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Armature Inspection and Test

  1. Remove the starter (see STARTER REMOVAL AND INSTALLATION ).
  2. Disassemble the starter as shown in Exploded View .
  3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
    Fig 1: Identifying Armature
    G05454011Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. 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 5, or recondition with #500 or #600 sandpaper (B).
    Fig 2: Checking Commutator Surface With Sandpaper
    G05454012Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.

    Commutator Diameter 

    Standard (New): 28.0 mm (1.10 in.) 

    Service Limit: 27.0 mm (1.06 in.) 

    Fig 3: Checking Commutator Diameter
    G05454013Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. 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 (0.001 in.) max. 

    Service Limit: 0.05 mm (0.002 in.) 

    Fig 4: Measuring Commutator Runout
    G05454014Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D).

    Commutator Mica Depth 

    Standard (New): 0.50-0.80 mm (0.020-0.031 in.) 

    Service Limit: 0.20 mm (0.008 in.) 

    Fig 5: Identifying Commutator Mica Depth
    G05454015Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Check for continuity between the segments of the commutator. If there is an open circuit between any of the segments, replace the armature.
    Fig 6: Checking Continuity Between Segments Of Commutator
    G05454016Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. 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 7: Placing Armature On Armature Tester
    G05454017Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. 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 8: Checking Continuity Between Commutator And Armature Coil Core
    G05454018Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Starter Brush Inspection 

  11. Measure the brush length. If it is not within the service limit, replace the brush holder assembly or the armature housing.

    Brush Length 

    Standard (New): 14.0-14.5 mm (0.55-0.57 in.) 

    Service Limit: 9.0 mm (0.35 in.) 

    Fig 9: Measuring Starter Brush Length
    G05454019Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Starter Field Winding Test 

  12. Check for continuity between the brushes (A) and the motor wire (B). If there is no continuity, replace the armature housing (C).
    Fig 10: Checking Continuity Between Brushes And Motor Wire
    G05454020Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Check for continuity between each brush and the armature housing. If there is continuity, replace the armature housing.

    Starter Brush Holder Test 

  14. Check for continuity between the (+) brush holder (A) and (-) brush holder (B). If there is continuity, replace the brush holder assembly.
    Fig 11: Checking Continuity Between (+) Brush Holder And (-) Brush Holder
    G05454021Courtesy 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): 13.7-17.7 N (1.40-1.80 kgf, 3.09-3.97 lbf) 

    Fig 12: Measuring Brush Spring Tension
    G05454022Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Overrunning Clutch Inspection 

  16. Slide the overrunning clutch (A) along the shaft. Replace it, if it does not slide smoothly.
    Fig 13: Inspecting Overrunning Clutch
    G05454023Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Hold the drive gear (B), and turn the overrunning clutch in the direction shown to make sure it turns freely. Also make sure the overrunning clutch locks in the opposite direction. If it does not lock, replace the overrunning clutch assembly.
  18. 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 flywheel or torque converter ring gear. Replace it if the starter drive gear teeth are damaged.

    Planetary Gear Inspection 

  19. Check the planetary gears (A) and internal ring gear (B). Replace them if they are worn or damaged.
    Fig 14: Checking Planetary Gears And Internal Ring Gear
    G05454024Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Starter Reassembly 

    NOTE: Refer to Exploded View  as needed during this procedure.
  20. Install the starter solenoid and the planetary gear assembly (A) to the gear housing (B) by aligning the reference marks (C).
    Fig 15: Installing Starter Solenoid And Planetary Gear Assembly To Gear Housing
    G05454025Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. When you replace the brush holder or the armature housing, you need 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.
  22. Pry back the 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 16: Prying Brush Spring With Screwdriver
    G05454026Courtesy of AMERICAN HONDA MOTOR CO., INC.
  23. Pry back the brush spring with a screwdriver, then position the brush on the armature housing (A) about halfway out of brush holder (B). Release the spring to hold it in place.
    Fig 17: Identifying Armature Housing And Brush Holder
    G05454027Courtesy of AMERICAN HONDA MOTOR CO., INC.
  24. Install the armature housing (A) and armature (B) by aligning the slotted point (C) to the projection (D).
    Fig 18: Installing Armature Housing And Armature To Projection
    G05454028Courtesy of AMERICAN HONDA MOTOR CO., INC.
  25. Push each brush down until it seats against the commutator, then release the spring against the end of the brush.
    Fig 19: Pushing Brush Down Against Commutator
    G05454029Courtesy of AMERICAN HONDA MOTOR CO., INC.
  26. Install the end cover (A) by aligning the reference marks (B).
    Fig 20: Installing End Cover By Aligning Reference Marks With Torque Specifications
    G05454030Courtesy of AMERICAN HONDA MOTOR CO., INC.
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