My boat suffered from exactly this issue. Not enough current made it through about 8 feet of 16 gauge wire, a starter button exposed to salt water, and back through another 8 feet of thin wire to reliably pull the solenoid all the way in. It would just click and not start.
I solvled it with another relay - a solenoid-solendoid if you will.
The starter button activates the relay and the relay activates the solenoid. This has worked perfectly ever since
How you find out if this is the issue: Get a short piece of wire and jump between the battery wire on the back of the solenoid and the connection for the wire that goes to the starter button.
WARNING: This will make a spark or two. This is the ultimate in non-ignition protected. Make sure no gas fumes are present before trying this trick.
I solvled it with another relay - a solenoid-solendoid if you will.
The starter button activates the relay and the relay activates the solenoid. This has worked perfectly ever since
How you find out if this is the issue: Get a short piece of wire and jump between the battery wire on the back of the solenoid and the connection for the wire that goes to the starter button.
WARNING: This will make a spark or two. This is the ultimate in non-ignition protected. Make sure no gas fumes are present before trying this trick.
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