Brent...I removed the cluster of wires from the stud and polished everything with a red scotch pad. The all were tiight on terminals with no signs of corrosion. I removed the positive battery cable, fished it through the cabinet, inspected and gently recrimpted the ends. Everything was bright and shiney and the case was not dry rotted and looked perfect. Put everything together and the same click at the relay. I checked voltage and everywhere I hit for positive voltage read 12.68v. Battery cable voltage when disconnected read 13.37v. The zero wire at the relay 0v. Everywhere I could check ground either on the frame, cabinet, or components I was getting perfect tone on the probe. The only spot I could not get ground, were at the two screws holding the voltage regulator to the frame. I forgot to mention. I had the voltage regulator replaced last fall as a preventative maintenance measure recommended by a “authorized tech”. Does anyone know if the screws holding the voltage regulator to the cabinet insulated so ground cannot be detected? Could this be possibly a source of my issue? My problem started just after this was replaced.
Did battery voltage drop anywhere during the crank cycle? I did say to read battery voltage on the stud during crank cycle.