Hyundai Kona Quiz
Engine Control System/Fuel System

Starter Repair Procedures

In this manual: Engine Control System/Fuel System
General Information — 17Engine Mechanical System — 85Engine Electrical System — 50Emission Control System — 26Engine Control System/Fuel System — 152DCT (Dual Clutch Transmission) System — 50Four-Wheel Drive (4WD) System — 21Propeller Shaft and Axle (2WD-FF) — 28Suspension System (without ECS) — 32Steering — 21Restraints — 38Brake System — 64Body (Interior and Exterior) — 205Body Electrical System — 1Heating, Ventilation, and Air Conditioning — 66
31steps
~186min
4/5difficulty
02040608010053.940N·mlb·ft
Tightening torque found on this page
Done 0 of 31

Removal

  1. Turn the ignition switch OFF and disconnect the negative (-) battery terminal.
  2. Remove the air cleaner. (Refer to Engine Mechanical System - "Air Cleaner")
  3. Remove the nut securing the starter solenoid "B" terminal, then disconnect the starter cable (A) and ST connector (B).
  4. Remove the starter (A) after loosening the mounting bolts.

    Starter mounting bolt: 42.2 – 54 N·m

Installation

  1. Install in the reverse order of removal.

Disassembly

  1. Disconnect the M terminal (A) on the magnetic switch unit.
  2. Loosen the screws (A), then disconnect the magnetic switch assembly (B).
  3. Loosen the through bolts and remove the brush holder assembly (A), yoke (B), and armature (C).
  4. Remove the lever seal (A) and lever plate (B).
  5. Remove the end frame (A) and packing (B).
  6. Disconnect the planetary gear (A).
  7. Disconnect the planetary shaft assembly (A) and the lever (B).
  8. Press the stopper (A) using a socket (B).
  9. Remove the snap ring (A) using pliers (B).
  10. Disconnect the stopper (A), overrunning clutch (B), internal gear (C), and planetary shaft (D).
  11. Assemble in the reverse order of disassembly.

Installation

  1. Assemble in the reverse order of disassembly.

Inspection

Armature Inspection and Test
  1. Remove the starter motor.
  2. Disassemble the starter as shown at the beginning of this procedure.
  3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
  4. Inspect the commutator surface (A). If the surface is dirty or burnt, resurface it with sandpaper or on a lathe according to the following specifications, or polish with #500 or #600 sandpaper (B).
  5. Check the commutator diameter. If the diameter is below the service limit, replace the armature. Commutator diameter Standard (new): 33.0 mm (1.2992 in) Service limit: 32.4 mm (1.2756 in)
  6. Measure the commutator runout (A).
    • If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
    • If the commutator runout exceeds the service limit, replace the armature.
    Commutator runout Standard (new): 0.02 mm (0.0008 in) max. Maximum service limit: 0.05 mm (0.002 in)
  7. Check the undercut depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the correct depth. Cut away all of the mica (C) between the commutator segments. The undercut must not be too shallow, too narrow, or V-shaped (D). Commutator mica undercut depth: Standard (new): 0.5 mm (0.0197 in.) Limit: 0.2 mm (0.0079 in.)
  8. Check for continuity between the commutator segments. If there is an open circuit between any segments, replace the armature.
  9. Using an ohmmeter, check that there is no continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.
Inspect the starter brushes. Worn or oil-soaked brushes must be replaced.Starter Brush Holder Test
  1. Check that there is no continuity between the (+) brush holder (A) and the (-) plate (B). If there is continuity, replace the brush holder assembly.
  2. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
  3. Rotate the overrunning clutch in both directions. Check that it locks in one direction and rotates smoothly in the opposite direction. If it does not lock in either direction, or locks in both directions, replace it.
  4. If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly. (The gear is not sold separately.) Check the condition of the flywheel ring gear or torque converter if the starter pinion gear teeth are damaged.
Inspect the overrunning clutch.

Cleaning

  1. Do not immerse the parts in cleaning solvent. Immersing the yoke and/or armature assembly may damage the insulation. Wipe these parts only with a cloth.
  2. Do not immerse the drive in cleaning solvent. The overrunning clutch is pre-lubricated at the factory, and the solvent will wash the lubricant out of the clutch.
  3. The drive may be cleaned with a brush moistened with cleaning solvent, and then wiped dry with a cloth.

Test yourself

A quick Hyundai Kona quiz: every answer comes with an explanation and a link to the manual page.