Starting System: Overhaul Kia Rio III

Reassembly

1. Reassemble in the reverse order of disassembly.

Scheme 18

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Scheme 20

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.
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.
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.

Scheme 21

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.
3. Connect a voltmeter (15-volt scale) across starter motor.
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

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1. Remove the starter.
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. 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).
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)
6. Measure the commutator (A) runout. 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): 0.05mm (0.0020in.) max Service limit: 0.08mm (0.0031in.) max
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): 0.5mm (0.0197in.) Limit: 0.2mm (0.0079 in.)
8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.
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.