I have a 2011 Suzuki Boulevard S40 that I bought new in May 2011.  The original, wet-cell battery is no longer able to retain a charge, so I need to replace it.

Several weeks ago, I was able to remove both the positive and negative terminal cables to slide out the battery for charging.  I put the battery back in the bike after it was fully charged and rode on extended rides several times a week for two weeks before the battery finally would no longer start the bike nor hold a charge.  So I need to replace it with a new one.

The bike has been sitting for 6 weeks due to my fight with pneumonia.  I was able to remove the positive battery cable just fine, but the negative one is being stubborn.  The positive terminal was clean, but the negative one was caked with battery acid dust.  I scraped that away and attempted to unscrew the 10 mm bolt holding the negative battery cable to the terminal, but it just turns and turns.  The bolt is attached to a hex nut, which simply turns in tandem with the bolt.

Ideally, I'd put a wrench on the hex nut to hold it while turning the bolt with a 10 mm socket wrench.  But there isn't enough room for one.  There is a small (about 1/8") opening where the cable itself attaches to the lead that bolts to the terminal.  I've tried jamming a thin screwdriver in there to hold the nut while I try to unscrew the bolt, but the nut keeps turning.

Any ideas short of cutting the negative battery cable?  And if I do have to cut the cable --
1. Is that a single cable that I can remove and replace?
2. How long is that cable?
3. Where does its other end attach to?

Thanks, all, very much for your advice.  You guys are extremely helpful and save everyone a lot of headaches and unnecessary expense.  I just want to get the bike running again because I miss the open road with it.  I never even sat on a bike much less rode one until I was 52 -- and I absolutely LOVE it!  

Merry Christmas,

Steve

I have to say I wouldn't have thought of taking off the other end until I had removed the fenders and rear valve stem cap. Good call Serowbot. I will post a story when I get my bike running again, but since your battery is no good now and the terminals are soft you may be able to cut the terminal with a screwdriver (chisel) or even nibble away with a pair of plies. Having sold and serviced batteries I have seen one explode on a freezing day because we put it on a charger without noticing it was frozen. Also, I play caveman as much as the next guy, but you can be terribly maimed or blinded by battery acid. Take time to find glasses and even gloves to protect your skin. And always stick with Serowbot's advice and always disconnect the neg side first and hook it back last. My observation has been that lots of times a bad battery will leak around at least one terminal and put some rapid rust on your bolts.

It actually looks like the negative wire is wrapped into the harness...

I'd rather bust the battery getting it out than cut that wire.
So,.. don't cut it...

Quote:

Keep trying... jam a thicker screwdriver... lastly, bust the lead terminal...
.. but, don't cut the wire... ...

JMHO...


PS... once it's out...  I cut the neg side opening bigger in the battery box,... I also cut away some at front to make carb removal easier...
Once you have the battery out,.. you might consider doin' the same...

Yup, i'm with the majority, if your going to replace the battery, break the battery, not the terminal wire end.

See if you can jam a screwdriver (flathead) or small crow bar behind the square bolt head (or hexagon which ever). A small pair of vise-grip pliers will hold it if you can get a grip. Or just simply pry it off the battery terminal and don't worry about cracking the battery, just be careful of the acid if you do crack it.

Slightly off-topic, but.....has anyone come up with a mod to the battery box that would enable battery inspection?  Here in Arizona I need to keep a constant check on my electrolyte level, and to do so I have to remove the battery, which as you know is a bit of a pain.  Maybe cut the inspection window bigger and bolt in some plexi?

My experience with plexi is that it eventually scratches up and turns foggy. That would probably happen pretty quick since you'll be wiping road grime off of it to see the battery. I'd go glass and maybe silicone it in place on the inside of the box.

Even with the battery out, sitting on the bench I have difficulty in determining the fluid level.  Trying to view that thru a dirty window will be next to impossible.  Cut windows anywhere you want, treat the edges so they don't rust.

Musselman Honda is where I got mine... a Bikemaster for about $70.00...
That's as cheap as internet... I buy local when I can...
Best price in Tucson... ...