Bought an '86 coupe in November. It has operated well with no electrical issues until recently. (Started blowing the CTSY/CLK fuse a week ago)

Friday as I pulled into my driveway I smelt and saw smoke from under the hood. I quickly opened to hood and saw a flame. My first reaction was to blow on it, which actually worked to put it out!!
It appears as if there was something that melted and burned as well as causing the wire pictured ( I believe it is the cooling fan heat switch connection) to have the insulation burn off.

I was thinking that it may have been a piece of the plastic spark plug wire spreader ( which was broken ). I have questions such as:
What would cause it to get to hot to burn the wire/plastic?
What could have gotten down there to catch fire?
Pictures here:
http://i178.photobucket.com/albums/w...a/100_0688.jpg
http://i178.photobucket.com/albums/w...a/100_0687.jpg
http://i178.photobucket.com/albums/w...a/100_0686.jpg

Now, here's an other issue which just began and may be related>
On the trip home, I had to turn three times to get the starter to turn over. Battery was registering at 10.4 as I turned the key. I made one stop on the way, and the first time I tried to start up the starter made a small "clunk" but wouldn't turn over. The second turn of the key it growled a but and then turned over. (I will note that all winter in the very cold weather, the car started up without a hitch.)
Does this sound like the starter is gone?
Is it possible that could have caused wires to overheat?

I just need some thoughts and direction on this issue.
Any help is appreciated. NOt sure what to do or check.

Ed

 

The exhaust manifold is hot enough to ignite insulation or plug wire looms that fall on it. If you have to hit, "crank", several times to get your starter to crank, then you have burned pitted contacts in the starter solenoid. The starter solenoid at the end of its stroke forces two large copper contacts together that switch current to the starter motor. These contacts get pitted and blackened from the large current they switch and eventually make too poor a connection to supply the 100+ amps the starter motor requires. You can replace these contacts. Use the search function and you will find a Toyota part number for these contacts or call an auto electric shop.

 

My 86 had about 130K on the original starter. It started to drag on start like a dying battery. Then one day, bam. No starter. Wouldn't turn. Opened the cover to find the brushes were ground down to the steel holders.

Replacement starter took care of the problem.

 

Yes, a piece of loom will ignite if left on manifold.
The wire is for the temp gauge sender.
Your low bat voltage sounds like the problem with the crank attempts.

 

Hmmmm...
So, I guess I should repair/replace the starter.
Then clean up the melted mess
Reinsuate the temp gauge sender wire ( Heat Shrink Tube?)
Get looms of some kind (Preferably ones tat won't melt!)

What do you think?

 

That's the thermo switch for the fan I believe.At least it is on mine.It's more probable the shorted wire drained the battery than the other way around.If you ground that wire your fan should run all the time.

 

The spade connector is for temp sender. If it were the aux fan switch and it was shorted, it would only run the fan with ignition on.
Here is a pic of my extra aux fan switch connector, which is just like the knock sensor connector.