Intermittent charging mystery

Andy Higham said:

Those connections have got hot due to poor conductivity.
A pair of pliers is not a suitable tool for crimping connectors, get the correct tool

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Also, you are spot on - I did use pliers on a Leatherman multi-tool when those connections were made back in 2018. I did use a crimping tool today with the connectors that I had. I have to get a couple more and have just spliced and taped in a couple of spots until I get to a store. Thanks again.

Supercat said:

Thanks! The short I mentioned wouldn't cause that?

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The AC wires and terminals have to be low resistance because current is large and resistance causes the voltage at the point of the resistance to rise, thus generating power as heat.

A boat supply store should have tinned copper wire in various gauges and colors. It’s also multi strand fine and very flexible. I use crimp and seal connectors with the proper tooling. The ones with the sealant are especially good. Use a heat gun or carefully a mini butane torch. Don’t burn the bike!