2022-03-16
TT453: BATTERY BEST PRACTICE INFORMATION

APPLIES TO
Harley-Davidson’s AGM and Li-Ion 12 Volt Batteries

SYMPTOMS
Battery Maintenance
Battery Testing Equipment
Battery Charging Equipment

Reason for Revision
Refer to Table 1.
Table 1. Document History
DATE
202203-16

REVISION DESCRIPTION
Link for M1391A was M1391
*

202006-16

2 Ampere-hour (Ah) Li-Ion Battery
*

202003-31

202002-18

201808-15

Fixed link GRX-3110HD Battery Diagnostic Station

Added LITHIUM-ION (LI-ION) 12 VOLT BATTERY (2 Ah )

Updating references
*

Updated TESTING EQUIPMENT - AGM : GRX-3110HD Battery Diagnostic Station , BEST PRACTICES THAT YIELD
RESULTS - AGM : Battery Best Practices , CUSTOMER PERSONAL STORAGE - LI-ION , BEST PRACTICES THAT
YIELD RESULTS - LI-ION , FITMENT KITS - LI-ION

*

Added VEHICLE CHARGING SYSTEM - LI-ION , FITMENT KITS - LI-ION : Table 12 , WARRANTY - LI-ION

Bulletin restructure to cover Lithium-Ion (Li-ion) battery information
*

Updated complete bulletin

*

Added TECHNICAL TIP GUIDE , ABSORBED GLASS MAT (AGM) BATTERIES , LITHIUM-ION (LI-ION) 12 VOLT
BATTERIES (4 Ah AND ABOVE )

Added BEST PRACTICES THAT YIELD RESULTS - AGM : Battery Best Practices & Battery Testing Best Practices ,
STORAGE - AGM & Table 9 , Figure 1
Update CHARGING EQUIPMENT - AGM : Table 7 , STORAGE - AGM : Battery Date Codes

201712-01

Updated TESTING EQUIPMENT - AGM : GRX-3110HD Battery Diagnostic Station , BATTERY MAINTENANCE - AGM :
Overcharging & Other Chargers & Undercharging , DEALERSHIP BATTERY MAINTENANCE - AGM : Vehicles
Demonstrating BOOM! Box Audio System , VEHICLE TRANSPORT MODE (Security Systems Only) - AGM :
Dealership Personnel

201711-16

Updated TESTING EQUIPMENT - AGM : GRX-3110HD Battery Diagnostic Station , BATTERY MAINTENANCE - AGM :
Undercharging , DEALERSHIP BATTERY MAINTENANCE - AGM : Vehicles Not on Display & Parts Inventory ,
CUSTOMER PERSONAL STORAGE - AGM & Table 6

DATE
201610-05

REVISION DESCRIPTION
Initial release

TECHNICAL TIP GUIDE
Table 2. AGM - Technical Tip Bulletin Guide
ABSORBED GLASS MAT (AGM) BATTERIES
PURPOSE FOR TECH TIP

*

Operational Vehicles

TESTING EQUIPMENT - AGM

*

Non-operational

*

GRX-3110HD Battery Diagnostic Station

*

Vehicles Demonstrating BOOM! Box Audio System

*

Fluke Digital Multimeter

*

Parts Inventory

CHARGING EQUIPMENT - AGM

CUSTOMER PERSONAL STORAGE - AGM

INITIAL BATTERY CHECK - AGM

VEHICLE TRANSPORT MODE (Security Systems Only) - AGM

BATTERY MAINTENANCE - AGM

*

*

Overcharging

BEST PRACTICES THAT YIELD RESULTS - AGM

*

Other Chargers

*

Battery Best Practices

*

Undercharging

*

Battery Testing Best Practices

Dealership Personnel

DEALERSHIP BATTERY MAINTENANCE - AGM

STORAGE - AGM

*

Vehicles Not on Display

*

Battery Stocking and Sales

*

Vehicles on Display

*

Battery Date Codes

Table 3. Li-Ion - Technical Tip Bulletin Guide
LITHIUM-ION (LI-ION) 12 VOLT BATTERIES (4 Ah AND ABOVE )
TESTING EQUIPMENT - LI-ION
*

Fluke Digital Multimeter

CHARGING EQUIPMENT - LI-ION
VEHICLE CHARGING SYSTEM - LI-ION

*

Parts Inventory

CUSTOMER PERSONAL STORAGE - LI-ION
VEHICLE TRANSPORT MODE (Security Systems Only) - LI-ION
*

Dealership Personnel

INITIAL BATTERY CHECK - LI-ION

FITMENT KITS - LI-ION

BATTERY MAINTENANCE - LI-ION

BEST PRACTICES THAT YIELD RESULTS - LI-ION

DEALERSHIP BATTERY MAINTENANCE - LI-ION

*

Battery Best Practices

*

Non-operational

*

Battery Testing Best Practices

*

Vehicles Demonstrating BOOM! Box Audio System

WARRANTY - LI-ION

Table 4. Li-Ion 2 Ah - Technical Tip Bulletin Guide
LITHIUM-ION (LI-ION) 12 VOLT BATTERY (2 Ah )
GENERAL

PURPOSE FOR TECH TIP
AGM Batteries: Tech Tip TT453 combines all battery, testing and charging information from Service Bulletins M1089,
M1089A, M1290, M1329, M1391, M1404 and M1418 and Tech Tips TT342 and TT440 into one document. This also
updates procedures and equipment to maintain, test or charge all Absorbed Glass Mat (AGM) batteries.
Li-Ion Batteries: To explain the benefits and clarify the usage of the Lithium LiFe batteries.

ABSORBED GLASS MAT (AGM) BATTERIES
TESTING EQUIPMENT - AGM
GRX-3110HD Battery Diagnostic Station
The HD BATTERY DIAGNOSTIC STATION (Part Number:GRX-3110HD) can perform a complete diagnostic
recharging and evaluation routine within 3 h. Read the instruction manual to perform battery testing. To download a
copy of the GRX-3110 instruction manual in Portable Document Format (PDF), login to H-Dnet and search for GRX3110 instruction manual.
GRX-3110HD is primarily a diagnostic tool and not recommended to provide a long-term charge.
It is important that the station has the latest software revision installed to ensure that the station performs the proper
diagnostic tests. To verify for the latest version, navigate the following steps on the GRX-3110:
Push RIGHT ARROW to view PRINT/VIEW > SELECT > Push RIGHT ARROW to view VERSION INFO > SELECT
Verify current update on Service Bulletin M1391A: MIDTRONICS GRX-3110 SOFTWARE UPDATE . This service
bulletin contains the current update and instructions on how to install that update.
NOTE
Login into Service Information Portal (SIP) through Google Chrome to view link.
M1391A
Severely discharged batteries no longer need to be jump-charged to begin charging. The GRX-3110 can test and
charge batteries at any beginning charge state. If the GRX-3110 determines the battery is healthy enough to accept a
charge, it will begin the charging and testing session which may take up to 3 h. During this session, the battery is
tested a number of times.
When the session is complete, a report displaying the test results including battery replacement indicator, charging
results, state of health and a generated warranty code are available. This information can be printed at the end of the
session or later if needed. However, all data will be overwritten when a new session is started.

If the battery voltage displayed on the final report is less than 12.5 V, continue to charge the battery until 100% charge
is achieved before placing it in service. This "top-off" charging can be done using any Harley-Davidson approved
charger. See Table 6 and Table 7 for list.

Fluke Digital Multimeter
The Digital Volt Ohm Meter (DVOM) is a hand-held device useful for basic fault finding and field service work or a
bench instrument which can measure to a very high degree of accuracy.
The Fluke 78 and 88 have been discontinued but will still work for all functions needed in testing electrical circuitry.
Fluke has replaced these models with the Fluke 789. See Table 5.
Table 5. Digital Multimeters
MODEL

PART NO.

STATE

Fluke 78

HD-39978

Discontinued

Fluke 88

HD-39978

Discontinued

Fluke 789

HD-48650-20

Offered

CHARGING EQUIPMENT - AGM
The selection of charging equipment can vary depending on the application. Harley-Davidson recommends the
following battery chargers. See Table 6 and Table 7.
Table 6. Harley-Davidson Chargers
DESCRIPTION

PART NUMBER

SuperSmart 750 mA

(North and South America,
except Argentina)

DESCRIPTION

PART NUMBER

66000038

Global 5 AMP (Japan)

66000045

SuperSmart 800 mA

66000004

2-Bank Multi-Output

99829-09

Global 1.25 AMP
(All, except Japan)

66000033

4-Bank Multi-Output

99847-09

Global 1.25 AMP (Japan)

66000034

Waterproof 800 mA (Europe)

99814-09

Global 5 AMP (Western Hem.)

66000041

Waterproof 800 mA (U.K.)

99816-09

Global 5 AMP (Europe)

66000042

Waterproof 800 mA (Australia)

99819-09

Global 5 AMP (U.K.)

66000043

Waterproof 800 mA (Japan)

99820-09

Global 5 AMP (Australia)

66000044

Table 7. Deltran Chargers
DESCRIPTION
10-Bank 2 AMP

HD PART NUMBER

DELTRAN IDENTIFICATION

66000040

021-0134

INITIAL BATTERY CHECK - AGM
Test initial battery voltage within 10 days of receipt. This applies to batteries in vehicles and replacement parts
inventory.
NOTE
When battery is out of vehicle, testing is done directly across the positive and negative battery terminals.
1. Test voltage using a DVOM between main fuse [5B] terminal A and ground. If voltage is greater than or equal to
12.5 V, voltage is within normal specifications. Charge as needed to keep voltage above 12.5 V.
2. If voltage is less than 12.5 V, test battery with HD BATTERY DIAGNOSTIC STATION (Part Number:GRX3110HD), follow instructions on station and on print out.

BATTERY MAINTENANCE - AGM
When a battery is received, whether P&A or in a new vehicle, follow these guidelines. It is the dealership's
responsibility to maintain new batteries above 12.5 V after initial battery check. Do not call Technical Service for
warranty authorization on batteries not properly maintained at the dealership.

Overcharging
AGM type batteries are filled with the proper amount of electrolyte and then sealed. If a charger reaches too high a
charge voltage (14.6 V or above), the water in the electrolyte will begin to evaporate. This water vapor is released
through a one-way relief valve on the top of the battery case. Since the AGM battery is permanently sealed, the water
cannot be replenished and the battery becomes permanently low on electrolyte. This can result in loss of performance
and eventual battery failure. A sealed battery with concave sides is an example of one that has been overcharged and
has lost electrolyte. Overcharging with chargers designed for automotive use is a major cause of battery failure.

Other Chargers
The only approved chargers for Harley-Davidson AGM batteries are the Harley-Davidson chargers dated after 2010
and Deltran chargers listed in Table 6 or Table 7. Other chargers can allow the battery voltage to climb over 14.6 V
during charging causing the electrolyte in the battery to evaporate, resulting in loss of performance and eventual
battery failure.

Undercharging
If a battery charger does not bring the battery to a full charge, several problems can occur:
The rated battery capacity will not be reached and the charging system may not bring the battery to a full
charge, especially in those instances where customers take short rides or ride slowly with their electrical
accessories on.
If the vehicle is stored in a cold climate, an undercharged battery can freeze and crack.
If the vehicle is stored in a hot climate 25 °C (77 °F) or warmer, the battery will self discharge at a higher rate.
A battery that sits in an undercharged state for a long period of time will sulfate. Sulfate hardens on the battery
plates preventing proper recharge. A sulfated battery is not serviceable and must be discarded.
Harley-Davidson and Deltran battery chargers incorporate a protection circuit that does not allow charging if the
battery is below 5 V. If you encounter a very low battery, it can be connected to the GRX-3110HD.

DEALERSHIP BATTERY MAINTENANCE - AGM

Vehicles Not on Display
1. Remove main fuse when vehicle is stored.
NOTE
All batteries are to be tested monthly.
The battery discharges faster when the main fuse is installed. With the main fuse removed, a 100% charged
battery drops to 12.5 V in approximately five months.
2. Test battery voltage. If voltage is approximately 12.5 V, charge battery using one of the chargers in Table 6 or
Table 7 until the charger indicates the battery is fully charged (12.7 V or greater).
3. If voltage is less than 12.5 V, test battery with HD BATTERY DIAGNOSTIC STATION (Part Number:GRX3110HD), follow instructions on station and on print out.
4. If battery voltage drops below 12.5 V two months in a row, do the following:
a. Verify main fuse is removed. Remove if necessary.
b. Perform a milliampere draw test. See the Electrical Diagnostic Manual (EDM) for that vehicles platform. Repair
if necessary.
c. If main fuse is removed and draw test passed, file a warranty claim on battery.

Vehicles on Display

NOTE
Operational vehicles have the main fuse installed and keyed ignitions unlocked.
Non-operational vehicles have the main fuse removed.
Operational vehicles on display should have a battery charger installed, every other night. Vehicles that have higher
traffic or are displayed outside in 25 °C (77.0 °F) or greater should be charged nightly.

Operational Vehicles
1. Remove battery charger from the vehicle. Turn ignition ON for one minute to remove surface charge from battery,
then turn ignition OFF.
2. Test battery voltage. If charging procedure above was followed and battery voltage is less than 12.5 V, test battery
with the GRX-3110, follow instructions on station and on print out.

Non-operational
1. Test battery voltage. If voltage is approximately 12.5 V, charge battery using one of the chargers in Table 6 or
Table 7 until the charger indicates the battery is fully charged (12.7 V or greater).
2. If voltage is less than 12.5 V, test battery with the GRX-3110, follow instructions on station and on print out.
3. If battery voltage drops below 12.5 V two months in a row, do the following:
a. Verify that main fuse is removed. Remove if necessary.
b. Perform a milliampere draw test. See the Electrical Diagnostic Manual (EDM) for that vehicles platform. Repair
if necessary.
c. If main fuse is removed and draws test passed, file a warranty claim on battery.

Vehicles Demonstrating BOOM! Box Audio System

The vehicle that is being used to demonstrate BOOM! should be tested the same as an operational vehicle, but must
have a recommended charger installed at all times. The BOOM! system draws an excessive amount of current on a
vehicle that is not running. To compensate for that, a charging source must be connected to the vehicle.

Parts Inventory
1. Have 1 or 2 of each battery type on an Harley-Davidson approved charging station ready for retail. Rotation of first
in first out batteries to replace the topped off battery when retailed.
2. Test battery voltage. If voltage is approximately 12.5 V, charge battery using one of the chargers in Table 6 or
Table 7 until the charger indicates the battery is fully charged ( 12.7 V or greater).
3. If voltage is less than 12.5 V, test battery with the GRX-3110HD, follow instructions on station and on print out.

CUSTOMER PERSONAL STORAGE - AGM
Encourage the customer to purchase and use one of the battery chargers in Table 6 or Table 7. The battery chargers
work on conventional batteries as well as the AGM type batteries. The recommended battery chargers are specifically
designed for the new AGM type battery and provide proper charging automatically. These chargers prevent both overcharging and undercharging.

VEHICLE TRANSPORT MODE (Security Systems Only) - AGM
Transport Mode arms the security system with motion detection disabled for one ignition cycle: This allows movement
of the vehicle in an armed state.
If the vehicle is being transported and was not placed in Transport Mode, the security alarm activates due to motion
detection. This will eventually drain the battery.

Dealership Personnel
During a new vehicle purchase, the person familiarizing the customer with the vehicle needs to explain Transport
Mode.
Upon delivery:
Use Transport Mode if the vehicle is being transported.
Ensure the person delivering the vehicle informs and demonstrates to the customer, the operation of Transport
Mode.
Make sure that the customer is aware that the battery is fully charged at the time of delivery to 12.7 V or higher.
Other items to consider: Training material to review.
Battery Fact and Best Practices course 1542 is available through HDU online.
Shop Talk issue five of 2015 has more information on battery care and products.

BEST PRACTICES THAT YIELD RESULTS - AGM
Battery Best Practices
Use a recommended battery charger/tender on vehicles whenever possible.
The electrical system on early model vehicles typically only required the removal of the main fuse to disconnect