Hot Battery Cables

JIMMYD · 12-26-2006, 09:54 PM

I have an odd problem.
1993 Katana 1100. Hard to get bike started.
If I crank the starter for anything more then 4 or 5 seconds I notice wisps of smoke coming from the battery area.
If I touch the battery terminals or the cables after cranking a few times for more then a few seconds the cables and battery terminals are almost too hot to touch.

I just went through the carbs and replaced the CDI box (no spark) so I expect the bike to be a little had to start, but I'm afraid I'm going to melt the cables. The cables look a little deteriorated (insulation coming off/loose) so I suspect the previous owner had similar problems.

Anyone have ideas on how to remedy this problem?

md86 · 12-26-2006, 10:12 PM

New wires . Easy enough . Crappy wires that don't carry voltage adequately will get hot .

JIMMYD · 12-27-2006, 09:05 PM

Wow do the cables really go bad?

They look like the orginals from the factory.
Like I said they are in bad condition but I figured A WIRE (CABLE) is a cable is a cable, Unless the insultaiton breaks (which they have) then they must work ok. Even bare wires work.

Just my thoughts but the fact that the insulation has separated from the wires (cables) makes me nervous enough.
I could end up with a short that would cause some issues. Maybe that is the problem now but it only looks like the insulation has deteriorated near the cable connectors to the battery.

**steves** · 12-27-2006, 09:20 PM

They could be fried wires.

StevieB · 12-28-2006, 03:06 PM

Corrosion can easily build up, either on the clamps or along the cables. Cheap enough to replace them (even cheaper if you build your own.)

After you replace them, coat the clamps with a liberal application of petroleum jelly. Nothing works better: Axle grease works as well, but is messier and harder to get off other places, commercial battery sealer is much more expensive and often only readily available in airosol- messy and environmentally disasterous, even without CFC's (non-recyclable can, propane propelant that contributes to CO2 buildup/global warming.) Petroleum jelly is actually a byproduct of oil refining, and completly sterile due to the high temps in the cracker. Originally, no one knew what to do with the stuff.

trinc · 12-28-2006, 04:20 PM

the basics of it is most likely corrosion causing the wire to have more resistance. increasing the resistance and it will get hotter.

tim

The CyberPoet · 12-28-2006, 08:38 PM

Electricity at this voltage/power level travels as electrons over the outside of the wire rather than through the core of it. Thus, any surface corrosion or oxidation will impede their way and cause more heating. If you are getting smoke, there are points in the wire that the resistance is high enough that the electrons are jumping off the wire momentarily.

Bottom line: Replace the wire & terminals before you end up with a potential motorcycle fire.

Cheers,
=-= The CyberPoet

loudnlow7484 · 12-28-2006, 09:30 PM

I agree. Hot power cables are generally a sign of
A- too much current draw for a given cable gauge (size)
B- Old corroded cables.

The cables are plenty large in my opinion, so they must just be old, and corroding.

JIMMYD · 12-29-2006, 05:51 PM

Ok Fellas I trust your collective judgement.

As I said the wires have obviously become degraded to some extent as they have melted off the insulation such that some areas are bare.

I ordered a battery last week and cables Wednesday.
I'll install and give them a try some time next week.
I'll let you know.

Thanks
James

JIMMYD · 12-30-2006, 10:42 PM

Quote:

Originally Posted by JIMMYD

Ok Fellas I trust your collective judgement.

As I said the wires have obviously become degraded to some extent as they have melted off the insulation such that some areas are bare.

I ordered a battery last week and cables Wednesday.
I'll install and give them a try some time next week.
I'll let you know.

Thanks
James

12-26-2006, 09:54 PM	#1
JIMMYD Rookie Join Date: Jun 2006 Posts: 59 iTrader: (0) My Photos My Garage	Hot Battery Cables I have an odd problem. 1993 Katana 1100. Hard to get bike started. If I crank the starter for anything more then 4 or 5 seconds I notice wisps of smoke coming from the battery area. If I touch the battery terminals or the cables after cranking a few times for more then a few seconds the cables and battery terminals are almost too hot to touch. I just went through the carbs and replaced the CDI box (no spark) so I expect the bike to be a little had to start, but I'm afraid I'm going to melt the cables. The cables look a little deteriorated (insulation coming off/loose) so I suspect the previous owner had similar problems. Anyone have ideas on how to remedy this problem?

12-26-2006, 10:12 PM	#2
md86 Deadbeat dirtball Premium Member Join Date: Oct 2004 Location: 41035 Posts: 22,615 iTrader: (10) My Photos My Garage eBay ID: md86dammit	New wires . Easy enough . Crappy wires that don't carry voltage adequately will get hot . __________________ I am a fluffy lil cuddly lovable bunny , dammit !

12-27-2006, 09:05 PM	#3
JIMMYD Rookie Join Date: Jun 2006 Posts: 59 iTrader: (0) My Photos My Garage	Hot Battery Cable Wires Wow do the cables really go bad? They look like the orginals from the factory. Like I said they are in bad condition but I figured A WIRE (CABLE) is a cable is a cable, Unless the insultaiton breaks (which they have) then they must work ok. Even bare wires work. Just my thoughts but the fact that the insulation has separated from the wires (cables) makes me nervous enough. I could end up with a short that would cause some issues. Maybe that is the problem now but it only looks like the insulation has deteriorated near the cable connectors to the battery.

12-27-2006, 09:20 PM	#4
steves meh. Premium Member Join Date: Nov 2005 Location: 19403 Posts: 20,063 iTrader: (15) My Photos My Garage	They could be fried wires. __________________ -Steve Welcome to KatRiders.com! Click here to register Don't forget to check the Wiki! http://katriders.com/wiki

12-28-2006, 03:06 PM	#5
StevieB KR's Toughest Tree Hugger! Join Date: May 2006 Location: Marietta, GA Posts: 4,577 iTrader: (3) My Photos My Garage	Corrosion can easily build up, either on the clamps or along the cables. Cheap enough to replace them (even cheaper if you build your own.) After you replace them, coat the clamps with a liberal application of petroleum jelly. Nothing works better: Axle grease works as well, but is messier and harder to get off other places, commercial battery sealer is much more expensive and often only readily available in airosol- messy and environmentally disasterous, even without CFC's (non-recyclable can, propane propelant that contributes to CO2 buildup/global warming.) Petroleum jelly is actually a byproduct of oil refining, and completly sterile due to the high temps in the cracker. Originally, no one knew what to do with the stuff. __________________ "Stevie B" Boudreaux I ride: '01 Triumph Sprint ST Projects: Honda CB650 Bobber projects I, II and III Take care of: 81 Honda CM400,72 Suzuki GT550 Watch over/advise on: 84 Honda Nighthawk 700S (now my son's bike) For sale, or soon to be: 89 Katana 1100, 84 Honda V45 Magna, 95 Yamaha SECA II, 99 GSXR600, 95 ZX-6, 84 Kaw. KZ700, 01 Bandit 1200, 74 CB360.

12-28-2006, 04:20 PM	#6
trinc Kat Daddy Join Date: Oct 2004 Location: pdx, OR Posts: 1,472 iTrader: (0) My Photos My Garage	the basics of it is most likely corrosion causing the wire to have more resistance. increasing the resistance and it will get hotter. tim __________________

12-28-2006, 08:38 PM	#7
The CyberPoet Cloud Rider Join Date: Oct 2004 Location: Tampa, FL, sometimes Germany... Posts: 26,653 iTrader: (168) My Photos My Garage eBay ID: MotorcycleAnchor, and TheCyberPoet	Electricity at this voltage/power level travels as electrons over the outside of the wire rather than through the core of it. Thus, any surface corrosion or oxidation will impede their way and cause more heating. If you are getting smoke, there are points in the wire that the resistance is high enough that the electrons are jumping off the wire momentarily. Bottom line: Replace the wire & terminals before you end up with a potential motorcycle fire. Cheers, =-= The CyberPoet __________________ Remember The CyberPoet

12-28-2006, 09:30 PM	#8
loudnlow7484 Kat Legend Join Date: Jun 2005 Location: Rio de Janeiro, Brasil currently Posts: 6,018 iTrader: (2) My Photos My Garage	I agree. Hot power cables are generally a sign of A- too much current draw for a given cable gauge (size) B- Old corroded cables. The cables are plenty large in my opinion, so they must just be old, and corroding. __________________ Any and all statements by Loudnlow7484 are merely his own opinions, and not necessarily the opinion of Katriders.com. Anything suggested by him is to be followed at your own risk, and may result in serious injury or death. Responses from this member have previously been attributed to all of the following: depression, insomnia, nausea, suicidal tendencies, and panic. Please consult a mental health professional before reading any post by Loudnlow7484.

12-29-2006, 05:51 PM	#9
JIMMYD Rookie Join Date: Jun 2006 Posts: 59 iTrader: (0) My Photos My Garage	Hot Battery Cables Ok Fellas I trust your collective judgement. As I said the wires have obviously become degraded to some extent as they have melted off the insulation such that some areas are bare. I ordered a battery last week and cables Wednesday. I'll install and give them a try some time next week. I'll let you know. Thanks James

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