Mazda MX-5 Miata (1997+). Manual — part 95

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

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

Application

Specification

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

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

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.

Application

In. (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