[devicenull]

Go get some compressed air, and blow out every connector on the RC, fusebox, and OI. Thats just to make sure there's no metal or other things in the connector. Try a different tether cable if you have one.. Hooking up the back up battery at the same time *might* help things..

If none of this helps the cable heating up, stop using it and contact Innovation FIRST. You don't want to let the magic smoke out if its preventable.

Edit: Now that I think about it, I would contact IFI before you do anything more with the controller. If you can avoid using it, I would. Post on their tech forums, or call them.

Check your battery voltage too, it shouldn't be too high.. but if its higher then it would normally be that could cause it..