B ... and the flat edges of the D-washers are correctly located

22 Slide the shims onto the rear end of the armature shaft (see illustration 29.7b).Lubricate the shaft with a smear of grease, then insert the shaft into the rear cover, locating the brushes on the commutator as you do, taking care not to damage the brushes. Check that each brush is securely pressed against the commutator by its spring and is free to move easily in its holder.

23Fit new O-rings onto the main housing, then fit the housing over the armature and onto the rear cover, aligning the marks made on removal (see Step 2).

24Slide the shims and then the insulating washer onto the front end of the armature shaft (see illustration 29.5)and lubricate the shaft with a smear of grease. Apply a smear of grease to the inside of the front cover oil seal and fit the tabbed washer into the cover, making sure the tabs locate correctly (see illustration).Install the cover onto the main housing, aligning the marks made on removal (see Step 2).

25Ensure that the D-shaped washers are in place on the long bolts and slide a new O-ring onto each of the bolts. Check the marks on the rear cover, main housing and front cover are correctly aligned, then install the long bolts and tighten them securely, making sure the flat edge on each D-washer is correctly fitted against the front cover (see illustrations).

26 Remove the protective tape from the shaft end and install the starter motor (see Section 28).

30 Charging system testing -

general information and precautions

1 If the performance of the charging system is suspect, the system as a whole should be checked first, followed by testing of the individual components. Note:Before beginning the checks, make sure the battery is fully charged and that the voltage between its terminals is greater than 13 volts, and that all system connections are clean and tight (see Section 3).

2 Checking the output of the charging system and the performance of thevarious components within the charging system requires the use of a multimeter (with voltage, current and resistance checking facilities). Ensure that the multimeter battery is in good condition before commencing tests.

3 When making the tests, follow the procedures carefully to prevent incorrect connections or short circuits, as irreparable damage to electrical system components may result if short circuits occur.

4 If amultimeter is not available, the job of checking the charging system should be left to a Honda dealer or automotive electrician.

31 Charging system -

leakage and output tests

1 If the charging system of the machine is
thought to be faulty carry-out the following
tests with a multimeter.

Leakage test

2 Ensure that the ignition switch is OFF and
disconnect the lead from the battery negative
(-ve) terminal (see Section 3).

3 Set the multimeter to the Amps function
and connect its negative (-ve) probe to the
battery negative (-ve) terminal, and positive
(+ve) probe to the disconnected negative (-ve)
lead (see illustration).Always set the meter
to a high amps range initially and then bring it
down to the mA (milli Amps) range; if there is a
high current flow in the circuit it may blow the
meter's fuse.

Caution: Always connect an ammeter (multimeter set to Amps) in series, never in parallel with the battery, otherwise it will be damaged. Do not turn the ignition ON or operate the starter motor when the ammeter is connected - a sudden surge in current will blow the meter's fuse.