Kia Stinger CK Quiz
Engine Electrical System

Starter Motor

In this manual: Engine Electrical System
General Information — 8Maintenance — 27Engine Mechanical System — 47Engine Electrical System — 19Emission Control System — 12Engine Control System/Fuel System — 51Automatic Transmission System — 34All-Wheel Drive (AWD) System — 7Drive Shaft and Axle — 15Suspension System — 25Steering — 8Restraints — 19Brake System — 22Body (Interior and Exterior) — 47Front Seat Belt — 63Body Electrical System — 99Windshield Wiper/Washer — 11Heating, Ventilation, and Air Conditioning — 32
42steps
~252min
4/5difficulty
Done 0 of 42

Specifications

Specification

Item Specification
Rated Voltage 12 V, 1.2 kW
Number of Gear Teeth 11
Output
[No load, 11 V]		 Amperes Max. 70 A
Speed Min. 2400 rpm

Item Specification
Rated Voltage 12 V, 1.4 kW
Number of Gear Teeth 13
Performance
[No Load, 11.5 V]		 Amperes Max. 100 A
Speed Min. 1,915 rpm

Components and Component Location

Components

1. Front Bracket
2. Snap Ring
3. Plug
4. Overrunning Clutch Assembly
5. Internal Gear Assembly
6. Lever		 7. Lever Packing
8. Magnetic Switch Assembly
9. Planetary Shaft Assembly
10. Planetary Gear Assembly
11. Packing
12. Shield		 13. Terminal Assembly
14. Clamp Assembly
15. Brush Holder Assembly
16. Rear Bracket
17. Through Bolt

Description and Operation

Description

The starting system includes the battery, starter motor, magnetic switch, ignition switch, neutral safety switch (A/T), clutch pedal position switch (M/T), ignition lock switch, connecting wires, and battery cable.

When the ignition key is turned to the START position, current flows and energizes the starter solenoid coil.

The solenoid plunger and shift lever are activated, and the pinion gear engages with the ring gear. The contacts close and the starter cranks the engine.

To prevent damage caused by excessive rotation of the starter armature, the pinion gear overrunning clutch disengages when the engine starts.

In combination with the ISG function, the starter must perform much more work. Therefore, the starter is designed for a significantly higher number of starting cycles. The starter components are adapted to these higher requirements.

1. Solenoid 2. Brush 3. Armature 4. Overrunning clutch


Circuit Diagrams

Wiring Diagram

Repair Procedures

Removal

  1. Turn the ignition switch OFF and disconnect the negative (-) battery terminal.

  2. Remove the left engine mount bracket.

    (Refer to Engine Mechanical System - "Engine Mounting")

  3. Remove the starter solenoid "B" terminal nut (B), then disconnect the starter cable and ST connector (A).

  4. Remove the starter by loosening the mounting bolt (A).

Installation

  1. Install in the reverse order of removal.

Disassembly

  1. Disconnect the M terminal (A) from the magnetic switch assembly (B).

  2. Loosen the screws (A), then disconnect the magnetic switch assembly (B).

  3. Loosen the through bolts (A).

  4. Remove the brush holder assembly (A), the fork (B) and the armature (C).

  5. Remove the lever plate (B) and the lever packing (A).

  6. Remove the packing (A) and the shield (B).

  7. Disconnect the planetary gear (A).

  8. Disconnect the planetary shaft assembly (or reduction gear assembly) (A) and lever (B).

  9. Press the stopper (A) using a socket (B).

  10. After removing the snap ring (A) using pliers (B).

  11. Disconnect the snap ring (A), overrunning clutch (B), internal gear (C), planetary shaft (D), and/or sealing plate (E).

  12. Assembly is the reverse of disassembly.

Installation

  1. Assemble in the reverse order of disassembly.

Inspection

Starter Solenoid Inspection

  1. Disconnect the lead wire from the M terminal of the magnetic switch.

  2. Connect the battery as shown in the illustration. If the starter pinion gear pops out, the starter is operating normally.

  3. Disconnect the battery from terminal M.

    If the pinion gear does not retract, the hold-in coil is operating normally.

  4. Disconnect the battery from the housing as well. If the pinion gear retracts immediately, the starter is operating normally.

No-Load Test

  1. Place the starter in a vise with soft jaws, and connect a fully charged 12-volt battery to the starter as follows.

  2. Connect a test ammeter (150 A scale) and the carbon pile rheostat as shown. Illustration.

  3. Connect a voltmeter (15-volt scale) to the starter.

  4. Turn the carbon pile to the OFF position.

  5. Connect the battery cable from the negative battery terminal to the starter motor housing.

  6. Adjust until the battery voltage shown on the voltmeter is 11 to 11.5 volts.

  7. Make sure the maximum current is within specification and that the starter rotates smoothly and freely.

    [12 V, 1.2 kW]

    Current (Max.) Speed (Min.)
    70 A 2400 rpm

    [12 V, 1.4 kW]

    Current (Max.) Speed (Min.)
    100 A 1915 rpm

Armature

  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, correct it with a lathe according to the following specifications, or repair it with #500 or #600 sandpaper (B).

  5. Measure the commutator diameter. If the diameter is less than the service limit, replace the armature.

    Commutator diameter

    Standard (new): 29.4 mm (1.1575 in)

    Service limit: 28.8 mm (1.1339 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): 0.05 mm (0.0020 in) max.

    Service limit: 0.10 mm (0.0039 in) max.

  7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw to the correct depth. Remove all mica (C) between the commutator segments. The undercut must 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)

  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.

Starter Brush

  1. Brushes that are worn or contaminated with oil must be replaced.

    Brush length

    Standard: 12.3 mm (0.4843 in)

    Service limit: 5.5 mm (0.2165 in)

Starter Brush Holder

  1. Make sure there is no continuity between the (+) brush holder (A) and the (-) plate (B).

    If there is continuity, replace the brush holder assembly.

Overrunning Clutch

  1. Slide the overrunning clutch along the shaft.

    Replace it if it does not slide smoothly.

  2. Turn the overrunning clutch in both directions.

    Does it lock in one direction and rotate smoothly in the other? If it does not lock in either direction, or locks in both directions, replace it.

  3. If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly. (The gear is not sold separately.)

    Inspect the flywheel ring gear or drive plate if the starter pinion gear teeth are damaged.

Cleaning

  1. Do not immerse parts in cleaning solvent.

    Immersing the yoke assembly and/or armature may damage the insulation. Wipe these parts with a cloth only.

  2. Do not immerse the drive in cleaning solvent.

    The overrunning clutch is pre-lubricated at the factory, and solvent will wash the lubricant off 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 Kia Stinger CK quiz: every answer comes with an explanation and a link to the manual page.