Exploded View

Fig 1: Exploded View Of Starter Overhaul 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 the M terminal (see step  4 ), 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.
   Fig 2: Prying Brush Spring Using Screwdriver

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4. Remove the brush holder assembly (A).

   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

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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 7, or recondition with #500 or #600 sandpaper (B).
   Fig 4: Checking Commutator Surface

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7. 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 Using Digital Caliper

   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 (0.0020 in) 

   Fig 6: Measuring Commutator

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9. 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: Identifying Mica Depth

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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 For Continuity Between Segments Of Commutator Using Ohmmeter

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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 while the core is turned, the armature is shorted. Replace the armature.
    Fig 9: Checking Armature Core Using Hacksaw Blade

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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 Use Ohmmeter

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Overrunning Clutch Inspection 

13. Slide the overrunning clutch (A) along the shaft. Replace it if it does not slide smoothly.
    Fig 11: Sliding Overrunning Clutch Along Shaft

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14. 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

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15. 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 

16. 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 

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

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Brush Spring Inspection 

18. 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, 5.004-6.129 lbf) 

    Fig 15: Measuring Spring Tension Using Spring Scale

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    Planetary Gear Inspection 

    Fig 16: Identifying Planetary Gears, Armature Shaft Gear And Internal Ring Gear

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19. Check the planetary gears (A), the armature shaft gear (B), and the internal ring gear (C). Replace them if they are worn or damaged.

    Starter Reassembly 

20. Install the armature housing (A) and the armature (B) by aligning the slotted point (C) to the projection (D).
    Fig 17: Installing Armature Housing And Armature By Aligning Slotted Point To Projection

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21. 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 Back Brush Spring Using Screwdriver

    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

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23. Install the end cover to retain the brush holder.
    Fig 20: End Cover And Brush Holder With Torque Specifications

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