How to Replace J100 Battery Terminals

Key Steps

1. Remove the outer battery cover screws 0:06

• Remove the 8 outer screws from the battery cover.
• Start with the lower screws first, then flip the battery over to remove the remaining screws.
• Keep screws organized so they can be reinstalled in the same locations.

2. Remove the rubber terminal caps and top cover screws 1:01

• Use a spudging tool; if unavailable, use a pick or flathead screwdriver.
• Insert the tool into the side of each rubber cap and pry upward carefully.
• Remove all 4 rubber caps.
• Switch to a 3 mm driver and remove the screws underneath the caps.
• Lift the battery top open like a clamshell once all screws are removed.

3. Disconnect and protect the battery leads 2:04

• Remove the leads in this order:
  • Positive lead first
  • Negative lead second
  • Two signal harnesses last
• Use a Phillips-head screwdriver to remove the lead fasteners under the white silicone.
• Immediately wrap each removed terminal lead with ACE tape or electrical tape to prevent accidental contact.
• Repeat the wrapping step for the negative lead before removing the signal harness cables.

4. Separate the battery top from the cells 3:23

• Once all leads are disconnected, separate the battery top from the battery cells.
• Move the cells out of the work area to avoid damage during terminal replacement.
• Confirm the top assembly is fully independent before continuing.

5. Remove the old terminal set 3:39

• Identify the female positive terminal and female negative terminal.
• Remove the 4 screws per terminal set.
• After loosening all screws, pry the terminal upward and out of the cover.
• If the terminal is embedded in potting, use a heat gun on the lowest setting in 30-second increments to soften the material.
• If needed, use a spudging tool, flathead screwdriver, or mini pry bar to lift the terminal free.

6. Repair damaged potting and install the replacement terminal 5:09

• Inspect the area where the terminal was removed for peeled or damaged potting.
• Replace damaged potting with a marine-grade, waterproof, electrical-grade, heat-resistant silicone.
• Apply silicone to the exposed area.
• Position the new terminal in place and screw it down securely.
• Allow the cover to cure for 24 hours or for the full cure time specified by the silicone manufacturer.

7. Reconnect the battery leads in the correct order 5:48

• After curing, begin reassembly.
• Reattach the two signal cables first:
  • Signal cable 1
  • Signal cable 2
• Next, attach the negative terminal.
• Then attach the positive terminal.
• Start the screws by hand, then fully tighten them with a Phillips-head screwdriver.

8. Reseal the terminal leads and allow final cure time 7:04

• Reapply silicone to the areas where the white silicone was originally located.
• Tighten the terminal lead first, then apply the silicone sealant.
• Allow the silicone to cure for 24 hours before handling or reassembly.

9. Reassemble the battery and complete post-repair charging 7:33

• Reinstall the battery top.
• Install the 4 main screws.
• Flip the battery over and install the 2 screws on each side of the terminal.
• Tighten all 8 screws securely.
• After repair, perform slow charging for the first 3 cycles to verify proper battery performance and reduce risk of cell issues.

Cautionary Notes

• Disconnect and wrap leads immediately after removal to prevent short circuits.
• Apply heat only on the lowest setting and in short 30-second intervals to avoid damaging the battery cover or internal components.
• Do not proceed with reassembly until silicone has fully cured.
• Be careful when removing the negative terminal, as it may pull up or damage the potting material.
• Follow all battery safety procedures and work in a controlled, non-conductive area.

Tips for Efficiency

• Keep screws separated by step in labeled containers or trays.
• Use tape to mark removed leads so reinstallation order is clear.
• Inspect the potting and silicone condition before installing the new terminal to avoid rework.
• Plan for the full cure time in advance so the battery is not handled too early.