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Mine started doing something like this a couple years ago. About once every ten starts, when you hit the start button I get a clunk. I can hear the starter engage but it will not crank the motor over. Hit the starter button a couple more times and it spins and fires right up. Does this when hot or cold. So here is what I have done so far. Have not found the cure yet....have had two new power master ultra starters, two different batteries. Added new ground from battery to frame with dielectric grease. Did same for frame to engine. I also have load checked wiring up to dash.
I have concluded along with a couple local cobra guy (Rays idea) that the bevel on the starter gears is not rounded on the teeth enough so when starter gear tries to engage the fly wheel, it does not mesh. one of these days I will pull starter out again and file the edge of the starter teeth.
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