So unfortunately I wasn't home when my 250 went up in smoke. My teenage son was riding, says it started bogging down as if it were running out of gas. Then he saw smoke and turned it off. Upon inspection, the coil is split in half as if something expanded inside and cracked. Multiple wires are melted together, including the plug that goes to the top of the starter relay. What may have caused this? Also, the wiring harness is quite expensive. I figured I could replace most of it myself. But for one, I can't find the plug itself without buying the whole harness. Plus, I can't really tell what gauge wire was used. The green ground wire is intact, for the most part the 2 black wires on the relay plug are what's compromised. What gauge should be used? And if I can rig those wires and replace the coil, could I be in for a reoccurring underlying problem? Any advice would be much appreciated! Thank you

 

Hello, I was wondering what your solution was to fix your melted wire issue on your artic cat 250? I have one also and had the same wires melt on mine. I’d like to talk details with you about it if we can somehow? Thanks, Kyle