"Doesn't start" can mean a couple of different things. Based on most of what you listed, I assume you mean the starter won't crank the engine. Your description is hard to follow. You didn't say how anything was checked, why something arced, if the spinning starter cranked the engine, etc.
If I'm to guess the starter doesn't engage when you turn the ignition switch to "crank", you can break the system down into four parts, and each one has a test point in the starter relay socket. Be careful when you stick a test probe into the terminals because they spread very easily, and that will cause an intermittent connection. Just touch the probe on the terminals. Don't stick it all the way into them.
Using a test light with the clip lead grounded, test all four terminals in the relay socket. One must have 12 volts all the time. Of the remaining three, (usually the one next to the one with 12 volts all the time), one terminal should have 12 volts when the ignition switch is in the "crank" position. If it does not, suspect the neutral safety switch.
For the last two terminals, move the test light's clip lead to the battery positive post because we'll be testing for a good ground circuit. The test light should light up on both of those last two terminals. One is the ground for the relay's coil and one goes to ground through the solenoid on top of the starter.
Find which one of those terminals doesn't give the expected response, then holler back.
Saturday, February 8th, 2014 AT 5:54 PM