purcellzx9r Asked: Solenoid clicking on Starter, but starts if I bypass ignition?

Hi, I live on a narrowboat. Please do not be put off answering if you know nothing about boats as engine is taken from a car/taxi and principle is the same.

Went to China for 3 weeks, before I left everything was fine, girlfriend living on it when something blew and all power went out. she called an "expert" to repair "it" who seems to have moved around a few wires, left off some connections and left her without any power until I got home.

I have got everything up and running again (by basically putting it back to how it was) except the engine will not start with live and ignition wire connected to the starter solenoid.

I turn the key and there is a loud click coming from the solenoid. solenoid is good as it was bought brand new 3 months ago to replace a knackered one (teeth had worn).

1. If I connect the starter battery directly to the UPPER thread on the solenoid with the ignition cable also on that thread and turn the key….. loud click. This is how I believe it should be but instead of the loud single click, the engine should start

2. If I connect the starter battery directly to the LOWER thread on the solenoid with the ignition cable ON the upper thread WITHOUT turning the key….. starter motor spins but does not engage the engine, as I would expect because the igntion wire tells it to shoot forward to engage.

3. If I connect the starter battery directly to the lower thread on the solenoid with the ignition cable OFF, there are a few sparks, the starter shoots out, engages the flywheel and WILL START THE ENGINE.

Now whilst I'm happy to do this as an emergency measure to be able to move the boat, it's dangerous and a fire risk and my girlfriend would be petrified of doing this. Doesn't help that I am going to China again for nigh on a month as of sunday so need to get this fixed.

Wiring all looks good and properly insulated, engine is a BMC 2.2 I believe. There is a battery bank with isolator switch but this is not an issue as I have connected the starter battery only directly to the starter motor and the engine will engage.

I appreciate any help you can give.

WHY IS IT CLICKING INSTEAD OF STARTING?