The 10 Steps for replacing the battery, the
easy and quick way.
You need a nr.10 open-end wrench (closed wrench from PC toolkist will also do), a 5mm hex
wrench and a screwdriver (depending on battery connectors, PC toolkit screwdrivers are
fine).
- Remove the right air-duct.
- Remove the screw now uncovered, then remove the right top side panel. Removing the
saddle is not needed for this.
- Remove the step holder cover.
- Remove the saddlebag protector (= rear crash bar cover).
- Remove the bolt holding the lower side panel, just forward of the rear footpeg (with the
hex wrench). Remove the screw holding the forward part of the lower trunk side panel, just
right of the rear crash bar.
- Open the trunk and remove the most forward screw located on the inside of the trunk,
against the right side. It is covered by a little black cap (or should be). Removing this
screw should give the lower trunk side panel enough free play to unhook the retaining
hook, holding the lower trunk side panel and lower right side panel together. If you feel
you need more free play, remove more of these screws in the trunk.
- With the rear footpeg extended you should now be able to slide the aft side of the lower
right side panel downward and toward you over the aft footpeg. The fit is tight, but with
a little jiggling you should be able to clear the footpeg. At the same time you will see
the lower trunk side cover extending / bending outward because of the retaining hook. With
the screw from step 6 removed, the play should be plenty to bend it outward enough to
unhook it from the side panel. In the manual unhooking these panels looks easy, but I
couldn't do it without removing this little screw. Otherwise cracking was inevitable.
- Remove the bolt which holds the bracket which holds the battery ( with a nr. 10 wrench
in my case) and remove the bracket.
- Lift the battery out of it's tray, slide it forward, turn it towards you and slide it
out, after removing the cables. You can remove (part of) the cables with the battery in
it's tray, but you should be able to remove both the cables when you have the battery half
out of it's tray.
- Step 1 thru 9 took me 5 minutes (first time). Installing the battery is the other way
around and took me 10 minutes. I think I lost most time trying to reconnect the cables to
the battery, while the battery
was half in it's tray. Be aware of the (2) little square nuts inside the (2) battery cable
connectors. Don't let them slip away into the PC's undiscovered, dark, plastic caves.
Lifting the battery into / out of the tray can also be difficult because of the weight of
the battery combined with the fact that it's hard to get a grip on it when half inside the
PC. Don't forget to test the new battery (and it's connections) before closing up the
tupperware.
Good Luck !
Emile
http://fly.to/emile
http://go.to/pc800