Because the original terminals were abused, I soldered on some new Copper clamps. I avoided the Lead powder being thrown by the cutting wheel, and used a wood block under the anvil when air-chiseling the old ones off the cables (so I wouldn't shorten the cables). The red one fit easily into a 0ga (1/0) terminal, but it took some effort to get both black cables into a 00ga (2/0). It's not visible, but they're coated with XG-12 Electrical Grease.
IF THE IMAGE IS TOO SMALL, click it.



The right battery's red cable will be even harder...



Cleaning down to shiny metal is good maintenance for ANY exposed connection like the battery terminals & most ground ring terminals, or high-current case-grounded device (like a starter or alternator mount).

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Electrical Grease XG-12 (F8AZ-19G208-AA)


To bypass the voltage regulator and force the alternator to its peak output (at the current RPM), BRIEFLY ground the indicated or capped screw on the voltage regulator (back of the alternator). If the output does NOT spike, the alternator is probably bad. Don't keep it grounded any longer than it takes to get a voltage or current reading because the alt will overheat rapidly, especially at hi rev, and any electrical components (including the battery) can be damaged.

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DO NOT USE Silicone Brake Caliper Grease And Dielectric Compound XG-3A (D7AZ-19A331-A) on electrical connections or terminals.

Owner caption March 2020 · Photo 64 of 196