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Join Date: Jul 2006
Location: Kennett Square, PA
Sounds like you've been really thorough - what comes to mind now is the ground end of things. Check that all the ground wires are clean and coming into full contact with the frame (or whatever). Also, double-check that the starter lead is set up properly - the starter body itself serves to ground the unit, but the positive lead (from the relay) goes onto that little bolt at the bottom of the starter motor. There are some washers on the bolt that need to be in the right order for the thing to work - insulated washer, copper washer, positive lead, steel washer, bolt. If things still won't start, there's a possiblility that the insulation inside the starter unit is fubarred - but don't jump off that bridge just yet (it's an easy catch, but there are plenty of other troyubleshooting tips to be tried in the interim).