Starter Overhaul: Disassembly/Reassembly

Fig 1: Exploded View Of Starter System With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Remove the starter (see STARTER REMOVAL AND INSTALLATION ).
Disassemble the starter.
Armature Inspection and Test
Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.

Fig 2: Identifying Armature
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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 5, or recondition with #500 or #600 sandpaper (B).

Fig 3: Checking Commutator Surface
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Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator Diameter

Standard (New): 28.0-28.1 mm (1.102-1.106 in.)

Service Limit: 27.5 mm (1.083 in.)

Fig 4: Checking Commutator Diameter
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Measure the commutator 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 (0.001 in.) max.

Service Limit: 0.05 mm (0.002 in.)

Fig 5: Checking Commutator For Carbon Dust Or Brass Chips Between Segments
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D).
Commutator Mica Depth

Standard (New): 0.4-0.5 mm (0.016-0.020 in.)

Service Limit: 0.15 mm (0.006 in.)

Fig 6: Identifying Mica Depth
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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 7: Checking Continuity Between Segments Of Commutator
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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 or vibrates while the core is turned, the armature is shorted. Replace the armature.

Fig 8: Holding Hacksaw Blade On Armature Core
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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 9: Checking Continuity Between Commutator And Armature Coil Core
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Starter Brush Inspection
Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly.
Brush Length

Standard (New): 15.8-16.2 mm (0.62-0.64 in.)

Service Limit: 11.0 mm (0.43 in.)

Fig 10: Measuring Brush Length
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Starter Field Winding Test
Check for continuity between the brushes (A). If there is no continuity, replace the armature housing (B).

Fig 11: Checking Continuity Between Brushes And Armature Housing
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Check for continuity between each brush (A) and the armature housing (B). If there is continuity, replace the armature housing.
Starter Brush Holder Test
Check for continuity between the (+) brush holder (A) and the (-) brush holder (B). If there is continuity, replace the brush holder assembly.

Fig 12: Checking Continuity Between Brush And Armature Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Brush Spring Inspection
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 to specification, replace the brush holder assembly.
Spring Tension:

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

Fig 13: Measuring Spring Tension
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Overrunning Clutch Inspection
Check the planetary gears and the internal ring gear. Replace them if they are worn to damaged.
Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
Hold the planetary gear shaft (A), and turn the overrunning clutch assembly (B) both ways. If it does not lock in either direction or it locks in both directions, replace it.

Fig 14: Turning Clutch Assembly
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If the starter drive gear (C) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the flywheel ring gear. Replace it if the starter drive gear teeth are damaged.
Starter Reassembly
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.

Fig 15: Prying Brush Spring
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Install the armature in the housing, and install the brush holder. 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.
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 rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.

Fig 16: Installing Brush Holder
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Install the end cover (A) to retain the brush holder (B).

Fig 17: End Cover And Brush Holder With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.