brett wrote:
and now the pin that you bolt the cable to, has continuity to the body...

so its earthing the cable out at the starter motor..... would this cause my issues? Or is this perfectly normal??
Just be careful here, starter motors are very low resistance, they are nearly a short when measured on a multimeter. It will seem like its shorted when it is not necessarily so. That's how they get the current through that they do. Ohms law : Volts/Ohms = Current.
Quote:
Also are use using an up graded battery. say 400 amp hours (new technolgy) then use say a 40 year old battery cable rated for 200 amp per hour the product is heat as the energy has to go some where
Even if a battery is rated for 400 Amperes instantaneously, it doesn't mean it will pump that through the starter motor. It is capable of 400 Amps which is good, but it will only use what the starter motor needs. Once again, it is down to the total resistance. This is the internal resistance of the battery + the cable resistance + the starter resistance. Twelve volts divided by all this will give you the total current through the starter. It will only use what the starter motor allows.
If after all this, the starter turns over slowly, and there is no voltage drop across the solenoid, then the starter motor will need to be looked at by an auto spark.