P500 Dual battery charging system problem

[sam3006]

I installed the Warn dual battery kit on my 500, 2 years ago. It worked fine for a while, but now it only charges the cranking battery and no matter how hot it is, never sends a charge to the #2 battery, even when the main battery is showing full charge it still send all power to it. I replaced the SOLENOID RELAY with no change. I've looked for warn part # 80110, the black plastic part between the wire and solenoid in the picture and can't find it listed anywhere, not on Warn's web site or any parts places. I get inconsistent reading from my volt meter when checking the one on my 500 and after running all the connections and replacing the solenoid it's about the only thing left to try, if I could find one. Anyone else have an idea or guess to what could be the problem?

 

[Caper]

I installed the Warn dual battery kit on my 500, 2 years ago. It worked fine for a while, but now it only charges the cranking battery and no matter how hot it is, never sends a charge to the #2 battery, even when the main battery is showing full charge it still send all power to it. I replaced the SOLENOID RELAY with no change. I've looked for warn part # 80110, the black plastic part between the wire and solenoid in the picture and can't find it listed anywhere, not on Warn's web site or any parts places. I get inconsistent reading from my volt meter when checking the one on my 500 and after running all the connections and replacing the solenoid it's about the only thing left to try, if I could find one. Anyone else have an idea or guess to what could be the problem?

View attachment 81011

Didn’t know where you can find one but then again I didn’t think the 500 could have two batteries. Where does it go. Learn something new every day.
Caper

 

[trigger]

I installed the Warn dual battery kit on my 500, 2 years ago. It worked fine for a while, but now it only charges the cranking battery and no matter how hot it is, never sends a charge to the #2 battery, even when the main battery is showing full charge it still send all power to it. I replaced the SOLENOID RELAY with no change. I've looked for warn part # 80110, the black plastic part between the wire and solenoid in the picture and can't find it listed anywhere, not on Warn's web site or any parts places. I get inconsistent reading from my volt meter when checking the one on my 500 and after running all the connections and replacing the solenoid it's about the only thing left to try, if I could find one. Anyone else have an idea or guess to what could be the problem?

View attachment 81011

My guess is the second battery is dead. Pull it out and have it tested or try putting a charge on it. I have a second battery under the seat and just have them wired in parallel. An isolator really isn't needed on the P5. Good luck.

 

[Caper]

My guess is the second battery is dead. Pull it out and have it tested or try putting a charge on it. I have a second battery under the seat and just have them wired in parallel. An isolator really isn't needed on the P5. Good luck.

Did you put the battery in the plastic compartment under the drivers seat. And do you use a gell battery.
Caper

 

[Caper]

Did you put the battery in the plastic compartment under the drivers seat. And do you use a gell battery.
Caper

That sounds a bit easier , if I put one in. Thanks.
Caper

 

[trigger]

Did you put the battery in the plastic compartment under the drivers seat. And do you use a gell battery.
Caper

Here it is...
P500 - Battery Under Seat?

 

[sam3006]

I put a new #2 battery on it, if I charge it manually it works fine, just won't charge from the 500's system. It did work for about a year and a half. When I noticed the battery was too low to work the winch I put a new battery on it.
I mounted mine under the front hood.

 

[trigger]

I put a new #2 battery on it, if I charge it manually it works fine, just won't charge from the 500's system. It did work for about a year and a half. When I noticed the battery was too low to work the winch I put a new battery on it.
I mounted mine under the front hood.

Gotta be that isolator then. Voiced my opinion of them a few times but some guys swear by them. Sure would suck to be stalled out and trying to winch out of a hole and your second battery dies. That isolator wouldn't allow you to pull from the fully charged battery. @lee pointed out that the P1's have issues if the voltage drops too low, so maybe a manual one. It's not needed on the P5 though and it would have to be something pretty demanding to drain two batteries. Chuck that isolator and carry a little Noco. Just my 2...

 

[TeamCheap]

Gotta be that isolator then. Voiced my opinion of them a few times but some guys swear by them. Sure would suck to be stalled out and trying to winch out of a hole and your second battery dies. That isolator wouldn't allow you to pull from the fully charged battery. @lee pointed out that the P1's have issues if the voltage drops too low, so maybe a manual one. It's not needed on the P5 though and it would have to be something pretty demanding to drain two batteries. Chuck that isolator and carry a little Noco. Just my 2...

Interesting what size NOCO box would you recommend ??? I'm guessing a NOCO GB20 would be more than enough.

 

[trigger]

I carry one of these, 600 amp Bestek. Has jumpstarted trucks too. The days of jumper cables are long gone.

 

[TeamCheap]

I carry one of these, 600 amp Bestek. Has jumpstarted trucks too. The days of jumper cables are long gone.
View attachment 81093

I'll just use the viking jump box I got from HF for now, had it in the wife's car for that "just in case" moment, guess I'll just slip it in a freezer bag and store it in the front storage area.

I need to add an accessory battery to our P5 in the near future so I can add some lights and use the winch, I have such limited time to work on ours right now because it is at the other house.

 

[sam3006]

As for backup for the backup, I have a Noco Genius Model# GB40. It stays in my truck, but when I'm in the 500 away from home, like in Colorado or at deer camp, I have it in it. I also carry it in my boat. Last year my cranking battery went dead on my 200HP Evinrude while I was out on a lake, I jumped it with the GB40 and ran back to with trolling motor range of the launch ramp and stopped to fish some more. I started the 200HP motor 4 more times off the NOCO before it wouldn't crank it. Still had some power in it, but that 2000 year model Evinrude has to really spin to crank. I also like having the GB40 in my truck in case someone else needs a jump and I can help them out without hooking up to my truck. Pretty cheap insurance for about $100.

 

[Mudder]

Noco GB40 here, also got their battery clamp to cig. Plug adapter to run compressor and and water sprayer directly off extended battery terminals inder hood. Don’t want to risk blowing factory fuse in that muddy PITA OEM fuse box on the trails.