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Okay, so here is the status update...

The stationary switch is an "old style wishbone" type. I don't know why they call it that. I gave the wishbone a little bend towards the outer shaft and I worked. The pump still starts a little excitedly, but the sparks are gone. I believe that if I continue to play with the switch I can get it to work perfectly, but I just don't have the patience for that.

FYI-a new switch is around $110~$125. As we all know at that point, I should just buy a new motor.

I am kind of discouraged though, seems there isn't an exact science in adjusting these switches, maybe that's why they are so expensive.

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Q: How do you align stationary switch on an AO Smith pool motor?
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