How to take apart a starter switch
 

Twice this summer my starter switch stuck in the on position. Fortunately I have a kill switch. I now want to install an insulator kit (A-11450-X). I removed the switch but I cannot get it apart without deforming the copper terminal. Any advice would be appreciated.

Re: How to take apart a starter switch
 

Once the bolt is out it should just pull apart.....maybe it has tack-welded itself together...

Re: How to take apart a starter switch
 

on some of the starter switches there is a washer that screws down on the stud. if that is what you are having trouble with. just unscrew the washer with a pair of pliers.

Re: How to take apart a starter switch
 

There should be a couple of thin nuts on the switch post where the battery connects. Take both of those nuts totally off. Pay attention to how the insulating washers go in there as you tap down on the threaded stud that the nuts were on. Tap down, the big flat strip should come out. Pay attention to how the "pusher" is installed with the insulated piece between the hole in the flat metal strip and the metal tube.

Replacing the insulator inside may help with your stuck switch problem.

Now, really do yourself a favor and follow this tip when reassembling...

As you install the post in the body, and you are tightening up the first nut on the post to lock it into the body, place the tip of a small screwdriver into the switch between the flat metal strip and the switch body SO THAT WHEN YOU TIGHTEN THE FIRST NUT, THE FLAT METAL PIECE INSIDE DOES NOT JAM AGAINST THE INSIDE INSULATOR ON THE SIDE OF THE SWITCH BODY.

This is really important. When you attach the second nut, to hold the battery cable on, you DON'T want that stud turning, you don't want that flat piece of metal swinging over and jamming inside against the insulator. So get the first nut good and tight, and do it with a small screwdriver holding the flat metal piece in place when you tighten.

I hope this helps. Let us know if you have any problems.

Re: How to take apart a starter switch
 

Here is a tip for your starter switch.

Re: How to take apart a starter switch
 

For further information, there were early and late switches. The early is rectangular with the horizontal terminal on the back and the late is the one in post #2. Most are are late types and they are rebuildable with parts and reproduction replacements available. The early ones are rare and no parts are available other than old OEM used pieces.

If the terminal is copper then it is easily deformed by too much torque. It may have to be destroyed to get it off if the tread is galled. A person can use a regular bolt but the copper does transmit power better due to it's low resistance to current flow.