NEVER AGAIN!

Geo-TH,In

Well-known Member
I will never convert another honda to electric start. Honda used lock tight on the flywheel nut. Impact had to work to get it off. I have never seen lock tight on a flywheel, had I known, I would have used a little heat. Good thing they had 3 places to attach a gear puller or I would have never have removed the flywheel. The new flywheel had to be drilled and tapped so I could use a gear puller in the future. As you can see, I never thougth of removing the metal filings, which ended up on all 3 magnets. The only way to remove the starter is to pull the flywheel to get to the starter bolts.

The biggest problem was the starter. I had to drill the aluminum plate out. Then the factory hole, where the starter goes, was 4+ mm too small. Call guy where I got starter kit from and he said that I had to use a dremmel to enlarge it. That took a day.

The good news is that the engine started on the first crank. Pressure washer has sat for almost a year.

I would advise if you plan to convert over to electric, make sure the starter will fit the factory hole.

George
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rodger
Is your genny honda powered? If it is, ask about the starter. Trying to enlarge a 2.5 inch hole wasn't easy. It took me 3 days. Keep in mind, a retired day starts at 10 am, has many breaks, and ends by 3 pm. Well I worked overtime today, ended at 4 pm.

Measure diameter of starter and opening in engine block.

I'm happy the job is over and ended well. Love just touching the key and it starts. Saves my arm. I will never go through enlarging a hole again. If it doesn't fit, forget it.
George
 
You are WHINING! (Sounds like a normal day"s work with the stuff that comes through my shop!)
 
How in the world did they desighn it so the flywheel had to come off. When I try in my head,it seems to require taking additional steps just to prevent the starter coming out after removing bolts.
 
The heads of the bolts holding the starter in place are located behind the flywheel.

I had to remove the old flywheel to put the new one on with generator magnets and starter ring.

That's the flywheel I'm showing with all the metal filings it picked up from the drill press.

Then to remove the old flywheel, I had to make longer metric bolts by welding two 6x1 bolts together. Needed 3 long 6x1 bolts. Everything I did seemed like it was just one problem after the next.
George
 
(quoted from post at 13:13:11 10/03/13) The heads of the bolts holding the starter in place are located behind the flywheel.

This seems typical of Honda design. Had a friend foolish enough to own an Accord AND do his own work on it. Replacing the front rotors required removing the axles...
 

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