Mike,
This sounds like a faulty starter switch.
The circuit that you are trying to make is very simple, but does carry
a lot of current (still only 12volts so you won't electrocute you)
The "wiring diagram" is:
Battery -ve post to starter switch terminal.
Starter switch contacts ( controlled by pull cable)
Starter switch terminal to starter.
Battery +ve to frame.
Frame to engine block.
engine block to starter casing.
The current tries to find the easiest path, and as the starter has a
resistance, it is short circuiting through the starter switch. i.e
Battery -ve to starter switch to dash (frame), via starter pull cable.
You have prooved that since it didnt get hot once you had disconnected
the cable from the dash.
The starter switch contact needs to be electrically insulated from the
pull cable. Sounds like it isn't!
Get a new switch.
Guy
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