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Went to start my 08 FXDL yesterday and got a half crank then nothing. 2nd battery in 10 years. Thought it might just be time to replace it. When I took the battery out this (photo below) is what I found on the terminals. Its been connected to a battery tender since installed while sitting. Ive got it on a charge now. Seems to be taking it. Any thoughts. Been riding, some wrenching for 40+ years, this is a first for me. Seen terminals melt when connections get crossed but never this.
Was there a spacer on each terminal when you took the leads off? This is a common issue with aftermarket batteries (even when made by an official supplier). Notice how your terminals are slightly inset from the edge of the case? If your cables are attached without a small spacer (which most batteries ship with), they won't always sit fully flat against the terminal due to interference with the case. When they aren't completely flush, excess resistance can result... Which can end up burning the terminals.
Was there a spacer on each terminal when you took the leads off? This is a common issue with aftermarket batteries (even when made by an official supplier). Notice how your terminals are slightly inset from the edge of the case? If your cables are attached without a small spacer (which most batteries ship with), they won't always sit fully flat against the terminal due to interference with the case. When they aren't completely flush, excess resistance can result... Which can end up burning the terminals.
I think you nailed it. There was no spacer. Going to correct that with a spacer right now. Thanks for your help.
Terminals melt when they aren't making good contact. You're going to have to file your terminals flat then use the spacers to be sure you have lots of surface area contact between the terminal and the cable.
You're not going to repair that sufficiently enough for a good connection. Chalk it up to a lesson learned and buy a new battery. That's a problem waiting to happen.
Thanks everybody. Did use spacers and loctite👍 After filing down terminals flat spacers made up for surface lost as well. Charged and ridden this afternoon. They are tight now!
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Melted terminals 08 FXDL
