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Technical Information

 

Techincal Alerts

 

Sea-Doo® Personal Watercraft Installations

Sea-Doo® personal watercrafts tend to transfer an electrical load to the battery while in storage. Be confident that your ODYSSEY® battery can handle it. However, if not properly maintained, you may not get the top performance from your ODYSSEY battery. Read on to ensure your ODYSSEY battery is at its best at all times.

Issue – This brand of watercraft experiences an electrical load on the battery during storage, caused by a control module monitoring the lanyard socket. If the lanyard is left installed the electrical drain is 18 ma after 10 minutes of shutting down the engine. If the lanyard is removed, the electrical drain is 7 ma. These electrical loads are continuous and can accumulate to be significant over time. At 18 milli amps, the battery will lose 1 amp/hour of capacity in 55.5 hours or 10 amp/hours (Ah) in 23 days. On a PC 625, 10 Ah is 59% of battery capacity. Issue – This brand of watercraft experiences an electrical load on the battery during storage, caused by a control module monitoring the lanyard socket. If the lanyard is left installed the electrical drain is 18 ma after 10 minutes of shutting down the engine. If the lanyard is removed, the electrical drain is 7 ma. These electrical loads are continuous and can accumulate to be significant over time. At 18 milli amps, the battery will lose 1 amp/hour of capacity in 55.5 hours or 10 amp/hours (Ah) in 23 days. On a PC 625, 10 Ah is 59% of battery capacity.

Solution – For Sea-Doo watercraft always disconnect the lanyard from its socket when not riding the watercraft. Install a waterproof disconnect switch in the negative battery cable, so the battery can be disconnected after riding. Use switch P/N 32965 from Overton’s Marine Catalog or use the 12V, 6A Ultimizer charger suggested above.

Check your ODYSSEY battery voltage periodically for full charge, which is 12.84V. Recharge whenever below 12.65V.

Sea-Doo is a registered trademark of Bombardier Recreational Products Inc.

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ODYSSEY Short Service Life in Custom V-Twin Motorcycles

Issue – This notice provides helpful information to the designer, manufacturer, assembler, dealer and bike owner that may have experienced a short service life with the ODYSSEY® Drycell Battery model PC 545MJ installed in Custom V-Twin motorcycles.

The increasing popularity of the custom V-twin motorcycle with its big inch engine and high power starting requirement has introduced a new operational issue. New ODYSSEY batteries and other brands initially provide good starting power, but in a short time of use have no or poor starting power and appear to have prematurely failed.

Factory analysis of warranty returned batteries indicate these batteries have not failed and do not have factory defects. Batteries with this type of performance are at low charge levels only!

Cause - The custom bike requires 2 ½ times the starting power of stock HD engines, but have the same size battery and same 32 amp charging system. The custom bike is generally a short mileage in-town rider, with insufficient driving mileage to recharge the battery. V-twin charging systems only develop enough power to run the motorcycle until engine rpm is above 2,000, when excess power is diverted to charge the battery. Full charged ODYSSEY battery voltage is 12.85 volts. ODYSSEY Batteries with less than 12.40 volts cannot reliably start big inch engines.

Solution – ODYSSEY Batteries are a military grade design and mechanically indestructible. Military design prevents shorted cells and vibration damage. They provide deep-cycle reserve and high starting power. Use a 12V, 6A (OMAX-6A-1B) or 12V, 12A (OMAX-12A-1B) Ultimizer charger with dealer or owner installed quick disconnect harness to maintain ODYSSEY at full charge for maximum performance and life. Always connect the charger to battery first, then plug into the AC wall socket. Always unplug from the AC wall socket before disconnecting from battery. Charger will not over-charge as it switchs to storage charge after recharging. Consistent use of the Ultimizer charger will assure trouble free starting power, with 4-8 years of ODYSSEY service life.

Help - For ODYSSEY technical support call Bruce Essig at 660-429-7506.

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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. This battery is available through motorcycle dealers who distribute parts supplied from Custom Chrome, Chrome Specialties, Drag Specialties, Parts and Battery Plus Stores. 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
Send an email: bruce.essig@enersys.com

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