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Posted on Sep 27, 2009
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The new battery cable has 2 wires. One heavy

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.

  • Anonymous May 11, 2010

    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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  • Expert 43 Answers
  • Posted on Sep 27, 2009
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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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This can has two heavy duty wire going ot it and each is attached to each side of the can. Also there isi one or maybe two wire attached to the can but are much smaller, then you found the starter solenoid.

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I presume that the big battery cable is a no brainer, and kindly reference that terminal as 12:00 position.
With respect to the small cables, if you have become confused, ONE of them will become live when key is turned to the start position. That small cable goes to the 2:00 position. The other small wire(s) go to the small terminal at approx 10:00 position.
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