1. Bad Starter Motor:
- Even though the starter was bench-tested and found to be okay, it's still possible that it may be faulty when installed in the vehicle. A faulty starter motor can draw excessive current, causing the positive battery cable to overheat.
2. Corroded or Loose Battery Connections:
- Check the positive battery terminal and ensure it is clean and tightly connected. Any corrosion or loose connections can lead to high resistance and cause the cable to overheat. Clean the terminals with a wire brush and ensure they are securely fastened.
3. Bad Battery:
- A weak or damaged battery can cause the starter to draw more current than usual, resulting in overheating of the positive battery cable. Have your battery tested to make sure it's in good condition and holds a proper charge.
4. Faulty Starter Relay or Solenoid:
- If the starter relay or solenoid is malfunctioning, it can prevent the starter from engaging properly, causing the positive battery cable to heat up from excessive current draw.
5. Short Circuit:
- A short circuit anywhere in the starter circuit can cause the positive battery cable to overheat. Check for any damaged or frayed wires that may be causing the short circuit.
6. Faulty Ignition Switch:
- A faulty ignition switch can also cause intermittent cranking issues and may result in the positive battery cable overheating.
If you're uncomfortable troubleshooting these issues yourself, it's best to have your vehicle inspected by a qualified mechanic to identify the exact cause of the problem and have it repaired safely and effectively.
