A/T Model

Fig 1: Exploded View Of Starter With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Brush Holder Removal 

1. Remove the starter (see STARTER REMOVAL AND INSTALLATION )
2. Disconnect the motor wire from M terminal (see step 4 on STARTER SOLENOID TEST ), and remove the end cover
3. 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
4. Remove the brush holder assembly (A)
   Fig 2: Removing Brush Holder Assembly

   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   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

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

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Check the commutator diameter 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

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 (0 002 in) 

   Fig 6: Measuring Commutator Runout

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. Use a digital caliper or dial type caliper to check the mica depth (A) If the mica is is below the service limit, replace the armature

   Commutator Mica Depth 

   Standard (New) 0 50-0 90 mm (0 020-0 035 in) 

   Service Limit 0 20 mm (0 008 in) 

   Fig 7: Identifying Commutator Mica Depth

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
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

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

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Overrunning Clutch Inspection 

Starter Brush Inspection 

13. 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 59-0.63 in) 

    Service Limit 9 0 mm (0.35 in) 

    Fig 11: Measuring Brush Length

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Starter Brush Holder Test 

14. Check for continuity between the (+) brush holders (A) and the (-) brush holders (B) If there is continuity, replace the brush holder assembly
    Fig 12: Identifying Starter Brush Holder

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Brush Spring Inspection 

15. 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 27-2 78 kgf, 5.00-6.13 lbf) 

    Fig 13: Measuring Spring Tension

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Planetary Gear Inspection 

16. Check the planetary gears (A) and the internal ring gear (B) Replace them if they are worn or damaged
    Fig 14: Identifying Planetary Gear

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Overrunning Clutch Inspection 

17. Slide the overrunning clutch (A) along the shaft Replace it if it does not slide smoothly
    Fig 15: Sliding Overrunning Clutch

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
18. 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 16: Turning Drive Gear

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
19. 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 torque converter ring gear Replace it if the starter drive gear teeth are damaged

Starter Reassembly 

20. 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 17: Prying Brush Spring

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
21. Install the armature housing (A) and the armature (B) by aligning the slotted point (C) to the projection (D)
    Fig 18: Identifying Armature Housing, Armature And Slotted Point

    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: Identifying Brush Holder Assembly

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
23. Install the end cover to retain the brush holder
    Fig 20: Identifying End Cover To Brush Holder

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
24. Install the starter (see STARTER REMOVAL AND INSTALLATION )