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EV Battery Bolts - replacement job

September 10, 2015, 1:29 pm
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I'm a new member and recently bought a used 2010 EV. I am learning so much from this forum about re-building and retrofitting to fix the many short comings on design and materials so thanks very much! My latest was to replace 3 bad original batteries with new ones that match the other 5 which are new Trojan T-1275 batteries that the previous owner bought a few months before I bought it. So all 8 batteries are new finally...
But, I found all my battery bolts to be rotted badly with rust and not fit for duty. Instead of paying hundreds to by 12 replacement bolts ( Polaris Dealer wanted $49 each! and online I found $29) I designed and made my own bolts from stainless steel threaded rod. The whole project cost me about $80 including rods, washers, 8mm nuts and locktite (red high strength).

They are the same thread as the battery tray, 8mm x 1.25 thread. The 4 rods I bought are 1 meter long which makes it perfect to cut 3 sections at 13 inches each... the exact length I needed to make 12. I bought the rods and nuts, washers and locktite from Fastenal store in my town, they also have a web site, www.fastenal.com

I installed a nut 1/2 inch from the bottom and used locktite to make the nut permanent... use this nut to tighten the bolt into place in the tray. I found it important to buy a 8mm tap to clean out the hole first.

The plastic battery top straps are held on with a second nut installed from the top. This way the rod stays in its hole and all you have to do is remove the top nut and the strap comes off. This I found is very useful when adding water to my batteries. I used some marine grease on each end before inserting into the battery tray holes to resist rust and corrosion.

You can see my pictures at the link below hosted by Shutterfly - use the password TexasTea if asked. This is my first picture share so hope it works.

https://polarisrangerevforum.shutterfly.com/pictures
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Seat cover replacement

September 11, 2015, 4:09 am
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My 2011 has a tear in the seat (part you sit on). Where and how do I replace it?
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Dallas Area EV Service and Battery Recommendations

September 14, 2015, 8:47 am
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Hello, I'm a new member here. I decided to join after successfully changing the algorithm from 73 to 11 on my charger based on information found on this site.

Last year, we purchased a 2011 Ranger EV. We only use it on our small 10 acre property.

I am looking for a good place to take it for service in the Dallas area. We are near Rockwall on the east side of Dallas. So far, I have not found anyone who seems to have a good working knowledge of the EV. If you're from our area and could recommend a place, I would appreciate it.

Also if you could recommend a local place to purchase the US 12V XC batteries and exchange the cores of our old ones, that would be great. I'm still doing some testing, but our 4-year-old batteries, don't seem to be holding a charge very well. They were probably damaged from boiling over too frequently on the 73 algorithm setting by both myself and the previous owner. So I'm probably going to be looking at doing a complete battery replacement in the near future, whether by myself or a service department.

Thanks in advance for any recommendations you can provide.
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Replace PCM connector?

September 19, 2015, 11:01 am
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I have 2011 Polaris EV. New batteries and upgraded Delta charger by dealer in 2013. Noticed lately it would not hold charge long. Upon investigation, I see MPC has melted. I guess I need to change charger algorithm like every one else from 73 to 71? Problem is, how to I replace the melted MPC connecter? Is this a DYI project? Anybody have instructions on how to do it? or Is this best handled by Polaris dealer? Need to get fixed ASAP for trips I am taking to deer lease.
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Update on 72 algorithmn

September 19, 2015, 7:13 pm
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Today I rode my Ev for about ten miles and after the ride I changed the algo to 72. After several hours of charging the top of my batteries were starting to get moist from the bubbling. I stopped the charge and changed the algo back to 11. ( for the last year I have had the algo set at 11 with no moisture on top of the batteries). I will keep it at 11. Hope this helps.
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2000i Inverter

September 20, 2015, 5:42 am
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Went recently to hunting camp to spray roundup on food plots before discing and plugged the charger on the EV into a Powerhouse 2000i generator. seemed to have no problems. Its about a mile and a half to the farthest plot, terrain has several long steep hills to climb getting to the plots and also carrying 15 gallon sprayer loaded with water. also 3 5 gallon jugs for second load. ran for about a hours traveling 4 miles. I couldn't really tell how much the generator helped concerning added run time but it did not keep the battery meter from falling but it might have fell more without the generator running. This weekend we have a planting day at another camp and i plan to try it again. This time it will be all day, all the terrain will be flat and will be hauling seed and fertilizer back and forth to the plots while others run their seeders on the plots. Last year i recorded my trips on GPS and the EV went 18 miles and was down 30 percent on the battery meter. This year I will try the same but w the inverter connected.
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Front right axle: oops or oh s#!t?

September 20, 2015, 5:39 pm
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I have a 2015 EV that had a hard ride today - got stuck - and I used 4wd and my winch to help get it out. When I checked things over, saw that the front right axle had popped out. (see pictures.) Just looking at it, it is almost as if there's a nice gear there that could just be pushed back into place.

Is this "broken" or is it something that can just be popped back in? My dealer is a long way off and it's a pain to get my small car to haul the heavy EV.


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Wrench light

September 23, 2015, 1:59 pm
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Wrench light comes on after 3 seconds of turning the key to the on position. The unit will not move.

Any ideas? I've looked at the sensor on the brake handle (on dash), put in a jumper wire to bypass, same results.

Any tips would be appreciated.
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Battery Source in North Texas - (Good Deal Alert)

September 25, 2015, 11:59 am
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Just bought eight batteries from this gentleman. He rebuilds and customizes Club Car golf carts as a part-time business out of his home in Prosper, Texas. He also sells US12VXC batteries for quite a bit less than the other sources I've found.

Golf Cart Batteries, Prosper, Frisco, Celina, McKinney, Allen, Plano, Dallas and Surrounding Areas in North Texas

I got his permission to pass along the above link in case anyone is looking for new batteries in the north Texas area. His name is Dave.

Just wanted to pass on what I think is a really good deal.
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Lithium Ion Conversion

September 30, 2015, 3:02 pm
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I have started the process of converting my nearly new 2016 Ranger EV to Lithium Ion power. Why??? I hate lead acid batteries, they are so 1900 technology, and I am a techie at heart. I will be using Voltronix 260 Ah cells at a total cost for the conversion of just a little under $8000, less what ever I can get for the slightly used (three charges) LA batteries, like new hold own clamps, bolts and trays. And I don't need to spend $650 on a watering system, desulfators and battery pads! Asking price for the batteries is $150 each or all eight for $1000, for the bolts $100 and I will throw in the clamps and trays if anyone wants them. Attached is a photo of one of two battery boxes which I designed and built myself. I will keep you posted on progress.
I will also be making custom mud guards and fender flares from eighth inch ABS, using a heat gun to bend. No one seems to be making them commercially yet for the 2015-16 models.

Attached Images
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Front struts

October 1, 2015, 12:27 pm
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Had the front end jacked up today and noticed some oil around the top of the strut shocks. Took the tires off and put a jack under the strut to jack up and loosened the two bolts holding the shock in the strut. could reach inside the spring and move the bottom of the shock up and down the shaft. looks like both the shocks are shot on the front. had been hearing a poping sound when creeping forward or backward but haven't able to isolate it just know it comes from the passenger side. replaced bearing, pivot bearing and tie rod end with no luck. maybe this is it.
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New 26" Tires

October 2, 2015, 4:33 am
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Just installed new Carlisle ACT HD 26x9x12 and 26x11x12 tires on my EV. Man what a difference. Goes up muddy banks with ease now. On the downside they have a little vibration over the RipSaw tires. I would do the RipSaw over these in the future but for these are a close second.
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Polaris EV-Upset costomer in Charleston , SC

October 6, 2015, 11:03 am
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I have a Polaris EV. I have read most if not all of the post on this and other forums and know that I am screwed when it come to the motor and electrical issues that this cart has or will have! I just paid my local Polaris dealer $3300.00 to replace the 48v motor,at 57hrs of use (the new motor has only a 30 day warranty)!!!! My cart is out of the 6mos warranty. My dealer prompted me to use the customer service claim center and they were nice enough to help get the ball rolling, but I knew it was going to be a waist of time!!! I am pissed!!! And the claim manager at Polaris said that a warranty is a warranty!! I know this but at 58hrs don't you think there should be an exception to the rule? I am not asking for simpathy, i am planning to go the extra mile! I would like to reach out and ask if anyone has the E-Mail or PH# to Scott Wine-CEO of Polaris? If i can contact him directly and voice my complaints then I would feel like i have have done all i can do! If anyone has any other course of action i should take please feel free to contact me!!! Thanks, Chuck
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Oil pressure ?

October 8, 2015, 4:41 am
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My 2013 Polaris Ranger XP 800 has 25 psi at 6,000 rpm. What I was wondering is what should the oil pressure be at idle or around 1200 rpm. Does anybody know??
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Ranger EV problems

October 8, 2015, 8:15 am
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Hello all. I'm seeking any input you all may have regarding some issues I've been experiencing with my 2015 Ranger EV.

Here in the last couple months I've noticed some sever power loss while going up hill. This power loss is not a slow tapered loss, like you would experience if your batteries were at or near dead. But rather it is a jerking, in and out, in and out, power loss. I only experience it going up hill.

Battery posts had some pretty bad corrosion about a month ago. Cleaned them up and sprayed them down with a preventative. Fill with distilled water regularly. I don't think its is a battery issue. To me it seems more like a motor, transmission, differential issue.

Any thoughts?

Thanks in advance.
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2015-16 Ranger EV Mud Guards/Fender Flairs

October 11, 2015, 2:03 pm
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"IMHO the mud protection on the Ranger SUCKS. My old, almost worn out, Club Car XRT950 is 10,000% better in that department! It has real real fenders and a sealed storage area under the hood. If it were only electric!"

I have been able to find nothing in mud guards for 2015-16 Ranger EVs so..... While waiting for my charger and controller to be reprogrammed for Li Ion, and the whole Li Ion package to be delivered (next week, I hope), I have been fashioning mud guards for my 2016 Ranger EV from eighth inch ABS with the help of a heat gun. The front and under cargo bed guards are complete, but the latter are subject to future modification. The rear fender guards, to prevent splash into the battery box through the slot between the sides and the OEM guards, are nearly complete and I have plans for front fender protectors and side belly pans. Ultimately I envision the front fender protectors, side belly pans and rear fender guards to be tied together to essentially eliminate mud from the battery compartment.

In front I have the OEM brush guard so it dictates the maximum amount of fender flair. The flair is trimmed to just clear the brush guard. At the rear, the under bed guard runs out from the main frame of the bed to a 3 1/8" flair. I plan to replace the stock tires with more aggressive 16" tires before long. After that I will study the mud pattern under the guards and trim accordingly. The front of these guards are bent down at a 60 degree angle to prevent the rear tires slinging mud over the forward guard. This angle may be reduced after testing.

The side pans, which I am working on, will completely cover the undersides from the main frame members to the outer frame and side covers. The front fender protectors will be similar to commercial products for earlier EVs except they will extend out to form flares and will extend down and be bent back to protect the front ends of the side pans The bottom of the rear protectors will be bent forward over the side pans for protection.

I hope some of this makes sense :D.

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Amp Outputs for Various Delta-Q Algorithms?

October 12, 2015, 6:27 am
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My apologies if this has be answered elsewhere. I did a search and did not find it.

For every other battery charger I've ever used, I've been able to easily find the Amp output for the charger. All I've found for the Delta-Q is a Ah range for the batteries that the algorithm is recommended for. Why so secretive? Is this information available somewhere and I just haven't found it?

I recently installed new batteries, new battery trays, new bolts and cleaned up and repainted the frame. My Delta-Q is on algorithm 11 right now. I've spent quite a bit of time and money to get everything "like new" and I'd like to keep it that way.

Toward that end, I installed a BatteryMinder 48021 48v/2A charger/desufator and I hope to be able to use that rather than the Delta-Q a lot of the time. And I know people on this forum have had good experiences with algorithm 11. But I'd still like to know the outputs of the Delta-Q algorithms. Hoping someone has either found this information or has done some testing to figure it out.

THANKS! This site has been super helpful. I have found no better source of information than right here.
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Best Coating for Battery Trays?

October 16, 2015, 3:33 pm
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I am in the process of replacing my batteries and painting my battery trays. What would you all recommend for re-coating the trays and frame with? I have heard some people using truck bed coating but was unsure about the longevity. Has anyone every used the POR 15 spray coating? I also thought about using Industrial Rustoleum in a spray can. Thanks!
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Heater Options for 2016 EV

October 22, 2015, 7:11 am
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Recently purchased 2016 EV, looking for a heater.

Polaris says the heater kit for the 2010-2014 will not work in the 2015-2016. Evidently the plastic will melt per the local Polaris dealer and there were some changes to the dash/cab too.

What are you guys using for a heater in your 2015-2016 EV's?
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Anyone find fix for squeaky suspension?

October 29, 2015, 4:27 am
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Guys we love our EV's except for the squeaks and rattles. Anyone have a fix for the squeaky suspension system? We've tried spraying it down with oil etc on all the moving components but only helps a little. Any idea? After one guy standing on bed and jumping up and down the other listens for the squeaks and sounds like its coming from inside the shocks. Is that possible? If so probably why external lube is not correcting issue. The squeaks are louder than the already to loud AC motor. If I fix this issue though then will be a happy camper as we will do the same to all our EV's.
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