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Dual Battery Setup on a Honda ATV
This was done on a 2002 Rubicon however it could be done on any ATV.
Background:
This all started when I received a oversized 4500LB winch from Viper. Who was I to complain?
Well that winch draws some power and after the first time it killed my battery I decided it was time to do something different. My first thought was a better battery so I dropped the big bucks on a Ballistic Gel Battery. I learned shortly after that that wasn’t my answer. The Ballistic batteries are great for a lot of things but not running a 4500LB winch. So back to the drawing board.
I thought if I could use a AGM (Sealed Glass Mat) battery for the winch, a second battery for everything else and could separate the two as well as charge the two then I wouldn’t have any more issues with a dead battery from a winch.

Supplies needed:
Ballistic Evo2 Gel Battery $150.00, Ebay. These batteries are super small and can be mounted anywhere at any position.
14BX AGM Battery or your old primary battery for the secondary.
80 amp Stinger Isolater $18.00 Ebay
1 Add a circuit fuse I used a 10 amp fuse from O’Rielly’s $8.
Some 8 Guage cable and eyelet connectors, I had some surplus winch power cable. You could use standard battery cables with eyelets from any auto parts store.
Marine grade SPST push button switch $10pr Ebay
LED Indicator light (Optional) Radio Shack $8
Misc primary wire
Connecters
1 Inline fuse I used a 10 Amp
Misc. Stainless steel fasteners

Installation:
I relocated my primary battery and installed Isolator in storage trunk. I used the existing toolbox rubber strap and relocated the hooks to hold the batter in place. This is the same type of strap Honda uses for the OEM battery. Anything bolted into the storage trunk I used Stainless Steel screws or bolts. In order to make this work I pulled the storage trunk out. Modified the rubber strap hooks and drilled with a 1” hole saw from the back of the box to a matching hole in the back of the rear body plastics near the fuse box.
The on off switch was wired to the accessory fuse. I used a ADD-A-Circuit fuse and installed it on the AUX fuse in the main fuse panel. This is a key on circuit. The on off switch and LED indicator were mounted in the plastic cover where the Ignition switch is located. The purpose of the push button switch is to charge or isolate the secondary battery on a as needed basis. Being able to run my winch from the secondary battery without affecting the charging system or the primary battery, and then being able to recharge the secondary battery. This can also be useful for other 12V items you might run like a stereo.
I have included a wiring diagram, installation pictures of the final setup and pictures of the supplies/parts I used.



 

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Great write up man!!!! Thank you. Very informative.
 

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Discussion Starter #3
Maybe it will earn me a "Sticky" on my first real post? ????
 

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I could see that happening. Lol.

Some members here go thousands of posts without stickies. ;) Lol. RICH450ES

Is there anyway to do this less expensively??
 

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Discussion Starter #5
Making that diagram should count for something right?
 

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I already told you good job, you want a kiss on the forehead. Lmao!!! J/k.
 

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Discussion Starter #7
kisses are good..... Just not from YOU!!! LOL
 

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I've always wondered how to do this. Great job!
 

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I could see that happening. Lol.

Some members here go thousands of posts without stickies. ;) Lol. RICH450ES

Is there anyway to do this less expensively??
i wounder who youre talking about ss .......asss hole
 

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Discussion Starter #10
FYI, Ballistic warrantied my battery for me.. Now check this out! They sent me my new battery without me sending them the old one first! IF THAT AIN'T CUSTOMER SERVICE I DON'T KNOW WHAT IS!!! Awesome group there! They provided a return label for the old battery to go back, no questions asked, no hassles! If you get a chance check them out!

Ballistic Performance Components
 

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Great write up. Whenim done with all my bs with my bike I might have to try this.
 

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Thats a Great "How to" Should be made a sticky!

ohhh yea Welcome to the site!
 

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good job, man...but i would've just sent the 4500 back for a regular 3000-3500 atv winch!
 
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Definitely gonna be doing this once i get my 3500lbs winch
 

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I run a 3500 Superwinch on the 2015 Rubicon. I have never killed the battery or needed a 2nd battery...
 
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