Big Twin cut-off switch questions

[baytonemus]

I have removed, disassembled, and cleaned the cut-off switch from my 1963 Big Twin 40 (40352D). The diaphragm is in very good shaped. I treated it with some rubber rejuvenator fluid that I use on my motorcycle carb diaphragms. Two questions...

1) When I got this motor, neither the wire from the safety switch nor the main wire coming down from the magneto section were connected to the stud coming out of the center of the cut-off switch. They were both connected to the stud coming out of lower left corner of the cut-off switch. Are they both supposed to be connected to the center stud of the switch?

2) Where the stud passes through the body/cover of the cut-off switch there was what appears to be a piece of shrink tubing. Presumably, this is to insulate that bolt/stud from the housing. I'm figuring that this may have been an adaptation by a previous owner or boat mechanic. I would think that this would work OK but I'm wondering what was used for this originally.

Thanks!

 

[F_R]

Re: Big Twin cut-off switch questions

1. The black wire from the magneto goes to the center stud. Another black wire from the center stud leads forward to the ignition switch "M" terminal. The white wire from the safety switch goes to the corner nut on the cut-out Another white wire from that same corner nut goes to one of the small nuts on the starter solenoid.

2. I really don't know what they used to insulate that post from the housing, but it very well might have been shrink tube. Whatever insulates it is ok with me.

 

[baytonemus]

Re: Big Twin cut-off switch questions

1. The black wire from the magneto goes to the center stud. Another black wire from the center stud leads forward to the ignition switch "M" terminal. The white wire from the safety switch goes to the corner nut on the cut-out Another white wire from that same corner nut goes to one of the small nuts on the starter solenoid.

OK, that's helpful. I still don't have the electrical junction box, wiring harness, or starter solenoid, so I'm kind of in the dark. Seems like a wiring diagram for each model would have been a nice addition to the service manual. Does one exist anywhere?

2. I really don't know what they used to insulate that post from the housing, but it very well might have been shrink tube. Whatever insulates it is ok with me.

In that case, I'm going to shrink a new piece on there. Thanks again, F_R!

 

[F_R]

Re: Big Twin cut-off switch questions

The factory service manual has a model specific wiring diagram. www.outboardbooks.com Before you run out and buy a car solenoid, be aware that it won't work. You need the right kind. The look identical, but are different inside.

 

[baytonemus]

Re: Big Twin cut-off switch questions

OK, I feel like a dope. I do have the factory service manual but I was looking for the schematics in the electrical section and never bothered to look at the end of it. Duh.

And I have taken to heart your warning from an earlier thread about using a car solenoid. Even if I end up cobbling to together an electric starting system, I'll buy the correct solenoid. Seems like that would be the most critical part. If I can find a complete original box, solenoid, wiring harness, switch, & temp light for a reasonable price, I'll pick them up. Otherwise I think a generic switch and warning light could easily be made to work.

Where is that junction box usually mounted? Back near the motor?