Sounds like you're describing the smaller wire on the starter solenoid that could be bolted on or plugged in. If it's a plug-in connector, it likely has lost its tension. That will create some resistance, and that translates into heat build-up.
Lets start by clarifying exactly what we're trying to fix. Does the starter crank the engine now consistently and at the proper speed? If it does, you may have nothing more than an idle speed problem caused by disconnecting the battery. The Engine Computer lost its memory and has to relearn "minimum throttle" before it will know when it must be in control of idle speed. The engine will be hard to start unless you hold the gas pedal down 1/4". It also might not give you the normal "idle flare-up" to 1500 rpm when you start the engine, and the engine will want to stall when coming to a stop. To meet the conditions for the relearn to take place, drive at highway speed with the engine warmed up, then coast for at least seven seconds without touching the brake or gas pedals.
Saturday, November 9th, 2013 AT 1:03 PM