MAZDA MX-5 1997 Factory Repair Manual

Fig. 28: Exploded View Of Master Cylinder (Millenia)
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 37 © 2005 Mitchell Repair Information Company, LLC.

Fig. 29: Exploded View Of Master Cylinder (MX-6 & 626; With ABS &/Or A/T)
Courtesy of MAZDA MOTORS CORP.
SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Backing Plate Bolts (Rear)
B2300, B3000 & B400025-35 (34-47)
MX-3 & Protege33-43 (45-58)
MX-6 & 62637-50 (50-68)

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
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Sunday, July 05, 2009 1:51:03 PMPage 38 © 2005 Mitchell Repair Information Company, LLC.

Caliper Guide Bolts (Front)
Miata58-65 (78-88)
Millenia & 92946-62 (63-84)
MPV62-69 (84-93)
MX-6 & 62622-30 (30-40)
Caliper Guide Bolts (Rear)
Miata33-36 (45-49)
MPV28-36 (38-49)
Millenia & MX-312-18 (16-24)
MX-6 & 62626-29 (35-39)
Protege33-44 (45-60)
RX746-62 (63-84)
92928-36 (38-49)
Caliper Mount Bracket Bolts (Front)
Miata36-51 (49-69)
Millenia75-101 (102-137)
MPV66-79 (89-107)
MX-6 & 62658-74 (79-100)
92975-87 (102-118)
Caliper Mount Bracket Bolts (Rear)
Miata34-48 (46-66)
Millenia & MPV37-50 (50-68)
MX-3 & Protege33-44 (45-60)
MX-6 & 62634-48 (46-66)
RX734-49 (46-67)
92934-49 (46-67)
Front Caliper Mounting Bolt
B2300, B3000 & B400074-96 (100-130)
MX-3 & Protege30-36 (40-49)
RX758-72 (79-98)
Power Brake Unit Nuts
B2300, B3000 & B400016-21 (22-28)
Except B2300, B3000 & B400014-18 (19-25)
Rear Axle Lock Nut
Miata160-216 (216-294)
Millenia, MX-3, MX-6, Protege, RX7, 626 & 929131-173 (177-235)
Wheel Lug Nut
B2300, B3000 & B400085-115 (115-155)
All Other Models65-87 (88-118)
INCH Lbs. (N.m)
Wheel Cylinder Bleeder Screw (1) MX-3 & Protege52-78 (5.9-8.8)

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
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DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS
Wheel Cylinder Mounting Bolt (1) 88-108 (10-12)
(1)Information is not available at time of publication for B2300, B3000 & B4000.
ApplicationIn. (mm)
B2300, B3000 & B4000 - Front (1)
Original Thickness.94 (24)
Minimum Thickness.81 (21)
Miata
Front (2)
Original Thickness.79 (20)
Minimum Thickness (3) .71 (18)
Rear (2)
Original Thickness.35 (9)
Minimum Thickness (4) .31 (8)
Millenia
Front (5)
Original Thickness1.10 (28)
Minimum Thickness (6) 1.02 (26)
Rear (5)
Original Thickness.37 (9.5)
Minimum Thickness (4) .29 (7.5)
MPV
Front (2)
Original Thickness1.10 (28)
Minimum Thickness (6) 1.02 (26)
Rear (2)
Original Thickness.71 (18)
Minimum Thickness (7) .63 (16)
MX-3
Front (2)
Original Thickness.87 (22)
Minimum Thickness (8) .79 (20)
Rear (2)
Original Thickness.35 (9)

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 40 © 2005 Mitchell Repair Information Company, LLC.

Minimum Thickness (4) .31 (8)
MX-6 & 626
Front (2)
Original Thickness.94 (24)
Minimum Thickness (9) .87 (22)
Rear (2)
Original Thickness.39 (10)
Minimum Thickness (10) .31 (8)
Protege
Front (11)
Original Thickness.87 (22)
Minimum Thickness (8) .79 (20)
Rear (11)
Original Thickness.35 (9)
Minimum Thickness (12) .28 (7)
RX7
Front (2)
Original Thickness.87 (22)
Minimum Thickness.79 (20)
Rear (2)
Original Thickness.79 (20)
Minimum Thickness.71 (18)
929
Front (2)
Original Thickness.94 (24)
Minimum Thickness.87 (22)
Rear (2)
Original Thickness.71 (18)
Minimum Thickness.63 (16)
(1)Maximum lateral runout is .003" (.08 mm).
(2)Maximum lateral runout is .004" (.10 mm).
(3)If using a brake lathe to machine rotor on vehicle, minimum thickness is .74" (18.8 mm).
(4)If using a brake lathe to machine rotor on vehicle, minimum thickness is .33" (8.4 mm).
(5)Maximum lateral runout is .002" (.05 mm).
(6)If using a brake lathe to machine rotor on vehicle, minimum thickness is 1.06" (26.8 mm).
(7)If using a brake lathe to machine rotor on vehicle, minimum thickness is .66" (16.8 mm).

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 41 © 2005 Mitchell Repair Information Company, LLC.

DRUM BRAKE SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS
(8)If using a brake lathe to machine rotor on vehicle, minimum thickness is 82" (20.8 mm).
(9)If using a brake lathe to machine rotor on vehicle, minimum thickness is .90" (22.8 mm).
(10)If using a brake lathe to machine rotor on vehicle, minimum thickness is .35" (8.8 mm).
(11)Maximum lateral runout is .002" (.50 mm).
(12)If using a brake lathe to machine rotor on vehicle, minimum thickness is .31" (7.8 mm).
ApplicationIn. (mm)
B2300, B3000 & B4000 Drum Diameter
Original
9"9.00 (228.6)
10"10.00 (254.0)
Maximum Refinish Diameter
9"9.09 (230.8)
10"10.09 (256.3)
Millenia & MPV Parking Brake Drum Diameter
Original7.48 (190.0)
Maximum Finish Diameter5.51 (191.0)
MX-3 & Protege
Drum Diameter
Original7.87 (200.0)
Maximum Finish Diameter7.93 (201.5)
Wheel Cylinder Bore Diameter
MX-30.687 (17.46)
Protege0.75 (19.0)
MX-6 & 626 Drum Diameter
Original9.00 (228.6)
Maximum Finish Diameter9.06 (230.1)
Wheel Cylinder Bore Diameter0.687 (17.46)
929 Parking Brake Drum Diameter
Original7.48 (190.0)
Maximum Refinish Diameter5.51 (191.0)

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 42 © 2005 Mitchell Repair Information Company, LLC.

GENERATOR & REGULATOR
1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
DESCRIPTION & OPERATION
Generator is a conventional 3-phase, self-rectifying type with 6 diodes (3 positive and 3 negative) that rectify
current. Internal regulator is solid-state type.
ADJUSTMENTS
BELT DEFLECTION
Measure belt deflection in center of longest pulley-to-pulley span. See BELT DEFLECTION
SPECIFICATIONS table. If belt deflection is not as specified, adjust as necessary.
BELT DEFLECTION SPECIFICATIONS
TROUBLE SHOOTING
TROUBLE SHOOTING PRECAUTIONS
Observe the following precautions when trouble shooting or testing charging system:
Obtain code number and deactivate audio anti-theft system before disconnecting battery (if equipped).
DO NOT reverse battery cable connections. Rectifier will be damaged.
DO NOT use high voltage type testers.
Battery voltage should always exist at generator terminal "B".
DO NOT ground generator terminal "L" while engine is running.
DO NOT start engine with connector disconnected from generator terminals "L" and "S".
DO NOT apply battery voltage to terminal "L".
ON-VEHICLE TESTING
* PLEASE READ FIRST *
Application(1) Deflection - In. (mm)
New Belt0.22-0.28 (5.5-7.0)
Used Belt0.24-0.30 (6.0-7.5)
(1)With 22 lbs. (10 kg) applied to belt.
NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
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GENERATOR OUTPUT
1. Connect an ammeter (100-amp minimum) in-line between generator terminal "B" connector and terminal
"B" of wiring harness connector. See Fig. 1
. Turn headlights and all accessories on. Depress brake pedal.
Operate engine at 2500-3000 RPM.
2. Measure and record generator output. See GENERATOR MAXIMUM RATED OUTPUT
table. If
amperage is as specified, go to next step. If amperage is not as specified, repair or replace generator.
3. Turn off headlights and all accessories. Release brake pedal. Operate engine at 2500-3000 RPM and
measure amperage under no-load condition. No-load amperage should be 5 amps or greater. If amperage
is as specified, go to next step. If amperage is not as specified, repair or replace generator.
4. Operate engine at 2500-3000 RPM. Measure voltage between ground and terminals "S" and "L". If 14.1-
14.7 volts does not exist, repair or replace generator. If 14.1-14.7 volts exists, generator output is okay.
GENERATOR MAXIMUM RATED OUTPUT NOTE: Check generator wiring harness connections and drive belt tension. Battery
must be fully charged before testing. Wait at least 30 seconds after starting
engine before measuring system voltage.
CAUTION: Ensure generator terminal "B" does not contact ground.
ApplicationAmps
A/T70
M/T65

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
Microsoft
Sunday, July 05, 2009 1:53:16 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

Fig. 1: Identifying Generator Terminals
Courtesy of MAZDA MOTORS CORP.
BENCH TESTING

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
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Sunday, July 05, 2009 1:53:16 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

RECTIFIER/DIODE ASSEMBLY
1. Using an ohmmeter, check continuity of each diode in both directions (polarity). See Fig. 2
thru Fig. 4. If
diode shows high resistance in one direction and low resistance in other direction, diode is okay.
2. If diode shows low resistance in both directions, diode is shorted. If diode shows high resistance in both
directions, diode is open. If any diode is defective, replace rectifier assembly.
ROTOR & SLIP RINGS
Measure resistance between rotor slip ring contacts. See Fig. 5
thru Fig. 9 . If resistance is not within
specification, replace rotor. See ROTOR RESISTANCE SPECIFICATIONS
table. Check continuity
between individual slip rings and rotor core/shaft. If continuity exists, replace rotor.
ROTOR RESISTANCE SPECIFICATIONS
STATOR
Check continuity between stator coil leads and stator core. See Fig. 5
thru Fig. 9 . If continuity exists, replace
stator. Check continuity between leads of stator coil. If continuity does not exist, replace stator.
BRUSHES
Replace brushes if worn to limit line. See Fig. 5
thru Fig. 9 . Replace brush springs if corroded. For brush
replacement procedure, see OVERHAUL
.
Application(1) Ohms
Miata3.5-4.5
(1)If continuity does not exist, replace rotor.

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
Microsoft
Sunday, July 05, 2009 1:53:16 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.