SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2001
GROUP
Engine Electrical System Starting System
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COMPONENTS 
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REPLACEMENT OF BRUSHES AND SPRINGS 
  1. Brushes that are worn beyond wear limit line, or oil-soaked, should be replaced.

  1. When replacing field coil brushes, crush worn brush with pliers, taking care not to damage pigtail.

  1. Sand pigtail end with sandpaper to ensure good soldering.

  1. Insert pigtail into hole provided in new brush and solder it. Make sure that pigtail and excess solder do not come out onto brush surface.

  1. When replacing ground brush, slide the brush from brush holder by prying retaining spring back

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SERVICE POINTS OF ASSEMBLY 
INSTALLATION OF THE STOP RING AND SNAP RING

Using a suitable pulling tool, pull overrunning clutch stop ring over snap ring.

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REMOVAL AND INSTALLATION 
  1. Remove the battery negative terminal.

  1. Remove the air duct and air cleaner cover.

  1. Remove the air cleaner assembly, and speedo meter cable.

  1. Remove the starter motor.

  1. Installation is the reverse order of removal.

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CHECKING FOR OPERATION 
SERVICE, ADJUSTMENT PROCEDURES FOR PINION GAP ADJUSTMENT
  1. Disconnect the field coil wire from the M-terminal of the solenoid.

  1. Connect a 12V battery the S-terminal and the M-terminal.

  1. The pinion will move out.

    CAUTION
    This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
  1. Check the pinion to stopper clearance (pinion gap) with a feeler gauge.

    MEASUREMENT SPECIFICATION
    Pinion gap: 0.5-2.0 mm ( 0.02-0.079 in )
  1. If the pinion gap is out of specification, adjust by adding or removing gaskets between the solenoid and the front bracket.

MAGNETIC SWITCH PULL-IN TEST
  1. Disconnect the field coil wire from the M-terminal of the magnetic switch.

  1. Connect a 12V battery between the S-terminal and the M-terminal.

    CAUTION
    This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
  1. If the pinion moves out, then the pull-in coil is good. If it doesn't move out, replace the magnetic switch.

MAGNETIC SWITCH HOLD-IN TEST
  1. Disconnect the field coil wire from the M-terminal of the magnetic switch.

  1. Connect a 12V battery between the S-terminal and the body.

    CAUTION
    This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
  1. If the pinion moves out, everything is in order. If the pinion moves back and forth repeatedly the hold-in circuit is open. Then replace the magnetic switch.

FREE RUNNING TEST
  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:

  1. Connect a test ammeter (100-ampere scale) and carbon pile rheostat as shown is the illustration.

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

  1. Rotate carbon pile to the off position.

  1. Connect battery cable from battery negative post to starter motor body.

  1. Adjust until battery voltage shown on the voltmeter reads 11 volts.

  1. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely:

Current: Max. 90 Amps

Speed: Min. 3,000 rpm

MAGNETIC SWITCH RETURN TEST
  1. Disconnect field coil wire from the M-terminal of the magnetic switch.

  1. Connect a 12V battery between M-terminal and the body.

    NOTE
    This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
  1. Pull pinion out and release. If pinion returns quickly to its original position, everything is in order. If it doesn't, replace the magnetic switch.

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DISASSEMBLY 
REMOVAL OF SNAP RING AND STOP RING
  1. Press the stop ring to the snap ring side using a socket wrench.

  1. After removing the snap ring (using snap-ring pliers), remove the stop ring and the overrunning clutch.

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CLEANING STARTER MOTOR PARTS 
  1. Do not immerse parts in cleaning solvent. Immersing the yoke and field coil assembly and/or armature will damage insulation. Wipe these parts with a cloth only.

  1. Do not immerse drive unit in cleaning solvent. The overrunning clutch is pre-lubricated at the factory and solvent will wash lubrication from clutch.

  1. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

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INSPECTION 
CHECKING THE COMMUTATOR
  1. Place the armature on a pair of V-blocks, and check the run-out by using a dial gauge.

    MEASUREMENT SPECIFICATION
    Armature run-out 0.05 mm ( 0.002 in )
    MEASUREMENT SPECIFICATION
    Armature run-out 0.1 mm ( 0.0039 in )
  1. Check the outer diameter of the commutator.

    MEASUREMENT SPECIFICATION
    Outer diameter of the commutator 29.4 mm ( 1.157 in )
    MEASUREMENT SPECIFICATION
    Outer diameter of the commutator 28.4 mm ( 1,118 in )
  1. Check the depth of the undercut between segments.

    MEASUREMENT SPECIFICATION
    Depth of the undercut between segments 0.5 mm ( 0.020 in )
    MEASUREMENT SPECIFICATION
    Depth of the undercut between segments 0.2 mm ( 0.0079 in )
BRUSH HOLDER

Check for continuity between the brush holder plate and the brush holder.

The normal condition is no continuity.

OVERRUNNING CLUTCH
  1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction. If clutch does not function properly, replace overrunning clutch assembly.

  1. Inspect pinion for wear or burrs. If pinion is worn or burred, replace overrunning clutch assembly. If pinion is damaged, also inspect ring gear for wear or burrs.

FRONT AND REAR BRACKET BUSHING

Inspect bushing for wear or burrs. If bushing is worn or burred, replace front bracket assembly or rear bracket assembly.

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TESTING ARMATURE 
TESTING ARMATURE FOR SHORT-CIRCUIT
  1. Place armature in a growler.

  1. Hold a thin steel blade parallel and just above while rotating armature slowly in growler. A shorted armature will cause blade to vibrate and be attracted to the core. Replace shorted armature.

TESTING ARMATURE FOR GROUNDING

Check the insulation between the armature coil cores and the commutator segments. They are normal if there is no continuity.

CHECKING FOR ARMATURE COIL WIRING DAMAGE/DISCONNECTION

Check for continuity between segments. The condition is normal if there is continuity.