Brush Spring Inspection

13. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then attach a spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush. If the spring tension is not within specification, replace the spring.
Spring Tension:

15.7-17.7 N (1.60-1.80 kgf, 3.53-3.97 lbf)

Fig 1: Attaching Spring Scale (B) To Spring (C)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
14. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, and release the spring to hold it there.
NOTE: To seat new brushes, slip a strip of #500 or # 600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.

Fig 2: Prying Back Each Brush Spring With Screwdriver
Courtesy of AMERICAN HONDA MOTOR CO., INC.
15. Install the armature in the housing. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush.

Fig 3: Pushing Brush Down Against Commutator
Courtesy of AMERICAN HONDA MOTOR CO., INC.
16. Install the starter end cover (A) to retain the brush holder (B).

Fig 4: Installing Starter End Cover (A) To Retain Brush Holder (B)
Courtesy of AMERICAN HONDA MOTOR CO., INC.