31637-ZY6-000 Honda STAY, ALTERNATOR (Honda Code 7634769).

Disassembly
(1) Pinion set(2) Solenoid switch(3) Rear bracket(4) Brush holder(5) Brush(6) Armature(7) Yoke(8) Packing(9) Packing(10) Plate(11) Ball(12) Reduction gears(13) Lever(14) Front bracket(15) Overrunning clutch(16) Internal gear(17) Gear shaft
The pinion must be removed before removal or replacement of the following parts:1. Front bracket2. Reduction gears3. Overrunning clutch
(1) Removing Pinion
The pinion can be removed when it is held in the pushed-out position during energization of the solenoid switch. Disconnect the M-terminal connector and make a circuit that connects the starter motor and the battery as shown in the illustration. Close switches S1 and S2 to make the pinion come out and rotate. Then, open switch S2. The pinion will stop rotating but will stay in the pushed-out position. Apply a pipe-shaped implement to the pinion stopper and lightly tap it with a hammer to remove the pinion.If the pinion returns to the retracted position before disengagement of the stopper while the tool is being tapped, repeat the procedure from the beginning.
Removing pinion(2) Ball
The ball at the end of the armature acts as a bearing for movement of the armature in the thrust direction. When the armature is removed, the ball may stick to the grease on it. Be careful not to lose the ball.Inspection
(1) Armature
(a) Coil Short Circuit TestPlace the armature on a growler tester. Hold an iron rod parallel with the armature and slowly rotate the armature by hand. If the iron rod vibrates or is pulled toward the armature, the armature has a short-circuited coil and must be replaced.
Testing armature short circuit(b) Coil Ground TestCheck whether continuity exists between the commutator and shaft (or core). If continuity exists, the coil is grounded and the armature must be replaced.
Testing armature coil ground(c) Commutator Inspection(1) Measure the commutator's runout using a dial gauge. If the measurement exceeds the specified limit, rectify the problem, making sure that the outside diameter stays within specification. If the surface is rough or has stepped wear, rectify the problem with emery paper (#300-500).Unit: mm (in.)
Measuring commutator runout(2) Measure the commutator's outside diameter. If the measurement is out of specification replace the armature.Unit: mm (in.)
Measuring commutator outside diameter(3) Measure the molding undercut depth between segments. If the depth is smaller than the limit, cut the molding to a depth of 0.5 mm (0.02 in.).Unit: mm (in.)
Measuring commutator mica depth(2) Field Coil
(a) Coil Open Circuit TestCheck whether continuity exists between the terminal lead and each brush. If continuity does not exist, the filed coil has an open circuit and the yoke assembly must be replaced.
Testing field coil open circuit(b) Coil Ground TestCheck whether continuity exists between the yoke and each brush. If continuity exists, the coil is grounded and must be checked for defective insulation. If repair is impossible, replace the yoke assembly.
Testing field coil ground(3) Brushes and Brush Holders
(a) Brush WearMeasure the length of the brush. If the measurement is smaller than the limit, replace the brush. If the brush is worn unevenly or has a rough contact surface, rectify the problem with fine emery paper (#300-500).Unit: mm (in.)
Measuring brush length(b) Brush Spring ForceWith a new brush installed, pull the brush spring with a spring balance and read the load at the point where the spring leaves the brush. Replace the spring if its force is lower than the limit.Unit: N {kgf} (lbf.)
Measuring brush spring force(c) Brush Holder Insulation TestCheck whether continuity exists between the brush holder and the brush holder base. If continuity exits, replace the brush holder assembly.
Testing brush holder insulation(4) Overrunning Clutch
Make sure the pinion shaft rotates smoothly when turned clockwise (in the drive direction) and locks when turned counterclockwise. If the pinion shaft's operation is defective, replace the overrunning clutch.
Inspection overrunning clutch(5) Gear Shaft Thrust Gap
Adjustment of the gear shaft's thrust gap is not necessary.(6) Armature Thrust Gap
Adjustment of the Armature's thrust gap is not necessary.Assembly
Assembly sequence Inspection and Testing after Assembly
After assembling the starter, perform the following inspections and tests:(1) Inspection and Adjustment of Pinion Gap
(a) Connect the assembled starter to the battery as shown in the illustration. The pinion will come out and rotate slowly (SW1, 2: CLOSE). Then, remove the M-terminal connector to stop the motor (SW2 : OPEN).
Connecting starter to battery(b) Lightly push the pinion shaft toward the armature and measure the amount of axial movement, which corresponds to the pinion gap.(c) If the pinion gap is not within the 0.5 mm (0.02 in.) range, adjust it by increasing or decreasing the number if seals in the solenoid switch. (Increasing the number of seals reduces the pinion gap). It may be necessary to replace the lever to obtain the correct pinion gap.Unit: mm (in.)
Inspecting pinion gap
To prevent the solenoid switch from overheating, do not energize the solenoid switch for longer than 10 seconds.(2) No-Load Test
When the pinion gap has been correctly adjusted, connect an ammeter and a voltmeter between the starter motor and battery as shown in the illustration, then check the starter's no-load characteristics.
Use the thickest wires possible, and tighten each terminal firmly.