MAZDA MX-5 1997 Factory Repair Manual

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
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Sunday, July 05, 2009 1:56:16 PMPage 6 © 2005 Mitchell Repair Information Company, LLC.

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 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 (M/T).001 (.03)1.21 (30.8)
ApplicationStandard Length In. (mm)Minimum Length In. (mm)
Miata (M/T).67 (17.0).45 (11.5)
ApplicationStandard Lbs. (Kg)Minimum Lbs. (Kg)
Miata (M/T)(1) (1)

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
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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
(1)Information is not available at time of publication.
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 illustration for
exploded view of starter. See Fig. 4
.

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
Microsoft
Sunday, July 05, 2009 1:56:16 PMPage 8 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Exploded View Of Direct Drive Starter
Courtesy of MAZDA MOTORS CORP.
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")87-104 (9.8-11.7)

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
Microsoft
Sunday, July 05, 2009 1:56:16 PMPage 9 © 2005 Mitchell Repair Information Company, LLC.

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
Microsoft
Sunday, July 05, 2009 1:56:16 PMPage 10 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Starting System Wiring Diagram

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
Microsoft
Sunday, July 05, 2009 1:56:16 PMPage 11 © 2005 Mitchell Repair Information Company, LLC.

STARTER - REDUCTION GEAR
1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
DESCRIPTION & OPERATION
Reduction gear starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to
the drive housing.
Gear reduction is performed b
y coaxial planetary gear set. See Fig. 1.

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
Microsoft
Sunday, July 05, 2009 1:56:43 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.
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Fig. 1: Reduction Gear Type Starters
Courtesy of MAZDA MOTORS CORP.
TROUBLE SHOOTING

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
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Sunday, July 05, 2009 1:56:43 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

ON-VEHICLE TESTING
* PLEASE READ FIRST *
CIRCUIT TEST
If starter does not operate, check voltage at starter "S" terminal with ignition switch in START position. See
Fig. 2
. If voltage is greater than 8 volts and vehicle does not crank, repair or replace starter as required. If
volta
ge is 8 volts or less, check ignition switch, park/neutral switch (A/T) and wiring. NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article.
NOTE: On models with anti-theft system, obtain code number and deactivate audio
anti-theft system before disconnecting battery.
NOTE: Before testing, ensure battery is fully charged, battery cables and terminals are
clean and tight, and engine grounds are good.

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
Microsoft
Sunday, July 05, 2009 1:56:43 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Testing Reduction Gear Starter Circuits
Courtesy of MAZDA MOTORS CORP.
BENCH TESTING

1997 Mazda MX-5 Miata
STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear
Microsoft
Sunday, July 05, 2009 1:56:43 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.