High resistance in the solenoid.

Replace it.

Rob

Great info and many thanks! My plan of attack (cheapest to expensive):

1) Check all electrical connections to the solenoid, charge battery,
check all connections under the transom and tighten any thing that
looks loose...etc., wd-40 (dry) the connections, if failure then 2.

2) WD-40 the starter motor shaft and pinion gear; inspect for burrs or
wear, if clean of burrs and shaft well oiled, if failure then 3.

3) take out old solenoid and check the plunger / file - make sure the
contacts are clean - replace and test, if failure then 4.

4) replace the solinoid; swap out old one with new one ($36.00usd), if
failure then 5.

5) replace with refurbished (Johnson) bosch or prestolite starter motor
(approx $160.00usd for the refurbished part/ $225usd new) , if failure
then 6.

6) throw hands up; trailer the boat to the shop, at any point this
get's fixed - see you out on the lake fishin and water skiing! I'll
update when figured out. I'll keep the rec.boats updated on the fix
(may take a couple of weeks).

Bon Voyage and off to work on the 15' Crestliner (that boat jumps out
of the water with that 100hp Johonson on the back) I go - thanks
everyone; this one is nipped in the bud!