Starting System: Diagnosis Honda S2000 AP1

Symptom Troubleshooting Index

TROUBLESHOOTING CHART

Starter System Circuit Troubleshooting

Special Tools Required

Alternator, Regulator, Battery & Starter tester OTC3131 Available through the Honda Tool and Equipment Program 888-424-6857

Note. Air temperature must be between 59 and 100°F (15 and 38°C) during this procedure. '00-05 models: After the inspection, you must reset the engine control module (ECM) using the Honda Diagnostic System (HDS) (see HOW TO RESET THE ECM ), to clear any diagnostic trouble code (DTCs). '06-09 models: After the inspection, you must reset the ECM using the HDS (see ECM RESET ). Otherwise, the ECM continues to stop the fuel injectors from operating. The battery must be in good condition and fully charged.

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1. Connect the alternator, regulator, battery & starter tester (OTC3131) to the battery as shown. NOTE: The probe is not used for battery testing.
2. Do the BATTERY TEST. Does the display indicate GOOD or GOOD, LOW CHARGE? YES -The battery is OK. Go to step 3. NO -If the display indicates BAD BATTERY, replace the battery, then retest. If the display indicates CHARGE & RETEST, charge the battery, then retest.
3. '00-05 models: Remove the No. 2 (15 A) fuse from the under-dash fuse/relay box.
4. '06-09 models: Connect the HDS to the data link connector (DLC) (see step 2 on «HOW TO USE THE HDS (HONDA DIAGNOSTIC SYSTEM)»(ref-221338-S00364190892006022400000) ).
5. '06-09 models: Turn the ignition switch to ON (II).
6. '06-09 models: Make sure the HDS communicates with the vehicle and ECM. If it does not communicate, troubleshoot the DLC circuit (see «DLC CIRCUIT TROUBLESHOOTING»(ref-351945-S34342936082009122900000) ).
7. '06-09 models: Select ALL INJECTORS STOP in the PGM-FI INSPECTION menu with the HDS.
8. Set the parking brake, then with the clutch pedal pressed and the shift lever in neutral, press the engine start switch. Does the starter crank the engine normally? YES -The starting system is OK. Go to step 13 . NO -Go to step 9.
9. Check the battery condition. Check the electrical connections at the battery, the negative battery cable to the body, the engine ground cables, and the starter for looseness and corrosion. Then try cranking the engine again. Does the starter crank the engine? YES -Repairing the loose connection corrected the problem. The starting system is OK. Go to step 13 . NO -Based on the following symptoms, take the appropriate action: If the starter does not crank the engine at all, go to step 10. If the starter cranks the engine erratically or too slowly, go to step 11 . If the starter does not disengage from the flywheel ring gear when you release the engine start switch, check the following: Solenoid plunger and switch malfunction Dirty drive gear or damaged overrunning clutch
10. Make sure the shift lever in neutral, then disconnect the BLK/WHT wire (A) from the starter S terminal. Connect a jumper wire from the battery positive terminal to the S terminal. Does the starter crank the engine normally? YES -Check the following items in the order listed until you find the problem circuit: NOTE: After the problem in the circuit is found and repaired, go to step 13 . Check for an open or short in the BLK/WHT wire and connectors between the starter cut relay and the starter. Check for an open or short in the ORN wire and connectors between the ignition switch and the starter cut relay. Check for an open or short in the LT BLU wire and connectors between the starter cut relay and the clutch interlock switch. Check for an open or short in the BLU/WHT wire between the starter cut relay and the engine start switch. Check for an open or short in the BLK/YEL, BLK/WHT wire between the ignition switch and the engine start switch. No. 3 fuse in the under-dash fuse/relay box. The ignition switch (see «IGNITION SWITCH»(ref-221387) ). The engine start switch. The clutch interlock switch (see «CLUTCH INTERLOCK SWITCH TEST»(ref-351944-S06077000252009122900000) ). The starter cut relay (see «ELECTRICAL COMPONENT LOCATOR»(ref-318213) ). Body ground (G401, G501). NO -Replace the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-351944-S09754876552009122900000) ), or repair the starter (see «STARTER OVERHAUL»(ref-351944-S35891237682009122900000) ) as necessary.
11. Do the STARTING TEST. NOTE: The probe is used for starter testing. Is the cranking voltage greater than or equal to 8.7 V and the current draw less than or equal to 380 A ('00-05 models) or 230 A ('06-09 models)? YES -Go to step 12. NO -Replace the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-351944-S09754876552009122900000) ), or remove and disassemble it, and check for these problems: Open circuit in starter armature commutator segments Drag in the starter armature Shorted armature winding Excessive drag in the engine Excessively worn starter brushes Open circuit in the starter brushes Dirty or damaged helical spline or drive gear Faulty overrunning clutch
12. Remove the starter, and inspect its drive gear and the flywheel ring gear for damage. Replace any damaged parts.
13. '00-05 models: Reinstall the No. 2 (15 A) fuse in the under-dash fuse/relay box.
14. '00-05 models: Select ECM reset with the HDS (see «ECM RESET»(ref-221338-S21370699772006022400000) ).
15. '06-09 models: Select ECM reset (see «ECM RESET»(ref-221338-S21370699772006022400000) ) in the PGM-FI INSPECTION menu to cancel ALL INJECTORS STOP with the HDS.
16. Do the ECM idle learn procedure: '00-05 models (see «ECM IDLE LEARN PROCEDURE»(ref-221331-S11515083082006022400000) ) '06-09 models (see «ECM IDLE LEARN PROCEDURE»(ref-221342-S09897997502006022400000) )

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1. Disconnect the clutch interlock switch connector, then remove the clutch interlock switch (see «CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT»(ref-221348-S05111791412006022400000) ).
2. Check the clutch interlock switch connector terminals for continuity. There should be no continuity between the terminals with the switch (A) released, and there should be continuity with the switch pressed.
3. If the clutch interlock switch is faulty, replace it.
4. Install the clutch interlock switch, and adjust it (see «CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT»(ref-221348-S05111791412006022400000) ).

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1. Do the battery terminal disconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-221385-S11486664822009111300000) ).
2. Disconnect the positive starter cable (A), the BLK/WHT wire (B), and the motor wire (C).
3. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). There should be continuity. If there is continuity, go to step 5 . If there is no continuity, replace the solenoid.
4. 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.
5. Connect the positive starter cable, the BLK/WHT wire, and the motor wire.
6. Do the battery terminal reconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-221385-S11486664822009111300000) ).
7. '00-05 models: Do the engine control module (ECM) idle learn procedure (see «ECM IDLE LEARN PROCEDURE»(ref-221342-S09897997502006022400000) ).

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1. Disconnect the wires from the S terminal and the M terminal.
2. 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 10 seconds.
3. Connect the battery as shown. Make sure you disconnect the starter motor wire from the M terminal. If the starter pinion moves out, it is working properly.
4. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil of the solenoid is working properly.
5. Disconnect the battery from the starter body. If the pinion retracts immediately, it is working properly.
6. Clamp the starter firmly in a vise.
7. Reconnect the wire to the M terminal.
8. Connect the starter to the battery as shown, and confirm that the motor runs.
9. If the electric current meets the specification when the battery voltage is at 11.5 V, the starter is working properly. Specification MODEL SPECIFICATION '00-03 models: 1.0 kW '04-09 models: 1.1 kW 90 A or less (Electric current)

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1. Do the battery terminal disconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-221385-S11486664822009111300000) ).
2. '00-05 models: Disconnect the air hose (A) and the breather pipe (B), then remove the air cleaner housing cover (C) and the air cleaner assembly (D).
3. '06-09 models: Disconnect the intake air temperature (IAT) sensor connector (A) and the breather pipe (B), remove the manifold absolute pressure (MAP) sensor harness (C) from the holder, then remove the air cleaner housing cover (D) and the air cleaner assembly (E).
4. '00-05 models: Disconnect the air control solenoid valve connector (A) and the vacuum hoses (B), remove the harness clamps (C), then remove the air cleaner housing (D).
5. '06-09 models: Remove the IAT sensor harness clamps (A), then remove the air cleaner housing (B).
6. Remove the drive belt (see «DRIVE BELT INSPECTION»(ref-351946-S40867756362009122900000) ).
7. Disconnect the 4P connector (A) and the positive alternator cable (B) from the alternator.
8. Remove the mounting bolts, then remove the alternator.
9. Disconnect the positive starter cable (A) and the BLK/WHT wire (B) from the starter.
10. Remove the two bolts holding the starter, then remove the starter.

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1. Install the starter, then connect the positive starter cable (A) and the BLK/WHT wire (B) to the starter. Make sure the crimped side of the ring terminal faces away from the starter when you connect it.
2. Install the alternator.
3. Connect the 4P connector (A) and the positive alternator cable (B) to the alternator.
4. Install the drive belt (see «DRIVE BELT INSPECTION»(ref-351946-S40867756362009122900000) ).
5. '00-05 models: Install the air cleaner housing (A), then install the harness clamps (B), connect the air control solenoid valve connector (C) and the vacuum hoses (D).
6. '06-09 models: Install the air cleaner housing (A), then install the IAT sensor harness clamps (B).
7. '00-05 models: Install the air cleaner assembly (A) and the air cleaner housing cover (B), then connect the air hose (C) and the breather pipe (D).
8. '06-09 models: Install the air cleaner assembly (A) and the air cleaner housing cover (B), then install the MAP sensor harness (C) to the holder, connect the IAT sensor connector (D) and the breather pipe (E).
9. Do the battery terminal reconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-221385-S11486664822009111300000) ).
10. Start the engine to make sure the starter works properly.
11. '00-05 models: Do the engine control module (ECM) idle learn procedure (see «ECM IDLE LEARN PROCEDURE»(ref-221331-S11515083082006022400000) ).

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1. Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-351944-S09754876552009122900000) ).
2. Disassemble the starter. Armature Inspection and Test
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
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).
5. Check the commutator diameter. 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.)
6. Measure the commutator 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.)
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): 0.4-0.5 mm (0.016-0.020 in.) Service Limit: 0.15 mm (0.006 in.)
8. 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.
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.
10. 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. Starter Brush Inspection
11. Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly. Brush Length Standard (New): 15.8-16.2 mm (0.62-0.64 in.) Service Limit: 11.0 mm (0.43 in.) Starter Field Winding Test
12. Check for continuity between the brushes (A). If there is no continuity, replace the armature housing (B).
13. Check for continuity between each brush (A) and the armature housing (B). If there is continuity, replace the armature housing. Starter Brush Holder Test
14. Check for continuity between the (+) brush holder (A) and the (-) brush holder (B). If there is continuity, replace the brush holder assembly. 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 the spring tension is not to specification, replace the brush holder assembly. Spring Tension: 15.7-17.7 N (1.60-1.80 kgf, 3.53-3.97 lbf) Overrunning Clutch Inspection
16. Check the planetary gears and the internal ring gear. Replace them if they are worn to damaged.
17. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
18. Hold the planetary gear shaft (A), and turn the overrunning clutch assembly (B) both ways. If it does not lock in either direction or it locks in both directions, replace it.
19. If the starter drive gear (C) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the flywheel ring gear. Replace it if the starter drive gear teeth are damaged. Starter Reassembly
20. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, and release the spring to hold it there.
21. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush. 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 rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.
22. Install the end cover (A) to retain the brush holder (B).

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