Overrunning Clutch Inspection

14. While 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 assembly.

Fig 1: Holding Drive Gear And Turning Gear Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
15. While 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 assembly.
16. If the starter drive gear is worn or damaged, replace the gear cover assembly. Check the condition of the flywheel ring gear if the drive gear teeth are damaged.
17. 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 2: Setting Armature In Brush Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
18. While squeezing a 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).
19. Install the armature and brush holder assembly in the housing.
NOTE: Make sure the armature stays in the holder.
20. Reassemble the starter in the reverse order of disassembly.