I have a toyota 42-5fg25 that we have changed the battery, ignition switch and checked all wires/cable in starting circuit and it will not crank unless you put it on a charger. It only has to be hooked up for a sec and it will start right away. Don't have a clue on whats going on. Thanks.
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Check for voltage drop between starter and keyswitch, you are not allowed more than.2 of voltage drop. A lot of these units were not getting enough voltage to crank over, also a relay added to crank circuit would correct your problem and must be wired properly as well as fused.
Is the ground cable hooked up on the top starter bolt? I suppose you have checked the neutral start switch, we used to have a lot of problems with the main harness plug in the dash on the 5 series when I worked for the dealer. Just some thoughts
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