Any ideas as to why both positive and negative terminals would melt while connected. To clarify, I am not new to motorcycles. I own 7. 2 of which have been rebuilt by myself. 3 are current build projects. The issue is on my 2004 Road King. Ironically the battery has a full charge and less than 6 months old. Napa Legend battery. I have already got a replacement, so no photos available. It starts and runs normally. Lastly, there are no additional accessories on the bike. Not only did it melt the terminals, it melted the protective lead covers and the bottom of my seat. Thoughts.

 

Very common for poor / loose connections at the battery to cause this ... Good Luck

 

Terminals loose is the most common issue. Next would be the where the cable is crimped to the wire becomes resistive. If the battery is new, most likely issue is loose terminals.. You should always check after some miles. It should be part of your regular maintenance also.. While you are at it, check the shift lever fits on the shafts in both the front and where the arm comes out of the tranny.

 

I also add star lock washers to the battery bolts....just an extra form of insurance to make sure the bolts stay snug.

 

Did you use the terminal spacers that should have come with that Napa battery? They come attached (along with the screws) to the red plastic terminal cover