Exploded View

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Fig 1: Exploded View Of Starter With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

NOTE: Refer to the exploded view above during this procedure.

Brush Holder Removal

Remove the starter (see STARTER REMOVAL AND INSTALLATION ).
Disconnect the motor wire from the M terminal (see STARTER PERFORMANCE TEST ), and remove the end cover.
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.

Fig 2: Prying Brush Spring With Screwdriver
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the brush holder assembly (A).
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 3: Identifying Armature
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 8, or recondition with #500 or #600 sandpaper (B).

Fig 4: Checking Commutator Surface
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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: Checking Commutator Diameter With Digital Caliper Or Dial Type Caliper
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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: Measuring Commutator Runout
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 Commutator Mica Depth
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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: Placing Armature On Armature Tester
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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: Checking Continuity Between Commutator And Armature Coil Core
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Overrunning Clutch Inspection
Slide the overrunning clutch (A) along the shaft. Replace it if it does not slide smoothly.

Fig 11: Sliding Overrunning Clutch
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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
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
Check for continuity between the (+) brush holders (A) and the (-) brush holders (B). If there is continuity, replace the brush holder assembly.

Fig 14: Checking Continuity Between (+) Brush Holders And (-) Brush Holders
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 it is not within the standard, replace the brush holder assembly.
Spring Tension

Standard (New): 22.26-27.26 N (2.270-2.780 kgf, 5.004-6.128 lbf)

Fig 15: Checking Brush Spring Tension
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Planetary Gear Inspection
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 Gears, Armature Shaft Gear And Internal Ring Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Starter Reassembly
Install the armature housing (A) and the armature (B) by aligning the slotted point (C) to the projection (D).

Fig 17: Identifying Armature Housing And Armature
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 Brush Spring With Screwdriver
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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: Installing Brush Holder Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the end cover to retain the brush holder.

Fig 20: Brush Holder And End Cover With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.