Harley-Davidson 12 Volt Batteries Instruction Sheet
Contents
1. BATTERIES AWAY FROM CHILDREN 00063a WARNING Never remove warning label attached to top of battery Failure to read and understand all precautions contained in warning could result in death or serious injury 00064a Table 1 Battery Electrolyte Antidote Physical Loc Procedure ation External Flush with water Internal Drink large quantities of milk or water followed by milk of magnesia vegetable oil or beaten eggs Call doctor immediately Eyes Flush with water and get immediate medical attention AwarninG Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 00019e NON SPILLABLE This is a ready filled activated SEALED BATTERY NEVER remove strip Refer to owner s manual or instruction sheet for charging procedure O AH Cy eS WD suo 9 l i ur peLgnE E D USE GET CAUSE BNDNEsS I FLAMES I BLINDNESS OR aa MEDICAL OR INJURY SMOKING amp A DANGER POISON FLUSH EYES IMMEDIATELY WITH WATER I ae SEVERE BURNS HELP FAST ry on OF REACH OF CHILDREN DO NOT OPEN BATTERY Figure 1 Battery Warning Label J01575 1 of 4 CARE AND MAINTENANCE Voltmeter Test See Table 2 The voltmeter test provides a general indicator of battery condition Check t2. If battery releases an excessive amount of gas during charging decrease the charging rate Overheating can result in plate distortion internal shorting drying out or damage 00413b 8 See Table 3 for charging conditions Step away from the battery and turn on the charger 2 of 4 Table 3 Battery Charging Rates Estimated Times Amp Hour State of Charge Typical Charging Times Hours Part Number Voltage of 5 Amp Charger 2 Amp Charger 1 5 Amp Charger 0 75 Amp Charger Charge 12 Amp Hour 12 7V 100 Full Full Full Full A cata 65948 126V 75 1 6 2 5 3 0 5 0 12 3 V 50 2 2 4 0 5 0 9 0 12 0 V 25 2 8 5 5 7 0 13 0 11 8 V 0 3 4 7 0 9 0 17 0 19 Amp Hour 12 7 V 100 Full Full Full Full a 12 6V 75 2 0 3 4 4 2 7 3 12 3V 50 2 9 5 8 7 3 13 7 12 0V 25 3 9 8 1 10 5 20 0 11 8V 0 4 8 10 5 13 7 26 3 28 Amp Hour 12 7V 100 Full Full Full Full 0 82B 66010 126V 75 2 4 4 5 5 7 10 3 12 3V 50 3 8 8 0 10 3 19 7 12 0V 25 5 2 11 5 15 0 29 0 11 8V 0 6 6 15 0 19 7 38 3 Based on available Battery Tender charger sizes from Deltran Times provided for reference Chargers are automatic Continue charging until the charger indicates full Final letter of part number subject to change AWARNING Unplug or turn OFF battery charger before disconnecting charger cables from battery Disconnecting clamps with charger ON can cause a spark and batter
3. TANF BY J01575 INSTRUCTIONS REV 2009 04 17 HARLEY DAVIDSON 12 VOLT BATTERIES GENERAL Kit Number 65948 00A 65989 90B 65991 82B 66010 82B 65958 04A 65989 97C 66010 97C Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required IWAN IN The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references service manual information A service manual is required for this installation and is available from a Harley Davidson Dealer Kit Contents There are no Service Parts available with this kit General Battery Information All Absorbed Glass Mat AGM batteries are permanently sealed maintenance free valve regulated lead calcium and sulfuric acid batteries The batteries are shipped pre charged and ready to be put into service Do not attempt to open these batteries for any reason WARNING Batteries contain sulfuric acid which could cause severe burns to eyes and skin Wear a protective face shield rubberized gloves and protective clothing when working with batteries KEEP
4. ed area Keep open flames electrical sparks and smoking materials away from battery at all times KEEP BATTERIES AWAY FROM CHILDREN 00065a J01575 3 See applicable service manual and remove the battery from the motorcycle Place the battery on a level surface 4 Inspect battery for damage Replace battery if visibly damaged or frozen 5 Inspect battery charger verify that the charger leads are not damaged frayed or loose WARNING Unplug or turn OFF battery charger before connecting charger cables to battery Connecting cables with charger ON can cause a spark and battery explosion which could result in death or serious injury 00066a CAUTION Do not reverse the charger connections described in the following steps or the charging system of the motorcycle could be damaged 00214a 6 Connect the red charger lead to the positive terminal of the battery 7 Connect the black charger lead to the negative terminal of the battery WARNING Explosive hydrogen gas which escapes during charging could cause death or serious injury Charge battery in a well ventilated area Keep open flames electrical sparks and smoking materials away from battery at all times KEEP BATTERIES AWAY FROM CHILDREN 00065a IWIN NIN If battery becomes hot gassing or spewing of electrolyte can occur which could cause death or serious injury Unplug or turn OFF the charger until battery cools 0041 2b CAUTION
5. esulting sparks can cause a battery explosion which could result in death or serious injury 00068a CAUTION Do not over tighten bolts on battery terminals Use recommended torque values Over tightening battery ter minal bolts could result in damage to battery terminals 00216a J01575 is00251 Fa Adapter flange nut Adapter Battery cable Battery terminal C1 ON Terminal bolt Figure 3 Terminal Adapter Kit 3 Refer to a service manual and connect the battery On most models insert bolt through battery positive cable red into threaded hole of battery positive terminal Tighten bolt to 60 70 in Ibs 6 8 7 9 Nm Insert bolt through negative battery cable black into threaded hole of battery negative terminal Tighten bolt to 60 70 in lbs 6 8 7 9 Nm NOTE Battery part number 66010 82B requires a battery terminal adapter kit when used on 1980 1992 model motorcycles This adapter kit is part number 66056 00 and is packaged with the battery 4 For battery part number 66010 82B when used on 1980 1992 model vehicles use the terminal adapter kit as fol lows a See Figure 3 Insert existing terminal bolt through hole in adapter and secure adapter to terminal Tighten bolt b Place battery cable on top of adapter screw connec tion and secure cable with adapter nut Tighten nut to 60 70 in Ibs 6 8 7 9 Nm c Repeat procedure for other terminal 5 Clean battery cable connec
6. he voltage of the battery to verify that it is in a 100 fully charged condition If the open circuit disconnected voltage reading is below 12 7 V charge the battery and then check the voltage again after the battery has set for one to two hours If the voltage reading is 12 7 V or above perform a load test Table 2 Voltmeter Test For Battery Charge Conditions VOLTAGE OCV STATE OF CHARGE 12 7V 100 12 6 V 75 12 3 V 50 12 0 V 25 11 8 V 0 Disconnection and Removal Refer to a service manual for specific disconnection and removal steps Pay attention to all warnings and cautions within the manual and remove battery from battery box tray Battery Charging AWARNING Batteries contain sulfuric acid which could cause severe burns to eyes and skin Wear a protective face shield rubberized gloves and protective clothing when working with batteries KEEP BATTERIES AWAY FROM CHILDREN 00063a 1 Never charge a battery without first reviewing the instruc tions for the charger being used N Perform a voltmeter test to determine the state of charge See BATTERY TESTING VOLTMETER TEST If battery needs to be charged proceed to Step 3 CAUTION Remove battery from motorcycle before charging Electro lyte leakage will damage motorcycle parts 00213a WARNING Explosive hydrogen gas which escapes during charging could cause death or serious injury Charge battery in a well ventilat
7. ored in a warm area above 60 F 16 C NOTE Harley Davidson Constant Monitoring Battery Chargers may be used to maintain battery charge for extended periods of time without risk of overcharging or boiling When returning a battery to service after storage refer to the instructions under BATTERY CHARGING 3 of 4 sm02838 77 oF 25 C BERR EEE 105 F 40 5 C m s mmm s m 1 Capacity 2 Months of non use Figure 2 Battery Self Discharge Rate INSTALLATION Battery Cable Routing Route all battery cables as described in the applicable service manual Battery Installation and Connection e Clean battery cable connectors of oxidation and apply a light coat of Harley Davidson Electrical Contact Lubricant 99861 02 to battery terminals and cable connectors N Place the fully charged battery into the motorcycle in the correct position See the applicable service manual CAUTION Connect the cables to the correct battery terminals Failure to do so could result in damage to the motorcycle electrical system 00215a WARNING Batteries contain sulfuric acid which could cause severe burns to eyes and skin Wear a protective face shield rubberized gloves and protective clothing when working with batteries KEEP BATTERIES AWAY FROM CHILDREN 00063a WARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the r
8. tors of any oxidation and apply a light coating of Harley Davidson Electrical Contact Lub ricant HD 99861 02 to the battery terminals and cable connectors NOTE Failure to secure battery properly may cause battery to mal function and will void battery warranty 6 Secure battery using procedures in the applicable service manual 4 of 4
9. y explosion which could result in death or serious injury 00067a 9 After the battery is fully charged turn off or unplug the battery charger then disconnect the black battery charger lead to the negative terminal of the battery 10 Disconnect the red battery charger lead to the positive terminal of the battery 11 Mark the charging date on the battery Battery Storage WARNING Batteries contain sulfuric acid which could cause severe burns to eyes and skin Wear a protective face shield rubberized gloves and protective clothing when working with batteries KEEP BATTERIES AWAY FROM CHILDREN 00063a CAUTION Do not allow battery to completely discharge The electro lyte in a discharged battery will freeze The more dis charged a battery is the more easily it can freeze and crack the battery case 00218a J01575 If the motorcycle will not be operated for several months such as during the winter season remove the battery from the motorcycle and charge fully See BATTERY CHARGING See Figure 2 Self discharge is a normal condition and occurs continuously at a rate that depends on ambient temperature and the battery s state of charge Batteries discharge at a faster rate at higher ambient temperatures To reduce self discharge rate store battery in a cool not freezing dry place Charge the battery every month if stored at temperatures below 60 F 16 C Charge the battery more frequently if st
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