TechManual_2009 yuasa

7/31/2019 TechManual_2009 yuasa

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Technical Manual


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High power unit provideserror proof operation

to fully charge sealed

maintenance free andconventional lead

acid batteries

Combining the latest technology and

a host of user-friendly features, this

compact, high power unit

provides optimum amperage returnand is designed to fully charge

and maintain conventional andsealed maintenance free batteries


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PREFACE:A Practical Understanding of Lead Acid Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION ONE: Battery Basics and SafetyAbout this book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3About YUASA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4The Lead Acid Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6The Yuasa Battery Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Yuasas Conventional Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7YuMicron Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7YuMicron CX Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 (MF) VRLA and High Performance Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION TWO: Selecting and Installing a New BatterySelecting the Proper Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10About Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Battery Activation for Conventional and YuMicron Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Activating Standard Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION THREE: Inspecting, Testing and ChargingThe Discharge Charge Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Reasons for Self-discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15Ampere-Hour and Cold Cranking Amps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Inspecting a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17Battery Testing Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Battery Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Chargers and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20

Charging a New Standard Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2Quick Charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION FOUR: Maintenance and StorageMonthly Maintenance for Conventional and YuMicron Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Sulfation and Freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23

SECTION FIVE: Sealed VRLA BatteriesNew Generation Battery Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Sealed VRLA Battery Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25How a Sealed VRLA Battery Differs from Conventional Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Activation and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

To Activate a Sealed VRLA Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27Measuring Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Discharge Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Self-discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Choosing a Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Charging a Newly Activated Sealed VRLA Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Routine Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Charging Instructions for Sealed VRLA Batteries with Voltage of 11.5 or Less . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Routine Maintenance for Sealed VRLA Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

GLOSSARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-40

CONTENTS

TABLEOF


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Lead acid batteries are relatively simple in design.Dissimilar metal plates are immersed in an electrolytesolution consisting of sulfuric acid and water. Theseare then insulated from each other with a permeable,non-conductive material, which allows the transfer ofions. The transfer of ions occurs during the dischargeand recharge of the battery. Also occurring is the changein specific gravity or density of the electrolyte. Duringthe discharge period, sulfuric acid is drawn from the

electrolyte into the pores of the plates. This reducesthe specific gravity of the electrolyte and increases theconcentration of water. During the recharge, this actionis 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 thebattery plates. Although this is the normal activity withinthe battery during discharge, a timely recharge isrequired to drive out the sulfuric acid into the electrolyte.Without this recharge, the lead sulfate will continue todevelop and become difficult if not impossible tobreakdown during recharge. Once this advanced

sulfation develops, permanent capacity loss or totalfailure of the battery is likely. Besides the sulfationconcerns, many other detrimental actions are takingplace inside the battery while in a discharged condition.

The corrosive effect on the lead plates and connectionswithin the battery is greatly increased due to the reducedspecific gravity of the electrolyte. The corrosion of theplates will typically result in a gradual reduction inperformance followed by battery failure. The corrosionassociated with the inter cell connectors and the connectingwelds will in many instances result in a sudden batteryfailure. The corroded connector may have sufficient

integrity to support low drain accessories such as lightsand instruments, but lack the necessary strength toprovide the high discharge current required to startthe vehicle. This corrosive effect can also dissolve thelead into solution, which in turn may compromise the plateinsulators and result in micro shorts. Another conditionthat frequently occurs in a discharged battery is freezing.In a deeply discharged battery, the electrolyte has a

reduced specific gravity and becomes a higher percentageof water than sulfuric acid. During this condition, thebattery may freeze at temperatures as high as 32F.The electrolyte in a fully charged battery will not freezein temperatures down to -65F.

Deep discharge can be created by a multitude ofcondit ions, but the predominant reason is neglect.During long periods of storage, the battery state of

charge must be checked and maintained per the batterymanufacturers recommendations. Other conditions that candrain the battery are inoperative or inadequate chargingsystems on vehicles, parasitic or key off drains, loose ordirty terminal connections, etc. Although many of theseconditions can be corrected, often the problems youcannot correct may be overcome by a periodic chargingschedule. You can establish a routine by which you checkand charge your battery or choose to permanently attacha Yuasa Automatic Charger while the vehicle is not in use.

When charging your bat te ry, always re fe r to th einstructions on both the battery and the charger. While

maintaining your battery at a full state of charge willinsure optimum life, overcharging may significantlyreduce it. With a conventional type battery that offersaccess to the cell compartments, the periodic addition ofdistilled water may be required. Water loss is normal inthese batteries through the process of electrolysis andevaporation. Low electrolyte levels that expose the leadplates to the air will result in permanent damage to thebattery. Maintain the electrolyte levels above theminimum fill lines on the battery and at or below themaximum line. A sealed VRLA (Valve Regulated LeadAcid) battery should be maintained with the same careas a conventional type battery with the exception of the

addition of distilled water. Sealed VRLA batterieshave a predetermined quantity of electrolyte added atthe factory or in the field using the acid bottle specifiedfor the battery. Once activated, the battery is permanentlysealed and must never be opened.

A little bit of care and understanding of how your batteryoperates and is maintained will insure maximum service life.

A Practical Understandingof Lead Acid Batteries

PREFACE

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About this book

If youre looking for more than everyday information about batteries, read on.

Maybe youre a retailer, the expert whose battery knowledge and recommendations guidecustomers every day. Perhaps you are a service technician or dealer the person vehicle

owners turn to with questions. Or maybe youre an enthusiast set on knowing everythingabout your bike and how to keep it running.

Whatever your reason for wanting to boost your battery IQ, YUASA is pleased to providethis copy of the ultimate battery book.

Its filled with in-depth information: how batteries work, maintenance and installation tips and howto get maximum power and life from your battery. Well talk about chargers and testers. Ofcourse, well 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 comesto powersports vehicle batteries, we wrote the book! Were the largest manufacturer and distributorof small engine starting batteries in North America.

If you purchased a motorcycle, snowmobile, personal watercraft, ATV, riding mower or gardentractor manufactured in the U.S., chances are the battery that starts it was made by Yuasa. Infact, our batteries are original equipment in just about every major make of powersports vehicles.

If youve bought a replacement battery for your powersports vehicle, most likely it was made byYuasa. Altogether, we manufacture approximately three million batteriesengine starting applications at our Reading, Pennsylvania

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Features and Benefits

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Component Features Benefits

Cast Grid Special Grid Design Severe vibration resistance & improvedconductivity

Active Material Proprietary Formulation Reduced shedding, maximum utilization, &long service life

Pasted Plates Specified Thickness Ensures vibration resistance through& Weight precise compression & proper service life

through specified active material balance

Dried-Charged Tank Formed & Properly dried plates in a sealed batteryPlates Dried Plates have a virtually limitless shelf-life, while

still retaining 70-80% state of charge whenfilled with acid

Top Lead Through-Partition-Construction, Shorter current path for increasedConnections Large Straps electrical conductivity & higher startingcurrents, heavier parts for

maximum durability

Case-Cover Thermal Bonded Plastic Air tight seal to prevent air ingressSeal & acid seepage

Terminal- Cover Patented Poly-Seal Eliminates acid seepage, reducesSeal Terminal corrosion, & extends battery life

Case & Cover Polypropylene Superior resistance to gasoline & 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 reducesbattery sulfation potential

YuMicron

Separator Leaf Separator Polyethylene leaf with glass mat sheet bonded for compression to withstand

severe vibration conditions

YTX

Separator Absorbed Glass Mat Absorbs acid while creating cell compressionfor extreme vibration resistance

Top Lead Alloy Calcium Alloy Increased weld strength & severe

vibration resistanceVent System Valve & Flame Arrestor Valve relieves excess pressure to prevent

bursting, flame arrestor frit preventsinternal combustion

High Performance Maintenance Free

Grid System Computer-Designed Increased conductivity for higher startingRadial Grids wattage, increased vibration resistance

Separator Puncture Resistant High puncture resistant separator for increasedAGM Material service in high vibration applications

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Battery Basics and Safety


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Lets look first at battery basics: what abattery is and how it works.

Lead acid batteries are used as a power source for vehiclesthat demand a constant and uninterruptible source ofenergy. Just about every vehicle today does. For example,street motorcycles need lights that operate when theengine isnt running. They get it from the battery.Accessories such as clocks and alarms are battery-driven.

The Lead Acid BatteryStarting your vehicle depends on a battery.

Technically speaking, the battery is an electrochemical device that converts chemical energy to electricaenergy. The first thing you notice inside a battery isthe cells. Each cell has about two volts (actually2.12 to 2.2 volts, measured on a DC scale). A 6volt batter y will have three cells. A 12-vol t batterysix cells.

HEAT SEALED CASE TO COVER

protects against seepage andcorrosion bonded unit gives extra strength.

THRU-PARTITION CONSTRUCTION

provides shorter current path with less resistance thanover the partition construction you get morecranking power when you need it!

SPECIALACTIVEMATERIALis compounded towithstand vibration,prolong battery lifeand dependability.

PATENTEDSEALED POSTprevents acidseepage, reducescorrosion extendsbattery life.

POLYPROPYLENE COVER

AND CONTAINERgives greater resistance to gas and oil and impact in extreme weather conditions!

SPECIAL SEPARATORprovides high cranking power.

HEAVY DUTY GLASS MATresists shedding of active material evenunder severe vibration.

SPECIAL GRIDDESIGNwithstands severe vibration,assures maximum conductivity.

S t a n d a r d F e a t u r e s

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Whats different? First theres cranking power: YuMicronhas more because YuMicron batteries boost plate surface

area with thin, high-tech separators that make room fortwo extra plates in each cell. YuMicron also has a specialintercell connector that minimizes resistance to furthermaximize power. It has a special glass mat that resistsvibration damage.

Just for the record, lets state how the Conventional andYuMicron batteries arent different: theyre both lead-anti-mony batteries, for openers (other batteries in YUASAsline, including the YuMicron CX, use lead-calcium tech-nology). They have certain things in common that wethink should be part of every battery: like sealed posts toresist corrosion, tough polypropylene covers and contain-

ers, and heat sealed construction for a strong, bondedunit. And both share certain design features, like specialseparators 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 theYuMicron features might not be a big deal to a lawn trac-tor owner, but a feature like our unique cover designthat minimizes electrolyte spillage is going to be reallyimportant to the guy on a watersport vehicle or ATV.

Each YUASA line of batteries has its unique featuresthat account for differences in price and differences inperformance and thats what makes it the right batteryfor a particular vehicle. Buy what you need. Dontpay for what you dont need.

The cells consist of lead plates that are positive andnegative charged. Inside the cell theyre stacked alter-

nately negative, positive, negative. Insulators or sep-arators usually fiberglass or treated paper areplaced between the plates to prevent contact. Crankingcurrent increases as the plate surface area in the bat-tery increases the more plates in a cell, or the largerthe plates, the greater the current capacity (or flow ofelectricity). Typically, capacity increases as the amountof active material increases in the battery.

The alternate plates in each cell are connected at thetop into two groups, one positive and one negative.Each cells groups of plates are then connected in series positive to negative to those in the next cell.

Basically, thats the internal hardware. Next, a solutionof sulfuric acid and distilled water the electrolyte isadded. And the action starts. A reaction between thelead plates and the electrolyte sets off a chemicalchange. This in turn creates the electrical charge in abattery.

Thats the process, in a nutshell, that makes every batterywork. 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 orterminal location. Thats true for different brands, as wellas for different lines produced by the same manufacturer.Take two types of YUASA batteries, for example: ourConventional and YuMicron batteries.

POINTS TO REMEMBER

A battery converts chemical energy to electrical energy.

Each cell has approximately 2 volts: 3 cells for a 6-volt battery, 6 cellsfor a 12-volt battery.

Inside each cell are electrically charged positive and negative leadplates, isolated from each other by separators.

Chemical action between plates and electrolyte creates anelectrical charge.

Current is the flow of electricity.

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The industry standard for motorcycles, snowmobiles and ridingmowers, our Conventional Battery is anything but conventionalThis workhorse is engineered to protect against seepage and corro-sion... withstand vibration... and deliver high cranking power, evenwhen the weathers dealing its worst. Its the rugged, reliable anddependable battery that customers are looking for!

These features are built into our conventional manifold vented battery..and every battery in the YUASA line:

G Patented separators provide high cranking powerG Through-partition construction delivers

maximum powerG Unique sealed posts resist corrosion for longer

battery lifeG Polypropylene cover and container resist damage

from gas, oil, impactG Heat-sealed, bonded unit construction protects against

seepage and corrosion

Personal watercraft, snowmobiles and ATVs make special demands and YUASAs YuMicron Battery meets them head-on. The high-tech

power-boosting design also makes YuMicron ideal for accessory-ladentouring bikes and modified machines.

G Heavy duty glass mat resists vibration damageG Special thin YuMicron Separator packs in extra plates,

delivers up to 30% more cranking power than conventional typesG Through-the-wall intercell connector minimizes internal

resistance, maximizes powerG Sulfate Stop curbs plate sulfation and provides longer life

The right battery for the right job thats where it all starts. YUASAs comprehensive line has the right small enginestarting battery... whatever the vehicle, however tough the application.

YUASAs Conventional Battery

The YUASA battery line...

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YuMicron

Personal watercraft, snowmobiles and ATVs make special demands and YUASAs YuMicron Battery meets them head-on. The high-tech

power-boosting design also makes YuMicron ideal for accessory-ladentouring bikes and modified machines.

G Heavy duty glass mat resists vibration damageG Special Separator packs in extra plates,

30% more cranking power than conventional typesG Through-the-wall intercell connector minimizes internal

resistance, maximizes powerG Sulfate Stop curbs plate sulfation and provides longer life

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Sealed (MF) VRLA and High Performance

Sealed (MF) VRLA (Valve Regulated Lead Acid) means a batterythats perfect for people who have better things to do than batterymaintenance! Our permanently sealed VRLA battery never needsrefill ing; however, it still needs periodic charging. Ideal for motorcycles,scooters, ATVs, riding mowers and personal watercraft.

G Spill-proof design means virtually no possibility of leaksGAdvanced lead-calcium technology pumps up

starting powerG Sulfation retardant dramatically reduces battery-killingplate sulfation

GAnd, sealed VRLA batteries hold voltagelonger and need less charging in standby or storage mode

G High Performance version provides greater crankingpower with 12 extra plates per battery

For top power, less maintenance and longer life, YuMicron CX is thebattery of choice. The first motorcycle battery built on lead-calciumtechnology, YuMicron CX is specially designed for todays big, complexmachines, where higher cranking power is a must. It delivers all thefeatures of the standard YuMicron plus...

G Unique CX design for higher cold cranking ampsG Lead-calcium technology reduces water loss and

servicing by 66% compared to lead antimonyGAnd, CX substantially reduces self-discharge for

longer time between charges

YuMicron CX

8

(MF) VRLA and High Performance

(MF) VRLA (Valve Regulated Lead Acid) meansbattery thats perfect for people who have better things to do thanbattery maintenance! Our permanently sealed VRLA battery neverneeds refil ling; however, it still needs periodic charging. Ideal formotorcycles, scooters, ATVs, riding mowers and personal watercraft.

G Spill-proof design means virtually no possibility of leaksGAdvanced lead-calcium technology pumps up

starting powerG Sulfation retardant dramatically reduces battery-killingplate sulfation

GVRLA batteries hold voltagelonger and need less charging in standby or storage mode

G High Performance version provides greater crankingpower with 12 extra plates per battery

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POINTS TO REMEMBER

Ventilate battery charging area.

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

medical care.

All safety considerations are important... review them frequently.

9

As with anything, with batteries you have to know whatyoure doing. Batteries can be dangerous. But they dont

have to be if some simple safety precautions are followed.

Basically, working with batteries poses two hazards:potentially explosive gases that are given off duringcharging, and sulfuric acid, which is very corrosive.

Heres an 8-point list thatll help keep thosehazards under control:

1. ABSOLUTELY NO SMOKING, SPARKS OR OPENFLAMES AROUND BATTERIES. Batteries can producehydrogen and oxygen; if they ignite the battery can rupture.

2. On conventional batteries, loosen vent caps whencharging and ventilate the entire charging area. Abuild-up of hydrogen and oxygen levels in the battery or in the room where its being charged can createa hazard.

3. If a battery feels hot to the touch during charging,stop charging and allow it to cool before resuming.Heat damages the plates, and a battery thats too hotcan rupture.

4. Never put the red sealing cap back on thebattery once you take it off. If you do,gases trapped inside can explode. Makesure the vent tube isnt kinked or blocked,for the same reason.

5. Properly connect charger to battery: positive topositive, negative to negative. Unplug the charger or

turn it off before you disconnect the leads; that cutsdown on the chance of sparks.

6. Always wear eye protection, protective gloves andprotective clothing.

7. Clean up acid spills immediately, using a wateand baking soda solution to neutralize (1 lb. bakingsoda in 1 gal. water).

8. Make sure acid container is clearly marked andthe work area is well lighted.

If sulfuric acid is swallowed or splashed inthe eyes, take immediate action. While thediluted sulfuric acid used as electrolyte can burn theskin, this type of injury is generally less seriousSulfuric acid in the eyes can cause blindness. Seriousinternal injuries or death can result from ingesting sulfuric acid.

Antidotes:External flush with water.Internal drink large quantities of milk or water,

followed by milk of magnesia, vegetable oil orbeaten eggs. Call a poison control center ordoctor immediately.

Eyes flush for several minutes with water, getimmediate medical attention.

Battery Safety

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Selecting the Proper Battery

POINTS TO REMEMBER

Check current Applications Book or microfiche for right replacement battery.

There may be two or more right batteries choose by performance needs.

Double check numbers before activation and installation.

High Maintenancecc Model Year Performance F re e Yu Mi cr on C on ve nt io na lMaintenance VRLAFree

KAWASAKI

1000 KZ1000-P Police '02-'03 YTX20HL-BS YTX20L-BS - -

KZ1000-P Pol ice '82-'01 YTX20HL-BS* YTX20L-BS * YB18L-A -

KZ1000-C Pol ice '80-'81 YTX20HL-BS* YTX20L-BS * YB16L-B -

KZ1000-C Police, Z1-R '78-'79 YTX14AHL-BS - YB14L-A2 -

KZ1000, LTD '77-'80 YTX14AHL-BS - YB14L-A2 -

KZ1000-E ST, Shaft '79-'80 YTX20HL-BS * YTX20L-BS * YB16L-B -

KZ1000-G Classic '80 YTX14AHL-BS - YB14L-A2 -

KZ1000, LTD, CSR '81-'83 YTX20HL-BS* YTX20L-BS * YB18L-A -

KZ1000-R Rep li ca '82-'83 YTX20HL-BS* YTX20L-BS * YB18L-A -

Z1000 '03-'04 - YTX9-BS - -

MOTORCYCLE

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cranking power. And if the added benefit of neveradding water again appeals to you, go with the High

Performance Maintenance Free or the Maintenance FreeVRLA style batteries.

A few words of advice: always double-check that youhave the right battery for your application before youcharge and install it. If you have any questions, checkout our website atwww.yuasabatteries.com orcontact us toll free at1-866-431-4784.

Warning: In the event you want toupgrade to a sealed VRLA battery,please ensure you have the proper

charging voltage. Always refer to yourservice manual.

Selecting the right battery is an important decision.Youd be amazed how often the problem with a battery

is that its the wrong one for the application.

To make doubly sure youre on track, youll need one oftwo things either the latest YUASA BatterySpecifications and Applications book, or the originalequipment (OE) microfiche. Of course, you can alwaysgo to the old battery youre replacing. The trick, though,is to make sure its the original. Otherwise, you may besimply repeating the same problem that caused the bat-tery to need replacing.

OK, lets say youre replacing the battery on an '81

Kawasaki a KZ1000-C Police, 1000cc.

Referring to the YUASA Battery Specifications andApplications book, you firs t look under the Kawasakilisting. Then find the right engine size 1000cc, whereyou find the KZ1000-C Police. Youre looking for an '81,so the place to be is '80 to '81. The chart on this pageshows what it looks like.

If this were a sensor-equipped battery which it isnt the applications book would mark it with a footnote ().That tells you to order it with a sensor.

Whats the right battery? Youll see there are three of them:a High Performance Maintenance Free YTX20HL-BS, aMaintenance Free VRLA YTX20L-BS, and a YuMicronYB16L-B battery. Any of these will do fine. If yourmachine has increased compression modifications to theengine, for example, you might want the additional

2SECTION

Selecting and Installing aNew Battery


13/44

About SensorsMany of todays motorcycles use batteries equippedwith sensors. They re either buil t in the battery, or

packed with it.

A sensor is a low fuel warning light. It tells you whenyoure gett ing low in this case, on electrolyte. Thesensor causes a warning light to flash, signaling thatits time to add water to the battery. The cutaway viewsbelow show what a sensor looks like.

Sensors are sort of particular: they dont go with justany battery. Which means its important to replace theold battery and sensor with the correct YUASA sensorbattery listed in the applications book. So, sensor rule

one is this: replace both battery and sensor at thesame time.

But the sensors original equipment, you say. Doesnmatter. Being OE doesnt mean it s OK in another manufacturers battery. In fact, OE sensor plugs vary considerably in length, size and diameter. A plug thats toolong can short out a battery and mess up the electricasystem. If the plugs short, the warning light will flashway too early.

Note, too, that even YUASAs sensor batteries are nointerchangeable; they have different vent locations, sensor wire lengths and diameter of cylinder connectors.

POINTS TO REMEMBER Replace battery and sensor at same time.

Original equipment sensor isnt OK for a new battery.

Sensor batteries and sensors are not interchangeable checkApplications Book.

COVER

MAX

MIN

ACID LEVEL

LEAD

CUT-AWAY VIEW OF SENSOR

LENGTH OF SENSOR

11

2SECTION



14/44

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 hasfallen, refill with acid to upper level.

4. A batter y must be comple tely charged beforeinstallation. Charge for three to five hours at the currentequivalent of 1/10 of its rated capacity found in theYuasa Applications Book.

5. During charging, batteries can spit electrolyte outthe open vent. Take care to loosely refit vent caps.

6. Check du r i nginitial charging to seeif electrolyte level hasfallen, and if so, fillwi th acid to theUPPER LEVEL. Afteradding, charge foranother hour at samerate as above to mixwater and acid. Note: this is the last time electrolyteshould be added, but distilled water should be addedas required.

7. When chargings done, replace plugsfirmly. Do not apply excessive pressure.Finger tighten only. Do not over-tighten.

8. Wash off spilled acid with water and baking sodasolution, paying particular attention that any acid iswashed off the terminals. Dry the battery case.

Battery Activation for Conventional and YuMicron TypesSealed at the factory, a new YUASA battery has anindefinite shelf life as long as it remains sealed, with

the red cap in place, and is stored at room tempera-ture. Once its unsealed, a battery should be activated,charged and installed. The plates of an unsealed,uncharged battery begin to oxidize. That makes itmore difficult to charge later. (We talk more aboutsulfation later in this book.) And if its charged and sitsaround, it starts to discharge and sulfate; how fastdepends on temperature.

Here are the steps for act ivat ing most bat teries,including YUASAs Conventional, YuMicron, YuMicronCX. (Sealed VRLA YT or YI batteries are activated

differently, see page 26.)

Activating Standard Batteries

1. Right before adding electrolyte, removefilling plugs. Also remove the sealing tube the redcap and throw it away. (Putting this cap back on afterthe batterys filled with acid can cause an explosion.)

2. Place bat tery on alevel surface. Fill batterywith elect rolyte (a sulfuricacid dilution with a specific

gravity of 1.265). Do notuse water or any other liquidto activate.

Electrolyte should be between 60F and 86F beforefilling. Fill to UPPER LEVEL as indicated on battery.

NOTE: Never activate a battery on the vehicle.Electrolyte spillage can cause damage.

YB2.5L-C 2.5 3 3/16 2 3/4 4 1/8

YB2.5L-C-1 2.5 3 3/16 2 3/4 4 1/8

YB3L-A 3 3 7/8 2 1/4 4 3/8

YB3L-B 3 3 7/8 2 1/4 4 3/8

YB4L-A 4 4 3/4 2 3/4 3 5/8

YB4L-B 4 4 3/4 2 3/4 3 5/8

YB5L-B 5 4 3/4 2 3/8 5 1/8

CAPACITY DIMENSIONS INCHESBATTERY AH ( 1/16 IN)

TYPE (10H-R)L W H

YUMICRON Battery Specifications

RatedCapacity

12

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15/44

As we mentioned earlier, an elect rochemical actionwithin the battery produces electr icity. To understand

it, lets look inside a battery again: youll see cellsmade up of lead plates. Some plates are positivecharged. Others are negative charged. Theres alsothe electrolyte a sulfuric acid solution that conductsthe current. It sets off the chemical process that takesplace in the battery.

So what goes on when a battery discharges?

The electrolyte reacts chemically with the lead plates and its not exactly a match made in heaven: it turnsthem into lead sulfate. If sulfate reminds you of sulfa-tion, youre 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 itsoxygen. The electrolyte turns to water. Now youknow why a discharged battery filled with waterinstead of electrolyte can turn into an ice block whenthe temperature drops even into the 20s. On the otherhand, a properly-charged battery wont freeze until themercury gets way down in the minus range.

The chemical process causes free electrons to slowly

gather on the negative plates. They just hang thereuntil a load is placed on the battery a light or startersswitched on which causes a swarm of electrons to rushto the positive plates.

I f the chemical process just went on and on,unchecked, the lead plates would soon turn totally tolead sulfate, the electrolyte would become pure water,

and the chemical and electrical activity inside the bat-tery would come to a standstill. Its bad for a battery

So is allowing a battery to remain discharged for aprolonged period. Recharging becomes hard oimpossible.

The good news: except in extreme cases, the process ofdischarging can be reversed. You work that magic byputting a larger voltage on the battery for example,14v on a 12v battery. Thats charging.

Heres what goes on when a battery charges:

The electrical charge flowing back in causes the leadsulfates to send their sulfate back into the electrolyte

As a result, both the electrolyte and the plates return totheir original composition.

Youll notice bubbles in an actively-charging batteryThats called gassing. It occurs because hydrogen andoxygen gases are liberated as the charging currenbreaks down the water.

Several things are actually happening here. Theprocess breaks down water into hydrogen and oxygenvapor, which escapes out the vent tube. You have toreplace that loss. Add distilled water to each cell afte

charging. Then give the battery a mixing charge foanother hour. The hydrogen and oxygen gases thaare given off can also build up pressure in the battery which is why batteries are vented, and why the ventubes cant be bent or blocked. Very importantlyhydrogen and oxygen are very explosive. It bearsrepeating that sparks, flames and cigarettes aroundcharging batteries can be a one-way ticket to trouble.

POINTS TO REMEMBER

Deep discharge or prolonged discharge leads to harmful sulfation.

A discharged battery freezes much faster than a charged battery.

Charging can reverse discharging.

Charging gives off hydrogen and oxygen, which are explosive.

The Discharge Charge Cycle

13

3SECTION

Inspecting, Testingand Charging


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14

Batteries have a natural tendency to discharge. Thereare a number of reasons why: self-discharge, high

temperatures, drain from electrical accessories on avehicle, and shor t trips that arent enough to rechargethe battery.

Self-Discharge: Self-discharge goes on all the time. Itsa battery fact of life that they get weaker from just sit-ting. How rapidly batteries self-discharge depends, firstof all, on battery type. Lead-calcium batteries, such asYUASAs CX, YT, YI, discharge more slowly than conven-tional batteries. At room temperature lead-calcium dis-charges one third slower than conventional lead-antimonybatteries.

Temperature: Outside temperature plays a big part,too. As the mercury goes up, batteries discharge faster.Particularly in hot climates, that can mean trouble: every18F doubles the discharge rate, so a battery at 95Fdischarges twice as fast as one at 77F. And temperatures

Keep in mind that at the same time accessories are draw-ing on the battery, the batterys self-discharging, too. Thecharts below show how fast a battery is discharged byself-discharge and by current drain:

Checking Current Drain

Reasons for Self-dischargeof 130F are battery-killing. Been in a closed-up garageor 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 todaysnewer and bigger bikes clocks and computer memory,for example will discharge the battery continuously, evenwhen the ignitions off. The drain can be considerable.You can find out the drain, in milli-amperes, by discon-necting the negative terminal and putting a multimeter in line.It should look like this:

Current Drain (Y50-N18L-A)Days From Days From

Discharging 100% Charged to 100% Charged toAmpere 50% Discharged 100% Discharged

7 mA 60 Days 119 Days10 mA 42 Days 83 Days15 mA 28 Days 56 Days20 mA 21 Days 42 Days30 mA 14 Days 28 Days

Self-discharge CharacteristicsRelation between Storage Period (months)

and Remaining Capacity (%)

100

90

80

70

60

50

400 1 2 3 4 5 6 7

Storage Period (month)

RemainingCapa

city(%)

104F(40C)

104F(40C)

77F(25C)

77F(25C)

32F

(0C)

32F(0C)

Sealed VRLA Standard

MotorcycleBattery

YuasaMultimeter

NegativeBattery

Cable

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17/44

Lets see what happens as the two work together todischarge a battery:

The battery, starting out 100% charged, has a 30mAdischarge rate from electrical accessories on themotorcycle.

At an average outdoor temperature of 77F a lead-antimony battery loses about half its capacity in only12 days due to the combination of self-discharge and

current drain. In another 12 days, its completelydead. In other words, it doesnt take long for the dou-ble whammy of self-discharge/accessory drain toknock out a battery for good.

If current drain is measurable when the motorcycle is

turned off, you can do one of two things: disconnectthe 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 wilshorten its life. Check the batterys condition witheither a hydrometer or voltmeter (or a multimeter). Thesection 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 fora short trip to work?

You cant assume that occasional use orshort trips (under 15 or 20 miles) will keepthe battery charged. In fact, theyre probably going

to add to drain, because the bikes charging systemdoesnt have enough time to make up for losses fromnormal starting and self-discharge. Youre going tohave to charge the battery more often. Maybe everymonth or so, depending on temperature.

Does the surface the vehicles parked on, or a batteryssitting on, contribute to how well it holds a charge?You sometimes hear experts say parking on concretewill accelerate discharge. Bet them its not so. Thencollect. Concrete, macadam, wood, dirt, stones, sand makes no difference. A battery discharges at thesame rate, no matter what surface its on.

And heres a hint: if a battery suddenly dies and theresno apparent reason for it, check the electrical systembefore you buy a new battery. One of lifes little let-downs is to shell out dollars for a new battery whenyou didnt need to and then still have the problem.

POINTS TO REMEMBER

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 130F kill batteries.

Self-discharge and short trips cause drain.

The more electrical accessories you add to a bike, the greater thecurrent drain.

15

Current Drain

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 (+)

Self-discharge

12 Days 200 Days to 100% Loss = 6.0% Available Capacity

Total Loss

Current Drain 43.0% Available Capacity

Self-discharge +6.0% Available Capacity

Loss in 12 Days 49.0% Available Capacity

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Ampere-Hour and Cold Cranking AmpsThere 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 bookits abbreviated as AH) is a batterys ability to delivercurrent for an extended period of time. Because lowtemperatures slow down the chemical reaction inside abattery, a battery will have a lower ampere-hour ratingin cold temperatures than in warm ones.

Most small engine batteries are rated at 10 hours. Thatsays they have to last at a given discharge rate thatlong. A 14 ampere-hour battery, for example,

discharges at a rate of 1.4 ampere-hours for10 hours. At this point, cell voltage has dropped to1.75v per cell (10.5v for a 12v battery, or 5.25v for a6v battery). Usually, the larger the plates, the greaterthe ampere-hour rating.

Inspecting a BatteryIts good policy to always inspect a battery before youtest it. Heres how:

1. Make sure the batterytop is clean and dry. Thatsnot just because of lookingpretty: a dirty battery actuallydischarges across the grime ontop of the case. Use a softbrush and any grease-cuttingsoap or baking soda solution.Make sure plugs are finger tight

so cleaning materials dont get into cells and neutralizethe acid.

2. Inspect battery terminals, screws, clampsand cables for problems: breakage, corrosion orloose connections. Clean the terminals and clamps with awire brush and coat terminals with no ox grease.

3. Inspect case for obvious damages such as cracksor for leaks; look for discoloration, warping or raisedtop, which may indicate that battery has overheated orbeen overcharged.

POINTS TO REMEMBER

Capacity or ampere-hour rating: a batterys ability to discharge current

over time. Cold cranking amps measure battery high rate performance in

cold weather.

16

Cold start rating the high rate or the cold crankingamps, abbreviated C.C.A. in the YUASA applications

book tells how well a battery can be expected tostand up to low temperatures. This rating depends onthe number of plates and their surface area. The rat-ings arrived at by discharging a cold (0F) battery at ahigh rate for example, 150 amperes while dis-charge is monitored with a voltmeter.

Generally, as displacement per cylinder increases, sodoes the cranking current but since starting systemsdiffer by model and manufacturer, the best advice is tocheck the application book for OE replacement. If aspecial application demands higher cranking power,

select an appropriate alternate unit from the YUASAbattery line. Once again, match battery features toneeds. Cold start rating is important in a snowmobile.A lawn tractor owner probably doesnt care... unlesshe plows snow, too.

3SECTION


.


19/44

4. Check electrolyte leveland add distilled water if

necessary. Dont add acid only water. Before any tests,charge the battery so the waterand electrolyte mix.

5. Check the vent tube. Make sure its not kinkedpinched or otherwise obstructed. On a motorcycle, i

should exit away from the drive chain and from belowthe swing arm. Small cuts in the tube near the batteryvent are OK; theyre an emergency escape for gas incase the tube becomes obstructed.

POINTS TO REMEMBER

Inspect before you test.

Dirt on top of case causes discharge. Look for obvious damage to battery and connectors.

Add water if electrolyte is low.

Make sure vent tube is clear.

Battery Testing DevicesHow much of a charge does a battery have? There aretwo easy and reliable ways to find out:1) a hydrometer, which comes in floating ball and

calibrated float types, or2) a voltmeter (or multimeter, which gives DC voltagereadings).

Which is best?

If youre choosing between two hydrometers,opt for the calibrated float type. It gives you anexact specific gravity reading (that is, the density of theelectrolyte compared to water); thats much more accuratethan floating balls. For readings on calibrated float andfloating ball hydrometers, see Methods of CheckingBattery Condition chart on the next page.

A voltmeter or multimeter can be used where a hydrometercant. Most sealed VRLA or low maintenance batterieshave to be tested with a voltmeter.

Battery testing requires a voltmeter that canmeasure DC voltage. Remember to always connecta voltmeter parallel to the circuit being tested, observingpolarity; otherwise, the pointer will travel in the wrongdirection. Its a good idea to periodically check avol tmeter against another one of known accuracy.

Hydrometer

YuasaMultimeter

17

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20/44

Battery Testing

Methods of Checking Battery Condition

State of Syringe Digital 5-BallCharge Hydrometer Voltmeter Hydrometer

100% Chargedw/Sulfate Stop 1.280 12.80v 5 Balls Floating

100% Charged 1.265 12.60v 4 Balls Floating75% Charged 1.210 12.40v 3 Balls Floating50% Charged 1.160 12.10v 2 Balls Floating25% Charged 1.120 11.90v 1 Balls Floating0% Charged less than 1.100 less than 11.80v 0 Balls Float ing

POINTS TO REMEMBER Use a voltmeter or hydrometer to test state of charge.

In extreme cold or heat, youll have to adjust hydrometer readings.

Battery can be tested with or without electrical load applied.

Unloaded testing is simplest.

Applying a load and reading voltage at battery is more accurate.

18

A batterys specific gravity changes with temperature.Ideally, readings should be taken at 77F. Is it reallygoing to matter if youre off a couple of degrees one wayor another? Probably not. If youre working somewhere

thats uncomfortably hot or cold, its time to use the oldconversion factors: add .001 to the specific gravity read-

ing for each 3F above 77F or subtract .001 from thespecific gravity reading for each 3F below 77F. Cellvoltage can be found by adding .84 to the specific gravity.

Note, too, that YUASAs Sulfate Stop, a chemical addi-tive that increases battery life by drastically reducing sul-fate buildup, changes the specific gravity readings; theyllbe higher than with ordinary batteries.

Test sealed VRLA types with a voltmeter ormultimeter. If the stabilized open circuit voltage isbelow 12.5v, the battery needs charging. For a stabilizedopen 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 testsfor motorcycle batteries. Youll need a voltmeter or multi-meter.

Low-load test: Basically, this means turning on thebikes lights and taking a voltage reading at the battery.Remember, hook positive (+) to positive (+), negative (-) tonegative (-). The battery in a 12v system should have atleast 11.5v DC with the lights on. A 6v system shouldhave at least 5.75v DC. If voltage drops below these lev-els, its time to charge.

High-rate discharge test: This is the best test of bat-tery condition under a starting load. Use a load testingdevice that has an adjustable load. Apply a load of threetimes the ampere-hour rating.

At 14 seconds into the test, check battery voltage: agood 12v battery will have at least 10.5v, and a good 6vbattery, at least 5.25v. If the readings low, charge.

There are two types of battery tests: unloaded andloaded. An unloaded test is made on a battery without

discharging current. Its simplest and most commonlyused. If you need a precise reading, loaded testing is theanswer. Its more accurate.

UNLOADED TESTING:Check charge condition usingeither a hydrometer or voltmeter. With a voltmeter,voltage readings appear instantly to show the state ofcharge. Remember to hook the positive lead to thebatterys positive terminal, and the negative lead to thenegative 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 to1.280 indicates a full charge. A reading of 1.230to 1.260 indicates the battery should be charged beforetesting. The chart below shows the charge level asmeasured by syringe float hydrometer, digital voltmeterand five-ball hydrometer.

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Chargers and ChargingTheres a simple rule of thumb about batteries, and ifyoure a dealer or a mechanic, you know that people

ignore it all the time: for a battery to operate the way itssupposed to, it has to be fully charged before its used...and kept fully charged throughout its life.

A charger basically brings a new battery, or a batterythat has been discharged, to full capacity. Plugged into awall socket, it sends direct current, flowing in the oppositedirection of the discharge, into the battery.

Charging actually reverses the destructive chemicalprocess that goes on as a battery discharges: the leadplates and electrolyte, which were being transformed intolead sulfate and water, are restored to their originalcomposition. If a battery has been damaged forexample, its badly sulfated, or the plates have beendamaged from overheating or freezing it may notaccept a charge.

TYPES OF CHARGERS:There are five basic types ofbattery chargers. With all of them, hook the positivecharger lead to the positive battery terminal, and thenegative to the negative. Some chargers on the marketdeliver a low charging voltage that cant fully charge thebattery; avoid them if youre buying a charger. A 12volt, 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, dont use a charge greater than 2 to 2.5 amps formaintenance purposes. A badly discharged battery withvery high internal resistance may never accept a chargefrom a standard charger. It would then require specialcharging 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 usuallyhave. It charges the battery at a fixed rate. Different

ampere-hour batteries have different charge rates. Formost motorcycle and other small engine start-ing batteries, charge them at 1/10 of therated ampere-hour values in the YuasaApplications Book, see example on page 12 for ratings.

Battery voltage increases with the amount ofcharge. Find charging time for a completely dischargedbattery by multiplying the ampere-hour rating by 1.3when charging with standard current. The chart on page21 shows the approximate time needed to fully chargelead-antimony batteries using a trickle or taper charger.

The chart on page 32 shows the approximate time neededto fully charge sealed VRLA batteries.

Test the battery during charging, and continue charg-ing until all cells are gassing. Use either a voltmete(or multimeter) or hydrometer. The specific gravity othe electrolyte in all cells in a fully-charged batteryshould come to at least 1.265 in a conventional battery and 1.280 in a YuMicron and sealed VRLA batterywith Sulfate Stop.

19

Specific Gravity Reading Using a Hydrometer

CX & CX &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

Electrolyte Temperature

80OF 40OFState

of

Charge

During charging, check the electrolyte level periodicallyand add water preferably distilled to keep thee lec t ro ly te leve l up to the l ine. I f the bat terybecomes hot to the touch, stop charging. Resume afteit has cooled.

Note that permanently sealed batteries YUASAssealed VRLA battery, for example generally can be tested only with a voltmeter or multimeter. These batteriesare fully charged when the voltage peaks and thenbegins to fall.

Unless using an automaticcharger, do not hook abattery to a trickle charg-er and leave it uncheckedfor longer than overnight.

After about eight hours maxi-mum, careful monitoring isrequired.

Caps need to be replaced fingertightened after chargings done.

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20

TAPER CHARGER: Similar to the trickle charger, theautomatic taper charger charges at a fixed voltage. As

the batterys voltage increases with the amount of charge,the current drops accordingly.

A drawback of both the automatic taper and trickle charg-ers is speed... they dont have it. As the chart on page 20shows, it can take days to bring a discharged battery upto 100%. Here, too, check batteries for overheating asthey charge.

CONSTANT CURRENT CHARGER:A professional-quality charger, the constant current makes chargingsimple. It maintains a constant supply of current to thebattery at all levels of charging. You select the charging

POINTS TO REMEMBER

Fully charge battery when new and keep it fully charged.

Test charging batteries as necessary for overheating, water and stateof charge.

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 BatteryThe most important thing to remember about charging a newbattery is do it!

A battery out of the box with only adding electrolyte isapproximately 80% charged. Our recommendation is to ini-tial charge, bringing the battery to 100% before use. This

completes the electrochemical process. However, a long ridewith a regulated charging system may also bring the bat-

terys capacity to a higher level.

Note: See Section 5 for charging sealed VRLAbatteries.

current. As the battery voltage increases with the amountof charge, this charger automatically increases the charging

voltage to maintain the current output.

CHARGER/MAINTAINER:This type of charger mon-itors the voltage constantly during charging and standbymodes. When battery voltage reaches a specified lowlevel, the charger/maintainer then delivers a full charge.Then when the battery gets to the specified voltage, itautomatically drops to a float charge.

HIGH RATE CHARGER:Not for use with small enginestarting batteries. They force a high current into the bat-tery, which can lead to overheating and plate damage.

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dont . We dont recommend i t , and here swhy: on ly the sur fac e ar ea of the bat te ry plat es

can be quick charged. A lower current chargesthe battery more uniformly. That means betteper formance. Also, excess ive charging ra tesincrease the chance of overheat ing, which canmean battery damage.

The rule of thumb is to charge a new battery for three to fivehours 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 qu ick charging? The quick answer is

Approximate Charge Times (Hours) Using a Trickle (0.25 Amp) Charger

75% 13 15 18 23 24 2550% 25 30 35 45 48 50

25% 38 45 53 68 71 75

0% 50 60 70 90 95 100

Approximate Charge Times (Hours) Using a 1 Amp Taper Charger

75% 6 7 8 10 10 11

50% 11 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 11 13 17 18 19

0% 13 15 18 23 24 25

State Battery Typesof 12N10 12N12 12N14 YB18 YB16 Y50

Charge

Charging Times

21

POINTS TO REMEMBER

A new battery after activation is approximately 80% charged.

Initial charging is always recommended. NEVER quick charge.

Charge a new battery at a rate equal to 1/10 of its rated capacity.

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24/4422

Batteries dont demand a lot of attention. But not givingyour ba tt er y the at tent ion it needs can le ave you

stranded... or poorer by the cost of a new battery.

How often should you maintain a battery? Aboutmonthly under usual conditions. However, rechargingis necessary when lights get dim, when the startersounds weak, or when the battery isnt used for morethan two weeks.

Important as it is, theres really not much to batterymaintenance. Basically, just follow the procedure out-lined in the section Inspecting a Battery.

That means:G Check electrolyte level.G Keep the top free of grime.G Check cables, clamps and case for obvious damage

or loose connections.G Clean terminals and connectors as necessary.G Make sure exhaust tube is free of kinks or clogs.G Replace caps, finger tighten only.

Then, test the battery with either a hydrometer or volt-meter. Keep it charged to 100%.

Monthly Maintenance for Conventional and YuMicron TypesFor extended storage, remove the battery from the vehicleand charge to 100%. Charge the battery every month if

stored at temperatures below 60F. Charge every twoweeks if stored in a warm area (above 60F). Make surebatteries are stored out of reach of children.

Sulfation and Freezing

Two of the biggest battery killers sulfation and freez-ing arent 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.

Lets back up just a minute: we said earlier that dis-charge turns the lead plates into lead sulfate. This leadsulfate is actually a crystal. If the discharge continuesuninterrupted, the sulfate crystals grow and blossominto sulfation and a problem. The section titledReasons 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 leadmaterial oxidizes and sulfates, and it doesnt take longbefore it wont hold a charge. (Low electrolyte levelscause another problem, too: acid in the electrolytebecomes more concentrated, causing material to cor-

rode and fall to the bottom. In sufficient quantity, it willshort out the battery.)

Keeping a battery charged, disconnecting thebattery cable during storage, and keepingelectrolyte levels up eliminate the problem.For added protection, YUASAs YuMicron, YuMicron CXand Sealed VRLA batteries are treated with a specialchemical formula called Sulfate Stop. This dramaticallyreduces sulfate crystal buildup on plates. The result: longerbattery life.

How good is Sulfate Stop?

We simulated a constant discharge condition on twobatteries with a 10-watt bulb.

Even after being totally drained for a week, the batterywith Sulfate Stop made a 90% recovery.

The untreated battery: useless.

Storage

If the vehicle is in storage or used infrequently,disconnect the battery cable. That eliminatesdrain from electrical equipment. Check battery every twoweeks and charge as necessary.

4SECTION

Maintenanceand Storage


25/44

POINTS TO REMEMBER

Monthly maintenance and testing are a must.

Most important: make sure battery is charged and fluid level is correct.

Disconnect cables or pull battery for storage. Keep fully charged to prevent sulfation and freezing.

Freezing: It shouldnt bother you unless a battery isinadequately charged. Looking one more time at the

discharge process, remember that electrolyte acid becomeswater as discharge occurs. Now, it takes Arctic temperaturesto freeze acid. But water... as we all know, freezing startsat 32F. A sign of this is mossing little red lines on theplates. Freezing can also crack the case and buckle theplates, which means the battery is permanently damaged.

A fully-charged battery can be stored at sub-freezing temperatures with no damage. As thechart at right shows, it takes -75F to freeze electrolyte ina charged battery. But at just a couple degrees belowfreezing at +27F a discharged batterys electrolyteturns to ice. Thats a difference of more than 100Fbetween the low temperatures a charged and dischargedbattery can stand.

Electrolyte Freezing Points

Specific Gravityof Electrolyte Freezing Point

1.265 -75F1.225 -35F1.200 -17F1.150 + 5F1.100 +18F1.050 +27F

23

At temperatures such as these, incidentally, the self-discharge rate of a battery is so low that a recharge

usually isnt needed for months. But to stay on the safeside, test.

4SECTION

Maintenanceand Storage


26/44

SEALED VRLA BATTERYCONSTRUCTION

New Generation Battery TechnologyVRLA batteries and what makes them special .

FeaturesThe sealed VRLA battery is the battery for vehicles thatmay be stored for long periods (riding mowers, personalwatercraft, or scooters or cycles during the off-season,for example), or where spills could be a problem(ATVs or personal watercraft). YUASAs sealed VRLAbatteries deliver:

G No topping Fill it just once, to activate. No needto check electrolyte level or add water ever again.

G Reduced self-discharge Grids manufacturedfrom a special lead-calcium alloy hold the charge

longer a real plus with storage or occasional use.G Easy, instant activation The one-push

electrolyte container makes filling a snap.

G Enhanced safety A safety valve vents gasesproduced by overcharging. In case of fire, the flamearrestor disk minimizes explosion risk.

24

Yuasas innovative sealed VRLA (Valve Regulated LeadAcid) batteries are a new generation made possible by

advanced gas recombinant technology. These includethe YT and YI ser ies bat teries. We refer to them assealed 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 asealed VRLA battery. Be sure to follow the instructionsin this section.

2. While Yuasa sealed VRLA batteries dramaticallyreduce the need for maintenance, they do need periodiccharging. Its important to remember this and to know

how to go about it.3. When considering upgrading to a sealed VRLAbattery that did not come OE in your vehicle, checkto make sure your charging system has aregulated output between 14.0 - 14.8v.

Lets take a closer look at Yuasas innovative sealed

5SECTION

Sealed VRLA

Batteries

HEAT SEALEDCASE TO COVERprotects against seepageand corrosion bondedunit gives extra strength.

THRU-PARTITIONCONSTRUCTIONprovides shorter current path with lessresistance than over the partition

construction you get more crankingpower when you need it!

SPECIALACTIVE MATERIALis compounded to withstandvibration, prolong battery lifeand dependability.

PATENTEDSEALED POSTprevents acidseepage, reducescorrosion extendsbattery life.

POLYPROPYLENECOVER AND CONTAINERassures reserve electrolyte capacity forcooler operating temperatures; givesgreater resistance to gas and oil andimpact in extreme conditions!

SPECIAL SEPARATORmakes the battery spill-proof.Valve regulated design eliminateswater loss and the need to refillwith acid.

SAFETY VALVE/FLAME ARRESTORrelieves excess pressure.

SPECIAL GRIDDESIGNwithstands severe vibration,assures maximum conductivity.


27/44

POINTS TO REMEMBER

Gas Recombinant technology produces a more compact battery.

After activation, no need to check electrolyte or add water.

Sealing strip is permanently inserted its never removed.

Gas is recombined in the battery; theres no vented gas and vent tube.

25

The basic discharge-charge cycle is still going on thatswhat makes any battery tick. But to understand whats

different, lets do a little review:

A battery is basically a box containing lead plates. Someplates have a positive (+) charge, some negative (-)Theyre immersed in a current-conducting electrolyte solu-tion that sets off the electrochemical process that produceselectricity. Think of a battery as a machine that produceselectricity through a continuous process of charging anddischarging.

During discharge, sulfuric acid electrolyte solution reactswith the lead plates, turning them into lead sulfate. Theelectrolyte sulfuric acid solution made up of hydrogensulfur and oxygen gives up its sulfur and some of itsoxygen and turns to water.

PbO2 + Pb + 2 H2 SO4 2 PbSO4 + 2 H2 O

The process reverses with charging. Electrolytes andplates return to their original composition. The chargingcurrent breaks down water into its component gaseshydrogen (from the negatively charged plate) and oxygen (from the positive plate). Gases escape out the ventube. With a conventional battery, water is added toreplace that loss.

Heres the real secret of a sealed VRLA battery: the nega-tive plate never becomes fully charged so, no hydrogengas. The positive plate still makes oxygen, but instead obeing forced out the vent tube, it reacts with the chargedactive material to become water again. Thats gasrecombinant technology. Thats the magic of YUASAsnon-spillable, sealed VRLA battery.

G Compact design High efficiency in a smallpackage, with no vulnerable exhaust tubes or other

protrusions to break or kink.

How a Sealed VRLA BatteryDiffers from Conventional Types

Some of a sealed VRLA batterys differences are obvious.Its noticeably more compact. The reason: no free elec-trolyte, making it more volume efficient a fancy wayof saying it can be smaller. Since the battery is filled withelectrolyte just once (at activation), then sealed, you wontfind a row of filling plugs. Instead, a single sealing plugstrip permanently covers filler ports. Also, there are novent tubes after all, these batteries are sealed!

But as with any magic, theres more than meets the eye.The heart of a sealed VRLA battery is what you dont see.

1. The plates are comprised of special lead-calciumalloy grids and charged active material. Lead-calciumreduces self-discharge the battery holds its chargelonger. The construction of the sealed VRLA batterycauses freed gas to recombine inside the battery insteadof 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 makethe battery non-spillable.

3. Sealed VRLA batteries have an internal safety valve.If battery pressure soars due to accidental overcharging, itopens to release excess gas, preventing a battery rupture.

The unique design affects what happens inside the battery.

5SECTION

Sealed VRLABatteries


28/4426

G Use only the electrolyte container that comes

with the battery. Sealed VRLA battery electrolyteis a higher concentration of sulfuric acid. All sealedVRLA battery electrolyte containers arent the same.Each contains the proper amount of electrolyte for itsspecific battery.

GAlways wear plastic gloves and protectiveeyewear. No Smoking, see page 9 for full safetyinstructions.Of course, dont forget safety precautionswhen storing or handling electrolyte solution.

Activating sealed VRLA batteries is easy, although a littledifferent from conventional activation. For problem-free

start-up and operation, follow the procedure outlinedhere. A few things to keep in mind before you get rolling:

G Store the battery in a cool, dry place out ofdirect sunlight.

G Do not remove the foil sheet covering thefiller port until activation.

GAfter removing the electrolyte container capstrip, do not peel, pierce or otherwise openthe sealed electrolyte receptacles. Dont

separate the individual cells.

G Read electrolyte handling instruction andprecautions on the label.

Activation and Installation

Save

thisstrip

To Activate a Sealed VRLABattery

1. Place the battery on a level surface. Battery must beout of the vehicle.

2. Remove electrolyte container from vinyl bag. Removethe strip of caps. Put the strip aside youll usethis later as the battery sealing plug. Use onlythe dedicated container that comes with the battery. It con-tains the proper amount of electrolyte for your specificmodel important to service life and operation. Do notpierce or otherwise open the sealed cells of the electrolytecontainer. 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. Youll see air bubbles as theports fill. Do not tilt the electrolyte container.

Warning: Improper activation or excessiveoverchargering (possibly by equipmentfailure) could cause damage to the batteryor vehicle by forcing acid out of thesafety vent.

See next page.

5SECTION



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27

Never pry off sealing caps: its danger-ous and damaging.

Remember: unlike a conventionalbattery, the sealed VRLA battery wont

be topped off during its life.

4. Check the electrolyte flow.Keep the container inplace for 20 minutes or

longer until it emptiescompletely. If no air bubblesare coming up from the fillerports, or if container cellshavent emptied completely,tap the container a few times. Dont remove the contain-er from the battery until its empty. The battery requires allthe electrolyte from the container for proper operation.Make sure the electrolyte container empties completely.

5. Remove the electrolyte container. For batteries withratings of less than 18Ah, let the battery stand for 20 - 60minutes. For batteries great than 18Ah, and/or having the

High Performance rating (designated by an H inthe part number/name), allow the battery to stand for1- 2 hours. This will allow the electrolyte to permeate intothe plates for optimum performance. Yuasa sealed VRLAbatteries have the amp hours (Ah) printed on the front ofthe battery.

6. Newly activated sealed VRLA batteriesrequire an initial charge. After adding electrolytea new battery is approximately 75-80% charged. Fully inser

cap strip over the filling holes as shown in drawing aboveImmediately charge your battery after the stand period, tobring it to a full state of charge. See Charging aNewly Activated Sealed VRLA Battery onpage 31.

The battery is sealed. There is no need to remove the stripof caps or add electrolyte for the life of the battery.

7. If the battery is only filled with electrolyte, but nobeing given a supplementary charge, the open circuivoltage will be approximately 12.7 to 12.8v, as shownin the graph below. The reasons for the voltage being

low are that: The capacity reached by filling with electrolyte i

approximately 75-80% of the fully charged capacity.

The electrolyte around the plates gets its concentrationlowered temporarily.

5SECTION


Fully insert capstrip over filling holes

by hand. Do notpound or hammer.


30/44

How healthy is your sealed VRLA battery? Since a sealed

VRLA battery is sealed and the sealing caps are never

removed you wont be able to check the state of thecharge 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:

G 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. If less, it needs an

additional charge.

G The graph top right shows open circuit characteristics

of the sealed VRLA battery after end of charging

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 circuitvoltage 1 hour after end of charge.

G For a battery that has been in use, refer to the graph

bottom right to determine state of charge from

open circuit voltage.

Measuring Voltage

Relation between State of Chargeand Open Circuit Voltage

14

13

12

11

10

100 75 50 25 0State of Charge (%)

OpenCircuitVoltage(v)

Ambient Temperature32-104F (0~40C)

28

Open Circuit Voltage Characteristicsafter End of Charge

181716151413121110

0 10 20 35 40 50 60Elapsed Time (minutes)

TerminalVoltage(v)

Ambient Temperature77F (25C)Charge Open Circuit

POINTS TO REMEMBER

Use a voltmeter to determine state of charge. Because sealing caps arenever removed, you cant test specific gravity.

Dont use a quick charge for initial activation.

A battery that has just been activated or charged needs to stabilize1 hour for an accurate voltage reading.

5SECTION



31/44

(10 hour rate dischargecharacteristics)

TerminalVoltage(v)

2C

1C

0.6C0.4C

0.2C 0.1C

29

Think about what types of vehicles a sealed VRLA batterygoes into: most arent like the family car, driven day-in,

day-out. Theyre probably used once in a while, ormaybe even stored for weeks or months at a time.

That demands a special kind of battery one withextra power to reliably start that engine, every time. InYUASAs sealed VRLA batteries, the plate groups are spe-cially designed to deliver that. The graph to the rightshows the increase in discharge time of a sealed VRLAbattery compared to a conventional Yumicron batteryat both cold and room temperatures. The graph belowshows the cold temperature performance of the sealed

VRLA battery as the load increases. C equals theAmp Hour Capacity Rating of the battery.

Discharge Characteristics

Starting the engine is a big part of the batterys job, butnot all. Electrical accessories and safety systems lightsand horn need a stable supply of electricity. Nowyoure concerned with the batterys low rate dischargecharacteristics. This steady, low rate discharge is

measured in 10-hour rate discharge. The graphabove shows the discharge characteristics of YUASAsYT or YI sealed VRLA batteries at different current ratesNote that battery capacity is a function of the currenbeing used (or discharge current) x time.

13

12

10

8

6

0 1 2 3 4 5 6 7 8 9 10 11Discharge Duration (hour)

Discharge Characteristics of aSealed VRLA Battery by Capacity

(C = 10 hour rate capacity)

TerminalVoltage(v)

Sealed VRLAConventional

0 1 2 3 4Discharge Duration (minute)

12

10

8

6

High Rate Discharge Characteristics of a

Sealed VRLA 4 AH Battery20A Discharge Characteristics

77F (25C)14F (-10C)

5SECTION



32/4430

Lead-calcium technology definitely slows self-discharge,but a combination of heat and idleness will still drain a

sealed VRLA battery, like the conventional one. Youll findstep-by-step charging instructions later in this section.

Constant self-discharge is a fact of life for all batteries.They lose strength as they sit there doing nothing. The

good news is that lead-calcium technology in a sealedVRLA battery slows down the self-discharge processsubstantially. Conventional lead-antimony batteriesdischarge at about 1/100 volt a day the lead-calci-um sealed VRLA battery, 1/300 volt per day. Lookingat it another way, a conventional battery fully chargedand stored for a month will lose roughly a third of itscharge; the sealed VRLA battery handled the sameway 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 down on it isnt doing any favors to the battery inyour vehicle. Excessive heat will prematurely shorten thelife of the battery.

Some people figure sealed VRLA batteries are sogood, theres no need to worry about routine charges.Flattering, but wrong. Forgetting routine chargingcan mean a one-way ticket to the battery graveyard.

Self-discharge

Self-discharge CharacteristicsRelation between Storage Period (months)

and Remaining Capacity (%)

100

90

80

70

60

50

400 1 2 3 4 5 6 7

Storage Period (month)

RemainingC

apacity(%)

104F(40C)

104F(40C)

77F(25C)

77F(25C)

32F

(0C)

32F(0C)

Sealed VRLA Standard

Match your sealed VRLA battery to the right charger. The wrongone can cause permanent damage and poor performance.

Yuasa offers a complete line of chargers to activate andmaintain your battery to factory specifications.

G Do not use a larger than recommended amp charger toreduce charging time. That permanently damages thebattery and voids the warranty.

G To find recommended current output in amps,divide battery amp hour capacity rating by 10.Example: 14 AH 10 = 1.4 amp current.

Choosing a Charger

POINTS TO REMEMBER High rate discharge sealed VRLA batteries deliver extra starting power.

Lead-calcium technology substantially slows self-discharge.

Routine charging is required to maintain a full charge.

Yuasa 1.5 AmpAutomatic Charger

Yuasa 900 mAAutomatic Charger

Yuasa sealed VRLA batteries have the amp hours printedright on the front of the battery. If youre not sure, refer toapplication manuals at the dealer. Select the charger thatcomes closest to the value of that figure.

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33/44

31

CHARGING INSTRUCTIONS FOR NEWLY ACTIVATED

SEALED VRLA BATTERIES

Charging a Newly Activated Sealed VRLA Battery

5SECTION


Sealed VRLA batteries require an initial charge. If you areusing a constant current charger, refer to the standard (STD.)

charging method printed on the battery. If you are using an

automatic type taper charger, check to make sure that thecharger current (amps) is equal to or greater than the stan

dard (STD.) charging method listed on the battery.

Yuasa Automatic Chargers and Accessories are the safest and most convenientmethod for error proof charging and battery maintenance.

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 shouldbe 12.8v or higher after the battery is charged and sits for at least 1 - 2 hours.

If less, it needs an additional charge.

YTX20L-BSCHARGINGMETHOD

THIS IS A SEALED BATTERY; THE SEALING CAPS SHOULD BE CONSIDERED PERMANENT.

DO NOT REMOVE THE CAPS TO ADD WATER OR TO CHARGE THE BATTERY; CHARGE AT12V AT THE AMPERAGE AND HOURS STATED BELOW.

STD.: 1.8A X5~10h or QUICK:9.0A X1.0hCHARGING METHOD: 1.8 Amps x 5-10 hrs

CHARGINGME

THOD:1.8Amps

x5-10hrs

OR


34/44

The single most important thing to maintaining a sealedVR LA ba tt er y is dont let it sit discharged:

keep it fully charged. A sealed VRLA motorcyclebattery should be kept to near fully charged for peakper formance. In fact, it can need charging more oftenthan a car battery because its probably not used routinelyand, therefore, not automatically charged.

Use the following guidelines for boost charge. Alwaysverify battery condition before charging, and 30 minutesafter charging.

GA fully charged battery should read 12.8v or higher after

battery has been off the charger 1 - 2 hours.

Routine ChargingOVERCHARGING CAN HARM YOUR BATTERY BEYOND

RECOVERY.

A word on overcharging: dont. Because of the charac-teristics of a sealed VRLA battery, too much of a boostcharge will decrease the volume of electrolyte. Thelonger the overcharge time, the greater the drop in elec-trolyte and starting power.

Water cant be added to the sealed VRLA battery to make upthe difference. Overcharging can warp plates, makingfuture charging difficult or impossible. Watch charging timescarefully, or ideally, use a Yuasa Automatic Charger. Alwaysstop charging if the battery becomes really warm to the

touch. Let it cool down 6 - 12 hours and resume charging.

32

Caution:Always wear safety glasses and charge in a ventilated area. If battery gets really warm to the touch, discontinuecharging and allow battery to cool down. No sparks, flames or smoking when charging.

State Charge Time*of Voltage Action (Using a constant

Charge current charger@ std. amps specified

on the battery)

100% 12.8v - 13.0v NoneCheck at 3 months None Required

from date ofmanufacture

75% -100% 12.5v - 12.8v May need slight charge, if no 3 - 6 hourscharge given,

check in 3 months

50% - 75% 12.0v - 12.5v Needs charge 5 - 11 hours

25% - 50% 11.5v - 12.0v Needs charge At least 13 hoursverify stateof charge

0% - 25% 11.5v or less Needs charge 20 hours(see special instructions

on page 33)

* Charging times can vary depending on type of charger. Follow the chargers instructions.

0%

25%

50%

75%

100%

11.5 V 11.9 V 12.3 V 12.7 V 13 V

VOLTAGE

%o

fCHARGE

*Approximate

charge time

3-6 hours

5-11 hours

13-20 hours

*Approximate charge time using a constant current charger atstandard amps specified on the battery. Charging times mayvary depending on type of charger.

5SECTION


A word on overcharging: dont. Because of the charac-teristics of a sealed VRLA battery, too much of a boost

charge will decrease the volume of electrolyte. Thelonger the overcharge time, the greater the drop in elec-trolyte and starting power.

Overcharging can harm your battery beyond recovery.

Water cant be added to the sealed VRLA battery tomake up

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