Hi I just got back from a 4 month deployment to Iraq and when to start my 2006 HD Street Bob (FXDBI) and the battery was dead so I went to the local auto shop and bought a replacement battery and the bike then started fine. I let it warm up for about ten minutes and took it out around the block. The bike died during my trip around the block but I was able to restart it and make it home before it died again in my drive way. This time I could here the bike clicking with the bike turned to off, so I took a look at the battery (which was installed correctly) and the positive terminal was melted. There was no arcing I could see between the terminal and the battery housing. Do you think this is a bad battery or something else wrong with the bike? Maybe a bad voltage regulator or alternator? I don’t want to put another battery in a melt it too. Can you help?
Marc, Welcome home. Battery was either not fully charged, always use a Harley battery, or terminals were not tight enough (most likely the cause when positive side melts ). Perform a proper charge system test according to the 06 service manual and Softail Edition DVD. Dynas are a real bear to tighten the terminals but it must be done right, also check grounds to frame.
Wrench Safe, FMH