Hi John,
I had the same behavior from two Bosch starters in my 740.
They would both quit dead, randomly, sometimes months between failures.
They started normally when shorting the solenid contacts with a big screwdriver.
I think that the solenoid and fork linkage etc, may be binding requiring
more current to engage. You could use a relay at the starter if the solenoid simply needs more current. That might be a good solution, relays are cheap,
and solenoids cost more than complete starters with the solenoid.
The service port for my 1993 940 breaks out of the high driver side engine bay harness just even with the drivers side of the battery. It is a single short pink wire to a plastic shell and it is a 1/4" female spade connector.
You just need a short jumper to the Positive terminal with the ignition in KPII
to start.
Good luck, Bill
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