Installation and removal of the battery
Removal of the batteries
- Raise the backrest and pull it forward, but don't remove
it from the roll bar completely.
- Disconnect the batteries as
described in another section already.
- Remove the interconnection cables between the batteries.
For the loosening of the screws a box end spanner SW 13
is suitable. With 100Ah batteries the terminal clamps
have so little clearance at the front and top of the
battery compartment that they can't be removed at all. In
this case, just remove the interconnection cables from
one pole of each battery.
- Remove the hoses of the gas diverting system. (Generally
absent on US vehicles - RRY)
- Loosen the wing nuts of the battery mountings. The
threaded rods of the battery supports are now removed
Here in the
picture, the battery support hung up into the battery basket. The
" wings " of the plastic wing nut break easily.
With older vehicles there are also still these bars, which are
likewise embodied in the battery basket.
- First remove the middle battery, only if this is gone can
one the two other batteries remove.
This is best done with two people, each pushes with a
hand on the roll bar and pulls with the other hand the
battery at the handle.
If one is alone, relieve your back by standing behind the
vehicle, and bracing your forehead on the roll bar - it
sounds perhaps strange, it is however practical - the
battery can one carefully set on the motor or the trunk
edge around before standing up and lifting it completely
from the vehicle.
When reconnecting the batteries, one must first discharge the
capacitors of the motor control and on-board electronics,
At this battery one must remove first the covers of the
degassing system and fold the handles upward. (This does not
apply to most US vehicles - RRY)
- The next battery is the left one. The removal goes here
also again quite well, if one uses the roll bar for the
support of the back. One places oneself left beside the
vehicle (facing the rear -RRY) and reaches with the left
hand to the left of the roll bar, with the right hand on
the right of it. Put your gut right up against the roll
bar to brace yourself.
- In the case of the right battery one proceeds similarly.
Here runs however the wiring harness, which one should
press first something beside the battery. With the
removal, and still more with the installation, one must
watch out here, so that one does not hurt these.
Installation of the batteries
The installation of the batteries runs always similar to the
removal. In the case of the right battery one must pay attention
much to the wiring harness. Sometimes it helps to fix the wiring
harness with vertical strips luggage tape so that the battery by-slips
to it. With the newer vehicles one has mostly no problem with the
- The battery supports only after using the batteries
- The battery hold down must lock into the battery basket
as shown here without the batteries. One removes the wing
nut and the large wearing part and locks the rod manually
to the battery basket. Wiggle the rod between the
batteries so it's perpendicular and reinstall the wearing
part and the wing nut. Possibly one must hold the
threaded rod in addition with a vise-grip. The art is not
dropping the rod.
- Put the interconnection cables so that the terminal
clamps are aligned with the pole surface. If the terminal
clamp does not want to draw down, open the screw at the
clamp as far as possible, and pry the clamp open.
Pounding on the clamps with a rubber hammer is not the
true method, since the battery is mechanically strongly
stressed by this abuse.
- It is important in the case of older batteries to clean
and grease the pole.
One can put the handles of the Yuasa
batteries then between the batteries, so that you are somewhat
cleared up - not as here -
- Gas removal system again attach
- Make sure with new Yuasa batteries that the lateral plugs
are distant for gas deriving system for locking, where
hoses are attached.
- Follow the separate instructions to reconnect the
- With installation of the 100Ah batteries into older
vehicles (before Serial number 2000) it can work rather
closely. The opening of the battery room was cut in
former times somewhat smaller, so that one must extend
this if necessary something (approx. 3-5mm).
- If the batteries are removed one should its battery
basket carefully examine. El does not have many metal
parts, but the battery basket is very rust susceptible,
in particular if the acid has spilled. Here is the usual
program: rust remover applies - rust-converting primers -
priming - if necessary liquid plastic around the basket
again to encase. Carefully examine the sheet metal around
the motor mounting plate for cracks. With older vehicles
this place was not strengthened.
NEVER OPERATE THE BATTERY CHARGER WITHOUT
letzte Änderung 12.09.99