The Odyssey And The Pig

The battery arrived just as UPS stated a full seven days after I ordered it. I could not install it last Thursday when it arrived as I went to Las Vegas for the weekend to catch a couple shows. This past Monday being Columbus Day, I had it off so the Odyssey PC545 install was completed in my KLR650. Below is a write up and pictures on how it was done. As for the battery itself...I am pleased. It starts the pig right up with a quick squeal of the starter. I can honestly say I believe it starts better than when I had my Checker purchased Jeep Liberty battery connected to it. Loads of cranking amps and a hot spark.

First off there are a couple of ways to do this. Really it boils down to if you want to extend\replace cables or reroute them. I was not sure if you could reroute them but as it turns out you can with minimal effort. Same rules apply in that it must be mounted side ways with the negative side down.

As for tools, assuming you are not gonna go cutting and extending cables the only items you really need are below. A Phillips head, 10MM socket wrench a set of Allen keys, a small knife and some needle nose pliers. You may also need some scissors and a way to trim the metal bracket to size. I used a hand held grinder.

I picked up a few things from Ace hardware. I got some automotive Sponge tape and a galvanized metal bracket with a few flat stainless steel screws. I recommend some Blue Loctite also.

You will have to remove the side plastic and seat. Both can be done with the tools listed above.

Now you want to remove the old battery. You will need to disconnect the drain tube and unscrew the bottom metal bracket holding the battery in as seen.

Unbolt the battery terminals (in my case 10mm bolts) starting with the negative (Black) terminal first then the positive (red) last.

Gently pull the battery out from the left side. The plastic casing will come out with it.

This is what the old stock battery and how the new Odyssey PC545 look like side by side. We get a better understanding as to why the Odyssey has to be mounted sideways.

Nope not gonna fit.

One of the first things I did was cut the zip tie holding the battery cables to the frame. This will give you more room to play with routing the cables. After sliding the Odyssey in and trying to connect the cable to the terminals it still was not quite enough... but close. (Cut where my finger is touching)

By routing the negative cable back around the frame I was able to get enough with the main cable but it was just a little to short with this smaller M\F bullet connector that stemmed off from the main cable to the accessory cable that routed under the seat. (You may choose to extend this smaller cable if you are familiar with electrical otherwise there is another option.)

Instead of cutting and extending this cable I instead opted to reroute the main accessory cable. I simply began unbolted the clip holding it to the frame and disconnecting all these M\F bullet and clip connectors.

You can see in this pic that I rerouted the main accessory cable back under the tank and pulled it through the left side instead of directly through the middle. The negative M\F Bullet connector now reaches just fine. (See new accessory cable placement where my finger are.)

Make sure to connect all the M\F Bullets and pin\clip connectors back properly. Pulling cables back under the frame will be needed. As seen now, all connectors bolts, bullets and clips fit just fine.

Now that we know the battery fits and all cables are adjusted properly we need to secure the battery in the case. To do this I used some foam inside the plastic case to fill in the gaps and provide some vibration reduction and cushioning for the battery. I put three cut to length rubber padded tape for the bottom, two for each side and one for the back. Add more if you want. Reinsert the Odyssey while supporting it slowly and carefully as it can snag and tear the foam tape on insertion. There will be some resistance but not to much if its supported.

I also measured and cut to length the metal bracket I got from ace hardware and used another strip of the sponge rubber tape on it.

Now you want to take that homemade bracket with the rubber tape facing toward the battery and use the stainless steel screws to screw the padded bracket into the plastic of the air intake. They go in easily enough with some pressure on the Phillips head. (I used Blue Loctite to make sure the screws did not back out easily.)

Bolt the terminals back on starting with the positive first and check all the other connectors.

Now all you have to do is put the seat back on as well as the side panels and tighten everything down. You can still see the negative terminal with all of the plastic back on but at least now it is a lot easier to jump or jump another bike with only a couple screws needing to be removed.

Finally a little video of starting the KLR after the install.