Exploded View

Fig 1: Exploded View Of A/T Model With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Brush Holder Removal 

1. Remove the starter .
2. Disconnect the motor wire from M terminal (see step  4), and remove the end cover.
3. Pry back each brush spring with a screwdriver, then position the brush on the brush holder (A) about halfway out of its holder. Release the spring to hold it in place.
   Fig 2: Identifying Brush Holder

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4. Remove the brush holder assembly.

   Armature Inspection and Test 

5. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
   Fig 3: Identifying Armature

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6. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step  7, or recondition with #500 or #600 sandpaper (B).
   Fig 4: Identifying Commutator And Sandpaper

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Check the commutator diameter with a digital caliper or dial type caliper. If the diameter is below the service limit, replace the armature.

   Commutator Diameter 

   Standard (New): 28.9- 29.0 mm (1.138- 1.142 in) 

   Service Limit: 28.0 mm (1.102 in) 

   Fig 5: Measuring Diameter Of Commutator Using Vernier Caliper

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8. Measure the commutator (A) runout:
   • If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
   • If the commutator runout is not within the service limit, replace the armature.

   Commutator Runout 

   Standard (New): 0.02 mm (0.0008 in) max. 

   Service Limit: 0.05 mm (0.0020 in) 

   Fig 6: Identifying Commutator

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9. Use a digital caliper or dial type caliper to check the mica depth (A). If the mica depth is below the service limit, replace the armature.

   Commutator Mica Depth 

   Standard (New): 0.50- 0.90 mm (0.0197- 0.0354 in) 

   Service Limit: 0.20 mm (0.0079 in) 

   Fig 7: Checking Mica Depth Of Commutator Slots

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10. Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.
    Fig 8: Checking Continuity Between Segments Of Commutator

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11. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core while the core is turned, the armature is shorted. Replace the armature.
    Fig 9: Identifying Armature, Armature Tester And Hacksaw Blade

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12. Use an ohmmeter to check for continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.
    Fig 10: Identifying Commutator, Armature Coil Core And Armature Shaft

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    Overrunning Clutch Inspection 

13. Slide the overrunning clutch (A) along the shaft. Replace it if it does not slide smoothly.
    Fig 11: Sliding Overrunning Clutch Along Shaft

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14. Hold the overrunning clutch (A), and turn the drive gear (B) in the direction shown to make sure it turns freely. Also make sure the drive gear locks in the opposite direction. If it does not lock, replace the overrunning clutch assembly.
    Fig 12: Turning Drive Gear

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15. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the idler gear and the torque converter ring gear. Replace it if the starter drive gear teeth are damaged.

    Starter Brush Inspection 

16. Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly.

    Brush Length 

    Standard (New): 15.0- 16.0 mm (0.591- 0.630 in) 

    Service Limit: 9.0 mm (0.354 in) 

    Fig 13: Measuring Brush Length

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Starter Brush Holder Test 

17. Check for continuity between the (+) brush holders (A) and the (-) brush holders (B). If there is continuity, replace the brush holder assembly.
    Fig 14: Identifying (+) And (-) Brush Holders

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    Brush Spring Inspection 

18. 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 it is not within the standard, replace the brush holder assembly.

    Spring Tension 

    Standard (New): 22.3- 27.1 N (2.27- 2.76 kgf, 5.00- 6.08 lbf) 

    Fig 15: Identifying Brush, Spring And Spring Scale

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    Planetary Gear Inspection 

19. Check the planetary gears (A), the armature shaft gear (B), and the internal ring gear (C). Replace them if they are worn or damaged.
    Fig 16: Identifying Planetary Gear, Armature Shaft Gear And Internal Ring Gear

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    Starter Reassembly 

20. Install the armature housing (A) and the armature (B) by aligning the slotted point (C) to the projection (D).
    Fig 17: Identifying Armature Housing, Armature, Slotted Point And Projection

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21. Pry back each brush spring with a screwdriver, then position the brush on the brush holder about halfway out of its holder. Release the spring to hold it in place.
    NOTE: To seat the new brushes, slip a strip of # 500 or #600 sandpaper, with the grit side up, between the commutator and the each brush, and smoothly turn the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.
    Fig 18: Prying Back Each Brush Spring Using Screw Driver

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
22. Install the brush holder assembly. Next, pry back each brush spring again, and push each brush down until it seats against the commutator, then release the spring against the end of the brush.
    Fig 19: Pushing Down Each Brush Till Commutator

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23. Install the end cover to retain the brush holder.
    Fig 20: Brush Holder And Related Replacement Components With Torque Specifications

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24. Install the starter .