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Periodic Maintenance Battery
This section has been organized into sub-sections After being in service, batteries require regular
which show common maintenance procedures for the cleaning and recharging in order to deliver peak
KYMCO ATV. performance and maximum service life. The following
procedure is recommended for cleaning and
NOTE: KYMCO recommends the use of new maintaining lead-acid batteries. Always read and follow
gaskets, lock nuts, and seals and lubricating all instructions provided with battery chargers and battery
internal components when servicing the products.
engine/transmission. WARNING
NOTE: Some photographs and illustrations used Anytime service is performed on a battery, the fol-
in this section are used for clarity purposes only lowing must be observed: keep sparks, open flame,
and are not designed to depict actual cigarettes, or any other flame away. Always wear
conditions. safety glasses. Protect skin and clothing when
NOTE: Critical torque specifications are located
in Section 1.
handing a battery. When servicing battery in
enclosed space, keep the area well-ventilated. Make
2
sure battery venting is not obstructed.
SPECIAL TOOLS 1. Remove the battery hold-down; then disconnect the
battery cables (negative cable first).
A number of special tools must be available to the 2. Disconnect the vent hose.
technician when performing service procedures in this 3. Remove the battery from the battery compartment;
section. then thoroughly wash the battery and battery com-
partment with soap and water.
Description p/n NOTE: If battery posts, cable ends, or the
battery case has a build-up of white/green
Compression Tester Kit powder residue, apply water and baking soda
Oil Filter Wrench E052
to neutralize acid; then flush off with warm
soapy water.
Tachometer 4. Using a wire brush, clean the battery posts and cable
ends removing all corrosive buildup. Replace
Timing Light damaged cables or cable ends.
Valve Clearance Adjuster E012 5. Add clean distilled water to bring fluid level to the
UPPER level line.
NOTE: Special tools are available from the
KYMCO Spare Parts Department. WARNING
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.
Lubrication Points
CAUTION
Never use electrolyte (sulfuric acid) to "top off" the
It is advisable to lubricate certain components period- battery. Use only distilled water or severe battery
ically to ensure free movement. Apply light oil to the damage may occur.
components using the following list as reference.
6. Using a multimeter, test the battery voltage. The
A. Throttle Lever Pivot/Cable Ends meter must read 12.5 or more DC Volts for a fully
charged battery.
B. Brake Lever Pivot/Cable Ends
NOTE: At this point, if the meter reads as speci-
C. Auxiliary Brake Cable Ends fied, the battery may be returned to service (see
step 10).
D. Shift Lever Cable End
7. If the meter reads less than specified voltage, charge
the battery using the following guidelines.
2-3