battery-prep-&-maintenance-61-008-82-2045-282

( Service-Informatio&n Group: 61 February Bulletin No.: General Electrical 1982 61 008 82 (2045) – For U.S.A. and Canada Only – Re: Batteries – Preparation and Maintenance There have been various complaints that the electrical capacity of our motorcycle batteries is too low, and we therefore would like to issue full details for the preparation of these batteries and their maintenance. 1. General Instructions Never bring a naked flame close to a battery or into a room in which batteries are charged, nor produce any sparks, or permit smoking in such areas, or an explosion may result. Exercise great care when handling battery acid, which could cause personal inj,ury and damage clothing. Wear protective goggles. “· • If any acid splashes on the skin or clothing, rinse off immediately with large amounts· of water. -‘,. • ~-:,_·_:.:.~_, . .~- . ‘ If the skin is already broken or scratched, keep these areas away from lead (the metal .used in battery cells) i~ after·:~’”‘ working on or with batteries, always:wash hands.·•· ·.,·: Do not place any tools on top of the battery, as this could cause a short-circuit between the terminal posts and result in an explosion. Always use chemically-pure battery acid, having a specific gravity of 1,280 (or 1,2~0 for batteries used in tropical climates). To dilute sulphuric acid, use only distilled or desalinated water. Do not add any substances such as proprietary battery performance improvers or similar additives, or the warranty will be rendered invalid. CAUTION: Always check ~nJ ins~all breeder tube and routing correctly. Bulletin No.: 61 008 82 (2045) ; -2- 2. Preparing for Use Remove cell plugs and take off any adhesive strips or sealing discs. When fillin~ the battery, it should be at a temperature of at least 50°F (the acid should also be at this temperature or above) . Fill the battery cells with the acid up to the acid level mark (if provided) or to a specified height of 6 mm above the plates (not above the separators). Do not use a metal funnel to add the acid. The best method of measuring battery acid level is to insert a thin glass or clear plastic tube until it rests on top of the plates, then close off the upper end with the finger, so that the depth of the acid can be seen when the tube is removed. Allow the battery to stand for one hour or until cool, then shake or tilt it slightly to eliminate trapped air and add more acid if necessary until the level returns to the specified height. Since batteries have only 60 percent of their nominal output capacity when filled, they must be charged. The recommended charging current in Amperes (A) is 1/10 of the quoted battery capacity; that is to say, 2.8 A (or approximately 3 A) on a battery rated at 28 Ah. During charging, the acid temperature must not exceed 131°F; if it does, interrupt the charging process or reduce the charging current until the temperature remains helow this figure. After charging has been completed, check the acid level and correct it if necessary by adding distilled or desalinated water up to the specified height above the tops of the plates in each cell. Do not top up with acid. Reinstall cell plugs. We suggest the positive (+) side be attached first. After connecting the cables, apply a light coat of acid-free, acid-resistant grease (e.g. Vaseline). Keep the battery clean and dry. Check acid level at monthly intervals. Top up with distilled w;:it-,=,r i-f ,:::,v;:inr,r;:d-;r,n nl”‘ronrc: .::inr! t-hio .::iroirl 1,::,.uc1 in t-h,=, 1″‘<=>11c ( ( ( Bulletin No. : 61 008 82 (2045) -3- 3. Treatment of Battery when Storing Motorcycle for Winter If the vehicle is taken off the road or the battery is stored out of use for a lengthy period, the battery must either be trickle-charged continuously at a very low current, (approximately 0.03 A), or recharged at intervals of one to two months. Never leave a battery to stand in a flat (discharged) state. Batteries stored out of use must be kept cool and dry. 4. Troubleshooting – Batteries Malfunction Cause Remedy Acid level too law overcharging, evapora- ‘Ibp up with distilled or tion (particularly in desalinated water (if the hot weather) battery is still charged) Acid overflCJ..vs fran . 1. O’large voltage too Check·voltage regulator and cells. high adjust or renew as necessary 2. Acid level too high Draw off excess acid with the bulb-type hydra:reter Specific gravity of 1. Battery is flat Recharge battery acid too lCJ..v 2. Alternator faulty Ci.eek alternator 3. ·Short-circuit in Oleck electrical system vehicle’s wiring 4. Acid diluted–main- Restore acid to correct tenance error strength Specific gravity of Acid added instead of Restore acid to correct acid too high distilled water . strength Battery output is J.. Battery is flat Recharge battery too low; severe 2. Charge voltage too Adjust or renew voltage lCJ..v regulator 3. connecting terminals Clean connecting terminals; loose or oxidized grease lightly with Bosch Ft 4 O v 1 grease, particularly on undersides. Tighten tenninal l:ol ts f inuly 4. Battery is dischar- Re.new the battery ging itself at too rapiC: a rate, due to impurities in acid ~-=- Bulletin No.: 61 008 82 (2045) -4- Malfunction Cause Remedy 6. Battery exhausted Fenew battery –paste fallen out of cell plates 7. Acid level belcw tops Add distilled or desalinated of plates water to specified height Battery life is too 1. Excessive vibration Oleck resilient battery tray short rrountings 2. Battery may be Battery output too lc,,,..r. “sulphated” See section #5 3 . Impure batte:ry acid Renew battery . Battery regularly 1. Fault in alternator, Repair or renew alternator discharged voltage regulator, or voltage regulator. Make or cable connections sure that wiring connections are clean and tight 2. Too many items of If rrotorcycle is used rrostly equiprent supplied for short joUIT1eys (in town, fran battery at night),.switch off unnecessary consumers (lights, heated handlebar grips, non- ( standard or additional driving lights, etc. ) Battery regularly Fault in voltage r~- Renew voltage regulator or overcharged later or possibly in have it adjusted; check alternator alternator Dicxie rectifier out Battery poles connected Discharge battery, then of action (for wrong way around (in- recharge to correct polarity rrachines with correct polarity alternator) .•·· Lj Bulletin No.: 61 008 8-.,,—–,,_(2045) QUICK REFERENCE CHART GOOD BATTERY SUSPECT BATTERY ACTION SPECIFIC GRAVI’rY CHART ~ATES ( +} CHOCOLATE WHITE (-) GREY BROKEN OR CORRODED REPLACE 1300 EDIMENT NONE OR VERY SEDIMENT UP TO 1280 LITTLE PLATES (SHORTING OUT) REPLACE 1240 1200 _ RE.f~RG~ __ :~ OLTAGE ABOVE 12V BELOW 12V TEST t-~ CHARGE 118 _; : ~ 114 : ~ _-. i LECTROLYTE FILL AND I ‘ 110 i LEVEL ABOVE PLATES BELOW TOP OF PLATES TEST l CHARGE ,, 108 -l •’ 104 1 iPECIFIC ABOVE 1.200 ON BELOW 1.100 OR A GRAVITY ALL CELLS DIFF. OF MORE TEST THAN 0.20 BETWEEN – CHARGE 100 NO MORE THAN CELLS I-‘ 0.20 DIFF. I-‘ N LJ “”‘ IJI m -.J co \0 0 0 0 0 0 a 0 0 0 0 0 BETWEEN CELLS % OF CHARGE