I've been dealing with this frustrating problem for a while now..

So.. I'm having the exact same situation as this guy (not my video) was in his youtube video here:
It is not EVERY time.. I would say.. more often than not though.

I have replaced the starter (used - but different)
I have tried disconnecting the clutch safety switch
Load tested the battery (works fine)
The issue occurred with my OEM flywheel and my ACT flywheel.

I'm kind of at a loss..
Any help would be appreciated.

 

Bump?

 

+1 for having this issue for years now. Noticed it more when it's hot outside (over 85) or have been running the car for some time (hour or so). Could be a temperature thing but I've not found this little gremlin.

 

I've torn the harness apart and replaced all the wires, the issue finally went away when I ran a ground from my trunk relocate directly to the engine with 2/0 welding cable then I replaced all the 4Gauge **** oem wire with 1/0 welding cable and put breakers in instead of fuses. This finally fixed the problem.
My guess was bad ground and bad starter main wire, do you have your battery in your trunk?

 

Battery is in stock location.

I was thinking it could also be some sort of extra resistance/voltage drop.

 

Stock fuel pump?

 

To my knowledge, yes, I havent done anything to it, and it is stock as far as I can see (& know) except the intake that came on it.

 

if u have changed all that stuff already, i would check your ground wires, make sure the mounting point is BARE metal and not just scuffed paint.

my initial guess was the teeth on the starter or the flywheel is worn. but u stated u changed all those already. so, hopefully its just a ground wire.

 

My wife had the same issue on her Evo . So I did all you did but to find out it was the ignition it self . So took a part the plastic piece around the steering column and when I did I could move the ignition piece left and right . So I went to Mitsubishi and bought the worn plastic piece and that saved my night mare . I would be stuck in parking lots for hours trying to start it

 

I also followed this guy's suggestion:Here

I have not replaced it, but I went in and tried rotating it, disconnecting the wire attached to it.

I presume that's the piece you meant you replaced by "worn plastic piece"?

 

yes that piece

 

Ok awesome thanks.

I will try to give the grounds a check, and then possibly replace the switch if I cant find anything ground related.