TECH: Installing a Ballistic Performance 8 Cell Lithium Battery in Your TUONO

[KIRK!]

OK, I can't speak one way or another yet as to the performance of the Ballistic batteries, but I did put one in my '05 Tuono today. I'll add to this thread as to how it performs in the weeks to come.

-Added 5/2/12- OK, only TWO days in and I'm pulling the Ballistic back out. It stumbled hard (barely starting the bike) this morning on startup and caused a dash reset. Maybe the 12-cell would do better, but I'm not taking the chance and this is the model recommended for the Tuono. For now, the stocker goes back in and the Ballistic goes down the road. The install is still valid, I guess, if you decide to use one of these batteries. Reminds me of the old adage - if it sounds too good to be true, it probably is.

OK, three more starts today, three more resets. And yes, I have done the brown connector and Yamaha relay upgrades.

Update - the seller on eBay (worldwide_motorcycle_equipment) who I bought it from is facilitating a return even though I cut up the foam. First class seller.

The first thing you notice, and honestly it was a little shocking when I opened the box, is how small and insanely light the Ballistic batteries are. It literally feels like it's empty. I had to get online again to reassure myself it was supposed to weigh this little (like 10-15% of the stocker) and be this small. It is dwarfed when you set it in the battery tray and obviously the stock hold-down configuration will not work.

http://imagehost.vendio.com/preview/sp/speedgeeks/battery01.jpg
http://imagehost.vendio.com/preview/sp/speedgeeks/battery02.jpg
http://imagehost.vendio.com/preview/sp/speedgeeks/battery03.jpg


The Ballistic batteries come in a cardboard box and are secured in a closed cell foam tray. I figured that if it could survive the USPS in this foam it could survive in the Tuono battery tray. I didn't think about documenting the install until I'd already started cutting the foam so I reassembled it so you could see what it looked like as shipped. It was originally one piece with just the hole for the battery.

http://imagehost.vendio.com/preview/sp/speedgeeks/battery04.jpg


I measured the inside of the battery tray and it was approximately 3.5"x6". I knew I wanted the battery to sit at the rear of the tray so I could use the stock hold-down so I cut the center of the foam piece out accordingly. The saw from my miter box cut the foam easily and fairly straight.

http://imagehost.vendio.com/preview/sp/speedgeeks/battery05.jpg
http://imagehost.vendio.com/preview/sp/speedgeeks/battery11.jpg


The cut down foam fit the tray nicely and the battery is actually pretty secure because of the snug fit.

http://imagehost.vendio.com/preview/sp/speedgeeks/battery06.jpg
http://imagehost.vendio.com/preview/sp/speedgeeks/battery07.jpg


You can see that the stock hold-down sits above the Ballistic battery.

http://imagehost.vendio.com/preview/sp/speedgeeks/battery08.jpg


My first thought was to fabricate a whole new hold-down, but then it became obvious that I could just shim the stock one. I had some 3/8" thick solid rubber in my stash of junk (originally bout at my local Ace Hardware store) and it turned out to be the perfect thickness, so I cut it to size and, after test fitting, super glued it to the hold-down.

http://imagehost.vendio.com/preview/sp/speedgeeks/battery09.jpg
http://imagehost.vendio.com/preview/sp/speedgeeks/battery14.jpg
http://imagehost.vendio.com/preview/sp/speedgeeks/battery10.jpg
http://imagehost.vendio.com/preview/sp/speedgeeks/battery12.jpg


It definitely took some persuasion to get the battery cables to sit in the right place and to get the bolts started. I ended up using the bolts from the old battery because they were longer. The ones that come with the Ballistic battery are about half the length. Once in place, and with the hold-down tightened up, it is VERY secure and doesn't look half bad.

http://imagehost.vendio.com/preview/sp/speedgeeks/battery13.jpg


The first start up was strong and so was the second. I'll let you know how it performs on a daily commuter basis

[speedkelly]

I have a Shorai battery in my Tuono, works great. LFX18 size/model. Never had one trip re-set with this battery. I have changed out the original starter relay and did the brown wire fix. My comute to work is only 13 miles. Yet will now start instantly, multiple times on my short 20 minute ride. I'm impressed with this new battery technology.

[WileECoyote]

Will you please let us/me know the stock number? I was just jumping on here to ask about these things as I have completely redone my T Including the tail section which requires a smaller battery. Are they made to be mounted laid down or sideways? You"ve done a nice job fitting it up.

[KIRK!]

Will you please let us/me know the stock number? I was just jumping on here to ask about these things as I have completely redone my T Including the tail section which requires a smaller battery. Are they made to be mounted laid down or sideways? You"ve done a nice job fitting it up.

They only make one 8 cell. The box says part #2113-0259. I'm not sure if that is Ballistic's number or not.

[WileECoyote]

Okay, I will tread away from work and look them up. Nice write up, maybe post in mod forums?

[The Foreigner]

Not to shit on your thread but .. Shorai /endofstory :)

[KIRK!]

Not to shit on your thread but .. Shorai /endofstory :)

OK, what does that mean? Shorais are great batteries. Tests I read rated them nearly the same.

[WileECoyote]

This is two threads you have interupted with bs Foreigner. (see Tip Over Switch) If you insist on being an asshat take it elsewhere. Now back on topic, I did have a look and know this will work for me. Thank you Kirk.

[KIRK!]

This is two threads you have interupted with bs Foreigner. (see Tip Over Switch) If you insist on being an asshat take it elsewhere. Now back on topic, I did have a look and know this will work for me. Thank you Kirk.

Cool. Like I said, I have only read tests and reviews on these batteries. These and the Shorais seems too good to be true, but time will tell.

[tscott]

What was the cost Kirk?

[KIRK!]

What was the cost Kirk?

Got it on eBay for $140

[madart]

I know a few blokes that have used these (and the SHORAI'S) in custom bike applicatons,(Harley- which is good shake test and ducati) and so far they have proved very good.
Apart from the light weight and compactness, they can be mounted any way you wish, sieways upside down etc. which is great for hiding them away.
Aparrently they do have to be taken in for a 'ballance' service yearly though.

[The Foreigner]

OK, what does that mean? Shorais are great batteries. Tests I read rated them nearly the same.

Worded it wrong, meant to say Shorai's are the nuts thats all.

[The Foreigner]

This is two threads you have interupted with bs Foreigner. (see Tip Over Switch) If you insist on being an asshat take it elsewhere. Now back on topic, I did have a look and know this will work for me. Thank you Kirk.

I interrupt any thread that contains dangerous borderline stupid ideas. Nothing more , dont take it personal as some noob ass may read your thread one day and think its cool to remove a tip over switch and then make an easily avoidable mess next time he crashes.

[KIRK!]

Worded it wrong, meant to say Shorai's are the nuts thats all.

No problem. I would like to see a thread on here with actual real world comparisons.

This thread however is just an install.

[WileECoyote]

Looking to buy two, one for my T and now my 996. That is quite a weight/size difference. The 996 has a behemoth of a 14 size battery that is capable of fitting in my lawn tractor.

[WileECoyote]

I interrupt any thread that contains dangerous borderline stupid ideas. Nothing more , dont take it personal as some noob ass may read your thread one day and think its cool to remove a tip over switch and then make an easily avoidable mess next time he crashes.

I apologize publicly Foriegner and to Kirk for screwing up his thread. I can be an ass at times. Point well taken.

[The Foreigner]

Thanks bud, sorry Kirk for the slight derail :) Apologies to you too

[KIRK!]

OK, only TWO days in and I'm pulling the Ballistic back out. It stumbled hard (barely starting the bike) this morning on startup and caused a dash reset. Maybe the 12-cell would do better, but I'm not taking the chance. For now, the stocker goes back in and the Ballistic goes down the road. The install is still valid, I guess, if you decide to use one of these batteries. Reminds me of the old adage - if it sounds too good to be true, it probably is.

[Clint_Fister]

I'm a visitor from the 750 DD Forum - but as I've owned 3 RSVRs I don't feel too out of place here.

I think this may just solve your issue as well...

I'm still trying to get to the bottom of why neither of the Evo 2 LiFe batteries I've got, work with my DD. Ballistic Components are at a loss as to why neither will crank the starter.
When I bypass the solenoid, the 8-cell spins the starter really strong, so, surely the solenoid can only be the culprit. I've changed the original for a new pattern part. Same result.
As it's only rated at 50 Amps, you'd have to suspect it just isn't up to the job of handling the output surge.

I've found a thread by a guy who had solenoid issues with a Futura. His solenoid was responsible for a 3v drop in output to the starter.
His solution - to put a Ford car starter in it's place that's good for 100 amp constant and 400 amp surge.
As these tend to be only used on older cars - and the type he used not being available in the UK, I've ordered one from
the US. Once I've fitted it (as you may suspect, it's a bit bigger!) I'll post up the result.

[speedkelly]

Ok, I give my 2 cents here. I do not have the Ballistic battery but a Shorai. I'm not even sure if they are the same type of battery? All I know is they weigh next to nothing.

We all know that the charging system on our Aprilia's is a weak point. First things first is to take care of the brown wire connector mess, then upgrade the starter solenoid, all very easy and cheap to do. Once this has been done most standard (read heavy) batteries will work just fine.

My first experience with the Shorai battery was not so great. I went with the smaller rated battery LXF14 (read cheaper) but had a few dash re-sets. Bike would start, but I could only get 2 or 3 starts out of the battery then it would re-set the dash? I first put this down to my commute being to short to put back the volts I was using to start the bike on my 13 mile 17-20 minute daily commute. I contacted Shorai and they sent me a stronger/more highly rate LFX18 battery, since installing this battery I have not had any starting or dash re-set issues. I have started the bike ten times in a row and no dash re-sets.
I'm really happy with the battery, bike will now start really easy, spins over super fast in the mornings, and no more dreaded dash re-sets. No need for battery tenders, the peace of mind knowing that my bike will start was well worth the added cost of this battery, plus with the weight I saved over the stock lead acid battery it almost cancels out the extra weight of running the stock boat anchor muffler!

[KIRK!]

I have done both of those electrical upgrades.

Three more crappy reset starts today.



Ok, I give my 2 cents here. I do not have the Ballistic battery but a Shorai. I'm not even sure if they are the same type of battery? All I know is they weigh next to nothing.

We all know that the charging system on our Aprilia's is a weak point. First things first is to take care of the brown wire connector mess, then upgrade the starter solenoid, all very easy and cheap to do. Once this has been done most standard (read heavy) batteries will work just fine.

My first experience with the Shorai battery was not so great. I went with the smaller rated battery LXF14 (read cheaper) but had a few dash re-sets. Bike would start, but I could only get 2 or 3 starts out of the battery then it would re-set the dash? I first put this down to my commute being to short to put back the volts I was using to start the bike on my 13 mile 17-20 minute daily commute. I contacted Shorai and they sent me a stronger/more highly rate LFX18 battery, since installing this battery I have not had any starting or dash re-set issues. I have started the bike ten times in a row and no dash re-sets.
I'm really happy with the battery, bike will now start really easy, spins over super fast in the mornings, and no more dreaded dash re-sets. No need for battery tenders, the peace of mind knowing that my bike will start was well worth the added cost of this battery, plus with the weight I saved over the stock lead acid battery it almost cancels out the extra weight of running the stock boat anchor muffler!

[WileECoyote]

Okay so now I'm bummed out as I've ordered an 8 cell and am waiting delivery. I also have the mods done to the charge system/starter circuit. Is it possible that you've loose connections or something simple? You appear to be on the ball so, no mud thrown just a suggestion. (I dont want any misunderstandings, I have learned from my mistake)

[KIRK!]

I double checked everything. It just doesn't have the oomph.



Okay so now I'm bummed out as I've ordered an 8 cell and am waiting delivery. I also have the mods done to the charge system/starter circuit. Is it possible that you've loose connections or something simple? You appear to be on the ball so, no mud thrown just a suggestion. (I dont want any misunderstandings, I have learned from my mistake)

[dnol04]

I sorted my dash resets with the usual brown connector, better battery etc..
Still found a little lazy starting from time to time so fitted a switch to kill the power to the headlight when starting and found it helped alot. Have since fitted a relay to cut the power to the headlight when the start button is pressed. Got the idea from a post by BigK I think it was on here.

[speedkelly]

"O" One other mod I made was to replace the center bulb to 35W/H4 bulb (ebay $7.00) instead of using the original 55W/H4Not sure if it really makes that much of a difference, but every little bit has to help. The main reason I changed it was my headlight glass would get so hot with the 55W bulb! It's not an issue with the 35W bulb.

[WileECoyote]

Hmmm, sounds like I might have options other than eating a 140 dollar battery.

[KIRK!]

Reinstalled the stock battery everything works great. Bummer about the Ballistic.

[Ario]

[QUOTE=speedkelly;3104770]then upgrade the starter solenoid, [QUOTE]

what's this mod about? I've done headlight switch, brown connector mod, charging mod (14[V] now) and still I can't burn one fuel tank without at least one dash reset ! this is rather annoying. maybe solenoid mod is my solution but how to do it?

[speedkelly]

[QUOTE=speedkelly;3104770]then upgrade the starter solenoid, [QUOTE]

what's this mod about? I've done headlight switch, brown connector mod, charging mod (14[V] now) and still I can't burn one fuel tank without at least one dash reset ! this is rather annoying. maybe solenoid mod is my solution but how to do it?

Just do a quick search under soleniod. It's a very quick fix. Ten minutes really, remove seat, and replace soleniod. You can buy them on ebay for $15-20 all day long.

[WileECoyote]

Well, Ballistic installed as well as the headlight switch mod. No problems after 2 days..................................

[planter87]

did you guys buy your batteries from af1? just having a look at their little write up blurb.

Please note the following conditions not covered under warranty:

-Physical Damage: Crashed, submerged, opened, or over torqued batteries are not subject to warranty coverage. -Overdischarge: While Ballistic Performance batteries have a slow self discharge rate, it is not infinite. Ballistic Performance batteries that are discharged below 11.2V will not be subject to warranty coverage. -Overvoltage or Overcurrent charging: Batteries that are not charged using Ballistic Performance approved battery chargers will not be subject to warranty coverage. -Short Circuit of battery terminals. Extreme care must be taken with Ballistic Performance batteries to ensure that the battery terminals are not short circuited during installation or operation. Short circuited batteries will not be subject to warranty coverage.

This product can not be shipped internationally.

must be hard to stop it going below 11.2 v when cranking and whats the deal with only being able to use their own type of charger to charge it up?