Starters: Overhaul Kia Rio I рестайлинг

OVERHAUL

Use illustration to aide in overhaul. (Scheme 6)or (Scheme 7).

Scheme 6

Scheme 7

Disassembly

1. Remove nut from "M" terminal. see scheme 1
2. Remove field wire from "M" Terminal.
3. Remove solenoid screws and magnetic switch. (Scheme 8) NOTE: If pinion depth shims are found between solenoid and drive end housing, remove them and set aside. (Scheme 9)
4. Remove solenoid plunger spring. (Scheme 10)
5. Disengage plunger from lever and remove plunger. (Scheme 11)
6. Remove bolts from rear cover. Separate motor assembly from drive end housing. Also separate motor assembly from planetary gear set, if present. (Scheme 12)
7. Remove lever from drive pinion. (Scheme 13)
8. Remove drive stopper from snap ring using a deep well socket or similar tool. (Scheme 14)
9. Remove snap ring from its groove in pinion shaft.
10. Remove stopper and drive pinion from pinion shaft. (Scheme 15)
11. Remove two brush plate screws and rear cover. (Scheme 16)
12. Remove armature from field coil housing.
13. Remove armature washers from the end of the armature.

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Reassembly

1. Reassemble armature washers to the end of armature.
2. Reassemble armature in field coil housing.
3. Reassemble rear cover and tighten two brush plate screws to specification. (Scheme 16) See «TORQUE SPECIFICATIONS»(ref-164133-S22030173942004072200000).
4. Reassemble drive pinion and stopper on pinion shaft.
5. Place snap ring on its groove in pinion shaft. (Scheme 15)
6. Reassemble stopper.
7. Reassemble lever on drive pinion. (Scheme 13)
8. If present, reassemble planetary gear set to motor assembly.
9. Reassemble motor assembly in drive end housing.
10. Place bolts in rear cover and tighten. (Scheme 12) See «TORQUE SPECIFICATIONS»(ref-164133-S22030173942004072200000).
11. Engage plunger in lever. (Scheme 11)
12. Insert solenoid plunger spring. (Scheme 10)
13. Reassemble magnetic switch and tighten solenoid screws to specification. See «TORQUE SPECIFICATIONS»(ref-164133-S22030173942004072200000).
14. Apply battery power to the "S" terminal and ground starter motor body. Ensure pinion ejects outward and then stops.
15. Measure clearance (pinion gap) between pinion and stopper. CAUTION: Be careful not to let electricity flow continuously for more than 10 seconds.
16. If pinion gap is not within specified range, adjust it by increasing or decreasing the number of washers used between solenoid and drive housing. The gap will become smaller if the number of washers is increased. NOTE: DO NOT use more washers than plates.
17. Connect field wire to "M" terminal.