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Stihl MS440 Kill Switch Question

Discussion in 'Chainsaws and Power Equipment' started by MrWhoopee, Aug 2, 2025 at 10:58 AM.

  1. MrWhoopee

    MrWhoopee

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    I am replacing the lever that controls the choke/kill switch on my MS440. I need to transfer the brass contact from the old one but can't figure out how to remove it. Don't want to burn my bridges by destroying the old lever, so I thought I'd ask here if someone knows how to release it.

    MS440 choke lever.jpg
     
  2. Chud

    Chud

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    huskihl maybe could answer your question?
     
  3. huskihl

    huskihl

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    I guess I don’t know that I have ever removed that piece. Does it slide straight out the end? I can take a look at one tomorrow if I remember and let you know
     
  4. MrWhoopee

    MrWhoopee

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    I pulled quite hard, it doesn't come out that way. There's a square hole in the opposite end, but it doesn't seem to release by pushing a pin in that way. The new part offers no clues as to what might retain it.
     
  5. huskihl

    huskihl

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    I’ll try and remember to take a look tomorrow
     
  6. Woodtroll

    Woodtroll

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    I think the copper contactor has a tab on each wide side - this one is spring-loaded, correct? Use either a knife or dremel tool to split the plastic on one edge, so you can spread it enough to pull the contactor out. You might also be able to slowly heat it enough with a torch to accomplish the same thing. Watch for the spring! o_O
     
  7. Lehman

    Lehman

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    Is this an aftermarket lever or oem? You’d think an oem one would have the ground tab on it. If not oem may not be worth the time to swap it since the master control seems to be a downfall for a lot of clone saws.
     
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  8. MrWhoopee

    MrWhoopee

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    Aftermarket. The OEM comes with the contact, but it's not installed.

    [​IMG]
     
  9. MrWhoopee

    MrWhoopee

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    So I managed to get it out by inserting a small nail into the square hole in the back (had to work the spring over to line up with the hole), then tapping the nail with a hammer. Didn't take much force to get it out and I didn't lose the spring. Still can't figure out how it's retained, but I pushed it into the new lever and it stays as it should. Call this one solved. Thanks to those who replied.
     
  10. Woodtroll

    Woodtroll

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    Good news! Thanks for the update!
     
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  11. Eggshooterist

    Eggshooterist

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    Good deal. My guess is it's an interference fit of sorts with the plastic being a bit elastic and the metal a tad larger than the hole, they stay together. I haven't had one in my hands though so I might be barking up the wrong tree so to speak.
     
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  12. MrWhoopee

    MrWhoopee

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    The contact slides freely under spring pressure, but stops at a certain point. When I grabbed the contact with pliers I couldn't pull it out. I couldn't see anything in the slot that would act as a stop, but there is obviously something.
     
  13. Eggshooterist

    Eggshooterist

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    Interesting.
     
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