2010 Yamaha Drive Battery Cable Issue

[newb24]

I'm having quite a weekend with the golf cart here.

So, went for a ride around the neighborhood tonight and started smelling something burning....

see attached.....the coating on the cable was melting and started melting the cap to the batteries. All batteries have sufficient fluid levels and all batteries cables looks to be in good shape.

So here is the whole story...obviously have four 12 volt batteries (i'd have to say they are all original batteries), recently installed some LED headlights, was directed to just attach the cables to the battery under the driver. In the process I noticed the one battery cable was snapped so I replaced with same gauge wire from a golf cart store down here. I took the time to clean up all the posts and re secure all the wires to the nuts/posts.

Lights and new wire have been installed for a week, cart has been driven on and off about everyday, we were not even 3 minutes into the ride tonight when we smelled and saw the burning.

I tried to take the nut off the post and the whole post just spins. I can't tighten or loosen it.

Anyone have any ideas or what I should do next?

[sportcoupe]

Your stack-up is wrong and may have contributed to the hot cable. The heaviest cable should always go on the battery first, followed by the next heaviest (charger cable) and finally any accessory wire.

You obviously have to at least replace that cable. Maybe more cables also. If you are still running the stock 6awg cables I'd change all of them to 4awg or larger.

[Wylie_Tunes]

Originally Posted by sportcoupe

Your stack-up is wrong and may have contributed to the hot cable. The heaviest cable should always go on the battery first, followed by the next heaviest (charger cable) and finally any accessory wire.

You obviously have to at least replace that cable. Maybe more cables also. If you are still running the stock 6awg cables I'd change all of them to 4awg or larger.

I agree with the wire stacking.

If the stud spins, battery is done. Could it have possibly been over tightened at some point?

[cgtech]

See the posts about trying to repair the damaged terminal, if you want to try to save that battery. I have done melted terminal repairs with good success (as long as you treat the repaired terminal correctly, with 2 wrenches). I drill the portion of the terminal that goes down into the battery (about 1" depth), use a tap to make 5/16" threads, use a cut short peice of all-thread to make a stud, and use a extra nut tightned under the wire terminals to lock the stud in the battery lead. This may allow you to continue to use the battery until its time to replace them all.

[newb24]

Thanks Wylie_Tunes and Sport Coupe

I didn't even notice that stacking, I was in such a rush to get the lights working and with that broken cable, I just put the new one on top of it not thinking....ugh. I was blinded by excitement of the LED headlights!

Thanks guys!

[Volt_Ampere]

Check that wire for heating after you restack. It should only get warm not hot.

[sportcoupe]

Warm being no more the 10 degrees above ambient air temp.

[newb24]

Thanks for all the quick replies and ideas.

I got all of the batteries out and cleaned everything up. There has been a lot of battery acid splashed around in that compartment, it has everything torn up, the one hold down is rotted solid into the plastic and all of the paint is eaten away on the underbody. That can't be good.

Anyway, I think trying to salvage this battery is something I'm not capable of, I'll do some more research and see if I want to attempt.


If I can't repair, is there any sense in just replacing 1 battery or just bite the bullet and go to 4?

Maybe even go to the 8 volt batteries?

Anyone want to give me some pros and cons on any of it? Or point me to a thread to see what I should do?

I can't believe I screwed this up.....ugh!