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Old March 10th, 2017, 07:27 AM   #1
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Joined: Jul 2016
From: Dehradun, India
Posts: 14

I Ride: 2014 Hyperstrada 821, KTM 390 Duke, Royal Enfield C5 , Yamaha R15, Homebuilt ACE FIREBALL 535
Battery Terminal Gremlins

My Hyperstrada stalled a couple of times , with all indicator lights off and no display. The Bike would come on after a few seconds of turning the ignition key and engine kill switch off and then on again. The ECU would reboot , and i saw the software version messages on the display. All wires , connectors and fuses were OK and i really was in no mood to dig deeper and planned to take it down to the dealer to have it checked out.
Last week , the bike refused to turn on and i just popped the seat to see if i could jiggle things around , hoping something would come up. As i shook the ECU , i saw some sparking at the battery terminal. A closer look under the rubber boot and a torch revealed a terminal connector that was broken clean through across the right angle bend.
It turns out that the terminal is made of Nickel Plated steel and is stamped into the 'L' shape. I fabricated a new clamp out of a sheet of Copper I had lying around and figured to keep the bike running well till I could get a spare cable .
Pics of the break and the fix are attached. Useful to check your terminals before you end up stranded on the road someday
Attached Thumbnails
Battery Terminal Gremlins-hyper-1.jpg   Battery Terminal Gremlins-img_20170305_125718764_hdr.jpg  
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Old March 10th, 2017, 07:42 AM   #2
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From: Minnesota
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I Ride: 13' Hyperstrada, 00' M900Sie
Quote:
Originally Posted by hexanerax View Post
My Hyperstrada stalled a couple of times , with all indicator lights off and no display. The Bike would come on after a few seconds of turning the ignition key and engine kill switch off and then on again. The ECU would reboot , and i saw the software version messages on the display. All wires , connectors and fuses were OK and i really was in no mood to dig deeper and planned to take it down to the dealer to have it checked out.
Last week , the bike refused to turn on and i just popped the seat to see if i could jiggle things around , hoping something would come up. As i shook the ECU , i saw some sparking at the battery terminal. A closer look under the rubber boot and a torch revealed a terminal connector that was broken clean through across the right angle bend.
It turns out that the terminal is made of Nickel Plated steel and is stamped into the 'L' shape. I fabricated a new clamp out of a sheet of Copper I had lying around and figured to keep the bike running well till I could get a spare cable .
Pics of the break and the fix are attached. Useful to check your terminals before you end up stranded on the road someday
I replaced all the starter/ground wiring with 4 gauge marine-grade wiring, with soldered-on heavy duty copper lugs. I'll try to get some photos up this weekend, but glad to know I won't have this issue!
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Old March 10th, 2017, 03:29 PM   #3
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From: California
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Thanks for the heads up!
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