Help with starting issue
 

i have a 1976 carrera 3.0 which i have owned for over ten years.i had the starter rebuilt due to not starting about a month ago.
this weekend i had an m&k exhaust installed and we crank the car up and it sounded amazing.i drove it out of the garage to hear it better and i turned it off.a few seconds latter it would not turn over.solenoid is engaging but starter will not turn.all i would hear is the solenoid clicking.i have done all what guys have suggested here as far as checking grounds and the yellow wire, the battery ground etc.
today after getting back from work i just tried to crank it up and to my surprise it fired right up.i drove it for 15 minutes and then put it in my garage and tried again three times and it starts right up.
i am now scared that this could happen again away from home.any idea what is happening and what is the remedy.
this is crazy.:rolleyes:

Inside the solenoid there is a set of contact points so when the solenoid is energized a round contact plate is drawn in and bridges a connection allowing the current to flow to the starter motor. Sometimes one side will wear more then the other so the plate does not make a good contact or sometimes not even touch. They may not have changed thes contacts inside the solenoid. To check it out you undo the bolts that hold the end plate on the solenoid and open it up. There is a spring under the plate so hold plate to control the spring from flying out. Pull out center core and note the round contact plate and the two side contacts. It is probably a dirty contact point in here. Most starters have this setup. I have had the same scenario. Was probably a coincidence that it happened after you did the work but if it was happening before maybe they did not change the contacts. Good luck. Thanks rob

it is common for starters to fail by working sporadically rather than failing all at once. if it happens away from home push start.

you might be surprised to find out how successful you'll be by putting it into 2nd gear and rolling it a couple of feet, then gently letting the clutch out (without "bump starting" it)....put into neutral and retry starting it. Something seems to get freed up whenever I did this.

if they did not replace the solenoid it was not a complete rebuild.

there are 3 contacts in there. one is the battery, one is the starter motor and the other is the one that connects the 2 others together to run the motor.
i dont know of any way to change the one on the solenoid itself, but they can be cleaned and what i do is rotate them so that new "meat" is on contact.
check my thread and you will see what i mean.

http://forums.pelicanparts.com/porsche-911-technical-forum/631173-solenoid-starter-rebuild-finally.html

if the solenoid is pulling in, it is either the solenoid contacts or there is not enough power to the starter to run the motor.
inspecting the grounds and other connections it not enough. they need to be removed and cleaned. dont forget the tranny to the body

thanks for the help.
i will take it and get it checked out.i have driven it the last two days with no issues.
scared thought.i could hapen again away from home.