Ok so i have a evo 9 MR and just recently did a full motor build. I have been driving the car around for the last 400 miles under no boost to break in the motor. I tried to start it up last night and all i would get is a slow crank followed by machine gun clicks.

Here are the following things i did to troubleshoot the problem:

1. charged original battery fully using a charger - same problem.

2. Bought a brand new battery and replaced current battery - same problem

3. Double checked all grounds to make sure nothing is lose

4. Double check the connections on the starter to make sure they were clean and tight - same problem.

5. banged on the starter with a hammer - lights taps...- same problem


anything else i should check for before looking for a replacement starter????

 

The clicking is the solenoid slug being pulled in by electromagnetic force created by a wire winding. The slug in the solenoid is connected to linkage that meshes the starter gear with the ring gear on the flywheel. At the end of its travel, the slug closes a switch which connects the starter motor to the battery by way of the thick insulated cable. The slug also compresses a spring.

Once the starter motor is connected to the battery, the current drain causes the voltage at the starter to drop to where solenoid winding can no longer hold the solenoid slug in place against the compressed spring. When the slug moves, the starter motor is disconnected, the voltage goes up and the slug pulls in again. Hence, the clicking sound.

Check that the battery cable is in good condition and that the end connections are bright and clean. Check that the connection for the small wire from the ignition switch is clean and that the wire is on tight. Check the battery voltage (across the battery posts using a VOM set to volts DC) when the starter is engaged. It shouldn't drop below 9 volts.

If all that is okay but the voltage at the battery shows a big dip, I would suspect the starter.

 

Where is the small wire from the ignition switch?