Exploded View

Fig 1: Exploded View Of Starter Components With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Armature Inspection and Test 

1. Remove the starter (see STARTER REMOVAL AND INSTALLATION ).
2. 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

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
3. 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 4, or recondition with #500 or #600 sandpaper (B).
   Fig 3: Checking Commutator Surface

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. 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 4: Checking Commutator Diameter Using Digital Caliper Or Dial Type Caliper

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
5. 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 5: Measuring Commutator Runout

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
6. 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): 0.40-0.50 mm (0.0157-0.0197 in) 

   Service Limit: 0.15 mm (0.0059 in) 

   Fig 6: Identifying Commutator Mica Depth

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. 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 Commutator Segments

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
8. 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 8: Testing Armature

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. 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 9: Checking Continuity Between Commutator And Armature Coil Core

   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Starter Brush Inspection 

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

    Brush Length 

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

    Service Limit: 4.3 mm (0.169 in) 

    Fig 10: Measuring Brush Length

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Starter Brush Holder Test 

11. Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly.
    Fig 11: Checking Continuity Between (+) Brushes And (-) Brushes

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Planetary Gear Inspection 

12. 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 12: Identifying Planetary Gears, Armature Shaft Gear And Internal Ring Gear

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Overrunning Clutch Inspection 

13. 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 13: Inspecting Overrunning Clutch

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
14. 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.
15. If the drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the torque converter ring gear to see if the drive gear teeth are damaged.

    Starter Reassembly 

16. 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 14: Identifying Armature, Brush Holder And Springs

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
17. 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 brush springs (D, E, and F).
18. Install the armature and brush holder assembly into the armature housing.