After replacing brushes and springs on a 1996 Evinrude’s starter, can it still have a dead spot? With batteries fully charged, and after a long high speed run followed by a short no-wake speed run, next time try to start results in slow, weak grind and engine may/may not make it to a start. Also recently replaced voltage regulator. That’s why I wonder about a dead spot, or, whatever else is the problem?
Any chance of corrosion inside your cables from the battery to engine?
I think jerk bait is right. I recently had exact same problem with my jeep. When motor was up to temp it would barely turn over, starter draws more amps when motor is hot. Checked battery connections they seemed fine. Figured starter was going bad so I replaced. Still had,same problem so thought battery was not providing enough amps perhaps it was just holding a surface charge. Got battery tested with load tester at auto shop and it checked out fine. Had a spare starter solenoid so I swapped, still no difference. Went through and started inspecting cables. Found corrosion under insulation on positive lead. Cut back and put on new terminals. Did same thing on negative lead where it ties to the block. Cleaned every connection point with sand paper and problem solved,
Thanks guys, the cables may be the problem. My batteries were submerged when bilge pump float switch gunked up, Put in new batteries and cut back cables and put on new connector tabs. Think I will have to go ahead and put on all new cables. Already installed new battery switch, the old one had “guacamole” all over the inside if the switch housing. Guess I better pony up for the new cable cost.
“Don’t tell fish stories where people know you; but particularly, don’t tell them where they know the fish.” Mark Twain