Hello all. This is only my second post in the forum and I think I put my first post in the wrong area. I am attempting a repair a 2003 TRX250. Although I don't have all the details yet, I was told that the "wires get hot when hooking up the battery to the point of melting the insulation" (battery now disconnected).

I am thinking it is a grounding problem, but thought I should check with the experts here before getting too far into it. I don't know of a stuck solenoid or starter could cause such an issue or maybe even a ground in the the kill switch or ignition. I am more of a car repair guy and don't know a lot about ATVs. Thanks for any advice that you might have.

Glenn

 

There isn't enough information here. The 250 is the last of the simple wiring systems produced by Honda. Thick positive wires go from battery to solenoid, then to starter. Thin positive wire goes from battery (or solenoid) to fuse, then to regulator and ignition switch. If you get a short big enough to heat this thin wire, it is going to blow the fuse. The only way the thick wires can get hot is if they are shorted to earth, or turning the starter motor. If the solenoid is stuck it can be turning the starter motor all the time, even with ignition off, but you can hear it doing that.