1997 MAZDA MX-5 Factory Repair Manual

Fig. 1: Direct Drive Type Starter
Courtesy of MAZDA MOTORS CORP.
INTERLOCK SWITCH (M/T) (CLUTCH START SWITCH)
Interlock switch is mounted on bracket near top front of clutch pedal. Disconnect interlock switch wiring
connector. Using ohmmeter, ensure continuity exists between interlock switch connector terminals when clutch

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
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pedal is depressed. If continuity does not exist, adjust or replace interlock switch.
BENCH TESTING
NO-LOAD TEST
Connect fully-charged 12-volt battery, voltmeter and ammeter to starter. See Fig. 2
. Using remote starter wires
or jumper, engage solenoid. Starter should spin smoothly. Compare readings with specifications. See NO
-
LOAD TEST SPECIFICATIONS table. If voltage is less than specified, amperage is more than specified or
shaft speed is less than specified, disassemble and inspect starter components.
NO-LOAD TEST SPECIFICATIONS
ApplicationSpecification
Voltage (Minimum)11.5
Amperage (Maximum)60
Shaft Speed (Minimum RPM)6600

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
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Fig. 2: Testing Direct Drive Starter Circuits
Courtesy of MAZDA MOTORS CORP.
SOLENOID TESTS

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
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Solenoid Pull-In Test
Connect positive battery lead to solenoid "S" terminal and negative battery lead to starter body. See Fig. 2 .
Starter pinion drive gear should extend outward and stop. If starter pinion drive gear does not extend, replace
solenoid.
Solenoid Hold-In Test
After performing solenoid pull-in test, with positive battery lead connected to solenoid "S" terminal and
negative battery lead connected to starter body, disconnect field lead ("M" terminal wire) at solenoid. Starter
pinion drive gear should remain extended. If starter pinion drive gear returns, replace solenoid.
Solenoid Return Test
Disconnect field lead ("M" terminal wire) at solenoid. Connect positive battery lead to solenoid "M" terminal
and negative battery lead to starter body. See Fig. 2
. Using screwdriver, pry overrunning clutch pinion drive
outward. Release screwdriver and ensure overrunning clutch pinion drive returns to original position.
Solenoid
1. Disconnect all wires from solenoid, including "M" terminal wire between solenoid and starter. Using
ohmmeter, ensure continuity exists between "S" and "M" terminals, and between "S" terminal and
solenoid body. See Fig. 1
and Fig. 2 . If continuity does not exist between specified terminals, replace
solenoid.
2. Using ohmmeter, ensure continuity does not exist between "M" and "B" terminals. If continuity exists,
replace solenoid.
PINION GAP ADJUSTMENT
1. Disconnect field lead ("M" terminal wire) at solenoid. See Fig. 2
. Connect positive battery lead to
solenoid "S" terminal and negative battery lead to starter body. Starter pinion drive gear should extend
outward and stop.
2. Quickly measure pinion gap between end of pinion drive and circlip retainer. See Fig. 3
. DO NOT
operate starter solenoid for more than 10 seconds. Pinion gap should be as specified. See PINION GAP
SPECIFICATIONS table.
3. If pinion gap is not within specification, adjust by increasing or decreasing thickness of solenoid shims
located between solenoid and drive housing.
PINION GAP SPECIFICATIONS CAUTION: Perform solenoid tests with starter and solenoid assembled. DO NOT
engage starter solenoid for more than 10 seconds during testing, or
damage to coil winding may result.
ApplicationIn. (mm)
Miata (M/T).02-.08 (0.5-2.0)

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
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1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
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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
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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
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