Starter Overhaul

Fig 1: Exploded View Of Starter Replacement Components 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 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.
   Fig 2: Identifying Screw Driver and Brush Spring

   
4. Remove the brush holder assembly (A).

   Armature Inspection and Test 

5. Disassemble the starter as shown at the beginning of this procedure in the Exploded View.
6. 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.
7. 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 Surface

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8. Check the commutator diameter with 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 (1.38-1.142 in) 

   Service Limit: 28.0 mm (1.102 in) 

   Fig 5: Checking Commutator Diameter

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. 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

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

    Commutator Mica Depth 

    Standard (New): 0.50-0.90 mm (0.00197-0.0354 in) 

    Service Limit: 0.20 mm (0.0079 in) 

    Fig 7: Cutting Away All Mica Between Commutator Segments

    
11. Use an ohmeter 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

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12. 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: Identifying Armature and Hacksaw blade

    
13. 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

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Overrunning Clutch Inspection 

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

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15. 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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16. 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 Brush Inspection 

17. 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 

18. 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 Holder Assembly

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Brush Spring Inspection 

19. 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.

    Standard (New): 22.6-27.26 N (2.27-2.78 kgf, 5.00-6.13 lbf) 

Planetary Gear Inspection 

20. Check the planetary gears (A) and internal ring gear (B). Replace them if they are worn or damaged.
    Fig 15: Identifying Planetary Gears & Internal Ring Gear

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Starter Reassembly 

21. Install the armature housing (A) and the armature (B) by aligning the slotted point (C) to the projection (D).
    Fig 16: Identifying Armature, Housing, Slotted Point & Projection

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22. 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 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 Back Brush Spring

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
23. 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 18: Pushing Each Brush Down

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24. Install the end cover to retain the brush holder.
    Fig 19: Identifying Cover To Retain Brush Holder

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
25. Install the starter (see Installation  )