I have a 250cc Hi bird that when I try to start it, while cranking, the wires to the battery get real hot. So hot the insulation on the wires starts to melt. I thought the battery was shorting out so I bought a new battery. As soon as I started cranking, the wires started to melt. It just started doing this. What can I do to fix this? If I need to replace a part, what is it & what part # do I need?

 

Could it be that the voltage regulator is bad or maybe the ground wire from the battery? Something is causing too much current making both + & - wires to get super hot.

 

If the wires only get hot when cranking, it could be a faulty starter, however it could also be a partially seized engine, which takes more power to spin over. If you can, remove the plug and spin the engine over by hand, if it is free enough, try a new starter.

 

With my old battery, if I put the battery charger to it, the starter would turn over fast & the bike would start. When I would stop & try to start again, it would turn over slowly. I would put the battery charger bat on & it would start but the wires would start to melt.
With the new battery, the starter turns over slowly & the wires get super hot. If I put the charger to it, it turns over faster but the wires still get super hot.
I have had this atv for 9 years & has never done this. If it is the starter, how hard is it to install?
Thank you for your help.

 

merryman, you are probably right about the starter. I put the battery charger booster on the battery & the starter still turned slow & the wires immediately got hot. The engine turns easily without the plug. I will remove the starter & see what type it is so I can order one. Thanks for your help.