Repair Procedures: Inspection

Starter Solenoid Inspection 

1. Disconnect the lead wire from the M-terminal of solenoid switch.
2. Connect the battery as shown. If the starter pinion pops out, it is working properly.
   NOTE:

   • To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.
   Fig 1: Inspecting Starter Solenoid

   Courtesy of KIA MOTORS AMERICA, INC.
3. Disconnect the battery from the M terminal.

   If the pinion does not retract, the hold-in coil is working properly.

   NOTE:

   • To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.
   Fig 2: Disconnecting Battery From M Terminal

   Courtesy of KIA MOTORS AMERICA, INC.
4. Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly.
   NOTE:

   • To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.
   Fig 3: Disconnecting Battery From Body

   Courtesy of KIA MOTORS AMERICA, INC.

Free Running Inspection 

1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor as follows.
2. Connect a test ammeter (150-ampere scale) and carbon pile rheostats shown is the illustration below.
3. Connect a voltmeter (15-volt scale) across starter motor.
   Fig 4: Free Running Inspection

   Courtesy of KIA MOTORS AMERICA, INC.
4. Rotate carbon pile to the off position.
5. Connect the battery cable from battery's negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11 volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely.

   Items	Current (Max.)	Speed (Min.)
   ISG type	95 A	3, 400 rpm
   Non-ISG type	95 A	2, 500 rpm

Armature Inspection And Test 

1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure. (Refer to DISASSEMBLY .)
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
   Fig 5: Armature

   Courtesy of KIA MOTORS AMERICA, INC.
4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #500 or #600 sandpaper (B).
   Fig 6: Cleaning Commutator Surface With Sandpaper

   Courtesy of KIA MOTORS AMERICA, INC.
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.

   Commutator diameter 

   Standard (New): 29.4 mm (1.1575 in)

   Service limit: 28.8 mm (1.1339 in)

   Fig 7: Checking Commutator Diameter

   Courtesy of KIA MOTORS AMERICA, INC.
6. Measure the commutator (A) runout.
   NOTE:

   • If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
   • If the commutator run out is not within the service limit, replace the armature.

   Commutator runout 

   Standard (New): 0.05 mm (0.0020 in.) max

   Service limit: 0.08 mm (0.0031 in.) max

   Fig 8: Measuring Commutator Runout

   Courtesy of KIA MOTORS AMERICA, INC.
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): 0.5 mm (0.0197 in.)

   Limit: 0.2 mm (0.0079 in.)

   Fig 9: Checking Mica Depth

   Courtesy of KIA MOTORS AMERICA, INC.
8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.
   Fig 10: Checking Continuity Between Segments Of Commutator

   Courtesy of KIA MOTORS AMERICA, INC.
9. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature.

Fig 11: Checking Continuity Between Commutator And Armature Coil Core

Courtesy of KIA MOTORS AMERICA, INC.