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Those era Dynas were known for weak starter wiring, but it shouldn't get hot like that just by sitting, so my first thought is that you have a nasty short. When you hook the battery terminals up, does it spark? Before you do ANYTHING else, you need to find that short. THEN we can diagnose other issues.
By chance, is the metal battery tray resting (contacting) on the positive bolt/terminal on the starter lug that sits about a 1/2 inch underneath the battery tray?
On my Dyna, when removing the battery you remove 2 bolts on the left (rear) side of the battery box. Then the battery box is lowered by rotating a larger bolt under the seat.
If it's lowered to far, a sharp metal edge on the underside of the battery box can cut thru the rubber boot protecting a starter lug (positive) that I mentioned earlier. This will cause a dead short. Lug on starter is positive, battery box is negative...contact equals dead short.
I have since replaced my rubber boot, and glued a piece of rubber to the underside of the battery box in that area to prevent this from happening again. The weight of the battery in the box and that sharp edge on the underside of the battery box, along with repeated battery removal or lowering to gain access to the battery terminals can cause this issue.
Just something to look at.
Besides that, it sounds like you have a dead short somewhere in the electrical/starting circuit or the battery is old and not holding a charge.
thank you and after todays work see below, i replaced starter relay and found rusted connectors today so i will clean up connections and check negative & positive cables to battery tomorrow. Thank you to all for your guidance!.
when installing new battery today small spark when putting neg. on, connected the lights came on for few seconds hit start button but nothing & all turned off. turned off and on click in for seconds then out.
i also have a click noise from starter relay switch area every 15 to 30 seconds just one tick when battery was connected? pulled battery and was at 12.1 but checked connectors, they all need cleaned up.
i also checked battery tray, previous owner cut hole battery box tray and rubber boot with black foam tape strip. positive 96, but title is non harley, said it was trip frame? strong bike, andrew gears trans. s&s.
Last edited by 96 wide glider; Mar 3, 2024 at 08:46 PM.
Reason: adding
Thank you to all, this is my Army brothers & he isnt doing well, I offered to help as much as my limited ability. After PM today this is what I have found & hopefully this will correct issue. Bike was running great, carb adjusted then my brother put socket over one plug to check firing & then he forgot & I am on other side of bike trying to crank with socket on plug... Here is pictures,. THANKS AGAIN
Appreciate your guidance & will be getting back into it soon. Owner bought new voltage regulator & plug wires so will try to cover spot on box, looks like someone cut tray for hole but still hits!!! Thank you & will let you know soon. Thanks again for heads up.
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