Exploded View

Fig 1: Exploded View Of Starting System With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Starter Disassembly 

1. Remove the starter (see STARTER REMOVAL AND INSTALLATION  ).
2. Remove the engine wire harness bracket (A) and the end cover (B).
   Fig 2: Identifying Engine Wire Harness Bracket And End Cover

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3. Remove the armature housing (A) and the armature (B).
   Fig 3: Identifying Armature Housing And Armature

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   Armature Inspection and Test 

4. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
   Fig 4: Identifying Armature

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5. Check the commutator (A) diameter with a digital caliper or dial type caliper. If the diameter is below the service limit, replace the armature.

   Commutator Diameter 

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

   Service Limit: 27.5 mm (1.083 in) 

   Fig 5: Checking Commutator Diameter Using Digital Caliper Or Dial Type Caliper

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6. 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

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7. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specification in step  5, or recondition with #500 or #600 sandpaper (B).
   Fig 7: Resurfacing Commutator Surface Using Emery Cloth

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

   Commutator Mica Depth 

   Standard (New): 0.40-0.50 mm (0.0157-0.0197 in) 

   Service Limit: 0.15 mm (0.0059 in) 

   Fig 8: Identifying Commutator Mica Depth

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9. 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 9: Checking Continuity Between Segments Of Commutator Using Ohmmeter

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10. 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 10: Identifying Armature, Armature Tester And Hacksaw Blade

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11. 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 11: Checking Continuity Between Commutator And Armature Coil Core Using Ohmmeter

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Starter Brush Holder Test 

12. Check for continuity between the (+), brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder set.
    Fig 12: Identifying Starter (+) Brushes And (-) Brushes

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    Starter Brush Inspection 

13. Measure the brush length, If it is shorter than the service limit, replace the brush holder set.

    Brush Length 

    Standard (New): 11.1-11.5 mm (0.437-0.453 in) 

    Service Limit: 4.3 mm (0.169 in) 

    Fig 13: Measuring Brush Length

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    Planetary Gear Inspection 

14. Remove the push nut (A), contact spring (B) and moving contact (C), then remove the brush holder set.
    Fig 14: Identifying Push Nut, Contact Spring And Moving Contact

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15. 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 15: Identifying Planetary Gears, Armature Shaft Gear And Internal Ring Gear

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    Overrunning Clutch Inspection 

16. Holding the drive gear (A), turn the gear shaft (B) clockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover set.
    Fig 16: Turning Gear Shaft Clockwise While Holding Drive Gear

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17. Holding the drive gear, turn the gear shaft counterclockwise. The gear shaft should rotate freely. If the gear shaft does not rotate smoothly, replace the gear cover set.

    Starter Reassembly 

18. When the brush holder is replaced: Replace the brush holder set with the moving contact (A), the contact spring (B), and the push nut (C).
    Fig 17: Identifying Moving Contact, Contact Spring, And Push Nut

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19. When the gear cover/reduction gear/plunger is replaced: Replace the new parts set with the contact spring (A) and the push nut (B).
    Fig 18: Identifying Contact Spring And Push Nut

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20. Install the brush into the brush holder, and set the armature (A) in the brush holder (B).
    NOTE: To seat the 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 19: Identifying Armature, Brush Holder And Brush Springs

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21. While squeezing a brush spring (C), insert it in the hole on the brush holder, and push it until it bottoms. Repeat this for the other three springs (D, E, and F).
22. Install the armature and the brush holder assembly (A) into the armature housing (B).
    NOTE: Make sure the armature brackets in the holder.
    Fig 20: Identifying Armature And Brush Holder Assembly With Armature Housing

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23. Install the end cover (A) with the engine wire harness bracket (B).
    Fig 21: End Cover And Engine Wire Harness Bracket With Mounting Bolts Torque Specifications

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24. Install the starter (see STARTER REMOVAL AND INSTALLATION  ).