My friend has a custom with an 80" evo that originally was getting too hot and the first battery actually melted some so a fuse or relay was put in on the line from the battery. IT's a silver metal box which leads me to believe it is a relay. Now, since the relay has been put in it will cut out every so often for no reason what so ever. I think that it is getting so hot that the relay is cutting out. Is there such thing as a bigger relay or should he put a big fuse next to the relay or what? Kinda hard to explain as the bike is not mine and I have not ridden it, but this is the best I can do thus far.

 

Sounds like a shorted wire...

Not a good thing to 'work-around'.

I'd try to find the wire/connection that is causing the problem.

 

A lot of relays and circuit breakershave a thermal cutout to protect it from burning out in the event of an "isolated" overcurrent/overheat situation. But if it keeps happening, ya gotta find the source of the problem....

 

So you're saying that there is an exposed wiring shorting it out somehwere?

 

Good possibility of that.

From the description you gave - I think it's a safe bet.

Kinda scary when you say it melted a battery.