1994 MAZDA MX-5 Workshop Manual

G STARTING SYSTEM Check 1 Check 3 Check 2 STARTER Caution Obtain the code number and deactivate the audio anti-theft system before disconnecting the bat- tery. (Refer to section T.) Removal / Installation 1. Disconnect the negative battery cable. 2. Disconnect the wiring from the starter. 3. Remove the starter bracket. (MT only) 4. Raise the front of the vehicle and support it with safety stands. 5. Remove the bolts and the starter. 6. Install in the reverse order of removal. Tightening torque Nut O: 10-11 N.m (100-120 kgfam, 87-100 in4bf) Bolt, Nut O: 38-51 N.m (3.8-53 kgf-m, 28-38 ft4bf) Bolt 0: 16-22 N.m (1.6-2.3 kgf.m, 12-16 ft-lbf) Bolt 0: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft-lbf) Gartner Banana

STARTING SYSTEM I 05-2.0mm {0.020-0.079 in) ( 45UOGX-038 BATTERY B+ Performance Inspection Pull-out test Verify that the pinion is pulled out with battery positive voltage connected to the S terminal and the starter body grounded. Pinion gap check 1. Measure the pinion gap while the pinion is pulled out. Specification: 0.5--2.0mm (0.020-0.079 in) 2. Adjust the pinion gap with an adjustment washer (between drive housing front cover and magnetic switch) if it is not within specification. Return test 1. Disconnect the motor wire from the M terminal. 2. Connect battery positive voltage to the M terminal and ground to the body. 3. Pull out the overrunning clutch with a screwdriver. Verify that it returns to its original position when released. No-load test 1. After adjusting the pinion gap, form a test circuit with a voltmeter and an ammeter. Note Use heavy gauge wires and tighten each terminal fully. 2. Close switch K to run the starter. 3. Check for the following: Starter type 0.95 -- kear shaft soeed rom I Min. 6.600 1 Min. 3.000 1 1.4 Voltage V Current A 4. If not as specified, check for the cause by referring to Inspection. I 11.5 Max. 60 11 Max. 90 Gartner Banana

STARTING SYSTEM Disassembly / Assembly 1. Disassemble in the order shown in the figure. 2. Inspect and repair or replace parts as necessary. 3. Assemble in the reverse order of disassemblv. Nvn {kgfscm, inlbf) 1. Magnetic switch 5. Yoke assemblv Inspection ................. page G-27 Inspection ................. page G-27 2. Rear housing 6. Brush holder assembly d 3. Front cover Inspection ................. page G-27 4. Armature 7. Drive pinion Inspection ................. page G-26 Gartner Banana

STARTING SYSTEM G 1. Magnetic switch Inspection ................. page G-27 2. Rear housing 3. Brush and brush holder ................. Inspection page G-27 4. Armature ................. Inspection page G-26 5. Yoke assembly ................. Inspection page G-27 6. Planetary gear 7. Front cover 8. Lever 9. Drive pinion 10. Internal gear 11. Gear shaft 12. Bearing Gartner Banana

STARTING SYSTEM Inspection Armature 1. Ground of armature coil Check for no continuity between the commutator and the .J core with an ohmmeter. Check the entire circumference of the commutator. Replace the armature if there is conti- nuity. 2, Insulation of armature coil Check for no continuity between the commutator and the shaft with an ohmmeter. Check the entire circumference of the commutator. Replace the armature if there is conti- nuity. 3. Runout of commutator (1) Place the armature on V blocks, and measure the runout with a dial gauge. (2) Repair with a lathe if the runout is small or replace,the armature if necessary. -1' Runout: 0.03mm (0.001 in) 4. Outer diameter of commutator Replace the armature if the outer diameter of the com- mutator is at the grind limit or less. 5. Roughness of commutator surface If the commutator surface is dirty, wipe it with a cloth; if it is rough, repair it with a lathe or fine sandpaper. Grind limit: 30.8mm (1.21 in) 6. Segment groove depth If the depth of the molding between segments is at the depth limit or less, undercut the grooves to the standard depth. Standard depth: 0.5--0.8mm (0.02-4.03 in) Depth limit: 0.2mm (0.008 in) Gartner Banana

STARTING SYSTEM Yoke assembly 1. Wiring damage of field coil (1) Check for continuity between the connector and the brushes with an ohmmeter. (2) Replace the yoke assembly if there is no continuity. 2. Ground of field coil (1) Check for no continuity between the connector and the yoke with an ohmmeter. (2) Repair or replace the yoke assembly if there is conti- . nuity. 3. Installation of field coil Replace the yoke assembly if the field coil is loose. Magnetic Switch 1. Wiring damage (S terminal - M terminal) Check for continuity between S terminal and M terminal with an ohmmeter. Replace the magnetic switch if there is no continuity. 2. Wiring damage (S terminal - body) Check for continuity between S terminal and the body with an ohmmeter. Replace the magnetic switch if there is no continuity. Brush and Brush Holder Insulation of brush holder Check for no continuity between each insulated brush and the plate with an ohmmeter. Replace the brush holder if there is continuity. Gartner Banana

STARTING SYSTEM LIMIT 1 I 45UOGX-043 STARTER INTERLOCK SWITCH (MT) Brush If the brushes are worn beyond the wear limit or if the wear is near the limit, replace the brushes. CONTACT PLATES IGNITION SWITCH mm {in} IG1 ROD Standard Wear limit INTERLOCK SWITCH 62-7 - STARTER MT 17 (0.67) 11.5 (0.45) The clutch pedal must be depressed during starting for battery power to be supplied to the starter. AT 17.5 (0.69) 12.0 (0.47) Inspection 1. Disconnect the interlock switch connector. 2. Check continuity of the switch with an ohmmeter. Pedal Depressed Released Continuity Yes No 1 3. If not as specified, replace the interlock switch. Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnlngs and audio antitheft system alarm conditions . i, CLUTCH INDEX ....................................... H- 2 OUTLINE ..................................... H- 3 SPECIFICATIONS ........................... H- 3 TROUBLESHOOTING GUIDE .................. H- 3 CLUTCH FLUID ............................... H- 4 ............................. PREPARATION H- 4 ............................ REPLACEMENT H- 4 .............................. CLUTCH PEDAL H- 5 .............................. ADJUSTMENT H- 5 REMOVAL / INSPECTION / INSTALLATION .... H- 6 ................. CLUTCH MASTER CYLINDER H- 7 PREPARATION ............................. H- 7 REMOVAL / INSTALLATION .................. H- 8 AIR BLEEDING ............................. H- 9 OVERHAUL ................................ H-10 CLUTCH RELEASE CYLINDER ................ H-12 PREPARATION ............................. H-12 REMOVAL / INSTALLATION .................. H-12 AIR BLEEDING (REFER TO PAGE H-9.) OVERHAUL ............................... H-13 CLUTCH UNIT ................................ H-14 PREPARATION ............................. H-14 REMOVAL / INSTALLATION .................. H-14 CLUTCH RELEASE COLLAR .................. H-17 INSPECTION ............................... H-17 CLUTCH COVER ............................. H-17 INSPECTION ............................... H-17 CLUTCH DISC ................................ H-17 INSPECTION ............................... H-17 PILOT BEARING .............................. H-18 INSPECTION ............................... H-18 FLYWHEEL ................................... H-18 INSPECTION ............................... H-18 35UOHX-001 Gartner Banana