| Technical Service
Bulletin
NUMBER 030825
Installing ODYSSEY PC 545MJ in Buell S1 Lightning
The Buell model S1 Lightning 1996 – 1999 was supplied
OEM with a battery under the trade name of Genesis with a
Genesis part number of G12V12Ah10EP. This battery with the
terminals located together on the narrow side of the battery
is no longer manufactured. There is a replacement, but installation
requires some minor attention.
The replacement battery is under the trade name of ODYSSEY
Drycell Batteries, model PC 545MJ. The PC 545MJ is a considerable
up grade over the Genesis battery.
| Comparison
|
G12V12Ah10EP |
PC
545MJ |
| Service
Life |
2-4
years |
6-10
years |
| 5
second cranking amps |
430
amps |
545
amps |
| CCA |
146
amps |
185
amps |
| Terminals |
M4
female |
M6
female |
| Terminal
Location |
Narrow
side |
Long
side |
| Vibration
Rating |
Commercial |
Military |
Installation Awareness –
There are two issues that must be addressed to install the
PC 545MJ battery.
1. The PC 545MJ has a slightly different top cover edge
design that interferes with the lower lip of the bikes battery
tray.
2. The terminals on the PC 545MJ are on the long side.
Installation Procedure –
1. Shim material approximately ¼ inch thick must
be cut to fill in the lower battery tray equal in height to
the lip at the end of the lower tray.
2. Install the negative battery cable onto the battery, torque
to 50 inch-pounds
3. Slide the battery with the negative terminal up towards
the bottom of the seat and into the battery tray.
4. Install the battery clamp bracket and tighten for a secure
fit.
5. Install the positive battery cable to the battery positive
terminal, torque to 50 inch-pounds.
6. Check that the battery is secure and tight in the battery
tray.
7. Installation is complete.
Technical questions should be directed to Bruce Essig at:
Tel: (660) 429-7506
Fax: (660) 429-1758
E-mail: bruce.essig@enersys.com
Sealed Rechargeable
DrycellTM - Deep Cycle Batteries |
