The new battery cable has 2 wires. One heavy duty wire to the starter and another lighter duty wire with a clip connection. When I plug the clip to gether it melted the wire. What would cause this when the key is on or off.
A DEAD short. The lighter duy wire that you "clipped" together is going to GROUND. Thats why the wire melted. You were pushing all the voltage and amperage of the new battery to GROUND. Doesn't matter whether the key is on or off, the key switch does not interrupt the circuit from that lighter duty wire if it goes to a ground. You need to chase the wire that you are clipping into and see if it is grounding or goes to ground. Did your previous battery have this same wire that clipped in?
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The small wire is for powering accessories. There is a short in that circuit -- trace that small wire and see what you find -- the short may be very near the battery if you're lucky. If not, some serious troubleshooting is needed. Please, let me know what you find, and maybe I can help with the troubleshooting.------------ Charlie
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