Question about 2002 Suzuki VS 800 Intruder

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Bad neg. battery cable -melted

I had a friend change the battery on my intruder . I rode it and the thing quit running. I saw that the neg battery cable had gotten so hot that it meltd What would have causee it to get that hot? did he put the battery in wrong?

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  • Suzuki Master
  • 5,128 Answers

There are a few possible issues: 1) there is a short (positive and negative wires touch each other or another part of the engine compartment somewhere. This could be a spot where the insulation is damaged on the cables, a problem with the battery or the starter). If the new battery is even a little larger than the old one, the terminal posts or the cables on those posts could touch another part of the engine or the engine cover. Check that there are no clearance issues before replacing the battery cable end. 2) The new battery provides too much current for the wire gauge. (Think of the difference in water flow between a fire hose and a drinking straw.) You may need heavier gauge wire (lower number) when you replace the battery cables. 3) The battery terminals are loose. Some batteries require the terminal posts be screwed into the battery and if it isn't fully tight, the intermittent contact could cause this. Make sure that the post is tightly inserted in the battery (use a wrench).

This can also happen if you jump start the vehicle and do not connect the wires properly.

I hope these ideas help you determine the problem and avoid it in the future.

Cindy Wells
(corrosion of the cables or battery posts can also give the problem.)

Posted on Oct 27, 2012

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Posted on Jan 02, 2017

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