Starting System: Overhaul Honda Civic IX

Disassembly

Note. Refer to the EXPLODED VIEW if needed during this procedure.

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1. Starter End Cover and Armature Housing Remove the end cover. Remove the armature housing.
2. Starter Armature Remove the armature.
3. Starter Armature - Inspection Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature. 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 3, or recondition with #500 or sandpaper (B). 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): 28.0-28.1 mm (1.102-1.106 in) Service Limit: 27.5 mm (1.083 in) 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) 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): 0.40-0.50 mm (0.0157-0.0197 in) Service Limit: 0.15 mm (0.0059 in) Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any of the segments, replace the armature. Place the armature (A) on an armature tester (B). Hold 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. 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) there is continuity, replace the armature.
4. Starter Brush Holder Assembly Remove the brush holder.
5. Starter Brush - Inspection Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly. Brush Length Standard (New): 11.1-11.5 mm (0.437-0.453 in) Service Limit: 4.3 mm (0.169 in)
6. Starter Brush Holder - Test Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly.
7. Starter Planetary Gear - Inspection Check the planetary gears (A), the armature shaft gear (B), and the internal ring gear (C). Replace them if they are worn or damaged.
8. Starter Ring Gear Remove the ring gear holder. Remove the switch plunger.
9. Starter Overrunning Clutch - Inspection Hold the drive gear (A), turn the gear shaft (B) counterclockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover set. Hold the drive gear, turn the gear shaft clockwise. The gear shaft should turn freely. If the gear shaft does not turn freely, replace the gear cover set. If the drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately.

Reassembly

Note. Refer to the EXPLODED VIEW if needed during this procedure.

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1. Starter Ring Gear Install the switch plunger. Install the ring gear holder.
2. Starter Brush Holder Assembly Install the brush holder.
3. Starter Armature 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 turn the armature. The contact surface of the brushes will be sanded to the same contour as the commutator. While squeezing a spring (C), insert it in the hole on brush holder, and push it until it bottoms. Repeat this for the other three springs (D, E, and F).
4. Starter End Cover and Armature Housing Install the armature housing. Install the end cover.

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1. Starter Exploded View Exploded View

Note. Refer to the EXPLODED VIEW if needed during this procedure.

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1. Starter End Cover and Armature Housing Remove the end cover. Remove the armature housing.
2. Starter Armature Remove the armature.
3. Starter Armature - Inspection Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature. 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 3, or recondition with #500 or sandpaper (B). 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): 28.0-28.1 mm (1.102-1.106 in) Service Limit: 27.5 mm (1.083 in) 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) Use a digital caliper or dial type caliper to check the mica depth (A). If the mica depth is below the service limit, replace armature. Commutator Mica Depth Standard (New): 0.40-0.50 mm (0.0157-0.0197 in) Service Limit: 0.15 mm (0.0059 in) Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any of the segments, replace the armature. 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. 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) there is continuity, replace the armature.
4. Starter Brush Holder Assembly Remove the brush holder.
5. Starter Brush Holder - Test Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly.
6. Starter Brush - Inspection Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly. Brush Length Standard (New): 11.1-11.5 mm (0.437-0.453 in) Service Limit: 4.3 mm (0.169 in)
7. Starter Planetary Gear - Inspection Check the planetary gears (A), the armature shaft gear (B), and the internal ring gear (C). Replace them if they are worn or damaged.
8. Starter Gear Cover Remove the ring gear holder. Remove the switch plunger.
9. Starter Overrunning Clutch - Inspection Hold the drive gear (A), turn the gear shaft (B) counterclockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover set. Hold the drive gear, turn the gear shaft clockwise. The shaft should turn freely. If the gear shaft does not turn freely, replace the gear cover set. If the drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately.

Note. Refer to the EXPLODED VIEW if needed during this procedure.

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1. Starter Gear Cover Install the switch plunger. Install the ring gear holder.
2. Starter Brush Holder Assembly Install the brush holder.
3. Starter Armature 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 turn the armature. The contact surface of the brushes will be sanded to the same contour as the commutator. While squeezing a spring (C), insert it in the hole on brush holder, and push it until it bottoms. Repeat this for the other three springs (D, E, and F).
4. Starter End Cover and Armature Housing Install the armature housing. Install the end cover.

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1. Battery Terminal - Disconnection Make sure the ignition switch is in LOCK (0), or the vehicle ignition in the OFF mode. Disconnect and isolate the negative cable with the battery sensor (A) from the battery. NOTE: Always disconnect the negative side first. To protect the battery sensor connector (B) from damage, do not hold it when removing the negative terminal. Do not disconnect the battery sensor from the negative terminal (C). Disconnect the positive cable (D) from the battery.
2. Vehicle Lift Raise the vehicle on a lift, and make sure it is securely supported.
3. Tire and Wheel-Removal, Front Right Remove the right front wheel.
4. Engine Undercover Remove the engine undercover (A).
5. Starter Remove the intake manifold bracket. Disconnect the connector. Remove the clamps and the connector. Remove the starter. Disconnect the cable and the connector.

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1. Starter Performance - Test Clamp the starter firmly in a vise. Make the connections for this test using the thickest (gauge) wire possible (preferably the same gauge as used on the vehicle). NOTE: To avoid damaging the starter, never leave the battery connected for more than 5 seconds. Connect the battery as shown, and check for continuity between the B terminal and the starter body. If there is continuity, it is working properly. Disconnect the battery from the starter body, and check for continuity between the B terminal and the starter body. If there is no continuity, it is working properly. Connect the starter to the battery as shown, and confirm that the motor runs. If the electric current meets the specification when the battery voltage is at 11.5 V, the starter is working properly Specification Electric Current: 90 A or less

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1. Starter Connect the cable and the connector. Make sure the cable crimped side of the ring terminal faces away from the starter when you connect it. Install the starter, then loosely install the upper mounting bolt (A) and the lower mounting bolt (B). Tighten the upper mounting bolt, then tighten the lower mounting bolt. Install the clamps and the connector. Connect the connector. Install the intake manifold bracket.
2. Engine Undercover Install the engine undercover (A).
3. Tire and Wheel-Installation, Front Right Install the right front wheel. NOTE: Before installing the wheel, clean the mating surfaces between the brake disc and the inside of the wheel.
4. Battery Terminal - Reconnection NOTE: If the battery performs abnormally, test the battery Clean the battery terminals. Connect the positive cable (A) to the battery. NOTE: Always connect the positive side first. Connect the negative cable and the battery sensor (B) to the battery. NOTE: To protect the battery sensor connector (C) from damage, do not hold it when installing the negative terminal. Apply multipurpose grease to the terminals to prevent corrosion.
5. Starter After Install - Check Start the engine to make sure the starter works properly

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1. Battery Terminal - Disconnection Make sure the ignition switch is in LOCK (0), or ignition in the OFF mode. Disconnect and isolate the negative cable with the battery sensor (A) from the battery. NOTE: Always disconnect the negative side first. To protect the battery sensor connector (B) damage, do not hold it when removing the negative terminal. Do not disconnect the battery sensor from the negative terminal (C). Disconnect the positive cable (D) from the battery.
2. Vehicle Lift Raise the vehicle on a lift, and make sure it is securely supported.
3. Splash Shield Remove the splash shield (A).
4. Starter Remove the starter bolts. Disconnect the cable and the connector. Remove the starter.

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1. STARTER PERFOMANCE - TEST Clamp the starter firmly in a vise. Make the connections for this test using the thickest (gauge) wire possible (preferably the same gauge as used on the vehicle). NOTE: To avoid damaging the starter, never leave the battery connected for more than 5 seconds. Connect the battery as shown, and check for continuity between the B terminal and the starter body. If there is continuity, it is working properly. Disconnect the battery from the starter body, and check for continuity between the B terminal and the starter body. If there is no continuity, it is working properly. Connect the starter to the battery as shown, and confirm that the motor runs. If the electric current meets the specification when the battery voltage is at 11.5 V, the starter is working properly. Specification Electric Current: 90 A or less

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1. Starter Install the starter. Connect the cable, and the connector. Make sure the crimped side of the ring terminal faces away from the starter when you connect it. Install the starter.
2. Splash Shield Install the splash shield (A).
3. Battery Terminal - Reconnection NOTE: If the battery performs abnormally, test the battery Clean the battery terminals. Connect the positive cable (A) to the battery. NOTE: Always connect the positive side first. Connect the negative cable and the battery sensor (B) to the battery. NOTE: To protect the battery sensor connector damage, do not hold it when installing the negative terminal. Apply multipurpose grease to the terminals to prevent corrosion.
4. Starter After Install - Check Start the engine to make sure the starter works properly

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1. Battery Terminal - Disconnection Make sure the ignition switch is in LOCK (0), or the vehicle ignition in the OFF mode. Disconnect and isolate the negative cable with the battery sensor (A) from the battery. NOTE: Always disconnect the negative side first. To protect the battery sensor connector (B) from damage, do not hold it when removing the negative terminal. Do not disconnect the battery sensor from the negative terminal (C). Disconnect the positive cable (D) from the battery.
2. Vehicle Lift Raise the vehicle on a lift, and make sure it is securely supported.
3. Tire and Wheel-Removal, Front Right Remove the right front wheel.
4. Engine Undercover Remove the engine undercover (A).
5. Starter Remove the intake manifold bracket. Disconnect the connector. Remove the clamps and the connector. Remove the starter. Disconnect the cable and the connector.

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1. Starter Solenoid - Test Remove the motor cable (A). Check the hold-in coil for continuity between the S terminal and the armature housing (ground) (B). There should be continuity: If there is continuity, go to step 3. If there is no continuity, replace the solenoid. Check the pull-in coil for continuity between the S terminal and the M terminal. There should be continuity: If there is continuity, the solenoid is OK. If there is no continuity, replace the solenoid. Connect the motor cable.

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1. Starter Connect the cable and the connector. Make sure the starter cable crimped side of the ring terminal faces away from the starter when you connect it. Install the starter, then loosely install the upper mounting bolt (A) and the lower mounting bolt (B). Tighten the upper mounting bolt, then tighten the lower mounting bolt. Install the clamps and the connector. Connect the connector. Install the intake manifold bracket.
2. Engine Undercover Install the engine undercover (A).
3. Tire and Wheel-Installation, Front Right Install the right front wheel. NOTE: Before installing the wheel, clean the mating surfaces between the brake disc and the inside of the wheel.
4. Battery Terminal - Reconnection NOTE: If the battery performs abnormally, test the battery Clean the battery terminals. Connect the positive cable (A) to the battery. NOTE: Always connect the positive side first. Connect the negative cable and the battery sensor (B) to the battery. NOTE: To protect the battery sensor connector (C) from damage, do not hold it when installing the negative terminal. Apply multipurpose grease to the terminals to prevent corrosion.
5. Starter After Install - Check Start the engine to make sure the starter works properly.