About a hour into a ride my 09 Dyna starts bucking on the highway then settles down, then is ok. About 1/2 hr later I come to a stop and the bike dies. Not even a click from the starter. Tow it home, pull battery ( about a year old) find negative terminal (black cable) melted.
WTF. Dead battery over charged? What to look for before I burn another battery or the bike.

 

terminal so melted couldnt tell if loose connection was the problem

 

Somewhere there is a positive wire grounding out with no load on it. I am surprised the circuit breaker did not pop. The battery could be bad. Inspect both battery cables (outside and inside the insulation), and make sure that they are tight. Electrical problems are a PITA. If you cannot see something is bad then it is a process of elimination starting with the stator and the coil, then disconnecting circuits at the fuse panel till you find the culprit.

 

You have a short somewhere. Figure that out before you destroy another battery while it's that close to your giblets.

Start with your most recent mod. Check all wires and connections. Look for rubbed or scorched paint. Smell for scorched materials too.

After that, move on to the next most recent change.

GM

 

changed exhaust system I had to remove and replace O2 sensors and wires.will check all connections. Thanks

 

Loose battery terminal connection will toast the terminal.

A short would blow the fuse, besides, there is no wire big enough to carry the current it would take to melt a terminal, except the battery cable itself.

Charge the battery fully and have it load tested, inspect all battery cables and connections.

 

I would agree with this.

 

I agree with Dan. The only problems I've ever seen with melted cables/terminals were the result of loose connections (or broken strands in the cable).

 

Classic loose connection

 

another vote for loose connection at the terminal