Changing Battery 2006 1600 Nomad

ChicagoKid · 06-18-2014, 11:13 AM

This should not be that complicated but I do not want to break or disconnect any wires unnecessarily.

I unbolted the bar that goes across the battery, and disconnected the terminals. However the bar that holds the battery in place also serves as a wiring harness and it appears that I can not remove it with out disconnecting the wires. Also there is ribbon cable that is attached to a bolt on the gas tank. I am wondering is there another way to remove the bar\wirring harness without disconnecting the wires? Also do I need to remove the ribbon wire from the gas tank?

2006 Kawasaki Nomad 1600

Thanks for any help.

pjn426 · 06-18-2014, 11:29 AM

The wires are connected to the bar with a plastic clip. Look closely and you'll see how to release it. Then just slide the wires and junction block out of the way to get at battery.

ChicagoKid · 06-18-2014, 11:49 AM

Pjn426
Thanks for your reply. I looked for a clip and I thought I found it but after disconnecting it I still can not move the bar far enough out of the way.

Here is what I am looking at.

There are three sets of wire connections, going accross the top of the bar. At the rear of the par there was a plastic clip that was holding some wires in place. That is the plastic clip I disconnected.

I also noticed that the middle set of wires attached to the bar does seem to have a plastic clip but also something that looks like a fuse, has the number 15 written on it.

Is that the plastic clip you are talking about?

pjn426 · 06-18-2014, 03:07 PM

The plastic clip holding the fuse is what I was referring to. I have a 2004 1500 and that is all that is attached to the hold down bracket. The rest of the wires just move out of the way to allow access to the battery.

pjn426 · 06-18-2014, 03:25 PM

Here's what the 1600 shop manual has for battery removal... isn't must help but you definitely have more wiring across your battery than I do.

•Remove the front seat
•Disconnect:
Fuel pump Connector
Fuel Level Sensor Connector
Battery (–) Lead Connector
Rear Turn Signal/Taillight Lead Connector
•Remove:
DFI Fuse
Nuts
Battery Holder
•Slide the black and red caps out.
•Disconnect the negative (–) cable from the battery first
and then the positive (+) cable from the battery.
CAUTION
Be sure to disconnect the negative (–) cable first.
Pull the battery out of the case.

cactusjack · 06-18-2014, 03:41 PM

The easiest way to remove/install a bettery is with a couple of zip ties. Run them through the battery posts to make little loops you can slip your fingers into, otherwise they are a bear to wrestle in that tight space.

Vulcan Bill · 06-18-2014, 10:35 PM

Should you decide to disconnect the harness plugs the trick with those is slide a small flat head screwdriver under the lock tab and lift up on it while gently pulling/wiggleing the connector.

ChicagoKid · 06-19-2014, 05:53 AM

PJN, I can't seem to get that remove that clip. There seems to be two metal pieces on the ends, do I lift up on those to remove it?

ChicagoKid · 06-19-2014, 07:31 AM

Vulcan Bill are you referring to the center plug that PJN is referring too?

ChicagoKid · 06-19-2014, 01:02 PM

Problem SOLVED, thanks for everyones help. Had to disconnect all the wires to get the battery out. Great Tip on the tie strips Cactus Jack

06-18-2014, 11:13 AM	#1
ChicagoKid Jr. Member Join Date: Jan 2013 Location: Chicago Posts: 48	Changing Battery 2006 1600 Nomad This should not be that complicated but I do not want to break or disconnect any wires unnecessarily. I unbolted the bar that goes across the battery, and disconnected the terminals. However the bar that holds the battery in place also serves as a wiring harness and it appears that I can not remove it with out disconnecting the wires. Also there is ribbon cable that is attached to a bolt on the gas tank. I am wondering is there another way to remove the bar\wirring harness without disconnecting the wires? Also do I need to remove the ribbon wire from the gas tank? 2006 Kawasaki Nomad 1600 Thanks for any help. Login or Register to Remove Ads Last edited by ChicagoKid; 06-18-2014 at 11:22 AM.
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06-18-2014, 03:25 PM	#5
pjn426 Jr. Member Join Date: Jul 2007 Posts: 24	Here's what the 1600 shop manual has for battery removal... isn't must help but you definitely have more wiring across your battery than I do. •Remove the front seat •Disconnect: Fuel pump Connector Fuel Level Sensor Connector Battery (–) Lead Connector Rear Turn Signal/Taillight Lead Connector •Remove: DFI Fuse Nuts Battery Holder •Slide the black and red caps out. •Disconnect the negative (–) cable from the battery first and then the positive (+) cable from the battery. CAUTION Be sure to disconnect the negative (–) cable first. Pull the battery out of the case. Login or Register to Remove Ads
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06-18-2014, 03:41 PM	#6
cactusjack Mega-Contributor Join Date: Sep 2007 Location: Where it doesn't snow...ever! Posts: 21,926	The easiest way to remove/install a bettery is with a couple of zip ties. Run them through the battery posts to make little loops you can slip your fingers into, otherwise they are a bear to wrestle in that tight space. __________________ Scott "Cactusjack" Hanks VBA #00105 H.O.G. #4250060 2011 H-D Ultra Limited 103ci :: 2011 HD Electra Glide Ultra Limited w/Stage 1 :: Rallies: Mesquite '08\|Custer '09\|Cortez '10\|Crescent City '11\|Kanab '12\|Antlers '12\|Estes Park '13\|Antlers '13\|Orofino '14\|The Dalles '17
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06-18-2014, 10:35 PM	#7
Vulcan Bill Sr. Member Join Date: Jul 2013 Location: Mesa Az Posts: 1,400	Should you decide to disconnect the harness plugs the trick with those is slide a small flat head screwdriver under the lock tab and lift up on it while gently pulling/wiggleing the connector. __________________ ---------------------------------------------------------------------------------------------------------------------------------------------------------------- '05 1600CL. Originator 18" Harley wheel mod, Dobeck TFI, True Duals, Mutazu hardbags, Flanders handlebars n' a bunch more. *Sometimes I miss the good ol' days but most times I'm just glad I survived them*
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06-19-2014, 01:02 PM	#10
ChicagoKid Jr. Member Join Date: Jan 2013 Location: Chicago Posts: 48	Problem SOLVED, thanks for everyones help. Had to disconnect all the wires to get the battery out. Great Tip on the tie strips Cactus Jack Last edited by ChicagoKid; 06-19-2014 at 04:06 PM.
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06-18-2014, 11:29 AM	#2
pjn426 Jr. Member Join Date: Jul 2007 Posts: 24	The wires are connected to the bar with a plastic clip. Look closely and you'll see how to release it. Then just slide the wires and junction block out of the way to get at battery.
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06-18-2014, 11:49 AM	#3
ChicagoKid Jr. Member Join Date: Jan 2013 Location: Chicago Posts: 48	Pjn426 Thanks for your reply. I looked for a clip and I thought I found it but after disconnecting it I still can not move the bar far enough out of the way. Here is what I am looking at. There are three sets of wire connections, going accross the top of the bar. At the rear of the par there was a plastic clip that was holding some wires in place. That is the plastic clip I disconnected. I also noticed that the middle set of wires attached to the bar does seem to have a plastic clip but also something that looks like a fuse, has the number 15 written on it. Is that the plastic clip you are talking about?
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06-18-2014, 03:07 PM	#4
pjn426 Jr. Member Join Date: Jul 2007 Posts: 24	The plastic clip holding the fuse is what I was referring to. I have a 2004 1500 and that is all that is attached to the hold down bracket. The rest of the wires just move out of the way to allow access to the battery.
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06-19-2014, 05:53 AM	#8
ChicagoKid Jr. Member Join Date: Jan 2013 Location: Chicago Posts: 48	PJN, I can't seem to get that remove that clip. There seems to be two metal pieces on the ends, do I lift up on those to remove it?
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06-19-2014, 07:31 AM	#9
ChicagoKid Jr. Member Join Date: Jan 2013 Location: Chicago Posts: 48	Vulcan Bill are you referring to the center plug that PJN is referring too?
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