electrical problems

[senseless_flight]

ok so i have an xb12r and for some reason i keep blowing/melting
my key switch relay.I'll buy a new one every couple weeks or so but they just end up heating up and melting the center metal bar on the relay and pretty much my bike wont start after that.I thought about buying a new box that the relays plugs into(hoping that will fix it).
any idea how i could fix this, I really use some help because i don't feel like taking it to Harley and getting raped.

 

[Buellysses]

Is the connection getting burned? Or just overheating?

My first thought would be a loose connection causing arcing in the connector.

 

[senseless_flight]

I think its over heating because it caused the plastic to melt where the relay plugs in.Plus touching the relay after a ride its super hot

 

[Buellysses]

There doesn't seem to be a real quick answer to this on google (and I'm too lazy to go pull one out of my bike), but what part number is the relay? From what I've been able to find it is a Tyco part, link to datasheet. Is that correct? or at least close? If not, what is the function of the pin that is melting off? I'm assuming its the N.O. contact.

If it is only one tab that is burning off consistently I am still going to say it's a loose connection. See if you can't get the connector out of the relay socket and pinch it up to tighten the connection.

You could also try putting an ammeter across pins 14 and 15 of the relay socket (corresponding to the common and N.O. relay pins) and starting the bike... see what kind of current is flowing.

With the prices of a new Buell, my third suggestion would be to drop a road flare in the gas tank. You may want to rig something up so you are FAR away from the bike. Then go get yourself a new one.