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Battery terminals melted

7530 Views 13 Replies 11 Participants Last post by  SCHMIDTY
I recently purchased a 2011 HD Street Bob. The bike will occasionally just shut off for a split second, the speed odometer, the engine and the lights will shut off and then a split second later come back to life. It does it just at random times, sometimes it wont do it for a week or so then it will do it once or twice during a ride and other times I cant even leave the parking lot because it is so bad.
I took the battery cover off and noticed my battery cables had pretty much welded themselves to the battery posts. my question is, what would cause this? Are these two problems related? does anyone know the correct stock amprage on this charging system? I looked at the stator and the regulator online and the only thing that it says will fit my bike is a 50 amp charging system when the main fuse is a 45 amp fuse.
HELLLLPPPPPP! :feedback:
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Loose connections at the battery posts would cause your problem.

When they are loose, they will arc due to the intermittent connection...

Arc just like an arc welder.
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Yep kainan nailed it! Both issues from loose connections at battery.


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I was really hoping to receive that answer. I am going to go buy a new battery tomorrow, any suggestions for what kind of battery I should get?
I like the Yuasa GYZ series batteries.

Your bike takes a GYZ20HL
Agreed with Kianam Loose Terminal connections
As usual, good info K
Great! Thanks for all the help!
I recently purchased a 2011 HD Street Bob. The bike will occasionally just shut off for a split second, the speed odometer, the engine and the lights will shut off and then a split second later come back to life. It does it just at random times, sometimes it wont do it for a week or so then it will do it once or twice during a ride and other times I cant even leave the parking lot because it is so bad.
I took the battery cover off and noticed my battery cables had pretty much welded themselves to the battery posts. my question is, what would cause this? Are these two problems related? does anyone know the correct stock amprage on this charging system? I looked at the stator and the regulator online and the only thing that it says will fit my bike is a 50 amp charging system when the main fuse is a 45 amp fuse.
HELLLLPPPPPP! :feedback:
I know this is an old post.. this just happened to me on my 2020 sportster.. loose connection for sure.. arc so hot that it melted the connector so many times and finally fell into pieces.. crazy
Also check your cables, the pos one, for a rub spot and shorting.
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I had to put a piece of rubber on neg side of wife's old sporty because it was tooo close to frame and melted a couple times
And I would replace the cables where possible. Once welded and broke free, hard to file them flat enough for a solid connection.
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I had this happen on two different bikes. What I figured out was that you are supposed to use those brass washers that come with a new battery. I didnt think I needed them but without them, my cables didnt sit flat on the terminals and would work loose, melt stuff, ruin batteries. I put the washers between the cable and the terminal, flat on the washer down. Tightened them up and they are staying tight. Kind of a duh moment for me.


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FYI when you get that new battery that requires the brass terminal spacers, clean the terminals and spacers with brake clean or alcohol swabs and apply the brass spacers to the terminals with super glue and put the bolt in to align the spacer and let the glue set. Now you'll be able to install the new battery without having to use that 3rd hand to keep that brass spacer in place !
Also that brass spacer is in the battery install kit due to patents on battery designs.
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