Ask The Editors: Melted Battery Cables

Too hot to handle.

If there was legitimate concern of the wires/ terminal melting down, you have an issue bigger than a stuck circuit typically. While continued electrical load does generate heat, the type to melt cables is most often caused by resistance.

The very first thing we would do is replace the battery cable itself (run a new wire from the terminal) – more than likely it’s internally frayed or cracked. This type of resistance to the flow of electricity can cause some pretty intense heat.

If after replacing the cable, you still experience this type of temperature output, then it comes time to get out the electrical multi-meter and start checking the individual circuits for shorts. Did you check to see if any of the machine’s fuses popped? If so, that will greatly narrow your search.

Fortunately, and unlike cars, an ATV’s electrical system is both pretty straight forward and nearly all exposed. Checking your circuits will be as simple as placing your meter on “continuity” and placing one lead of your meter at the start of a wire’s run and the other lead to its destination. Unequal ohms measurements are evidence of a short in the run.

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