Repair Procedures: Inspection: Notes

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.
   Fig 1: Identifying Alternator Armature

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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).
   Fig 2: Checking Commutator Surface

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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)

   Fig 3: Checking Commutator Diameter

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6. Measure the commutator (A) runout.
   1. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
   2. 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

      Fig 4: Measuring Commutator Runout

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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.)

   Fig 5: Checking Mica Depth

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8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.
   Fig 6: Checking For Continuity Between Segments Of Commutator

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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.
   Fig 7: Checking Continuity Between Commutator And Armature Coil Core Using Ohmmeter

   Courtesy of HYUNDAI MOTOR AMERICA