I had the exact same problem....sometimes it would make connection, sometimes it wouldn't. I put on a new starter switch, and the problem kept on. I put a small radiator clamp around the peice that pushes up against the starter switch, and wedged a small piece of rubber under the radiator clamp to space it out. So, when I push the starter, the radiator clamp with the rubber underneath it is what actually touches the starter button on the starter. Works great! Before I did that, I took the cap off of a fuel injector cleaner bottle and it fit perfectly on the starter switch button....it also worked like that, but I really didn't want a yellow plastic cap on the switch! HAHA! Now, what would cause the problem, I'm not for sure, but, I got mine going again! Cranks everytime now. GOOD LUCK!
