hi jeff,
i went through a similar experience with my 1990 8v92. i replaced the batteries and made sure the alternator was working right and when i convinced myself the starter was drawing too much current (more than 551amps you are referring to) and still had the problem. it ended up being the fuse between the ground and the batteries. a big fuse.btw, 551amps i believe at peak under load i think is normal. but someone please verify that.
the reason merge works is that it us just using the house batteries.
not sure that helps, but thats what it was for me. btw, the starter on my 8v92 weighed 80pounds. after i put a new one in i found out that there is a geared starter for the same price that weighs less than half.
i know you have a series 60, but i think all of this still is similar.
tom
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