Rich Grise wrote:
On Tue, 27 Oct 2009 16:55:17 -0700, T.Alan Kraus wrote:

Scenario facts: a piece of stranded copper battery cable about 3.5" long
with two soldered connectors at each end, used for ground connection on a
motorcycle battery. The cable broke in the middle with what looks like a
stress fracture. Cable was flexed many times, every time battery had to be
taken out or when battery had to be disconnected for electrical tests or
electrical modifications to motorcycle wiring.

Son contends it is the fault of soldering connectors onto cable, which
heat stressed the cable. I think it is copper work hardening when flexing
cable, thinking that heat if anything (maybe to low) would help anneal
copper.

Your opinion welcome.

It's a combination of factors. Just bite the bullet and buy a new cable.

Yes, it shouldn't had been soldered, and yes, every time you screw around
with it, it work-hardens the copper, and probably didn't do the
insulation any favors, so it's shot. Unless you're destitute, the new
cable will be your best bet; otherwise, you'll be dicking around with
kluges for the remaining life of the bike.

Cheers!
Rich

It has been replaced with a longer conductor made from much smaller
gauge individual copper wires built up into strands, and a stress relief
loop is now incorporated.
thanks