was reading the latest on this and with the ground switch off you must be connecting to actual posts of the battery's? being in parallel before trying to start/switching to 24 volt. Just a thought, but are you getting the same charge voltage at both batteries? And if you disconnect the starter cables at the starter, do you get 24 volts when trying to start? I leading to could it be the 12/24 switch not doing its thing? As if one battery is being over charged and then excessive current drain trying to start while still in 12volt position? I had the 12/24 system [switch shorted and burnt] removed it and put on a gear reduction starter using on two 12volt batteries in parallel, cheaper than a original starter, no problems for 3 years now, but that is a worse case scenario, not exactly what you have.
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