I have not seen this one posted yet so hopefully this becomes help for others as well.
I bought my first G1 this month. 2001 Blue 5speed with 114K on the OD. A few things that I have had to do to get it up to snuff and one of that last ones was the drivers door window rolls down but not always up. Taking apart the assembly everything is solid and nothing is broken. This drove me to think about the motor armature and contacts which might have build up and/or oxidation over time. Pulling it apart wow the surface looked nasty. So here is what I did and so far looks to have fixed my problems for less than an hour of work ans a small piece of sandpaper.
1) Removed door panel, window, and regulator assembly per Honda procedure. See following posting for service manual download if you don't already have it.
Download 2000-2006 Insight Service Manual PDF and Others
2) Remove screws that hold the motor housing in place on the actuator assembly. Screw might take a bit of force to get out. I used my cordless Makita Impact driver with the right size bit to get them loose easily. (Image “1.jpg”).
1.JPG
3) Rotate armature counter-counter clockwise to be able to remove from housing. End of armature is a worm drive that actuates the assembly this is why you need to rotate to remove. (Image “2.jpg”).
4) Clean armature surface that come in contact with housing contacts. I used 600 grit.
5) Clean both contacts on housing (Image “3.jpg”). I used 600 grit.
3.jpg
6) Wipe everything clean and reassembly. Good to go.
Stuck Window Regulator Fix with Pics
