Background: i went to start my CX130 and it made click sound at relay. after a couple of tries clicks stopped i looked back and smoke filled the battery area. I quickly turned the key off but display panel seemed to stay on longer than usual with key off. In summary, the starter relay had rusted up and shorted internally and voltage had ran down the ground wire (attached to outer shell of relay) to chassis grounding location just behind the cab. This short burned off all ground wire insulation from relay to ground connection behind cab. The wire stayed hot long enought to burn into some other wires' insulation and then melted itself through disconnecting relay from ground. I bought a new relay, pulled wiring harness out of cab and unbound harness to replace ground wire from relay to point behing cap. Soldiered all connection points for ground wire connectors and where other ground wires tied into that ground wire. Some non-ground wire's insulation had minor damage due to ground wire heating up. i put liquid tape on any spot where other wires' insulation was compromised. i I then put harness back together. (I have a question about which small wire goes to which little terminal on the lower part of relay). i put light-blue/red stripe wire on relay terminal towards engine and red/white stripe on terminal towards access door (this relay terminal was labeled "B"). I should have written this down when i took it apart but i did not. however, i think this is right given wire lengths. anyway, I then tried to start the machine. in the key-on position, the display panel comes up properly and i get that beep that it is ready to startup. But when i then turn key to start i hear a click which from the cab it sounds like the relay (not starter) but i cannot really tell. batteries look ok but i am topping them off with slow charge just in case. another note that may not be related to the problem above: with key out of ignition when i connect the battery to ground on final connection i can see there is a small current draw by seeing small spark (one like you might get shorting a D-Cell flashlight battery). i have had machine loose battery charge when just sitting for a long time and this may be the culprit for that discharge. is there something that might draw current the in cab when key is out? again, i am not sure this is related to the starting problem. any ideas on what else i should check for next? Thanks
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