Electrical Short that isn't Blowing a Fuse

[stamp11127]

I've corrected this post. Compared to mine there is a harness missing that connects to the lower large stud on the solenoid.
You should not have any volts on the small wire - check it again. If you have a helper, check the voltage on the wire when the ignition switch is turned to start.

 

[Tim Skinner]

The thin red one connected to the top post comes from the starter and the thicker one connected to the bottom is going to the battery

 

[Tim Skinner]

One other thing I done just for giggles was I took the smaller wire off and kept the larger one to the bottom post on took the negative side of the battery off put it back on and still got a spark when I put it back on

 

[Bedrck47]

Attached pic is of my 01 expy Your 01 should be the same

Make sure you install the nuts otherwise your connection will be no better than twisting wires together

 

[Tim Skinner]

nice picture - will do

 

[Tim Skinner]

They are connected the one missing was the one going to the alt

 

[Bedrck47]

Now recheck your voltage reading as stamp suggested and post the results

 

[Tim Skinner]

will do

 

[Tim Skinner]

Well sorry for the long Delay (work Calls) I connected all the wires back in their respective locations and achieved the same results, this weekend when my helper is available I'll have him hold the Key in the start position and I'll be able to get and post those results

 

[stamp11127]

Once you have your helper there is one more test to perform with the meter. Battery should be fully charged.

Voltage drop test:
Meter set on dc volts
Red lead on positive post (not clamp)
Black lead on the solenoid stud that goes to starter (lower stud?)
Attemp to start the engine for 2 seconds. Observe the reading.

Reading should be .2v or less. If it is above that amount move the black lead to the other large stud and repeat the test. Let us know the values. A high reading indicates excessive resistance in the wire.