Re: starter problem
Happens to me occasionally too. I've tried putting a small section of rigid plastic tubing between the copper strap and starter body to act as a spring to help push the copper strap back up, but is still sometimes welds itself to the contact. I believe that the original starter switch had a bronze strap, not copper. The bronze is stiffer and would naturally spring back better than the copper used in the repro switches. I've also found that the welding usually occurs when my battery doesn't have a full head of steam- like when it's been in the garage for a week, unused. I've been using the battery tenders to keep the charge topped off, and the frequecy of the welding is much less.
By the way- it's not good for the starter to run on like that. Even though it doesn't have the normal load of the engine that would cause it to overheat in no time, spinning free and fast for an extended period will cause the bushings to wear, and it will overheat the motor after a while. A battery quick disconnect is useful to cut power to the starter.
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