Cut out question
 

A friend is putting in a new wiring harness in his '29CCPU. When he touches the hot wire to the cutout terminal he gets a spark. Is this normal? Does it indicate the cutout contacts are closed? Suggestions? Thanks PS 6 volt, positive ground, stock cutout

Re: Cut out question
 

There is something wrong with the cutout. You say it is a stock cutout. Does that mean that it is the mechanical kind? If it is electronic and designed for negative ground, it will spark, and drain the battery, and may cause other problems. If it is mechanical, the points could be welded shut or there could be another problem inside. If you can,take the cover off for a peek.

Re: Cut out question
 

The cutout may be installed backward. The open feet should point towards the terminal post. It is also possible that the terminal insulator is damaged or missing causing a short.

Re: Cut out question
 

washer

Re: Cut out question
 

There are two insulating washers, one on each terminal screw. The thin one goes under the input side L bracket, the thick one the output terminal.

Re: Cut out question
 

It is normal for the wire to spark if it comes into contact with the metal cutout. Afterall, that wire is HOT. If you attempt to run the bolt through the wire end and attach it to the cutout, it's going to spark because you cannot avoid touching metal, either the cutout cover or the threads into the cutout. I usually disconnect a battery cable and then attach the wire to the cutout. It will not spark. Then while you watch the ammeter needle, touch the loose battery cable to its battery post. If the cable end sparks and/or you see the ammeter dip into the negative side, there is a short somewhere in the electrical system. If no spark and the ammeter remains at zero, you are ok.
Marshall

Re: Cut out question
 

Thanks to all for your suggestion. Turns out the problem was not the cutout, but, a defective new stoplight switch. After checking voltage from the ammeter to the cutout, and getting spark, we disconnected the connection from the cutout to the wiring harness. No sparks, which isolates the problem to something to do with the wiring harness. After a lot of tracing of wires in the harness, disconnected the stoplight switch and no spark. Quick continuity check of the switch from the terminals to ground showed an internal short. End of problem. Lesson learned, check your new stoplight switch before installation. Thanks again

Re: Cut out question
 

Job Well Done! Thanks for the update!