Re: Sticky starter switch plunger
So here is what I did. I took both switches apart and put the new insulator, brass contact, plunger and nylon plunger insulator into the old switch housing.
The biggest difference is just the fit of the plunger in the housing..the old one allows the plunger some freedom of movement where the new housing held it pretty tight at just one angle..
Taking the new plunger and wobbling it around to loosen the fit in the housing ought to help with it sticking, or you can swap parts as I did...
The only place that needs careful attention is where the contact bolt goes through the housing. There is potential for a nasty dead short here. The new switch had a fitted fiber washer that fit the hole nicely and should prevent any problems.
I installed a ground cutout switch so removal of the old switch was easy...if you do not have a cut-out you should disconnect the battery before removing the starter switch....
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