| VELOSTER(FS) >2013 > G 1.6 GDI > Engine Electrical System > Starting System > Starter>Repair procedures |

Removal and Installation
1. | Disconnect the battery negative terminal.
2. | Remove the air duct and air cleaner assembly. (Refer to EM group)
3. | Disconnect the starter cable (B) from the B terminal on the solenoid then disconnect the connector (A) from the S terminal.
4. | Remove the 2 bolts holding the starter, then remove the starter (A).
Tighting torque : 42.2 ~ 53.9 Nm (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
5. | Installation is the reverse of removal.
Disassembly
1. | Disconnect the M-terminal (A) on the magnet switch assembly (B).
2. | After loosening the 2 screws (A), detach the magnet switch assembly (B).
3. | Loosen the brush holder mounting screw (A) and through bolts (B).
4. | Remove the rear bracket (A) and brush holder assembly (B).
5. | Remove the yoke (A).
6. | Remove the packing (A), lever plate (B), lever (C) and the armature (D).
7. | Press the stopper (A) using a socket (B).
8. | Remove the stop ring (A) using stop ring pliers (B).
9. | Remove the stop ring (B), stopper (A), overrunning clutch (C) and armature (D).
10. | Reassembly is the reverse of disassembly.
Using a suitable pulling tool (A), pull the overrunning clutch stopper (C) over the stop ring (B).
Inspection
Armature Inspection And Test
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.
A. | If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
B. | 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.
Inspect Starter Brush Brushes that are worm out, or oil-soaked, should be replaced.
Bruch length Standard : 12.3 mm (0.4843 in) Service limit : 5.5 mm (0.2165 in)
Starter Brush Holder Test
1. | Make sure there is no continuity between the (+) brush holder (A) and (-) plate (B). If there is continuity, replace the brush holder assembly.
2. | Pry back each brush spring (A) with a screwdriver, then position the brush (B) about halfway out of its holder, and release the spring to hold it there.
3. | Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush.
To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.
Overrunning Clutch
1. | Slide the overrunning clutch along the shaft. Replace it if does not slide smoothly.
2. | Rotate the overrunning clutch both ways. Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both directions, replace it.
3. | If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (the gear is not available separately). Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.
Cleaning
1. | Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the insulation. Wipe these parts with a cloth only.
2. | Do not immerse the drive unit in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent will wash lubrication from the clutch.
3. | The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.