Check for any voltage drops across your cables. That starter wants the
maximum output of your battery and it wouldn't take much for it to be
robbed of those important voltages!
A multimeter is the way to go here. With the key on (just IGN, not START),
put a test lead between the postive battery terminal and the point where
the same cable attaches to the starter solenoid. It should read zero. If
it reads any voltage at all, that means that cable is using up part of the
available power with internal resistance. Check those connections and
replace until it does read zero.
You can do the same check on the cable that runs from the solenoid to the
starter itself, but you'll need to be cranking the engine over at the time
to do so (ign coil disconnected for safety). Again, any voltage across the
cable is robbing you of power.
Lastly, check the ground connections with the same method.
If you find a faulty cable, replace it. Same goes for connections, which
are far more likely to change conditions depending upon external factors
such as heat, vibration, etc.
-Vegaman Dan
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