Machine: 2008 RZR
Build date: 11-07
Purpose: During a skid plate removal I noticed the OEM wiring harness ran under the OEM battery box and was "sandwiched" between the battery box and the skid plate, actuals hangs down lower than the frame rail. There were noticeable wear marks on the skid place where the wiring harness loom had chafed. The harness did not have enough slack to reposition it, I thought this was a flaw in the OEM design/routing of the wiring harness, if the harness was about 3-5 inch's longer it could have been routed safely around the OEM battery box and not sandwiched between the battery box and skid-plate. I do feel it would have taken some time or a hard hit at that exact point before any damage would have been done to the wiring, but why be reactive when I can be pro-active, plus I got a larger battery out of the discovery. :-)
Costing:
Battery: $198.00 from local battery supplier. (Batteries Plus)
Materials: Aluminum Flat Bar $10.00 to $15.00 (Est) I used scrap I had laying around.
Difficulty:
Fabrication: Low (basic welding)
Installation: Low
Time:
Fabrication: Est. 2-hours. From design to completion.
Installation: 20-min
OEM Chassis and parts Modification(s):
OEM Battery Box: The OEM plastic battery box will need cut from adjacent under-seat storage tray. (See Attached Photos). Cut near the seam as close as you can to the OEM supporting bracket. (Use a flush cutting hand saw)
Drilling/Tapping: You will need to drill and either tap of use self-tapping screws on the frame rail and the inside OEM battery box supporting bracket.
Battery Specifications: CCA 550, 44-Amp hours (Compared to the OEM at 18-Amp Hours.
Odyssey PC1200
Materials Needed:
Aluminum Flat Bar: (All measurements are in inches)
1pc @ 1 1/2 X 1/8 X 12 1/2
2pc @ 1/2 X 1/4 X 8 1/2
2pc @ 1/2 X 1/4 X 5 1/4
2pc @ 1/2 X 1/4 X 6
1pc @ 1 1/4 X 1/8 X 8
1pc @ 2 X 1/8 X 6
1pc @ 2 X 1/8 X 7
1pc @ 2 X 1/8 X 8
1pc @ 1 1/4 X 1/8 X 5 1/4
Miscellaneous:
Screws: 5pc @ #10 X 3/4 Self tapping stainless steel.
Felt Pads: Cut to size (Heavy Duty Felt Blanket) Buy at Home Depot used to place under furniture feet.
Rubber Pads: 1/2 Buy at Home Depot used to place under furniture feet.
Battery reconnection:
The OEM ground lead will be too short and you will need to make a new cable, the OEM positive is long enough. I plan on adding a positive and negative terminal strip so I will not cover the reinstallation of the OEM battery leads.
Linear Mode
