height adjustment MAZDA MX-5 1997 Factory Repair Manual

Fig. 15: Adjusting Master Cylinder Push Rod
Courtesy of MAZDA MOTORS CORP.
BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH
1. Released pedal height is measured from carpet surface, on vertical portion of firewall, to pedal pad center.
Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Rotate switch away
from pedal. Loosen push rod lock nut. Rotate push rod until correct pedal height is as specified. See
BRAKE PEDAL HEIGHT SPECIFICATIONS
table.
2. Adjust pedal free play. See BRAKE PEDAL FREE PLAY
under ADJUSTMENTS. Tighten push rod
lock nut. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).
3. Rotate stoplight switch until it contacts pedal, then rotate an additional 1/2 turn. Tighten stoplight switch
lock nut to 10-13 ft. lbs. (14-18 N.m). Reconnect stoplight switch electrical connector.
4. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. Depress brake pedal with a pressure of 132 lbs. (60 kg).
5. Measure applied pedal height. See BRAKE PEDAL HEIGHT SPECIFICATIONS
table. If distance is
not as specified, check for air in system or worn pads. Repair as necessary.
BRAKE PEDAL HEIGHT SPECIFICATIONS
BRAKE PEDAL FREE PLAY
ApplicationIn. (mm)
Pedal Released6.8-7.1 (171-181)
Pedal Applied (1) 3.7 (95)
(1)Minimum height.

1997 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock
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929
1. Depress brake pedal several times. Depress parking brake pedal several times with a force of 44 lbs. (20
kg). If stroke is 5-7 notches, parking brake is properly adjusted. If stroke is not 5-7 notches, rotate
adjusting nut, located under parking brake pedal, until stroke is within specification.
2. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake pedal is
depressed one notch.
BRAKE PEDAL FREE PLAY
With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal
free play. See BRAKE PEDAL FREE PLAY SPECIFICATIONS
. Adjust play by loosening push rod lock
nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).
BRAKE PEDAL FREE PLAY SPECIFICATIONS
BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH
Miata, MPV, MX-3, MX-6, RX7, 626 & 929
1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.
Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Rotate switch away
from pedal. Loosen push rod lock nut. Rotate push rod until correct pedal height is obtained. See
BRAKE PEDAL HEIGHT SPECIFICATIONS
.
2. Adjust pedal free play. See BRAKE PEDAL FREE PLAY
. Tighten push rod lock nut to 18-25 ft. lbs.
(24-34 N.m).
3. Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight
switch lock nut 10-13 ft. lbs. (14-18 N.m). Reconnect stoplight switch electrical connector.
4. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure.
5. Measure applied pedal hei
ght. See BRAKE PEDAL HEIGHT SPECIFICATIONS . If distance is not NOTE: On B2300, B3000 & B4000, brake pedal free play is built into pedal linkage and
is not adjustable.
ApplicationIn. (mm)
Miata, MPV & MX-3.16-.28 (4-7)
Millenia, MX-6, Protege & 626.16-.47 (4-12)
RX7.12-.31 (3-8)
929.12-.47 (8-12)
NOTE: B2300, B3000 & B4000 are equipped with dual brake master cylinder and
vacuum booster. System is designed to permit full stroke of master cylinder
when brake pedal is fully depressed. Brake pedal height adjustment is not
required.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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as specified, check for air in system, rear brake adjustment (drum brakes) or worn shoes or pads.
BRAKE PEDAL HEIGHT SPECIFICATIONS
Millenia & Protege
1. Released pedal height is measured between brake pedal and stoplight switch mounting bracket. See Fig.
3 . Disconnect stoplight switch electrical connector and remove switch. Measure length "L" between
stoplight switch mounting bracket and brake pedal. See Fig. 3
. On Millenia, length should be .79-
.90" (20-23 mm). On Protege, length should be .71-.86" (18-22 mm).
2. On all models, if clearance is as specified, install stoplight switch. No adjustment is necessary. If
clearance is not as specified, loosen lock nut "B" and rotate self-locking nut "A" counterclockwise until it
does not contact brake pedal.
3. Loosen push rod lock nut and rotate push rod until correct clearance between brake pedal and stoplight
switch mounting bracket is obtained. Tighten push rod lock nut. Rotate self-locking nut "A" clockwise
until clearance between brake pedal and end of self-locking nut "A" is .004-.039 (.1-1.0 mm). See Fig. 3
.
Tighten lock nut "B".
4. Install NEW stoplight switch. Stoplight switch is automatically adjusted by pulling back on brake pedal
until stoplight switch click noise is heard. Reconnect stoplight switch electrical connector. Check
stoplight operation. Adjust pedal free play. See BRAKE PEDAL FREE PLAY
. Tighten push rod lock
nut to 18-25 ft. lbs. (24-34 N.m).
5. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure. On Millenia, distance should be 2.7" (70
mm). On Protege, distance should be 3.8" (95 mm). On all models, if distance is not as specified, check
ApplicationIn. (mm)
Pedal Released
Miata6.8-7.1 (171-181)
MPV7.5-7.9 (191-201)
MX-37.6-7.7 (193-196)
MX-6 & 6267.5-7.7 (191-196)
RX76.5-6.9 (165-176)
9297.4-7.7 (188-195)
Pedal Applied (1)
Miata3.7 (95)
MPV, MX-6 & 6263.3 (85)
MX-32.8 (70)
RX73.9 (100)
9291.6 (40)
(1)Minimum height.
NOTE: When adjusting brake pedal height, a NEW stoplight switch must be used.
Stoplight switch can only be adjusted one time.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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for air in system, rear brake adjustment (drum brakes) or worn shoes or pads.
Fig. 3: Adjusting Brake Pedal Height (Millenia Shown; Protege Is Similar)

Courtesy of MAZDA MOTORS CORP.
TESTING
PROPORTIONING VALVE
NOTE: B2300, B3000 and B4000 are not equipped with a proportioning valve.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
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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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