Battery Replacement with YUASA

Loose Positive Cable Meltdown

Since 2004 our talented techs have told us and shown us what loose battery connections can do. Check it out in this photo.

I carry a 10 mm wrench with me to check battery connections on long rides. I must have forgotten to check them on one ride and the positive terminal melted. Luckily it did not cause a fire or any other damage. That would have been a real pain in the wallet.

The HD battery was from 2013 and kept on a trickle charger when parked. It had a 6 year run and might have kept going if I had the positive cable tight. Not bad when average battery life is much less.

When we were in Las Vegas at AimExpo, we stopped by and saw the folks at YUASA to chat about their batteries. We reviewed the benefits of AGM batteries and the quality that YUASA has been known for since 1979. So after my meltdown, I decided to put one to the test. I reached out and they were nice enough to send me their AGM GYZ Series battery to replace the OEM battery.

We have several battery removal videos here on Fix My Hog and I will list them at the end of this article. I gathered some tools, my iPad logged into FMH, my service manual, dielectric grease and my patience.

This 2009 Sportster XL 1200 C negative connection to the battery is tough to get at on the battery while in the tray. On the video for XL battery removal our seasoned pro, Bob LaRosa, has the skill set and experience to remove and replace the negative via the battery. I recommend you do as I did if you ride an XL, remove the negative from the stud on the crankcase. First off and last on and make sure the rubber boot is on the starter cable nut to avoid making ground and sparks.

I removed the negative and positive cables and noted any additional connectors going to the posts. For me, it was the battery trickle charger wires and the power for the Cobra Fi 2000 PowrPro Tuner.


Follow your service manual and the simple instruction sheet from YUASA. They ask that you check and make sure the battery is fully charged.

I gave a quick cleaning to the battery box and inspection of the cables for wear. I installed the negative cable to the battery(with charger – wire) and taped the end that feeds down to the crankcase nut. I slid the YUASA battery into place. I connected the positive cable(with + charger wire and tuner power) and hooked the strap back in place. I removed the tape and installed the negative cable to the crankcase stud. My wobble extension was key to remove and replace this nut.

I double checked my work, added a couple tie wraps to hold the trickle charge wires in place, replaced the side cover and did a safety check to make sure everything was functioning correctly. Once all safety checks were done, I fired up the XL with ease.

It’s an easy DIY project to replace the OEM with YUASA’s GYZ Series AGM battery. With YUASA’s brass nuts, I’m sure my cables will stay on tight.

More about YUASA’s GYZ Series.

Related Videos:

XL Battery Removal
XL Battery Install and Electrical Check
Harley 103 Battery and Seat Removal
HD Motorcycle Battery Test Pre-Service
M8 Battery Check, Clean and Removal
Harley Davidson Charging System(TC Softail)
TC Dyna Battery Box
TC Dyna Battery Cable Attachment
Motorcycle Battery Maintenance and Overview
Motorcycle Battery Maintenance and Cleaning
Battery Cable Replacement on a Motorcycle
Read More in our Harley Tips under Harley Davidson Battery
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8 Responses to “Battery Replacement with YUASA”
  1. Roy

    Very good info. I am not a newbie Hog owner. Just a newbie at upkeep on ’em. Where do u get the ground, starter etc.. to replace on 86flhtc with 200000 m.

  2. john swack
    john swack

    I am trying to replace the battery on my 2006 sportster 1200 and cannot get the metal cover on nthe side that covers the battery to come off. I am afraid to force it , and the clips under the seat do not seam to want to let go. Do I just need to muscle it off or is there something I need to know?

    • Customer Service
      Customer Service

      “Hello John!

      That’s a great question!

      The ‘Ask an Expert’ section is currently for members to our online community. We do have a promotional offer if you are interested. This would include access to expert advice (like this), plus discounts, hours of Premium videos, etc. Please feel free to take a look. You can message us right back with your question if you decide to become a member and you will have a response within 1-2 business days from our experts!

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  3. Joel Parker
    Joel Parker

    Have a new battery that was installed yesterday and went to start today and battery was to weak to turn motor over what would drain the battery overnight

    • Customer Service
      Customer Service

      Hello Joel!

      Could we have the year and model of your bike?

      Thank you!

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  4. Timothy English
    Timothy English

    It must be a short I have a fuse that continues to blow. I’ll try to find it . Any help with that you have would be greatly appreciated.