Starters won't work when installed.

doubleKlutch

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2002 Mazda Protege5
I think I fried something in my starter electronics by bumping the starter while in gear.

-Clutch system failed; Clutch pedal rested on the floor.
-Tried to move the car by 'bumping' the starter. On the first attempt, the starter just went 'tick', and continues to only 'tick' since.
-AAA towed it to home driveway.
-Replaced clutch hydraulic hose line. Bled clutch. Clutch works again.
-Starter still only ticked. It's a clear and loud 'PING' with my head near the intake manifold.
-Tried a jump, but no difference. All electronics run strong.
-I got the car running on a hill and drove it out to my bay with a lift. Car ran fine. Engine is not seized.
-Used multimeter on the solenoid posts and found 12v difference between the posts in the ON position. Then found 0.0v difference between the posts in the START position. Starter is getting voltage and ignition switch signal.
-Removed old starter.
-DID NOT inspect flywheel.
-DID NOT bench test old starter.
-Installed new starter.
-Turned the key: 'TICK'.... Same exact behavior.
-Bench tested old starter: old starter runs fine. Drive gear extends, spins, and retracts when ignition signal post is powered/unpowered.
-Checked ground at engine, body-mounted wiper motor, and starter bolts. 0 to 0.2 ohms. (of course sometimes I find lots of resistence, like 65 ohms, but I can improve it by drilling the multimeter probe or tapping another spot).
-Ran out of day. Walked home. Logged online. Began this post.

Am I missing something?
What did I do wrong?
Any suggestions for the next step? Should I run a ground wire from the negative solenoid post directly to the battery?
I can't imagine how the flywheel could be problematic and cause a 'tick' at the solenoid, and then drive down the road fine?
Admittedly, I'm not very confident in my multimeter use, but is there anything else that I haven't considered?

Thanks for any thoughts.
 
I don't think you would hear a 'tick' if the clutch switch was the problem.

Try starting it with no clutch and see if you hear the 'tick',... I'm thinking you won't hear a 'tick' without the clutch in.
 
Positive battery terminal.

Checked the clutch switch; was fine.
Tried the ground wire, no luck.
Wired the solenoid +post directly to the battery +post and it cranked right up.
Cleaned and reassembled the terminal clamp; no problems now.
 
I don't think you would hear a 'tick' if the clutch switch was the problem.

Try starting it with no clutch and see if you hear the 'tick',... I'm thinking you won't hear a 'tick' without the clutch in.

I was wrong about that,... there definitely is a "tick" with the clutch not pushed in.
 

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