2001 500 4x4 -Electrical
 

[img]i/expressions/face-icon-small-sad.gif[/img] Really strange happenings in Alabama - She's been running great, then trouble cranking so I put a new battery in, spins the starter and clicks, like a bad battery. I check the battery and its fully charged. Clicking continues coming from the Neutral Relay, continue to try and then I notice smoke coming from rubber sleeve leading group of wires into the engine at a rubber boot (I assume this is the neutral switch). The wire gets so hot, so fast that the gray wire is melted to the rubber sleeve over the group of 4 wires. I thought it was a simple relay switch, so auto parts matched on and said it might work. Tried it but no luck.

Key has always been fairly touchy and has to be in the correct position with the gear lever in correct nuetral before the fan and indicator lights come on, but has always fired right up.

This one has me confused..... Any ideas?

2001 500 4x4 -Electrical
 

This may be totally wrong or not even the problem but there was a recall on warn winches for around that year which could cause electrical fires from overheating the lines. Maybe this could be related to the hot wires or may be right out in left field.

2001 500 4x4 -Electrical
 

That is good information. I will consider that. I have ordered and now printed off the wiring diagram, so I guess this weekend I will begin trying to run some things down. I hope its just a shorted out wire and not the CDI unit or something more substantial.....