2014 Teryx4 Dual Battery Installation [pics] - Kawasaki Teryx Forum
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post #1 of 40 (permalink) Old 02-11-2014, 01:54 PM Thread Starter
 
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2014 Teryx4 Dual Battery Installation [pics]

I am the kind of guy who likes to run my electronics. I like to run them non-stop. When I turn the key off, I want the tunes and the lights to keep going. The party should not stop when the tires stop rolling.

Yet Teryx and Teryx4 enthusiasts know that the stock electrical system, even in the newer rigs, is pretty meager. The charging system and the primary battery leave only but a small amount of wiggle room for aftermarket accessories. The stock battery is good for starting the 783cc motor and running a phone charger. I don't trust that U1 sized battery to start the engine back up when I'm a few miles from camp down in an area that isn't real accessible.

So it came time to think about dual batteries.

I went back and forth between a few setups. I really like the Fuel UTV dual Odyssey 925 battery holder. But the specs on the 925 as an auxiliary battery were not quite up to what I had in mind. I wanted something with more AH and more reserve capacity.

My electrical load is not completely over the top: a dome lamp, 40" LED lightbar, and SSV stereo. Realistically, my current draw is about 24A when everything is turned on, and slightly closer to the 20A mark when the stereo is at more nominal volumes.

The other big electrical parasite is the Warn ProVantage 4500lb winch. A winch will pull over 250A of current at maximum load; however, the winch isn't used continuously like the lights and stereo.

I went scouring the internet looking for the best battery I could find that was still reasonable in size. I wanted to mount the battery under the driver seat. When you look for good batteries on the internet, you come across the car audio community. Those guys know batteries that needed to meet similar requirements as I did: to be sealed, to have a decent reserve capacity for extended run time without charging, and to have great, dependable power.

I decided on the XS Power brand battery. I chose the XP2000 battery which is designed to be a supplemental power source in systems. The battery is sized to be a group 24 battery and rated at 80 amp hours. When I got my hands on this battery, it is a beast. I love it. Talk about nice.

I also determined I would need a battery separator, so I chose the Sure Power 1315 dual voltage sensing smart relay. It will connect the auxiliary battery to the main battery and charging system when the main battery's voltage is at or above 13.2V. The relay will open when the main battery voltage falls below 12.8V, separating the auxiliary battery from the main battery. This ensures that the main battery stays fully charged, connects the auxiliary battery for charging but only after the stock system is satisfied. Bottom line is if all your accessories are wired to the auxiliary battery, you do not have to worry about draining your starting battery!

I took my time wiring everything up. I use my Teryx4 800 in a lot of wet and muddy conditions. I followed generally accepted marine wiring practices which includes tinned wiring and making connections up with heat, shrink adhesive lined connectors and ring terminals.

The battery separator was wired up with Kicker Hyperflex 8AWG wire. The Blue Seas fuse block was wired with 4AWG wire. The wiring to my lights and other accessories is 14AWG wire from Anchor Marine.

All in all, this was a bit bigger project than I initially though it would be. It took me several days of working 2-3 hours at a time after dinner in the evening.

Check out a few of my pics.




The wiring I used





Here is a pic of the ring terminals
Don't bust my chops too bad for using a #10 terminal on a #8 wire... lol!





This is a 50A self resetting circuit breaker
The breaker is mounted inline from the main battery to the separator.





The Sure Power 1315 separator
It is mounted under the dash panel, to the right of the glove box.





Wiring under the console
I ran the charge wire and fuse block wire under the console, protected in loom.





The battery







Blue Seas Fuse Block




Voltage gauge
This was kind of an after-thought. I wanted to be able to see the status of my new auxiliary battery. I wired this cheap waterproof digital gauge into the cubby by the driver's left knee. I'm not sure if I will leave it or not.




So there you go. It's not perfect but it works pretty good so far.

2014 Kawasaki Teryx4 800
Warn ProVantage 4500-S
28" Terminators | MSA Kore | Highlifter Lift | 50" Lightbar | Dual Batteries
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post #2 of 40 (permalink) Old 02-11-2014, 03:59 PM
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Nice install thanks for the great pics and play by play.

2014 Kawasaki T4 Lime Green
Diesel M12s sitting on 30" Baby backs
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2010 Teryx T2
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post #3 of 40 (permalink) Old 02-11-2014, 04:44 PM
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Good write up.

2009 Kawasaki Teryx Sport Benchmark SBK, CNC ported heads, +1mm valves, VFJ clutch kit 60 grams, #1 red spring, LTI +5" suspension, FU2Chassis cage, Induced Fab doors, 27x9 Mongrels, DASA exhaust w/quiet cores, DASA impeller, OD clutch plate, KEBC plate, MSD, bored throttle bodies, FuelUTV Siphon break, UNI air filter, lime green secondary spring, Agressor seats, TripleX bench, 4" cube LED headlights, 6.5" LEDs on the A pillar, Fiber Skinz diff skids, UTV Inc. Temp gauge, UTV Inc. fan bypass, SSV stereo.
Safety is no accident

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post #4 of 40 (permalink) Old 02-11-2014, 05:00 PM
 
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Nice and clean!
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post #5 of 40 (permalink) Old 02-12-2014, 05:05 AM
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All I'm missing is the price of everything and source. This is exactly what I need. Lots of headlight dancing with beverages in my neck of the woods.
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post #6 of 40 (permalink) Old 02-13-2014, 03:10 PM
 
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That's about the same way I am going to do mine I even have the volt meter but mine is blue.

2012 teryx 4, 5000lb wide spool winch, roof, tusk grab handles more to come


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post #7 of 40 (permalink) Old 02-16-2014, 01:51 PM
 
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Very nice write up! And one Hell of a clean install
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post #8 of 40 (permalink) Old 02-17-2014, 06:19 AM
 
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Clean install. Good work and nice write up.



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post #9 of 40 (permalink) Old 02-17-2014, 06:30 AM
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Nice write up! Thanks for sharing.


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post #10 of 40 (permalink) Old 02-17-2014, 07:13 AM
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Clean install, nice

2012 teryx4 red eps
Fuel vent mod, Fat mat mod, Yellowtop optima,
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post #11 of 40 (permalink) Old 02-17-2014, 08:48 AM
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Very nice I'm looking to do this to mine and this gives me some good ideas.


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2014 T4 800 LE Green - Full Cabin enclosure, KFI 4500LB winch, LED Reverse Lights and more to come...
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post #12 of 40 (permalink) Old 02-17-2014, 09:38 AM
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GREAT write up. You do things first clast. Thanks for posting for the rest of us to see how it is done by the pimp daddy!!
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post #13 of 40 (permalink) Old 02-17-2014, 10:06 AM Thread Starter
 
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I do appreciate the kind words. I am not an electrician, but I do enjoy simple 12V wiring projects.

I'm surprised nobody has yet mentioned the lack of a fuse on the 4AWG wire that feeds the Blue Seas fuse block. I bought a waterproof 300A fuse holder to mount down under the seat at the auxiliary batter, but I have not yet installed it.

2014 Kawasaki Teryx4 800
Warn ProVantage 4500-S
28" Terminators | MSA Kore | Highlifter Lift | 50" Lightbar | Dual Batteries
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post #14 of 40 (permalink) Old 02-19-2014, 01:03 AM
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Chris nice work there, very clean install, & write up & pics! Looks like your setup will take care of all your needs! Thx for sharing.

2012 Green Teryx4 eps mostly stock, Kawasaki 1/2 windshield & roof. Champion 3000 lb winch. My own custom fender well/ floorboard guards with more improvements to come!
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post #15 of 40 (permalink) Old 02-20-2014, 12:35 PM
 
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very sweet, ready for warmer weather so i can start mine.
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post #16 of 40 (permalink) Old 02-20-2014, 05:56 PM
 
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nice job where did u find that bus bar?
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post #17 of 40 (permalink) Old 03-18-2014, 10:09 AM Thread Starter
 
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UPDATE:

I wanted to provide a update on this project and give some further feedback on how everything has worked and held up after a couple of months and several hard rides.

The dual battery has been flawless and given me the freedom to use my electrical accessories without fear of becoming stranded in a remote area. It also lets me put a cool beverage in the hands of some fun people, all the while let the tunes crank and the lights shine.

For example, it was about midnight down in the river bottom and the music was playing. All of a sudden a guy on a Polaris Sportsman sinks the back of his ATV when the 4WD would not engage. The spectacle looked something like this:



Guess who's lights shined on the ordeal for half and hour and guess who's winch raised this junk from the sugar sand bottom? Yep. The really cool thing was that we had already been down there for about an hour already. The battery provided all the power we needed.

On the way back, I had to self rescue. Again, I was able to winch and run the lights all I needed.






This was a weekend long ride. When I got back home I put the Teryx on the battery charger to recharge. The big auxiliary battery was showing about 12.2 volts resting before charging, and my AGM battery charger was registering about 35% when I hooked it up. That right there tells me the stock Teryx4 electrical system could not do what I was wanting to do, particularly the kind of engine off - lights on kind of activities that require substantial amounts of reserve capacity.

One other thing to note - my starting battery and my auxiliary battery are very different in size. I noticed that when I really started pulling a lot of amps out of the auxiliary battery that the Sure Power battery separator would open and close the relay more often than I was accustomed.

If you have ever used a smart relay separator before , you know that you can hear the relay opening and closing with an audible "THUNK."

What I determined was happening was that once the auxiliary battery's charge starts falling, and you still have your accessories running, the stator's capacity can't supply enough amperage to run the Teryx, maintain the stock battery above 13.2V, and charge the auxiliary battery. So what happens is something like this:

Start the Teryx up. About 10 seconds later, THUNK, the stock battery is fully charged and the relay begins charging the auxiliary battery.

THUNK, 60 seconds later the auxiliary battery has drawn so many amps from the stock battery that the stock battery's voltage has fallen to 12.8V and the relay opens for the stator to recover the charge in the stock battery.

THUNK, 15 seconds and the stock battery is fully charged again and the relay closes to resume charging the auxiliary battery.

The longer the engine is running and the stator is generating current, the less frequent the THUNKs become as the auxiliary battery recovers its state of charge. That recharge time also varies based on how many accessories I am running, because you have to remember the Teryx4 charging system is pretty meager. I would guess you only have about 15A of reserve current after powering the stock electrical system, headlights, etc.

Once the auxiliary battery recovers, the relay can then remain closed and you no longer hear the noise of it opening and closing.

It is a cool system. So far, I am thoroughly impressed.
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2014 Kawasaki Teryx4 800
Warn ProVantage 4500-S
28" Terminators | MSA Kore | Highlifter Lift | 50" Lightbar | Dual Batteries
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post #18 of 40 (permalink) Old 03-18-2014, 03:40 PM
 
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Quote:
Originally Posted by ChrisH View Post
UPDATE:

I wanted to provide a update on this project and give some further feedback on how everything has worked and held up after a couple of months and several hard rides.

The dual battery has been flawless and given me the freedom to use my electrical accessories without fear of becoming stranded in a remote area. It also lets me put a cool beverage in the hands of some fun people, all the while let the tunes crank and the lights shine.

For example, it was about midnight down in the river bottom and the music was playing. All of a sudden a guy on a Polaris Sportsman sinks the back of his ATV when the 4WD would not engage. The spectacle looked something like this:



Guess who's lights shined on the ordeal for half and hour and guess who's winch raised this junk from the sugar sand bottom? Yep. The really cool thing was that we had already been down there for about an hour already. The battery provided all the power we needed.

On the way back, I had to self rescue. Again, I was able to winch and run the lights all I needed.






This was a weekend long ride. When I got back home I put the Teryx on the battery charger to recharge. The big auxiliary battery was showing about 12.2 volts resting before charging, and my AGM battery charger was registering about 35% when I hooked it up. That right there tells me the stock Teryx4 electrical system could not do what I was wanting to do, particularly the kind of engine off - lights on kind of activities that require substantial amounts of reserve capacity.

One other thing to note - my starting battery and my auxiliary battery are very different in size. I noticed that when I really started pulling a lot of amps out of the auxiliary battery that the Sure Power battery separator would open and close the relay more often than I was accustomed.

If you have ever used a smart relay separator before , you know that you can hear the relay opening and closing with an audible "THUNK."

What I determined was happening was that once the auxiliary battery's charge starts falling, and you still have your accessories running, the stator's capacity can't supply enough amperage to run the Teryx, maintain the stock battery above 13.2V, and charge the auxiliary battery. So what happens is something like this:

Start the Teryx up. About 10 seconds later, THUNK, the stock battery is fully charged and the relay begins charging the auxiliary battery.

THUNK, 60 seconds later the auxiliary battery has drawn so many amps from the stock battery that the stock battery's voltage has fallen to 12.8V and the relay opens for the stator to recover the charge in the stock battery.

THUNK, 15 seconds and the stock battery is fully charged again and the relay closes to resume charging the auxiliary battery.

The longer the engine is running and the stator is generating current, the less frequent the THUNKs become as the auxiliary battery recovers its state of charge. That recharge time also varies based on how many accessories I am running, because you have to remember the Teryx4 charging system is pretty meager. I would guess you only have about 15A of reserve current after powering the stock electrical system, headlights, etc.

Once the auxiliary battery recovers, the relay can then remain closed and you no longer hear the noise of it opening and closing.

It is a cool system. So far, I am thoroughly impressed.
Thanks for posting an update. It's nice when people let us know how their mods are doing after the install and some usage in real world events. Thanks again for the follow up.
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post #19 of 40 (permalink) Old 03-18-2014, 05:50 PM
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Sounds awesome!

2012 Teryx4 EPS
814/Viking Shocks; FUTV Skids
JBS Floorboard Skids & Radiator Guards
Warn Provantage 4500-S winch
Rigid Industries D2's Driving & SR-10 Specter Driving (front)
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post #20 of 40 (permalink) Old 03-18-2014, 08:30 PM
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Chris thanks for helping me out today. I'm going with the same system you have I'll be starting a thread with pics on it and the stereo install. Thanks again without seeing your post I would have never known about this.
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post #21 of 40 (permalink) Old 03-29-2014, 01:18 PM
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I was wondering why you would use the bi-directional isolator vs the uni-directional one?
I'm not trying to bust your balls or anything. Just curious if there's an advantage to it.

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2014 Green T4- catvos lift, 30" evo's, warn 3k winch, BDK Cage..
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post #22 of 40 (permalink) Old 03-29-2014, 01:26 PM Thread Starter
 
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I bought the bi-directional separator for ease of charging, but now I think it's unnecessary. I would just get the uni-directional. I could have saved $5 bucks, lol.

2014 Kawasaki Teryx4 800
Warn ProVantage 4500-S
28" Terminators | MSA Kore | Highlifter Lift | 50" Lightbar | Dual Batteries
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post #23 of 40 (permalink) Old 03-29-2014, 01:35 PM
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Yeah, I've been looking at them for a while. I'm thinking about the uni-directional since I want to use a deep cycle battery for the secondary. This way the original is always the "main" battery. Probably not gonna make a whole lot of difference any who.

Follow me! I know where I'm going...I think.

2014 Green T4- catvos lift, 30" evo's, warn 3k winch, BDK Cage..
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post #24 of 40 (permalink) Old 05-09-2014, 08:41 AM
 
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I cant tell from the pics where you put the aux battery. please explain
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post #25 of 40 (permalink) Old 05-09-2014, 09:14 AM
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I had everything hooked up to my main battery when I decieded to install a second, after looking at everything and not wanting to rewire everything or extend the wireing I went with a smartstart marine isolator what it does is when your main battery gets low it automaticaly switches over to your aux batt to start the rig no hooking up wires for charging it does all internaly 1wire from main battery 1 wire from the aux battery and 1 ground wire all done

You did a great system if I haden't had all my stuff already installed and ran thru the cage I would be running the acc of aux batt. But this workes for me You do exellent work

2014 LE 800,warn pro 4500# winch, 20" led light bar, 6"led back up light, fusion stereo- rockford fosgate speakers -seriusxm tuner , dragonfire 3" harnesses , muzzy exhaust- w vfj tuner, alba racing cvt temp gauge,coolant temp gauge,fan bypass switch,relocated cvt inlet(under the dash) relocated fuel breather and filter,billett mirrors,fuel utv air filter, rugged radio's,duel batterys + smartstart, matt black STI beadlocks + 2nd set of sti hd5 beadlocks,gunmetal grey in 14" with
efx motoclaws
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pending work in progress you are never finished till they plant you in the ground

Last edited by desertdog01; 05-09-2014 at 09:18 AM.
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