Bazooka

[bobnoc1@yahoo.com]

Re-wired my 56 cub loboy. Rebuilt starter, new alternator, new coil, plugs and wires, charged battery. Everytime I try to start it, she turns over good, but sparks at the starter connection. Then nothing. Coil gets super hot, battery dies, no click, nothing. I'm about to shoot this thing with a bazooka. Anyone on in north Jersey or NE Pennsylvania can help? Will deliver and pay.

 

[staninlowerAL]

Sparking at the starter switch usually indicates faulty insulators inside the switch. No click/ no sound usually means there's no ground. Stan

 

[tst]

sparks at cables bad connection

 

[Ernie in Ky]

I’ve always wired the #1 terminal on the alternator plug to run through a diode or light and then to the ignition switch. I think you may be sending power back to the coil wired that way and that’s why your coil is getting so hot.

 

[Glen]

Everytime I try to start it, she turns over good, but sparks at the starter connection. Then nothing.

Hi,
The switch on top of the starter is supposed to have 2 pieces of insulation inside it, one at each side of the moving copper parts.
If it is sparking inside the switch, and there is no insulation, that could be why.
The insulation is thin, and shaped like the inside walls of the switch.
One of the experts on here has said the insulation can be made from flat parts of a one gallon plastic milk jug.

 

[Waif]

I agree with you likely missing the insulation on the sides of your switch.
Check for the copper lugs wear on the starter and check the switch's copper contact area for pitting and burning. A gap between the two and arcing isn't a good contact.

Your blue crimp piece by your coil is a weak method of contact. I'd reserve such for trailer wiring and still not like it. Sometimes the metal tab that is crushed/ depressed to tear the insulation on a wire fails to cut enough. Or spreads instead. or tips at an angle. Not much if any contact that way.
The blue/red wire going to it is stuck in the side of the cover that folds over. As if it does nothing and needs insulated on it's end to avoid shorting out.