Technical Service Bulletin

NUMBER 030825
Installing ODYSSEY PC 545MJ in Buell S1 Lightning

The Buell model S1 Lightning 1996 – 1999 was supplied OEM with a battery under the trade name of Genesis with a Genesis part number of G12V12Ah10EP.  This battery with the terminals located together on the narrow side of the battery is no longer manufactured.  There is a replacement, but installation requires some minor attention.

 The replacement battery is under the trade name of ODYSSEY Drycell Batteries, model PC 545MJ.  This battery is available through motorcycle dealers who distribute parts supplied from Custom Chrome, Chrome Specialties, Drag Specialties, Parts and Battery Plus Stores.  The PC 545MJ is a considerable up grade over the Genesis battery.

Comparison

G12V12Ah10EP

PC 545MJ
Service Life 2-4 years 6-10 years
5 second cranking amps 430 amps 545 amps
CCA 146 amps  185 amps
Terminals M4 female M6 female
Terminal Location  Narrow side Long side
Vibration Rating  Commercial Military

Installation Awareness –

There are two issues that must be addressed to install the PC 454MJ battery.

  1. The PC 545MJ has a slightly different top cover edge design that interferes with the lower lip of the bikes battery tray.

  2. The terminals on the PC 545MJ are on the long side.

 Installation Procedure –

  1. Shim material approximately ¼ inch thick must be cut to fill in the lower battery tray equal in height to the lip at the end of the lower tray.

  2. Install the negative battery cable onto the battery, torque to 50 inch-pounds

  3. Slide the battery with the negative terminal up towards the bottom of the seat and into the battery tray.

  4. Install the battery clamp bracket and tighten for a secure fit.

  5. Install the positive battery cable to the battery positive terminal, torque to 50 inch-pounds.

  6. Check that the battery is secure and tight in the battery tray.

  7. Installation is complete.

 Technical questions should be directed to Bruce Essig at:

Tel: (660) 429-7506
Fax: (660) 429-1758