperature usually refers to room temperature Alternating Current A pulsating electric current in which direction of flow is rapidly changed so the termi nal becomes in rapid succession posi tive then negative Abbreviated AC Ammeter An instrument for measur ing electrical current Ampacity Current carrying capacity in amperes Ampere The unit of electrical current equal to the steady state current pro duced by one volt applied across a resistance of one ohm Ampere Hour A measure of the volume of electricity being one ampere for one hour Itis used to express battery capacity and is regis tered by an ampere hour meter it can be obtained by multiplying the current in amperes by length of time that the current is maintained Ampere Hour Capacity The number of ampere hours that can be delivered by a storage battery under specified conditions as to temperature rate of discharge and final voltage Ampere Hour Efficiency The electrochemical efficiency of a storage battery expressed as the ratio of ampere hours output to the ampere hours input required for recharge Ampere Hour Meter An instru ment that registers the quantity of elec tricity in ampere hours Anode An electrode through which current enters any non metallic con ductor Specifically an electrolytic anode is an aa at which nega tive ions are discharged positive ions are formed or at which
7. The electrolyte sulfuric acid solution made up of hydrogen sulfur and oxygen gives up its sulfur and some of its oxygen and turns to water PbO T Pb 2 H SO 2 PbSO 2 H2O The process reverses with charging Electrolytes and plates return to their original composition The charging current breaks down water into its component gases hydrogen from the negatively charged plate and oxy gen from the positive plate Gases escape out the vent tube With a conventional battery water is added to replace that loss Here s the real secret of a sealed VRLA battery the nega tive plate never becomes fully charged so no hydrogen gas The positive plate still makes oxygen but instead of being forced out the vent tube it reacts with the charged active material to become water again That s gas recombinant technology That s the magic of YUASA S non spillable sealed VRLA battery 71 Gas Recombinant technology produces a more compact battery 7 After activation no need to check electrolyte or add water 7 Sealing strip is permanently inserted it s never removed 71 Gas is recombined in the battery there s no vented gas and vent tube Sealed VRLA Batteries SECTION Activation and Installation Activating sealed VRLA batteries is easy although a little different from conventional activation For problem free start up and operation follow the procedure outlined here A few things to keep in mind b
8. This corrosive effect can also dissolve the lead into solution which in turn may compromise the plate insulators and result in micro shorts Another condition that frequently occurs in a discharged battery is freezing In a deeply discharged battery the electrolyte has a A Practical Understanding of Lead Acid Batteries reduced specific gravity and becomes a higher percentage of water than sulfuric acid During this condition the battery may freeze at temperatures as high as 32 F The electrolyte in a fully charged battery will not freeze in temperatures down to 65 F Deep discharge can be created by a multitude of conditions but the predominant reason is neglect During long periods of storage the battery state of charge must be checked and maintained per the battery manufacturers recommendations Other conditions that can drain the battery are inoperative or inadequate charging systems on vehicles parasitic or key off drains loose or dirty terminal connections etc Although many of these conditions can be corrected often the problems you cannot correct may be overcome by a periodic charging schedule You can establish a routine by which you check and charge your battery or choose to permanently attach a Yuasa Automatic Charger while the vehicle is not in use When charging your battery always refer to the instructions on both the battery and the charger While maintaining your battery at a full state of charge will insure
9. a Newly Activated Sealed VRLA Battery Sealed VRLA batteries require an initial charge If you are using an automatic type taper charger check to make sure using a constant current charger refer to the standard that the charger current amps is equal to or greater than STD charging method printed on the battery If you are the standard STD charging method listed on the battery CHARGING INSTRUCTIONS FOR NEWLY ACTIVATED SEALED VRLA BATTERIES These batteries are a sealed VRLA construction which means NEVER REMOVE THE SEALING STRIP AFTER CHARGING IS COMPLETED If the battery gets very hot to the touch cease charging and allow battery to cool down Check voltage using a voltmeter Readings for a charged newly activated battery should be 12 8 or higher after the battery is charged and sits for at least 1 2 hours If less it needs an additional charge Yuasa Automatic Chargers and Accessories are the safest and most convenient method for error proof charging and battery maintenance Sealed VRLA Batteries SECTION Routine Charging The single most important thing to maintaining a sealed VRLA battery is don t let it sit discharged keep it fully charged A sealed VRLA motorcycle battery should be kept to near fully charged for peak performance In fact it can need charging more often than a car battery because it s probably not used routinely and therefore not automatically charged Use the following guid
10. because of looking pretty a dirty battery actually discharges across the grime on top of the case Use a soft brush and any grease cutting soap or baking soda solution Make sure plugs are finger tight so cleaning materials don t get into cells and neutralize the acid 2 Inspect battery terminals screws clamps and cables for problems breakage corrosion or loose connections Clean the terminals and clamps with a wire brush and coat terminals with no ox grease 3 Inspect case for obvious damages such as cracks or for leaks look for discoloration warping or raised top which may indicate that battery has overheated or been overcharged Inspecting Testing and Charging SECTION 4 Check electrolyte level and add distilled water if necessary Don t add acid only water Before any tests charge the battery so the water and electrolyte mix POINTS TO REMEMBER 1 Inspect before you test Add water if electrolyte is low m 7 Make sure vent tube is clear Battery Testing Devices How much of a charge does a battery have There are two easy and reliable ways to find out 1 a hydrometer which comes in floating ball and calibrated float types or 2 a voltmeter or multimeter which gives DC voltage readings Which is best If you re choosing between two hydrometers opt for the calibrated float type It gives you an exact specific gravity reading that is the density of the electro
11. charger the automatic taper charger charges at a fixed voltage the battery s voltage increases with the amount of charge the current drops accordingly A drawback of both the automatic taper and trickle chargers is speed they don t have it As the chart on page 21 shows it can take days to bring a discharged battery up to 100 Here too check batteries for over heating as they charge CONSTANT CURRENT CHARGER A professional quality charger the constant current makes charging simple lt maintains a constant supply of current to the battery at all levels of charging You select the charging current As the battery voltage increases with the amount of charge this charger automatically increases the charging voltage to maintain the current output CHARGER MAINTAINER This type of charger monitors the voltage constantly during charging and POINTS TO REMEMBER standby modes When battery voltage reaches a speci fied low level the charger maintainer then delivers a full charge Then when the battery gets to the specified volt age it automatically drops to a float charge HIGH RATE CHARGER Not for use with small engine starting batteries They force a high current into the bat tery which can lead to overheating and plate damage State of Sealed CX amp Charge VRLA YuMicron Conventional 100 13 0 127v 12 6v 75 12 8v 12 5v 12 4v 50 12 5v 12 2v 12 1v 25 12 2 12 0 11 9v 0 12 0v or less 11 9v or less 11 8
12. down on it isn t doing any favors to the battery in your vehicle Excessive heat will prematurely shorten the life of the battery Remaining Capacity Some people figure sealed VRLA batteries are so good there s no need to worry about routine charges Flattering but wrong Forgetting routine charging can mean a one way ticket to the battery graveyard m TT dms POINTS TO REMEMBER 7 High rate discharge sealed VRLA batteries deliver extra starting power 71 Lead calcium technology substantially slows self discharge 7 Routine charging is required to maintain a full charge Choosing a Charger Match your sealed VRLA battery to the right charger The wrong Yuasa sealed VRLA batteries have the amp hours printed one can cause permanent damage and poor performance right on the front of the battery If you re not sure refer to application manuals at the dealer Select the charger that Yuasa offers a complete line of chargers to activate and comes closest to the value of that figure maintain your battery to factory specifications i Do not use a larger than recommended amp charger to reduce charging time That permanently damages the battery and voids the warranty To find recommended current output in amps EM divide battery amp hour capacity rating by 10 Yuasa 900 mA Yuasa 1 5 Amp Example 14 AH 10 1 4 amp current Automatic Charger Automatic Charger Sealed VRLA Batteries SECTION Charging
13. drain In another 12 days it s completely dead In other words it doesn t take long for the dou ble whammy of self discharge accessory drain to knock out a battery for good IF current drain is measurable when the motorcycle is POINTS TO REMEMBER Ly Jg current drain turned off you can do one of two things disconnect the battery when the vehicle is in storage or charge the battery every two weeks to a full charge However cycling or continually recharging the battery will shorten its life Check the battery s condition with either a hydrometer or voltmeter or a multimeter The section on Testing a Battery has details Short Trips What if you use the vehicle now and then a couple of times a week for errands or even daily for a short trip to work You can t assume that occasional use or short trips under 15 or 20 miles will keep the battery charged In fact they re probably going to add to drain because the bike s charging system doesn t have enough time to make up for losses from normal starting and self discharge You re going to have to charge the battery more often Maybe every month or so depending on temperature Does the surface the vehicle s parked on or a battery s sitting on contribute to how well it holds a charge You sometimes hear experts say parking on concrete will accelerate discharge Bet them it s not so Then collect Concrete macadam wood dirt st
14. during discharge to the average volt age during subsequent recharge Voltage The difference in electrical potential that exists between the ter minals of a cell or battery or any two points of an electrical circuit Voltage Range difference between maximum and minimum cell voltages within a battery or string of cells when all cells are charging and discharging Voltmeter instrument for mea suring voltage VRLA Valve Regulated Lead Acid Sealed batteries which fea ture a safety valve venting system designed to release excessive internal pressure while maintaining sufficient pressure for recombination of oxygen and hydrogen into water Watering Adding water to battery electrolyte to replace loss from elec trolysis and evaporation Watt A unit of electric power equal to a current of one ampere under one volt of pressure Watthour unit of electrical ener gy or work equal to one watt acting or one hour Watthour Capacity The num ber of watthours a storage battery can deliver under specific conditions of temperature rate of discharge and final voltage Watthour Efficiency A storage battery s energy efficiency expressed as ratio of watthour output to the watthours of the recharge Watthour Meter An electric motor that measures and registers electrical energy in watthours Wet Shelf Life The time a wet sec ondary cell can be stored before its capacity falls to the point that the cell can
15. important to service life and operation Do not pierce or otherwise open the sealed cells of the electrolyte container Do not attempt to separate individual cells 3 Place electrolyte container sealed top of the cells down into the filler ports of the battery Hold the container level push down to break the seals You ll see air bubbles as the ports fill Do not tilt the electrolyte container Warning Improper activation or excessive overchargering possibly by equipment failure could cause damage to the battery or vehicle by forcing acid out of the safety vent Save this strip w See next page DDA Sealed VRLA Batteries SECTION 4 Check the electrolyte flow Keep the container in place for 20 minutes or longer until it empties completely If no air bubbles are coming up from the filler ports or if container cells haven t emptied completely tap the container a few times Don t remove the contain er from the battery until it s empty The battery requires all the electrolyte from the container for proper operation Make sure the electrolyte container empties completely SBOE 5 Remove the container For batteries 3 12 AH let stand for at least 30 minutes For batteries greater than 12 AH allow the battery to stand a minimum of 1 HOUR This allows the electrolyte to permeate into the plates for optimum performance Yuasa sealed VRLA batteries have the amp hours printed right on
16. it takes 75 F to freeze electrolyte in a charged battery But at just a couple degrees below freezing at 27 F a discharged battery s electrolyte turns to ice That s a difference of more than 100 F between the low temperatures a charged and discharged battery can stand POINTS TO REMEMBER At temperatures such as these incidentally the self discharge rate of a battery is so low that a recharge usually isn t needed for months But fo stay on the safe side test Specific Gravity of Electrolyte Freezing Point 1 265 E 1 225 39 F 1 200 17 F 1 150 S F 1 100 18 F 1 050 27 F 7 Monthly maintenance and testing are a must 7 Most important make sure battery is charged and fluid level is correct a Disconnect cables or pull battery for storage 7 Keep fully charged to prevent sulfation and freezing sealed VRLA Batteries SECTION New Generation BaHery Technology Yuasa s innovative sealed VRLA Valve Regulated Lead Acid batteries are a new generation made possible by advanced gas recombinant technology These include the YT and YI series batteries We refer to them as sealed VRLA batteries here Sealed VRLA batteries are easy to activate and maintain But keep these points in mind 1 There are important differences in activating a sealed VRLA battery Be sure to follow the instructions in this section 2 While Yuasa sealed VRLA batteries dramatically reduce the need for
17. of batteries to prevent gassing and temperature rise Fixed Resistance Discharge Discharge of a cell or battery through a fixed resistive load the current being allowed to fall off as the terminal volt age decreases Float Plate A pasted plate Float Charging A recharge ot a very low rate accomplished by con nection to a buss whose voltage is slightly higher than the open circuit voltage of the battery Foot Projections from the grid at the bottom edge used to support the plate group Formation or Forming Charge An initial charging process that elec trochemically converts the raw paste of the plates into charged active material lead peroxide in the positive plates and sponge lead in the negative plates Formed Plates that have undergone formation Freshening Charge charge batteries in storage to replace the standing loss and ensure that eve plate is periodically brought up to Full Charge Specific grovity of the electrolyte when cells are ully charged and properly leveled Gang Vent Vents for usually six adjacent cells that are connected to a common manifold Gassing Bubbles from gases being released at one or more of the elec trodes during electrolysis Glass Mat Fabric made from glass fibers with a polymeric binder si as styrene or acrylic which is used to help retain positive active material Gravity Specific gravity Gravity Drop The number of points
18. of its connection to an external circuit Loss of Charge Capacity loss in a cell or battery standing on open circuit as a result of local action Lug A portion of the grid used for sup port of the plate group usually a hang ing lug on the top edge of the grid Also a tab on the grid used for connec tion of plate to strap and other plates Machine Casting A fully or semi automatic grid or small parts casting operation MF Maintenance Free Battery A VRLA sealed absorbed glass mat AGM battery Manual Discharge Capacity test in which the operator disconnects the battery from the test load after all cells have reached the prescribed final volt age With fixed resistance loads boost cells are used to keep the dis charge rate fairly constant as the test cell voltages drop rapidly near the final voltage Electronic load manual discharges generally do not require boost cells Microporous Separator A veneer or grooved type separator made of any material ho has many microscopically small pores Milliampere One thousandth of an ampere Millivolt One thousandth of a volt Modified Constant Voltage Charge A charge in which charging current voltage is held substantially constant while a fixed resistance is inserted in the battery circuit produc ing a rising voltage characteristic at the battery terminals as the charge progresses Mold cost iron or steel form used to produce a casting of definite shape or o
19. prevent Vent System ursting flame arrestor frit prevents internal combustion High Performance Maintenance Free Grid System Increased conductivity for higher starting Computer Designed wattage increased vibration resistance Radial Grids Separator Puncture Resistant AGM Material High puncture resistant separator for increased service in high vibration applications SECTION The Lead Acid Battery Let s look first at battery basics what a battery is and how it works Lead acid batteries are used as a power source for vehicles that demand a constant and uninterruptible source of energy Just about every vehicle today does For example street motorcycles need lights that operate when the engine isn t running They get it from the battery Accessories such as clocks and alarms are battery driven Standard HEAT SEALED CASE TO COVER protects against seepage and corrosion bonded unit gives extra strength PATENTED SEALED POST prevents acid seepage reduces corrosion extends battery life POLYPROPYLENE COVER AND CONTAINER gives greater resistance to gas and oil and impact in extreme weather conditions SPECIAL SEPARATOR provides high cranking power Battery Basics and Safety Starting your vehicle depends on a battery Technically speaking the battery is an electrochemi cal device that converts chemical energy to electrical energy The first thing
20. you notice inside a battery is the cells Each cell has about two volts actually 2 12 to 2 2 volts measured on a DC scale A 6 volt battery will have three cells A 12 volt battery six cells Features THRU PARTITION CONSTRUCTION provides shorter current path with less resistance than over the partition construction you get more cranking power when you need it SPECIAL ACTIVE MATERIAL is compounded to withstand vibration prolong battery life and dependability SPECIAL GRID DESIGN withstands severe vibration assures maximum conductivity HEAVY DUTY GLASS MAT resists shedding of active material even under severe vibration SECTION The cells consist of lead plates that are positive and negative charged Inside the cell they re stacked alter nately negative positive negative Insulators or sep arators usually fiberglass or treated paper are placed between the plates to prevent contact Cranking current increases as the plate surface area in the bat tery increases the more plates in a cell or the larger the plates the greater the current capacity or flow of electricity Typically capacity increases as the amount of active material increases in the battery The alternate plates in each cell are connected at the top into two groups one positive and one negative Each cell s groups of plates are then connected in series positive to negative to those in the next cell Bas
21. ach 3 F below 77 F Cell voltage can be found by adding 84 to the specific gravity Note too that YUASA s Sulfate Stop a chemical addi tive that increases battery life by drastically reducing sul fate buildup changes the specific gravity readings they ll be higher than with ordinary batteries Test sealed VRLA types with a voltmeter or multimeter If the stabilized open circuit voltage is below 12 5v the battery needs charging For a stabilized open circuit reading first allow the battery to remain in an open circuit condition for at least 1 2 hours LOADED TESTING There are two types of loaded tests for motorcycle batteries You ll need a voltmeter or multi meter Low load test Basically this means turning on the bike s lights and taking a voltage reading at the battery Remember hook positive to positive negative to negative The battery in a 12v system should have at least 11 5v DC with the lights on system should have at least 5 75v DC If voltage drops below these lev els it s time to charge High rate discharge test This is the best test of bat tery condition under a starting load Use a load testing device that has an adjustable load Apply a load of three times the ampere hour rating At 14 seconds into the test check battery voltage a good 12v battery will have at least 10 5v and a good battery at least 5 25v If the reading s low charge 7 Use a voltmeter o
22. an be reversed You work that magic by putting a larger voltage on the battery for example 14 on a 12v battery Thats charging Here s what goes on when a battery charges The electrical charge flowing back in causes the lead sulfates to send their sulfate back into the electrolyte As a result both the electrolyte and the plates return to their original composition You ll notice bubbles in an actively charging battery That s called gassing It occurs because hydrogen and oxygen gases are liberated as the charging current breaks down the water Several things are actually happening here The process breaks down water into hydrogen and oxygen vapor which escapes out the vent tube You have to replace that loss Add distilled water to each cell after charging Then give the battery a mixing charge for another hour The hydrogen and oxygen gases that are given off can also build up pressure in the battery which is why batteries are vented and why the vent tubes can t be bent or blocked Very importantly hydrogen and oxygen are very explosive bears repeating that sparks flames and cigarettes around charging batteries can be a one way ticket to trouble 7 Deep discharge or prolonged discharge leads to harmful sulfation 7 A discharged battery freezes much faster than a charged battery 7 Charging can reverse discharging 7 Charging gives off hydrogen and oxygen which are explosive Inspecting Test
23. and allow battery to cool down No sparks flames or smoking when charging Sealed VRLA Batteries SECTION Charging Instructions for Sealed VRLA Batteries with Voltage of 11 5 or Less Batteries with voltage below 11 5v may require special equipment and procedures to recharge In charging an overdischarged battery having a terminal voltage of 11 5v or lower its internal resistance may be too high to charge at a normal charge voltage Therefore it may be necessary to raise the voltage of the battery initially 25v as a maximum and charge How to determine battery condition after boost charge Determine the condition of a sealed VRLA battery at least 1 2 hours after the charge by measuring the terminal voltage according to the table below Judgement Good Criteria 12 8 or higher 12 0 12 8v or lower Charge insufficient Recharge 12 0v or lower Unserviceable Replace Adjust voltage so that current will be at standard amps after 5 minutes for approximately 5 minutes If the ammeter shows no change in current after 5 minutes you need a new battery Current flowing into the battery at high voltage can become excessive Monitor amperage and adjust voltage as necessary to keep current at the battery s standard amp rating Charge for approximately 20 hours Routine Maintenance for Sealed VRLA Batteries Check voltage periodically using a voltmeter Recommended every 3 months from date of ac
24. ant Voltage Charge A charge that holds the voltage at the terminals at a constant value Container Housing for one or more cells commonly called a jar Cover The lid of an enclosed cell generally made of the same material as the container and through which the posts and vent plug extend Cover Inserts Lead or lead alloy rings molded or sealed into the cell cover and that the element posts are burned to thereby creating an effec tive acid creep resistant seal Creepage Travel of electrolyte up the surface of electrodes of other parts of the cell above the level of the main body of the electrolyte Curing Chemical conversion process that changes lead oxides and sulfuric acid to mixtures of basic lead sulfates basic lead carbonates etc which consequently forms the desired structures of lead or lead sulfate on negative and positive plates during formation Current The time rate of flow of electricity normally expressed as amperes like the flow of a stream of water Cut Off Voltage See Final Voltage Cutting of acid Dilution of solu tion of sulfuric acid to a lower concen tration Cycle discharge and its subse quent recharge Cycle Service Battery operation that continuously subjects a battery to successive cycles of charge and dis charge e g motive power service Deep Discharge Removal of up to 80 of the rated capacity of a cell or battery Dielectric Test An electric test per f
25. as with any magic there s more than meets the eye The heart of a sealed VRLA battery is what you don t see 1 The plates are comprised of special lead calcium alloy grids and charged active material Lead calcium reduces self discharge the battery holds its charge longer The construction of the sealed VRLA battery causes freed gas to recombine inside the battery instead of being vented allowing the battery to be sealed 2 Separators are made of a special fiber with superior heat and acid resistance These special separators make the battery non spillable 3 Sealed VRLA batteries have an internal safety valve If battery pressure soars due to accidental overcharging it opens to release excess gas preventing a battery rupture The unique design affects what happens inside the battery POINTS TO REMEMBER The basic discharge charge cycle is still going on that s what makes any battery tick But to understand what s different let s do a little review A battery is basically a box containing lead plates Some plates have a positive charge some negative They re immersed in a current conducting electrolyte solu tion that sets off the electrochemical process that produces electricity Think of a battery as a machine that produces electricity through a continuous process of charging and discharging During discharge sulfuric acid electrolyte solution reacts with the lead plates turning them into lead sulfate
26. ation of electric ener gy in which the cell after discharge may be restored to a charged con dition by an electric current flowing in a direction opposite to the flow of current when the cell discharges Charged A storage cell at maxi mum ability to deliver current The positive plates contain a maximum of lead oxide and a minimum of lead sulfate and the negative plates contain a maximum of sponge lead and a minimum of sul fate and the electrolyte is at maxi mum specific gravity Charged and Dry battery assembled with dry charged plates and no electrolyte Charged and Wet fully charged battery containing elec trolyte and ready to deliver current Charging The process of con verting electrical energy to stored chemical energy In the lead acid battery it converts lead sulfate in the plates to lead peroxide posi tive or lead negative Charging Rate The current expressed in amperes at which a bat tery is charged Circuit A system of electrical compo nents through which an electric current is intended to flow The continuous path of an electric current Cold Crank Test A test that applies a high rate of discharge to a battery at O F and the 30 second cell voltage must be above 7 2v Constant Current Charge A charge that maintains the current at a constant value For some types of batteries this may involve two rates called a starting and a finishing rate Constant Potential Charge or Const
27. de eUWWE VEZ eos OEE EOE Ee EO Ee UIS SE SI IU REIS 26 To Activate a Sealed VRLA 2 26 27 Measuring Voltage OR EROR 28 Discharge 5 8 8 HIM 29 SRN ENERE EISES RENRTRERTORERTSEHERERPTTPTPOPSPTRPCPEREROS 30 Choosing 30 Charging a Newly Activated Sealed VRLA 31 Routine Charging oso os 444 4490 17 09 95321 93 199001 0 599899899 EES oes 22 Charging Instructions for Sealed VRLA Batteries with Voltage of 11 5 1655 33 Routine Maintenance for Sealed VRLA 33 GLOSSARY Lead acid batteries are relatively simple design Dissimilar metal plates are immersed in an electrolyte solution consisting of sulfuric acid and water These are then insulated from each other with a permeable non conductive material which allows the transfer of ions The transfer of ions occurs during the discharge and recharge of the battery Also occurring is the change in specific gravity or density of the electrolyte During the discharge period sulfuric acid is drawn from the electrolyte into the pores of the plates This reduc
28. e or occasional use Easy instant activation The one push electrolyte container makes filling a snap Enhanced safety A safety valve vents gases produced by overcharging In case of fire the flame arrestor disk minimizes explosion risk THRU PARTITION CONSTRUCTION provides shorter current path with less resistance than over the partition construction you get more cranking power when you need it SPECIAL ACTIVE MATERIAL is compounded to withstand vibration prolong battery life dependability SPECIAL GRID DESIGN withstands severe vibration assures maximum conductivity SPECIAL SEPARATOR makes the battery spill proof Valve regulated design eliminates water loss and the need to refill with acid Sealed VRLA Batteries SECTION Compact design High efficiency in a small package with no vulnerable exhaust tubes or other protrusions to break or kink How a Sealed VRLA Battery Differs from Conventional Types Some of a sealed VRLA battery s differences are obvious Is noticeably more compact reason no free elec trolyte making it more volume efficient a fancy way of saying it can be smaller Since the battery is filled with electrolyte just once at activation then sealed you won t find a row of filling plugs Instead a single sealing plug strip permanently covers filler ports Also there are no vent tubes after all these batteries are sealed But
29. eep it running Whatever your reason for wanting to boost your battery IQ YUASA is pleased to provide this copy of the ultimate battery book It s filled with in depth information how batteries work maintenance and installation tips and how fo get maximum power and life from your battery We ll talk about chargers and testers Of course we ll also fill you in on the complete line of YUASA batteries chargers and accessories About YUASA The first thing you need to know about batteries is YUASA You might say that when it comes to powersports vehicle batteries we wrote the book We re the largest manufacturer and distributor of small engine starting batteries in North America IF you purchased a motorcycle snowmobile personal watercraft ATV riding mower or garden tractor manufactured in the U S chances are the battery that starts it was made by Yuasa In fact our batteries are original equipment in just about every major make of powersports vehicles IF you ve bought a replacement battery for your powersports vehicle most likely it was made by Yuasa Altogether we manufacture approximately three million batteries a year for small engine starting applications at our Reading Pennsylvania plant Battery Basics and Safety SECTION Cast Grid Special Grid Design Severe vibration resistance amp improved conductivity Active Material Proprietary Formulation Reduced shedding maximum utilization amp long service life
30. efore you get rolling Store the battery in a cool dry place out of direct sunlight Do not remove the foil sheet covering the filler port until activation After removing the electrolyte container cap strip do not peel pierce or otherwise open the sealed electrolyte receptacles Don t separate the individual cells Read electrolyte handling instruction and precautions on the label ELECTROLYTE FOR YTX12 B5 BATTERY randi 38 ton 17 orn a n ra PORSOM SULIUHIC GCI DANGER ULM mo 1 mt CAR Tad 951 TA 2 18 5 Use only the electrolyte container that comes with the battery Sealed VRLA battery electrolyte is a higher concentration of sulfuric acid All sealed VRLA battery electrolyte containers aren t the same Each contains the proper amount of electrolyte for its specific battery Always wear plastic gloves and protective eyewear No Smoking see page 9 for full safety instructions Of course don t forget safety precautions when storing or handling electrolyte solution To Activate a Sealed VRLA Battery 1 Place the battery on a level surface Battery must be out of the vehicle 2 Remove electrolyte container from vinyl bag Remove the strip of caps Put the strip aside you ll use this later as the battery sealing plug Use only the dedicated container that comes with the battery It con tains the proper amount of electrolyte for your specific model
31. elines for boost charge Always verify battery condition before charging and 30 minutes after charging A fully charged battery should read 12 8v or higher after battery has been off the charger 1 2 hours 100 50 25 50 11 5 12 0v 11 5 or less see special instructions on page 33 0 2576 OVERCHARGING CAN HARM YOUR BATTERY BEYOND RECOVERY A word on overcharging don t Because of the charac teristics of a sealed VRLA battery too much of a boost charge will decrease the volume of electrolyte The longer the overcharge time the greater the drop in elec trolyte and starting power Water can t be added to the sealed VRLA battery to make up the difference Overcharging can warp plates making future charging difficult or impossible Watch charging times caretully or ideally use a Yuasa Automatic Charger Always stop charging if the battery becomes really warm to the touch Let it cool down 6 12 hours and resume charging None Check at 3 months from date of manufacture None Required May need slight charge if no charge given check in 3 months Needs charge 5 11 hours At least 13 hours verify state Needs charge of charge Needs charge 20 hours Charging times can vary depending on type of charger Follow the charger s instructions Caution Always wear safety glasses and charge in a ventilated area If battery gets really warm to the touch discontinue charging
32. engine starting battery whatever the vehicle however tough the application YUASA s Conventional Battery 1241 4 1 YuMicron The industry standard for motorcycles snowmobiles and riding mowers our Conventional Battery is anything but conventional This workhorse is engineered to protect against seepage and corro sion withstand vibration and deliver high cranking power even when the weather s dealing its worst It s the rugged reliable and dependable battery that customers are looking for These features are built into our conventional manifold vented battery and every battery in the YUASA line Patented separators provide high cranking power Through partition construction delivers maximum power Unique sealed posts resist corrosion for longer battery life Polypropylene cover and container resist damage rom gas oil impact Heat sealed bonded unit construction protects against seepage and corrosion Personal watercraft snowmobiles and ATVs make special demands and YUASA s YuMicron Battery meets them head on The high tech power boosting design also makes YuMicron ideal for accessory laden touring bikes and modified machines Heavy duty glass mat resists vibration damage Special thin YuMicron Separator packs in extra plates delivers up to 30 more cranking power than conventional types Through the wall intercell connector minimizes internal resistance maximizes power Sulfa
33. ent for a short period of time Jar Housing or container for one or more cells Jar Formation Forming of plates in the cell jar Jumper A short length of conductor used to connect or cut out part of an electrical circuit Kilovolt One thousand volts Kilowatt One thousand watts Kilowatt Hours A measure of ener gy or work accomplished being 1000 watt hours Lead Pb Chemical element used in lead acid batteries Lead Burning Welding of lead or alloy parts Lead Hydrate A white lead com pound formed by reaction of very dilute electrolyte or water and metallic lead or lead alloys Lead Oxide A general term for any of the lead oxides used to produce bat teries Lead Peroxide A brown lead oxide which is the positive material in a fully formed positive plate Lead Plated Part Hardware that has a thin protective layer of lead elec trode deposited on the surface Lead Sponge The chief component of the active material of a fully charged negative plate Lead Sulfate A compound thot results from the chemical action of sul furic acid on oxides of lead or on lead metal Level Lines Horizontal lines molded or painted near tops of battery contain ers indicating maximum and minimum electrolyte levels Litharge A yellow red oxide of lead sometimes used in making active material Local Action A battery s loss of oth erwise usable chemical energy by cur rents that flow within the ele bat tery i honey
34. es the specific gravity of the electrolyte and increases the concentration of water During the recharge this action is reversed and the sulfuric acid is driven from the plates back into the electrolyte increasing the specific gravity During the discharge lead sulfate is being formed on the battery plates Although this is the normal activity within the battery during discharge a timely recharge is required to drive out the sulfuric acid into the electrolyte Without this recharge the lead sulfate will continue to develop and become difficult if not impossible to breakdown during recharge Once this advanced sulfation develops permanent capacity loss or total failure of the battery is likely Besides the sulfation concerns many other detrimental actions are taking place inside the battery while in a discharged condition The corrosive effect on the lead plates and connections within the battery is greatly increased due to the reduced specific gravity of the electrolyte The corrosion of the plates will typically result in a gradual reduction in performance followed by battery failure The corrosion associated with the inter cell connectors and the connecting welds will in many instances result in a sudden battery failure The corroded connector may have sufficient integrity to support low drain accessories such as lights and instruments but lack the necessary strength to provide the high discharge current required to start the vehicle
35. es battery capacity GLOSSARY Short Circuit Current The current that flows when the two terminals of a cell or battery are inadvertently con nected to each other Side Terminal SLI battery design with two through the container current connections on one side instead of two posts on top SLI Battery A battery for automotive use in starting lighting and ignition Sliver Slyver Extremely fine paral lel glass fibers used in retainers next to positive plates to retard shedding Smelting The primary process for recovering lead and antimony from scrapped batteries and scrap from bat tery manufacture Soaking manvfacturing process following pasting that soaks certain types of lead plates in sulfuric acid This provides a protective surface and also sulfate helpful in container and tank formation Soda Ash Sodium Carbonate Na CO3 used in neutralizing sulfuric acid in spills or effluents Spalling Shedding of active material usually from positives during formation due to incomplete or improper plate curing Sponge Lead Pb A poo mass of lead crystals and the chief material of a full charged negative plate Stacking cell assembly operation alternately piling plates and separators in a burning box prior to attachment of straps and posts Standard Battery Any of Conventional YuMicron or YuMicron CX batteries consisting of flooded elec trolyte and cell accessible construction Standing Loss Loss of c
36. harge by an idle cell or battery resulting from local action Starting Rate beginning charg ing rate that does not produce gassing or temperatures in excess of 110 F State of Charge The amount of electrochemical energy left in a cell or battery Strap Precast or cast on piece of lead or lead alloy used to connect plates into groups and to connect groups to the post Strap Center Spacing between cen ters of adjacent plates in a group Stratification Layering of high spe cific gravity electrolyte in lower por tions of a cell where it does not circu late normally and is of no use Sulfated A plate or cell whose active materials contain an apprecia ble amount of lead sulfate Sulfation Formation of lead sulfate on a plate or cell as a result of dis charge self discharge or pickling Sulfuric Acid H SO The princi pal acid compound of sulfur sulfuric acid in dilute and highly pure form is the electrolyte of lead acid storage cells Tack Burn A shallow burn used to tack together two lead parts Tank Formation Electrolytic pro cessing of plates prior to assembly in large tanks of acid Temperature Correction In stor age cells specific gravity and charg ing voltage vary inversely with temper ature while the open circuit voltage varies directly though slightly with tem perature Terminals The points on a battery to which the external circuit is connected Terminal Cable A length of insula
37. ically that s the internal hardware Next a solution of sulfuric acid and distilled water the electrolyte is added And the action starts A reaction between the lead plates and the electrolyte sets off a chemical change This in turn creates the electrical charge in a battery That s the process in a nutshell that makes every battery work So are all batteries the same Obviously not Actually there can be a number of differ ences and they go far beyond things like box size or terminal location That s true for different brands as well as for different lines produced by the same manufacturer Take two types of YUASA batteries for example our Conventional and YuMicron batteries POINTS TO REMEMBER Battery Basics and Safety What s different First there s cranking power YuMicron has more because YuMicron batteries boost plate surface area with thin high tech separators that make room for two extra plates in each cell YuMicron also has a special intercell connector that minimizes resistance to further maximize power It has a special glass mat that resists vibration damage Just for the record let s state how the Conventional and YuMicron batteries aren t different they re both lead anti mony batteries for openers other batteries in YUASA s line including the YuMicron CX use lead calcium tech nology They have certain things in common that we think should be part of every battery like sealed pos
38. ing and Charging SECTION Batteries have a natural tendency to discharge There are a number of reasons why self discharge high temperatures drain from electrical accessories on a vehicle and short trips that aren t enough to recharge the battery Self discharge Rate Characteristics at 77 F Lead Antimony 100 Self Discharge Self discharge goes on all the time a battery fact of life that they get weaker from just sit ting How rapidly batteries self discharge depends first of all on battery type Lead calcium batteries such as YUASA s CX YT YI discharge more slowly than conven tional batteries At room temperature lead calcium dis charges at 1 300 volt per day Conventional lead anti mony batteries discharge at 1 100 volt per day Temperature Outside temperature plays a big part too As the mercury goes up batteries discharge faster Particularly in hot climates that can mean trouble every 18 F doubles the discharge rate so battery at 95 F discharges twice as fast as one at 77 F And temperatures Self discharge Temperature Comparison e Lead Antimony Lead Calcium of 130 F are battery killing Been in a closed up garage or storage building on a hot summer day recently In many parts of the country its no trick for inside tempera tures to reach that Accessories Electrical accessories on some of today s newer and bigger bikes clocks and computer memory for e
39. ing voltage that can t fully charge the battery avoid them i you re buying a charger 12 volt 900 mA charger will meet most needs Of course too much of a charge can be a problem too it can cook a battery For small engine starting batter ies don t use a charge greater than 2 to 2 5 amps for maintenance purposes badly discharged battery with very high internal resistance may never accept a charge from a standard charger It would then require special charging equipment ALWAYS OBSERVE PROPER SAFETY PRECAUTIONS WHEN CHARGING BATTERIES TRICKLE CHARGER This is the charger a consumer as opposed to a battery retailer or garage will usually have It charges the battery at a Fed rate Different ampere hour batteries have different charge rates For most motorcycle and other small engine start ing batteries charge them at 1 10 of the rated ampere hour values in the Yuasa Applications Book see example on page 12 for ratings Battery voltage increases with the amount of charge Find charging time for a completely discharged battery by multiplying the ampere hour rating by 1 3 when charging with standard current The chart on page 21 shows the approximate time needed to fully charge lead antimony batteries using a trickle or taper charger The chart on page 32 shows the approximate time needed to fully charge sealed VRLA batteries Test the battery during charging and continue charg ing until all cells are ga
40. issolved in water Solutions of elec trolyte conduct electricity and are ecomposed by it For batteries elec trolyte implies a dilute solution of sulfu ric acid Electromotive Force EMF Electrical pressure or potential expressed in volts Element An ooy of a positive plate group negative plate group and separators End Gravity The specific gravity of a cell at the end of a prescribed dis charge Energy Density Ratio of battery content in watt hours to battery weight in volume Envelope separator folded and wrapped around a battery plate dur ing assembly Equalizing Charge extended charge given to a storage battery to ensure complete restoration of active materials in all the plates of the cells Expander ingredient in the neg ative paste that doe shrinking and solidilyin of the sponge lead of the finished plate thereby enhancing neg ative plate capacity Ferroresonant Charger A con stant volt power supply containing a special transformer capacitor combi nation that changes operating charac teristics as the draw is varied ensuring that voltage output remains constant Gravity The specific gravity of acid used to fill batteries Final Voltage The cut off voltage of a battery The prescribed voltage reached when the discharge is consid ered complete Finishing Rate The rate of charge in amperes to which charging current is reduced near the end of the charge for some ypes
41. it s dangerous and damaging Sealed VRLA Batteries SECTION Measuring Voltage How healthy is your sealed VRLA battery Since a sealed UIEU RR II VRLA battery is sealed and the sealing caps are never after End of Charge removed you won t be able to check the state of the charge by the old hydrometer and specific gravity test Rather use a voltmeter or multimeter to measure DC volt age It should be of class 1 accuracy or better Some basics to keep in mind Check voltage using a voltmeter Readings for a charged newly activated battery should be 12 8v or higher after the battery is charged and sits for at least 1 2 hours lf less it needs an 7 0 02 0 5060 additional charge Elapsed Time minutes The graph top right shows open circuit characteristics Relation between State of Charge of the sealed VRLA battery after end of charging and Open Circuit Voltage using a constant current charger set to the standard current of the specific battery As shown the open circuit voltage is stabilizing 30 minutes after end of charge Therefore to determine the state of charge and the health of the battery measure the open circuit voltage 1 hour after end of charge For a battery that has been in use refer to the graph bottom right to determine state of charge from 100 75 50 25 0 open circuit voltage State of Charge Don t use a quick charge for initial activation 7 A bat
42. ivalent of 1 10 of its rated capacity found in the Yuasa Applications Book YU M IC RO N Battery Specifications CAPACITY BATTERY AH TYPE DIMENSIONS INCHES 1 16 IN YB2 5L C YB2 5L C 1 Rated Mare Capacity 438 35 8 35 8 51 8 5 During charging batteries can spit electrolyte out the open vent Take care to loosely refit vent caps 6 Check during initial charging to see if electrolyte level has fallen and if so fill with acid to the UPPER LEVEL After adding charge for another hour at same rate as above to mix water and acid Note this is the last time electrolyte should be added but distilled water should be added as required 7 When charging s done replace plugs firmly Do not apply excessive pressure Finger tighten only Do not over tighten 8 Wash off spilled acid with water and baking soda solution paying particular attention that any acid is washed off the terminals Dry the battery case Inspecting Testing and Charging Vi The Discharge Charge Cycle As we mentioned earlier an electrochemical action within the battery produces electricity To understand it let s look inside a battery again yov ll see cells made up of lead plates Some plates are positive charged Others are negative charged There s also the electrolyte a sulfuric acid solution that conducts the current It sets off the chemical process that takes place in the battery So what goes o
43. lating on certain parts and fit tings Cadmium Electrode A third elec trode for separate measurements of the electrode potential of positive and negative plate groups Calcium Lead Alloy A lead base alloy that is sometimes used for battery parts in place of antimonial lead alloys Capacity See Ampere Hour Capacity Capacity Test A test that dis charges the battery at constant current at room temperature to a cutoff volt age of usually 1 75 volts cell Cast Forming a molten substance into shape by introducing the mate rial into a mold and allowing it to solidify Casting A metallic item such as one or more grids straps or connectors formed by pouring a molten substance into a mold and alsin it to solidity GLOSSARY Cast On Strap multiple connec tor that had been cast onto the plates directly in a combination mold burn ing jig contrasts with burning of plates and prefabricated straps Cathode An electrode through which current leaves any non metallic conductor Specifically an electrolytic cathode is an at which posi tive ions are discharged or negative ions are formed or at which other reducing actions occur Cell Primary cell designed to produce electric current through an electrochemical reaction that is not effi ciently reversible and hence the cell when discharged cannot be efficiently recharged by an electric current Cell Storage electrolytic cell for gener
44. lyte compared to water that s much more accurate than floating balls For readings on calibrated float and floating ball hydrometers see Methods of Checking Battery Condition chart on the next page A voltmeter or multimeter can be used where a hydrometer can t Most sealed VRLA or low maintenance batteries have to be tested with a voltmeter Battery testing requires a voltmeter that can measure DC voltage Remember to always connect a voltmeter parallel to the circuit being tested observing polarity otherwise the pointer will travel in the wrong direction It s a good idea to periodically check a voltmeter against another one of known accuracy 5 Check the vent tube Make sure it s not kinked pinched or otherwise obstructed On a motorcycle it should exit away from the drive chain and from below the swing arm Small cuts in the tube near the battery vent are OK they re an emergency escape for gas in case the tube becomes obstructed Dirt on top of case causes discharge Look for obvious damage to battery and connectors Yuasa Multimeter and Charging SECTION Battery Testing There are two types of battery tests unloaded and loaded An unloaded test is made on a battery without discharging current It s simplest and most commonly used If you need a precise reading loaded testing is the answer It s more accurate UNLOADED TESTING Check charge condition using either hydrome
45. maintenance they do need periodic charging lts important to remember this and to know how to go about it 3 When considering upgrading to a sealed VRLA battery that did not come OE in your vehicle check to make sure your charging system has a regulated output between 14 0 14 8v Let s take a closer look at Yuasa s innovative sealed SEALED VRLA BATTERY CONSTRUCTION PATENTED SEALED POST prevents acid seepage reduces corrosion extends battery life 5 HEAT SEALED CASE TO COVER protects against seepage and corrosion bonded unit gives extra strength TC r POLYPROPYLENE COVER AND CONTAINER assures reserve electrolyte capacity for cooler operating temperatures gives greater resistance to gas and ol and impact in extreme conditions SAFETY VALVE FLAME ARRESTOR relieves excess pressure VRLA batteries and what makes them special Features The sealed VRLA battery is the battery for vehicles that may be stored for long periods riding mowers personal watercraft or scooters or cycles during the off season for example or where spills eod be a problem ATVs or personal watercraft YUASA s sealed VRLA batteries deliver No topping Fill it just once to activate need to check electrolyte level or add water ever again Reduced self discharge Grids manufactured from a special lead calcium alloy hold the charge longer a real plus with storag
46. n when a battery discharges The electrolyte reacts chemically with the lead plates and it s not exactly a match made in heaven it turns them into lead sulfate If sulfate reminds you of sulfa tion you re right on target this build up of sulfate crystals is exactly what battery killing sulfation is In the process the electrolyte which contains hydrogen sulfur and oxygen gives up its sulfur and some of its oxygen The electrolyte turns to water Now you know why a discharged battery filled with water instead of electrolyte can turn into an ice block when the temperature drops even into the 20s On the other hand a properly charged battery won t freeze until the mercury gets way down in the minus range The chemical process causes free electrons to slowly gather on the negative plates They just hang there until a load is placed on the battery a light or starter s switched on which causes a swarm of electrons to rush to the positive plates If the chemical process just went on and on unchecked the lead plates would soon turn totally to lead sulfate the electrolyte would become pure water POINTS TO REMEMBER and the chemical and electrical activity inside the bat tery would come to a standstill It s bad for a battery So is allowing a battery to remain discharged for a prolonged period Recharging becomes hard or impossible The good news except in extreme cases the process of discharging c
47. nce of knowing when your battery is fully charged FORM YUA 069 Rev 4 04 PG 10 000 Mu AD YUASA Box 14715 Reading PA 19612 4715 Telephone 1 866 431 4784 Fax 610 929 1295 yuasabatteries com PRINTED IN U S A
48. nections Clean terminals and connectors as necessary Make sure exhaust tube is free of kinks or clogs Replace caps finger tighten only Then test the battery with either a hydrometer or volt meter Keep it charged to 100 If the vehicle is in storage or used infrequently disconnect the battery cable That eliminates drain from electrical equipment Check battery every two weeks and charge as necessary For extended storage remove the battery from the vehicle and charge to 100 Charge the battery every month if stored at temperatures below 60 F Charge every two weeks if stored in a warm area above 60 F Make sure batteries are stored out of reach of children Two of the biggest battery killers sulfation and freez ing aren t a problem if the battery is properly main tained and water level is kept where it should be Sulfation This happens because of 1 continuous dis charging or 2 low electrolyte levels Let s back up just a minute we said earlier that dis charge turns the lead plates into lead sulfate This lead sulfate is actually a crystal If the discharge continues uninterrupted the sulfate crystals grow and blossom into sulfation and a problem The section titled Reasons for Self discharge has the gory details Much the same happens if the fluid level is too low which exposes the plates to air Then the active lead material oxidizes and sulfates and it doesn t take long before it
49. not be easily recharged YUASA BATTERY ACCESSORIES Jumper Cables Battery Tester Digital Multimeter Part No Part No YUAOOBTYO Part No YUAOOACCOS5 e Easy to use easy fo store e Developed exclusively for the e Simple to use e Convenient storage bag Powersports industry e Easy and accurately measures e Heavy duty 8 ft 8 gauge accurate battery status current voltage and resistance cables won t stiffen or freeze e Eliminates the guesswork when Tangle resistant encased 9 Single load dynamic resistance your battery needs recharging technology minimizes battery drain during test rubber grips for safer use e A must for checking maintenance tree batteries as well as e lests both charged and dis conventional batteries charged batteries accurately e 90 day limited warranty e year limited warranty Part No 2 Part No Gu Battery Accessory Lead and Fused Ring Connectors Syringe Hydrometer Part No YUAMHYDRO e Simple quick connection e Can be used with Yuasa s 1 5 Amp and 900 mA chargers e Shows exact specitic gravity reading on conventional battery s condition applications ranging from motorcycles automobiles and personal watercraft to ATVs snowmobiles and riding mowers Battery Analyzer Part No YUADOACCO e Easy installation e Shows battery condition at the push of a button e Offers the confide
50. ones sand makes no difference A battery discharges at the same rate no matter what surface it s on And here s a hint if a battery suddenly dies and there s no apparent reason for it check the electrical system before you buy a new battery One of life s little let downs is to shell out dollars for a new battery when you didn t need to and then still have the problem Conventional lead antimony batteries discharge 1 100 volt per day Lead calcium batteries discharge more slowly 1 300 volt per day Higher temperatures mean faster discharge Temperatures over 130 F kill batteries Self discharge and short trips cause drain The more electrical accessories you add to a bike the greater the Inspecting Testing and Charging SECTION Ampere Hour and Cold Cranking Amps There are two battery ratings you need to know capacity or ampere hour rating and cold cranking amps or cold start rating Ampere hour rating in the YUASA Applications book it s abbreviated as AH is a battery s ability to deliver current for an extended period of time Because low temperatures slow down the chemical reaction inside a battery a battery will have a lower ampere hour rating in cold temperatures than in warm ones Most small engine batteries are rated at 10 hours That says they have to last at a given discharge rate that long A 14 ampere hour battery for example discharges at a rate of 1 4 ampere hours for 10 hou
51. optimum life overcharging may significantly reduce it With a conventional type battery that offers access to the cell compartments the periodic addition of distilled water may be required Water loss is normal in these batteries through the process of electrolysis and evaporation Low electrolyte levels that expose the lead plates to the air will result in permanent damage to the battery Maintain the electrolyte levels above the minimum fill lines on the battery and at or below the maximum line A sealed VRLA Valve Regulated Lead Acid battery should be maintained with the same care as a conventional type battery with the exception of the addition of distilled water Sealed VRLA batteries have a predetermined quantity of electrolyte added at the factory or in the field using the acid bottle specified for the battery Once activated the battery is permanently sealed and must never be opened A little bit of care and understanding of how your battery operates and is maintained will insure maximum service life SECTION Battery Basics and Safety About this book If you re looking for more than everyday information about batteries read on Maybe yov re a retailer the expert whose battery knowledge and recommendations guide customers every day Perhaps you are a service technician or dealer the person vehicle owners turn to with questions Or maybe you re an enthusiast set on knowing everything about your bike and how to k
52. or looks like Sensors are sort of particular they don t go with just any battery Which means it s important to replace the old battery and sensor with the correct YUASA sensor battery listed in the applications book So sensor rule oelecting and Installing one is this replace both battery and sensor at the same time But the sensor s original equipment you say Doesn t matter Being OE doesn t mean it s OK in another man ufacturer s battery In fact OE sensor plugs vary consid erably in length size and diameter plug that s too long can short out a battery and mess up the electrical system If the plug s short the warning light will flash way too early Note too that even YUASA s sensor batteries not interchangeable they have different vent locations sen sor wire lengths and diameter of cylinder connectors CUT AWAY VIEW OF SENSOR POINTS TO REMEMBER Ee _ LENGTH OF SENSOR ACID LEVEL MIN _ LEAD 71 Replace battery and sensor at same time 7 Original equipment sensor isn t OK for a new battery 71 Sensor batteries and sensors are not interchangeable check Applications Book New Battery SECTION oelecting and Installing a Battery Activation for Conventional and YuMicron Types Sealed at the factory a new YUASA battery has an indefinite shelf life as long as it remains sealed with the red cap in place and is stored at room tempera ture Once i
53. ormed on jars containers and other insulating materials to determine their dielectric breakdown strength Diffusion The intermingling or distri bution of particles or molecules of a liquid Direct Current A one direction cur rent Abbreviated DC Discharge Conversion of a battery s chemical energy into electrical energy Discharged A storage cell when as a result of delivering current the plates are sulfated the electrolyte is exhaust ed and there is little or no potential difference between the terminals Discharge Rate Any specified amperage rate at which a battery is discharged GLOSSARY Dry Charged Battery plates that have been subjected to the dry charg ing process Dry Charging Manvfacturing process in which tank formed battery plates are washed free of acid and then dried Efficiency The ratio of the output of a cell or battery to the input required to restore the initial state of charge under specified conditions of tempera ture current rate and final voltage Electrode conductor through which current passes in or out of a cell Electrode Electrolyte Potential The difference in potential between the electrode and the immediately adja cent electrolyte expressed in terms of some standard electrode potential dif ference Electrolysis Electrochemical reac tion that causes the decomposition of a compound Electrolyte Any substance that dis associates into two or more ions when d
54. other oxidiz ing reactions occur Antimonial Lead Alloy A commonly used alloy in battery castings The percentage of antimo ny varies from 1 2 to 12 Other substances are present in small quan tities either as inescapable impurities or by design to improve the proper ties of the cast part Antimony A hard brittle silver white metal with a high luster from the arsenic family Assembly 1 Combining various parts into a finished battery 2 Any particular arrangement of cells con nectors and terminals to form a bat tery Automotive Battery SLI battery of 3 or 6 cells used for starting lighting and ignition of cars trucks buses etc Average Voltage A storage bot tery s average value of voltage during a period of charge or discharge Battery Storage A connected group of two or more storage cells Common usage this term to single cell used independently Bridge The ribbed supporting struc ture in the bottom of a battery contain er that provides sediment space under the elements thereby preventing short circuits Burning Welding together two or more lead or lead alloy parts such as plates straps connectors Burning Center The center to cen ter distance between adjacent plates of the same polarity Burning Stick A lead or lead alloy stick used as a supply of joining mater ial in lead burning Cadmium A metallic element highly resistant to corrosion used as a pro tective p
55. r hydrometer to test state of charge Unloaded testing is simplest In extreme cold or heat you ll have to adjust hydrometer readings Battery can be tested with or without electrical load applied Applying a load and reading voltage at battery is more accurate Inspecting Testing and Charging SECTION Chargers and Charging There s a simple rule of thumb about batteries and if you re a dealer or a mechanic you know that people ignore it all the time for a battery to operate the way it s supposed 1o it has to be fully charged before it s used and kept fully charged throughout its life A charger basically brings a new battery or a battery that has been discharged to full capacity Plugged into a wall socket it sends direct current flowing in the opposite direction of the discharge into the battery Charging actually reverses the destructive chemical process that goes on as a battery discharges the lead lates and electrolyte which were being transformed into pnr sulfate and water are restored to their original composition If a battery has been damaged for example it s badly sulfated or the plates have been damaged from overheating or freezing it may not accept a charge TYPES OF CHARGERS There are five basic types of battery chargers With all of them hook the positive charger lead to the positive battery terminal and the negative to the negative Some chargers on the market deliver a low charg
56. r the Maintenance Free VRLA style batteries A few words of advice always double check that you have the right battery for your application before you charge and install it If you have any questions check out our website at www yuasabatteries com or contact us toll free at 1 866 431 4784 Warning In the event you want to upgrade to a sealed VRLA battery please ensure you have the proper charging voltage Always refer to your service manual uud MOTORCYCLE Mai M YTX20HL BS YTX20L BS KZ1000 P Police YB18L A KZ1000 C Police YBI6L B KZ1000 C Police 1 8 YB14L A2 KZ1000 LTD YB14L A2 KZ1000 E ST Shaft 19 YB16L B KZ1000 G Classic YB14L A2 KZ1000 LTD CSR YTX20HL BS YTX20L BS YB18L A KZ1000 R Replica YTX20HL BS YTX20L BS YB18L A 71000 1000 KZ1000 P Police 7 Check current Applications Book or microfiche for right replacement battery 7 There may be two or more right batteries choose by performance needs 7 Double check numbers before activation and installation New Battery SECTION About Sensors Many of today s motorcycles use batteries equipped with sensors They re either built in the battery or packed with it A sensor is a low fuel warning light It tells you when you re getting low in this case on electrolyte The sensor causes a warning light to flash signaling that it s time to add water to the battery The cutaway views below show what a sens
57. rn it off before you disconnect the leads that cuts down on the chance of sparks 6 Always wear eye protection protective gloves and protective clothing 7 Clean up acid spills immediately using a water and baking soda solution to neutralize 1 lb baking soda in 1 gal water 8 sure acid container is clearly marked and the work area is well lighted If sulfuric acid is swallowed or splashed in the eyes take immediate action While the diluted sulfuric acid used as electrolyte can burn the skin this type of injury is generally less serious Sulfuric acid in the eyes can cause blindness Serious internal injuries or death can result from ingesting sul furic acid Antidotes External flush with water Internal drink large quantities of milk or water followed by milk of magnesia vegetable oil or beaten eggs Call a poison control center or doctor immediately Eyes flush for several minutes with water get immediate medical attention Charging gives off gases no smoking sparks or flames Safety glasses or face shields protect against eye damage Acid swallowed or in the eyes requires immediate antidotes and All safety considerations are important review them frequently New Battery SECTION oelecting and Installing a Selecting the Proper Battery Selecting the right battery is an important decision You d be amazed how often the problem with a battery is that it s the wrong one for
58. rs At this point cell voltage has dropped to 1 75v per cell 10 5v for a 12v battery or 5 25v for a battery Usually the larger the plates the greater the ampere hour rating POINTS TO REMEMBER Cold start rating the high rate or the cold cranking amps abbreviated C C A in the YUASA applications book tells how well a battery can be expected to stand up to low temperatures This rating depends on the number of plates and their surface area The rat ing s arrived at by discharging a cold O F battery at a high rate for example 150 amperes while dis charge is monitored with a voltmeter Generally as displacement per cylinder increases so does the cranking current but since starting systems differ by model and manvfacturer the best advice is to check the application book for OE replacement If a special application demands higher cranking power select an appropriate alternate unit from the YUASA battery line Once again match battery features to needs Cold start rating is important in a snowmobile A lawn tractor owner probably doesn t care unless he plows snow too 7 Capacity or ampere hour rating a battery s ability to discharge current over time 71 Cold cranking amps measure battery high rate performance in cold weather Inspecting a Battery It s good policy to always inspect a battery before you test it Here s how 1 Make sure the battery top is clean and dry That s not just
59. ssing Use either a voltmeter or multimeter or hydrometer The specific gravity of the electrolyte in all cells in a fully charged battery should come to at least 1 265 in a conventional bat tery and 1 280 in a YuMicron and sealed VRLA battery with Sulfate Stop Electrolyte Temperature State of 80 F 40 F Charge CX amp CX amp YuMicron Conventional YuMicron Conventional 100 1 27 1 26 1 28 1 27 1 28 1 27 1 29 1 28 75 1 22 1 21 1 23 1 22 1 23 1 22 1 24 1 23 50 1 17 1 16 1 18 1 17 1 18 1 17 1 19 1 18 25 1 13 1 12 1 14 1 13 1 14 1 13 1 15 1 14 0 1 11 1 10 1 12 1 11 or less or less or less or less During charging check the electrolyte level periodically and add water preferably distilled to keep the electrolyte level up to the line If the battery becomes hot to the touch stop charging Resume after it has cooled Note that permanently sealed batteries YUASA s sealed VRLA battery for example generally can be test ed only with a voltmeter or multimeter These batteries are fully charged when the voltage peaks and then begins to fall Unless using an automatic charger do not hook a battery to a trickle charg er and leave it unchecked for longer than overnight After about eight hours maxi mum careful monitoring is required Caps need to be replaced finger tightened after charging s done Inspecting Testing and Charging SECTION TAPER CHARGER Similar to the trickle
60. t ed cable one end connected to the battery terminal post and the other fit ted with a plug receptacle lug or other device for connection to an external circuit Top Pour A method of casting in which molten metal is poured usual ly by hand into a top gated mold Treeing Growth of a lead dendrite or filament through a crack or hole of a separator short circuiting the cell Trickle Charge A low rate contin uous charge approximately equal to a battery s internal losses and capa ble of maintaining the battery in a fully charged state TVR temperature compensating voltage relay used in charging equipment Unformed A plate that has not been electrolytically formed Useful Acid The acid above the lower edges of the plates that takes part in the discharge reactions that occur within a cell Vent An opening that permits the escape of gas from a cell or mold Vent Plug The seal for the vent and filling well of a cell cover con taining a small hole for escape of gas Vent Well The hole or holes in a cell cover that allow fluids to be checked electrolyte to be added and gas to escape The vent plug fits into the vent well Verticals The members in a plate grid Volt The unit of measurement of electromotive force being the force needed to send a current or one ampere through a conductor with a resistance of one ohm GLOSSARY Volt Efficiency The ratio of the average voltage of cell or battery
61. t s unsealed a battery should be activated charged and installed The plates of an unsealed uncharged battery begin to oxidize That makes it more difficult to charge later We talk more about sulfation later in this book And if it s charged and sits around it starts to discharge and sulfate how fast depends on temperature Here are the steps for activating most batteries including YUASA s Conventional YuMicron YuMicron CX Sealed VRLA YT or YI batteries are activated differently see page 26 Activating Standard Batteries 1 Right before adding electrolyte remove filling plugs Also remove the sealing tube the red cap and throw it away Putting this back on after the battery s filled with acid can cause an explosion 2 Place battery on a level surface Fill battery with electrolyte a sulfuric acid dilution with a specific gravity of 1 265 Do not use water or any other liquid to activate Electrolyte should be between 60 F and 86 F before filling Fill to UPPER LEVEL as indicated on battery NOTE Never activate a battery on the vehicle Electrolyte spillage can cause damage 3 Let battery stand for at least 30 minutes Move or gently tap the battery so that any air bubbles between the plates will be expelled If acid level has fallen refill with acid to upper level 4 battery must be completely charged before installation Charge for three to five hours at the current equ
62. te Stop curbs plate sulfation and provides longer life SECTION YuMicron CX Battery Basics and Safety For top power less maintenance and longer life YuMicron CX is the battery of choice The first motorcycle battery built on lead calcium technology YuMicron CX is specially designed for today s big complex machines where higher cranking power is a must It delivers all the features of the standard YuMicron plus Unique CX design for higher cold cranking amps Lead calcium technology reduces water loss and servicing by 66 compared to lead antimony And CX substantially reduces self discharge for longer time between charges Sealed MF VRLA and High Performance ET I FORMA At Hi PIE Sealed MF VRLA Valve Regulated Lead Acid means a battery that s perfect for people who have better things to do than battery maintenance Our permanently sealed VRLA battery never needs refilling however it still needs periodic charging Ideal for motorcycles scooters ATVs riding mowers and personal watercraft Spill proof design means virtually no possibility of leaks Advanced lead calcium technology pumps up starting power Sulfation retardant dramatically reduces battery killing plate sulfation And sealed VRLA batteries hold voltage longer and need less charging in standby or storage mode High Performance version provides greater cranking po
63. ter or voltmeter With a voltmeter voltage readings appear instantly to show the state of charge Remember to hook the positive lead to the battery s positive terminal and the negative lead to the negative terminal A hydrometer measures the specific gravity of each cell The specific gravity tells the degree of charge generally a specific gravity of about 1 265 to 1 280 indicates a full charge reading of 1 230 to 1 260 indicates the battery should be charged before testing The chart below shows the charge level as measured by syringe float hydrometer digital voltmeter and five ball hydrometer State of Syringe Digital 5 Ball Charge Hydrometer Voltmeter Hydrometer 100 Charged w Sulfate Stop 1 280 12 80v 5 Balls Floating 100 Charged 1 265 12 60v 4 Balls Floating 75 Charged 1 210 12 40 3 Balls Floating 50 Charged 1 160 12 10v 2 Balls Floating 25 Charged 1 120 11 90 1 Balls Floating 0 Charged less than 1 100 less than 11 80v 0 Balls Floating A battery s specific gravity changes with temperature Ideally readings should be taken at 77 F Is it really going to matter if you re off a couple of degrees one way or another Probably not If you re working somewhere POINTS TO REMEMBER Inspecting Testing that s uncomfortably hot or cold it s time to use the old conversion factors add 001 to the specific gravity read ing for each 3 F above 77 F or subtract 001 from the specific gravity reading for e
64. tery that has just been activated or charged needs to stabilize 1 hour for an accurate voltage reading Sealed VRLA Batteries SECTION Discharge Characteristics Think about what types of vehicles a sealed VRLA battery goes into most aren t like the family car driven day in day out They re probably used once in a while or maybe even stored for weeks or months at a time That demands a special kind of battery one with extra power to reliably start that engine every time In YUASAS sealed VRLA batteries the plate groups spe cially designed to deliver that The graph to the right shows the increase in discharge time of a sealed VRLA battery compared to a conventional Yumicron battery at both cold and room temperatures The graph below shows the cold temperature performance of the sealed VRLA battery as the load increases C equals the Amp Hour Capacity Rating of the battery High Rate Discharge Characteristics of a Sealed VRLA 4 AH Battery Sealed VRLA EJ ED 14 F 10 C 77 F 25 C 0 1 2 3 4 Discharge Duration minute O IL O O NO Sealed VRLA Battery by Capacity Discharge Duration hour Starting the engine is a big part of the battery s job but not all Electrical accessories and safety systems lights and horn need a stable supply of electricity Now you re concerned wi
65. th the battery s low rate discharge characteristics This steady low rate discharge is measured in 10 hour rate discharge The graph above shows the discharge characteristics of YUASA s YT or sealed VRLA batteries at different current rates Note that battery capacity is a function of the current being used or discharge current x time Sealed VRLA Batteries SECTION Constant self discharge is a fact of life for all batteries Lead calcium technology definitely slows self discharge They lose strength as they sit there doing nothing The but a combination of heat and idleness will still drain a good news is that lead calcium technology in a sealed sealed VRLA battery like the conventional one You ll find VRLA battery slows down the self discharge process step by step charging instructions later this section substantially Conventional lead antimony batteries discharge at about 1 100 volt a day the lead calci _ Self discharge um sealed VRLA battery 1 300 volt per day Looking at it another way a conventional battery fully charged and stored for a month will lose roughly a third of its Sealed VRLA Standard charge the sealed VRLA battery handled the same way would lose about 10 Remember too ambient temperature affects battery dis charge Higher the temperature quicker the discharge for all batteries So the sealed garage or storage shed with the sun beat ing
66. the application To make doubly sure you re on track you ll need one of two things either the latest YUASA Battery Specifications and Applications book or the original equipment OE microfiche Of course you can always go to the old battery you re replacing The trick though is to make sure it s the original Otherwise you may be simply repeating the same problem that caused the bat tery to need replacing OK let s say you re replacing the battery on an 81 Kawasaki a KZ1000 C Police 1000cc Referring to the YUASA Battery Specifications and Applications book you first look under the Kawasaki listing Then find the right engine size 1000 where you find the KZ1000 C Police You re looking for an 81 so the place to be is 80 to 81 The chart on this page shows what it looks like If this were a sensor equipped battery which it isn t the applications book would mark it with a footnote T That tells you to order it with a sensor What s the right battery You ll see there are three of them a High Performance Maintenance Free 20 5 a Maintenance Free VRLA YTX20L BS and a YuMicron YB16L B battery Any of these will do fine If your machine has increased compression modifications to the engine for example you might want the additional POINTS TO REMEMBER cranking power And if the added benefit of never adding water again appeals to you go with the High Performance Maintenance Free o
67. the front of the battery Place cap strip loosely over filling holes 6 Newly activated sealed VRLA batteries require an initial charge After adding electrolyte a new battery is approximately 80 charged Place cap strip loosely over the filling holes as shown in drawing above Immediately charge your battery after the stand period to bring it to a full state of charge See Charging a Newly Activated Sealed VRLA Battery on page 31 After charging is completed press down firmly with both hands to seat the caps don t pound or hammer The battery is sealed There is no need to remove the strip of caps or add electrolyte for the life of the battery 7 graph below shows an open circuit voltage characteristic of a sealed VRLA battery just after the elec trolyte is filled If the battery is only filled with electrolyte but not being given a supplementary charge the open circuit voltage will be somewhere around 12 5 to 12 6 as shown in the graph below The reasons for the voltage being low are that The capacity reached by filling with electrolyte is about 80 of the fully charged capacity The electrolyte around the plates gets its concentration lowered temporarily About 30 Seconds Open Circuit Voltage v 0 2 4 6 8 10 Standing Time minutes Remember unlike a conventional battery the sealed VRLA battery won t be topped off during its life Never pry off sealing caps
68. tivation or 3 months from date of manufacture for batteries activated at the factory Keep in mind higher storage temperatures cause faster self discharge and require checking more often f you plan to store your vehicle for an extended time make sure your battery is fully charged Fully charged should read 12 8v 13 0v after standing 1 2 hours When a battery is in storage check and charge it if the voltage drops below 12 5v for YTX batteries Beyond that maintenance is the same as for any battery except you don t have to worry about electrolyte Keep the battery top free of grime Check cables clamps and case for obvious damage or loose connections Clean terminals and connectors as necessary For storage pull battery or disconnect battery cable Acid Sulfuric acid used to describe the electrolyte or liquid in a cell Active Materials Materials in a battery that react chemically to pro duce electrical energy they are fead peroxide positive and sponge lead negative Activation Making a dry cell func tional by adding electrolyte AGM Absorbed glass mat Air Oxidized A charged negative plate that has been removed from electrolyte and permitted to discharge in an air atmosphere Plates must then be recharged before they are capable of producing useful electrical energy Alloy A combination of two or more metals See Antimonial Lead Alloy and Calcium Lead
69. ts to resist corrosion tough polypropylene covers and contain ers and heat sealed construction for a strong bonded unit And both share certain design features like special separators and through partition construction Now does all this mean YuMicron is automatically a bet ter choice than the conventional battery Of course not It all depends on what you need to do Some of the YuMicron features might not be a big deal to a lawn trac tor owner but a feature like our unique cover design that minimizes electrolyte spillage is going to be really important to the guy on a watersport vehicle or ATV Each YUASA line of batteries has its unique features that account for differences in price and differences in performance and that s what makes it the right battery for a particular vehicle Buy what you need Don t pay for what you don t need 71 battery converts chemical energy to electrical energy 7 Each cell has approximately 2 volts 3 cells for a 6 volt battery 6 cells for a 12 volt battery 7 Inside each cell are electrically charged positive and negative lead plates isolated from each other by separators 7 Chemical action between plates and electrolyte creates an electrical charge 7 Current is the flow of electricity SECTION Battery Basics and Safety The YUASA battery line The right battery for the right job that s where it all starts YUASA s comprehensive line has the right small
70. ty protection e Sparktree operation e Durable construction for longer life e Battery accessory leads and fused ring connectors included e 121 output cord e 3 year limited warranty CONTENTS Ts PREFACE A Practical Understanding of Lead Acid 2 SECTION ONE Battery Basics and Safety About this book 3 POU 3 eulures ana i e ia 4 saree ENTENEN 342322 5k ba ea x a ER WA ene wenn ed LSEE RSS 4 The Lead Acid Battery sous ema 3 9353 22 deatar d a ded dod edu Ro 5 6 The Yuasa Battery 7 Yuoscs Conventional Ballary a iari RSS b dE EL RR RUE doc doen cud Pa at des MOMICION BONEY 505252 EET E T E T T TT TOT 4949 A eee eek be EEG eee YuMicron CX Battery 8 Sealed MF VRLA and High Performance Batteries 8 qq eeREERVUERFERREETE P EPERETPERKRPERTE IIS PIT 9 SECTION TWO Selecting and Installing New Battery Selecting the Proper 656553455408 SU PST 10 Sensors 255992 Gad 644 45 33 993 4 2949 03 995 hE EEE Gare ee 9 EO GE PARNE 11 Battery Activation for Conventional and YuMicron Types
71. unalloyed lead Plate A pasted grid Plate Centers Distance between center lines of adjoining plates of opposite polarity in a cell One half the size of a strap center upon which the plates of like polarity are burned Polarization Change in voltage at terminals when a specified current is flowing equal to the difference between the actual and the equilibrium constant open circuit condition poten tials of the plates exclusive of the inter nal resistance drop Porosity The ratio of open spaces or voids in a material to the volume of its mass Positive Plates The grid and active materials of a storage battery from which current flows to the external cir cuit when the battery is discharging Positive Terminal The terminal that current flows toward in the external cir cuit from the negative terminal Post Terminal or other conductor that connects the plate group strap to the outside of the cell Pure Lead Pig Lead Rated Capacity Ampere hours of discharge that can be removed from a fully charged cell or battery at a specif ic constant discharge rate at a specified temperature and at a specified cut off voltage Rate of Charge See Starting Rate and Finishing Rate Raw Plate An unformed plate Rectifier A device that converts alter nating ac current into unidirectional dc current because of a characteristic that permits appreciable flow of current in only one direction Red Lead A red oxide of lead
72. used in making active material Reference Electrode Electrode used to measure acid concentration or plate state of charge Resistance The opposition of a con ductor to the passage of an electrical current usually expressed in ohms Resistor A device used to introduce resistance into an electrical circuit Retainer A sheet of glass mat per forated or slotted rubber plastic or some other material installed on each face of the positive plates in certain types of cells to deter loss of active material Reversal A change in the norma polarity of a cell or battery Rib vertical or nearly vertical ridge of a grooved separator or spacer Secondary Lead Reclaimed as opposed to virgin lead Sediment The sludge or active material shed from plates that drops to the bottom of cells Sediment Space portion of a container beneath the element sedi ment from the wearing of the plates collects here without short circuiting Self discharge Loss of charge due to local action Separator A device in a storage battery that prevents metallic contact between plates of opposite polarity in a cell Series Cells All cells in a battery other than pilot cells They are so called because the cells are usually connected in series Series Parallel Connection Cells arranged in a battery so two or more strings of series connected cells each containing the same number of cells are connected in parallel this increas
73. utline Mold Coat spray applied to metal molds that acts as a release agent and an insulator against rapid heat transfer Moss Lead crystals that can grow at high current density areas of negative plates along edges at feet or at plate lugs and cause short circuiting Negative Plate The grid and active material that current flows to from the external circuit when a battery is dis charging GLOSSARY Negative Terminal The terminal from which current flows through the external circuit to the positive terminal when the cell discharges OHM unit of electrical resistance Oil of Vitriol Concentrated commer cial sulfuric acid abbreviated OV or Open Circuit The state of a battery when not connected to either a charg ing source or a load circuit Open Circuit Voltage The voltage at a battery terminal when no appre ciable current is flowing Oxide of lead A compound of lead and oxygen in one of several pro portions used to prepare battery paste Panel casting consisting of two or more grids made simultaneously in a single mold Pb Chemical symbol for lead PbO Chemical symbol for litharge PbO Chemical symbol for lead per oxide Pellet The portion of pasted material contained in a grid section framed by adjacent horizontal and vertical mem bers exclusive of forming bars Peroxide See Lead Peroxide Pig A cast bar of lead or lead alloy Pig Lead grade of highly refined
74. v or less 7 Fully charge battery when new and keep it fully charged 7 Test charging batteries as necessary for overheating water and state of charge 71 Trickle and taper chargers are generally slow Constant current and pulse chargers are professional quality High rate charger can cause battery damage Charging a New Standard Battery The most important thing to remember about charging a new battery is do it A battery out of the box with only adding electrolyte is approximately 80 charged Our recommendation is to initial charge bringing the battery to 100 before use This completes the electrochemical process However a long ride with a regulated charging system may also bring the battery s capacity to a higher level Note See Section 5 for charging sealed VRLA batteries Inspecting Testing and Charging The rule of thumb is to charge a new battery for three to five hours at a rate equal to 1 10 of its rated capacity But there are a lot of exceptions to that rule as this table shows Quick Charges What about quick charging The quick answer is don t We don t recommend it and here s why only the surface area of the battery plates can be quick charged A lower current charges the battery more uniformly That means better performance Also excessive charging rates increase the chance of overheating which can mean battery damage State Battery Types of 12 10 12 12 12 14 18
75. wer with 12 extra plates per battery SECTION Battery Safety As with anything with batteries you have to know what you re doing Batteries can be dangerous But they don t have to be if some simple safety precautions are followed Basically working with batteries poses two hazards potentially explosive gases that are given off during charging and sulfuric acid which is very corrosive an 8 point list that ll help keep those hazards under control 1 ABSOLUTELY NO SMOKING SPARKS OR OPEN FLAMES AROUND BATTERIES Batteries can produce hydrogen and oxygen if they ignite the battery can rupture 2 On conventional batteries loosen vent caps when charging and ventilate the entire charging area A build up of hydrogen and oxygen levels in the battery or in the room where it s being charged can create a hazard 3 battery feels hot to the touch during charging stop charging and allow it to cool before resuming Heat damages the plates and a battery that s too hot can rupture 4 Never put the red sealing cap back on the battery once you take it off If you do gases trapped inside can explode Make sure the vent tube isn t kinked or blocked for the same reason POINTS TO REMEMBER n Ventilate battery charging area EM medical care 1 Battery Basics and Safety 5 Properly connect charger to battery positive to positive negative to negative Unplug the charger or tu
76. won t hold a charge Low electrolyte levels cause another problem too acid in the electrolyte becomes more concentrated causing material to cor rode and fall to the bottom In sufficient quantity it will short out the battery Keeping a battery charged disconnecting the battery cable during storage and keeping electrolyte levels up eliminate the problem For added protection YUASA s YuMicron YuMicron CX and Sealed VRLA batteries are treated with a special chemical formula called Sulfate Stop This dramatically reduces sulfate crystal buildup on plates The result longer battery life How good is Sulfate Stop We simulated a constant discharge condition on two batteries with a 10 watt bulb Even after being totally drained for a week the battery with Sulfate Stop made a 90 recovery The untreated battery useless Maintenance and Storage SECTION Freezing lt shouldn t bother you unless a battery is inadequately charged Looking one more time at the discharge process remember that electrolyte acid becomes water as discharge occurs Now it takes Arctic temperatures to freeze acid But water as we all know freezing starts at 32 F A sign of this is mossing little red lines on the plates Freezing can also crack the case and buckle the plates which means the battery is permanently damaged A fully charged battery can be stored at sub freezing temperatures with no damage As the chart at right shows
77. xample will discharge the battery continuously even when the ignition s off drain can be consider able You can find out the drain in milli amperes by disconnecting the negative terminal and putting a multimeter inline It should look like this Checking Current Drain Negative Battery Cable Motorcycle Multimeter Battery Keep in mind that at the same time accessories are draw ing on the battery the battery s self discharging too The charts below show how fast a battery is discharged by self discharge and by current drain D 100 Days 104 F 77 F 200 Days 600 Days 32 F 550 Days 950 Days Current Drain Y50 N18L A 119 Days 83 Days 15 mA 28 Days 56 Days 20 mA 21 Days 42 Days 30 mA 14 Days 28 Days Inspecting Testing and Charging SECTION 12 Days x 0 030 Amps x 24 Hours 8 64 AH 8 64 AH 20 AH Y50 N18L A 43 0 Available Capacity PLUS 12 Days 200 Days to 100 Loss 6 0 Available Capacity Current Drain 43 0 Available Capacity Self discharge 6 0 Available Capacity Loss in 12 Days 49 0 Available Capacity Let s see what happens as the two work together to discharge a battery The battery starting out 100 charged has a 30mA discharge rate from electrical accessories on the motorcycle At an average outdoor temperature of 77 F a lead antimony battery loses about half its capacity in only 12 days due to the combination of self discharge and current

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