MAZDA MX-5 1997 Factory Repair Manual

NO-LOAD TEST
Connect fully-charged 12-volt battery, voltmeter and ammeter to starter. See Fig. 2
. Using remote starter wires
or jumper, engage solenoid. Starter should spin smoothly. Compare readings with specifications. See NO
-
LOAD TEST SPECIFICATIONS table. If voltage is less than specified, amperage is more than specified or
shaft speed is less than specified, disassemble and inspect starter components.
NO-LOAD TEST SPECIFICATIONS
SOLENOID TESTS
Solenoid Pull-In Test
Connect positive battery lead to solenoid "S" terminal and negative battery lead to starter body. See Fig. 2 .
Starter pinion drive gear should extend outward and stop. If starter pinion drive gear does not extend, replace
solenoid.
Solenoid Hold-In Test
After performing solenoid pull-in test, with positive battery lead connected to solenoid "S" terminal and
negative battery lead connected to starter body, disconnect field lead ("M" terminal wire) at solenoid. Starter
pinion drive gear should remain extended. If starter pinion drive gear returns, replace solenoid.
Solenoid Return Test
Disconnect field lead ("M" terminal wire) at solenoid. Connect positive battery lead to solenoid "M" terminal
and negative battery lead to starter body. See Fig. 2
. Using screwdriver, pry overrunning clutch pinion drive
outward. Release screwdriver and ensure overrunning clutch pinion drive returns to original position.
Solenoid
1. Disconnect all wires from solenoid, including "M" terminal wire between solenoid and starter. Using
ohmmeter, ensure continuity exists between "S" and "M" terminals, and between "S" terminal and
solenoid body. See Fig. 1
and Fig. 2 . If continuity does not exist between specified terminals, replace
solenoid.
2. Using ohmmeter, ensure continuity does not exist between "M" and "B" terminals. If continuity exists,
replace solenoid.
ApplicationSpecification
Voltage (Minimum)11
Amperage (Maximum)90
Shaft Speed (Minimum RPM)3000
CAUTION: Perform solenoid tests with starter and solenoid assembled. DO NOT
engage starter solenoid for more than 10 seconds during testing or
damage to coil winding may result.

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
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PINION GAP ADJUSTMENT
1. Disconnect field lead ("M" terminal wire) at solenoid. See Fig. 2
. Connect positive battery lead to
solenoid "S" terminal and negative battery lead to starter body. Starter pinion drive gear should extend
outward and stop.
2. Quickly measure pinion gap between end of pinion drive and circlip retainer. See Fig. 3
. DO NOT
operate starter solenoid for more than 10 seconds. Pinion gap should be as specified. See PINION GAP
SPECIFICATIONS table.
3. If pinion gap is not within specification, adjust by increasing or decreasing thickness of solenoid shims
located between solenoid and drive housing.
PINION GAP SPECIFICATIONS
ApplicationIn. (mm)
Miata A/T.02-.08 (0.5-2.0)

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
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1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
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Fig. 3: Checking & Adjusting Pinion Gap
Courtesy of MAZDA MOTORS CORP.
ARMATURE TEST
1. Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly
rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature.
2. Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If
continuity exists, replace armature. Check continuity between commutator and shaft. If continuity exists,
replace armature.
3. Check continuity between each commutator segment. If an open exists between any 2 segments, replace
armature.
COMMUTATOR TEST
1. Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted,
turn commutator in a lathe.
2. Maximum commutator runout and minimum diameter of commutator must not exceed specification after
turning. See COMMUTATOR SPECIFICATIONS
table.
3. Commutator mica undercut depth should be .020 -.030" (.50 -.80 mm). Minimum mica undercut depth
is .008" (.20 mm). If not within specification, undercut to standard depth.
COMMUTATOR SPECIFICATIONS
BRUSH TEST
1. Connect one ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity
exists, replace brush holder assembly.
2. Check brush length. See BRUSH LENGTH SPECIFICATIONS
table. If brush length is less than
specified, replace brushes.
3. Using brush spring scale, measure spring tension. See BRUSH TENSION SPECIFICATIONS
table. If
tension is less than specified, replace brush holder assembly. Ensure brushes move freely in holders.
BRUSH LENGTH SPECIFICATIONS
BRUSH TENSION SPECIFICATIONS
ApplicationMaximum Runout In. (mm)Minimum Diameter In. (mm)
Miata A/T.001 (.03)1.21 (30.8)
ApplicationStandard In. (mm)Minimum In. (mm)
Miata A/T.69 (17.5).47 (12.0)
ApplicationStandard Lbs. (Kg)Minimum Lbs. (Kg)
Miata A/T(1) (1)
(1)Information is not available at time of publication.

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
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FIELD WINDING TEST
1. Connect one ohmmeter lead to field coil lead ("M" terminal wire). Connect other lead of ohmmeter to
soldered portion of brush lead. If continuity does not exist, repair or replace field coil.
2. Check field coil for short to ground by connecting one ohmmeter lead to field coil lead ("M" terminal
wire) and other ohmmeter lead to field coil housing. If continuity exists, repair or replace field coil.
OVERRUNNING CLUTCH PINION DRIVE
Hold overrunning clutch housing and turn pinion gear by hand. If pinion turns in both directions or does not
turn at all, clutch is faulty. Replace clutch. DO NOT clean overrunning clutch with solvent, as it is packed with
grease and sealed by manufacturer.
REMOVAL & INSTALLATION
Removal & Installation
Disconnect negative battery cable. Raise vehicle on hoist. Remove engine undercover (if equipped). Disconnect
wiring from starter. Remove starter mounting bolts and starter. To install, reverse removal procedure. Tighten
starter mounting bolts to specification. See TORQUE SPECIFICATIONS
.
OVERHAUL
Fig. 4: Exploded View Of Coaxial Planetary Gear Type Starter
Courtesy of MAZDA MOTORS CORP. NOTE: On models with anti-theft system, obtain code number and deactivate audio
anti-theft system before disconnecting battery.
NOTE: Overhaul procedures are not available at time of publication. See illustrations
for exploded views of starters. See Fig. 4
.

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
ApplicationFt. Lbs. (N.m)
Starter Mounting Bolts28-38 (38-51)
Starter-To-Bracket Bolt12-16 (16-22)
INCH Lbs. (N.m)
Battery Cable Nut (Solenoid Terminal "B")80-115 (9-13)

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
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1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
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Fig. 5: Starting System Wiring Diagram

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
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STEERING COLUMN
1995-97 STEERING Mazda Motors Corp. - Steering Columns
DESCRIPTION & OPERATION
Steering columns are designed to be collapsible upon impact. The steering column consists of solid steering
shaft with a lower joint assembly. Some models are equipped with tilt steering. Turn signal, headlight, ignition
and windshield washer/wiper switches are mounted on column. Switches can be serviced by removing steering
wheel and column covers. All models are equipped with air bag restraint system consisting of an driver air bag
module, passenger air bag module (except 1995 MPV and 1995 Protege) and clockspring connector assembly
located in the steering column.
SYSTEM OPERATION CHECK
1. Turn ignition switch to ON or START position. AIR BAG warning light in instrument cluster should
illuminate for about 4-8 seconds, and then turn off. This indicates air bag system is functioning properly.
2. If any of the following conditions exists, air bag system is malfunctioning and requires servicing.
AIR BAG warning light does not illuminate as specified.
AIR BAG warning light remains illuminated for more than 8 seconds.
AIR BAG warning light illuminates while driving.
3. If air bag system components are replaced for any reason, air bag system must be checked for proper
function after repair. Repeat step 1). If AIR BAG warning light does not illuminate as specified, air bag
system is malfunctioning and servicing is required. See AIR BAG RESTRAINT SYSTEM article.
SERVICE PRECAUTIONS
Observe the following precautions when servicing air bag system.
Disable air bag system before servicing any air bag system or steering column component. See AIR BAG
DISABLING & ACTIVATING .
After disabling air bag system, wait at least one minute before servicing. Air bag system voltage is
maintained for approximately one minute after system is disabled. Failure to wait one minute before
servicing system may cause accidental air bag deployment and possible personal injury.
Obtain radio code number from customer and deactivate radio anti-theft function (if equipped) before
disconnecting battery.
Because of the critical operation requirements of system, DO NOT service any air bag system
component. Repairs are made by replacement only.
DO NOT use an ohmmeter to check resistance of air bag module, as it may cause air bag deployment.
When carrying a live (undeployed) air bag module, ensure trim cover is pointed away from your body. WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all WARNINGS and SERVICE PRECAUTIONS
.

1997 Mazda MX-5 Miata
STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

1997 Mazda MX-5 Miata
STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns
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This minimizes chance of injury in the event of accidental air bag deployment.
When placing a live air bag module on any surface, always face trim cover upward to reduce motion of
module if it is accidentally deployed.
If an open circuit is present, replace entire wiring harness. DO NOT attempt to repair wire(s).
Air bag system clockspring MUST be aligned in neutral position, since its rotation ability is limited. DO
NOT turn steering wheel or column after removal of steering gear.
A double-lock mechanism is used on clockspring connectors. DO NOT use excessive force when
disconnecting connectors, as damage to connector may occur.
AIR BAG DISABLING & ACTIVATING
DISABLING SYSTEM (MIATA, MILLENIA, MPV, MX-6, PROTEGE & 626)
1. Obtain radio code from customer and deactivate audio anti-theft function (if equipped). Turn ignition off.
Disconnect and shield negative battery cable. Wait at least one minute for back-up power supply to be
depleted. Remove lower cover panel(s) below left side of instrument panel.
2. On MPV, remove lower steering column shroud. On all models, disconnect Orange and Blue clockspring
connectors for driver air bag module. See Fig. 1
. On all models except 1995 Protege and 1995 MPV,
remove glove box compartment. Disconnect Orange and Blue connectors for passenger air bag module.
See Fig. 2
.
ACTIVATING SYSTEM (MIATA, MILLENIA, MPV, MX-6, PROTEGE & 626)
1. Ensure negative battery cable is still disconnected. On all models except 1995 Protege and 1995 MPV,
reconnect Orange and Blue connector for passenger air bag module. Install glove box compartment.
2. On all models, reconnect Orange and Blue clockspring connectors for driver air bag module. Install lower
cover panel(s). On MPV, install lower steering column shroud. On all models, reconnect negative battery
cable.
3. Turn ignition on. Check AIR BAG warning light to ensure air bag system is operating properly. See
SYSTEM OPERATION CHECK
. Activate audio anti-theft function (if equipped).
DISABLING SYSTEM (MX-3, RX7 & 929)
1. Obtain radio code from customer and deactivate audio anti-theft function. Turn ignition off. Disconnect
and shield ne
gative battery cable. Wait at least one minute for back-up power supply to be depleted. WARNING:Wait about one minute after disabling air bag system before servicing. Air
bag system voltage is maintained for about one minute after system is
disabled. Failure to wait one minute before servicing system may cause
accidental air bag deployment and possible personal injury.
CAUTION: When battery is disconnected, vehicle computer and memory systems
may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle.

1997 Mazda MX-5 Miata
STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns
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