MAZDA MX-5 1997 Factory Repair Manual

Fig. 14: Measuring Brush Spring Tension
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
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Fig. 15: Inserting Wire To Retain Brushes For Reassembly
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
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Fig. 16: Measuring Installed Depth Of Brush
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
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Fig. 17: Exploded View Of Generator
Courtesy of MAZDA MOTORS CORP.
WIRING DIAGRAMS

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
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1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
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Fig. 18: Charging System Wiring Diagram

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
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CLUTCH
1997-98 CLUTCHES Mazda - RWD
DESCRIPTION
All models use a hydraulically operated clutch. On all models except Miata, the clutch release bearing and
clutch release cylinder are combined into a single unit. No routine adjustments are necessary on B2300, B2500,
B3000 and B4000 models.
ADJUSTMENTS
CLUTCH PEDAL FREE PLAY
Miata
Measure clutch pedal free play. See Fig. 1 . See CLUTCH PEDAL FREE PLAY table. If free play is not
within specification, inspect hydraulic and mechanical system components. If adjustment is required, loosen
lock nut and rotate master cylinder push rod to obtain specified free play. Tighten lock nut.
CLUTCH PEDAL FREE PLAY
(1)
CLUTCH PEDAL HEIGHT
Miata
Measure clutch pedal height from bulkhead to front side of pedal pad. See Fig. 1 . See CLUTCH PEDAL
HEIGHT table.
CLUTCH PEDAL HEIGHT
(1)
CLUTCH DISENGAGEMENT HEIGHT
Miata
Measure clutch disengagement height, where clutch disengages, from pedal pad to bulkhead. See Fig. 1 . See
CLUTCH DISENGAGEMENT HEIGHT (MINIMUM)
table.
ApplicationIn. (mm)
Miata0.2-0.5 (5-13)
(1)See Fig. 1 .
ApplicationIn. (mm)
Miata6.89-7.28 (175-185)
(1)Measure to carpet on bulkhead. See Fig. 1 .

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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CLUTCH DISENGAGEMENT HEIGHT (MINIMUM) (1)
Fig. 1: Adjusting Clutch Pedal (Miata)

Courtesy of MAZDA MOTORS CORP.
HYDRAULIC SYSTEM BLEEDING
B2300, B2500, B3000 & B4000
ApplicationIn. (mm)
Miata2.68 (68)
(1)Measure to carpet on bulkhead. See Fig. 1 .

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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1. Using Clutch Disconnect Tool (T88T-70522-A), disconnect hydraulic line at transmission. See Fig. 2 .
Clean reservoir cap area. Fill reservoir with DOT 3 brake fluid. Maintain fluid level in reservoir during
bleeding procedure.
2. Using small screwdriver, press and hold internal mechanism of male coupler to open valve. While
holding valve open, have an assistant slowly press and hold clutch pedal to floor.
3. Remove screwdriver to allow valve to close. Release clutch pedal. Refill reservoir.
4. Repeat steps 2) and 3). Install reservoir cap. Reconnect hydraulic line. Tug hydraulic line lightly to verify
secure connection.
5. As rapidly as possible, operate clutch pedal for full 5-10 strokes. Wait 3 minutes. Repeat this step at least
3 more times.
6. Loosen bleed screw, located next to release cylinder connection. Have an assistant press and hold clutch
pedal. Tighten bleed screw. Release pedal. Refill reservoir. Check clutch operation.
Fig. 2: Removing Hydraulic Line (B2300, B2500, B3000 & B4000)

Courtesy of MAZDA MOTORS CORP.
Miata
1. Remove bleeder screw cap located at clutch release cylinder. Install vinyl hose onto bleeder screw.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Submerge other end of hose in container of brake fluid.
2. Fill reservoir with DOT 3 brake fluid. Have an assistant press and release clutch pedal several times, then
hold pedal down. With pedal pressed, loosen bleeder screw to let air and fluid escape.
3. Repeat step 2) until no more air bubbles emerge from hose. Tighten bleeder screw. Fill reservoir. Operate
clutch while inspecting for leaks. Check clutch and brake operation.
REMOVAL & INSTALLATION
CLUTCH ASSEMBLY
Removal (B2300, B2500, B3000 & B4000)
1. Disconnect negative battery cable. Shift transmission into Neutral. Remove gearshift lever. Raise and
support vehicle. Mark drive shaft flanges for installation reference. Remove drive shaft. Using Clutch
Disconnect Tool (T88T-70522-A), disconnect hydraulic line at transmission. See Fig. 2
. Plug hydraulic
line to prevent contamination. Disconnect wiring at transmission.
2. Remove starter. Remove exhaust components as necessary for clearance. On 4WD models, remove skid
plate and transfer case. On all models, secure transmission jack under transmission. Remove transmission
mount-to-crossmember nuts and bolts.
3. Remove nuts securing crossmember to frame side rails, and remove crossmember. Lower transmission
enough to gain access to transmission-to-engine block bolts. Remove transmission-to-engine block bolts.
Remove transmission.
4. If clutch parts are going to be reused, mark clutch cover and flywheel for reassembly reference. Loosen
pressure plate bolts evenly in crisscross pattern until springs are not under tension. Remove clutch cover
and clutch disc.
Inspection (B2300, B2500, B3000 & B4000)
1. Inspect disc for loose rivets, worn or defective springs, excessive wear, or oil contamination. Inspect
flywheel and clutch cover for burns, scoring, or grooves.
2. Measure flywheel and clutch cover runout. Resurface or replace flywheel and clutch cover if beyond
specification. See CLUTCH RUNOUT (MAXIMUM)
table.
3. Measure clutch disc runout. Replace disc if it is not to specification. See CLUTCH RUNOUT
(MAXIMUM) table. Inspect disc hub and input shaft splines for excessive wear. Hub must slide
smoothly on input shaft splines.
4. Inspect pilot bearing for wear. Apply inward pressure while rotating pilot bearing. If bearing sticks or has
excessive resistance, replace bearing. Check for tight fit in crankshaft. Replace as necessary. Inspect
release bearing for smooth operation, wear, damage, or looseness. Replace bearing as necessary.
CLUTCH RUNOUT (MAXIMUM)
ApplicationIn. (mm)
Disc0.028 (0.7)
Flywheel0.008 (0.20)

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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