HYDRAULIC AND PARK BRAKE SYSTEMS
Brake System Inspection
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-3
6
• Move the brake pedal from side to side to check for worn parts. Excessive side movement indicates
worn pedal mounting parts. If worn parts are found, replace the worn parts, then adjust the brake
pedal. See Brake Pedal Adjustment, Section 5, Page 5-1.
• Apply heavy pressure to the pedal and check for sponginess and excessive pedal travel. The pedal
should be firm, and the back of the brake pedal should be a minimum of 2 inches from the floor. If the
brake pedal feels “spongy”, perform the brake bleeding procedure. See Bleeding the Hydraulic Brake
System on page 6-29.
• Hold the brake pedal depressed with medium foot pressure (25 to 35 lb.) for 15 seconds. The pedal
should not continue dropping when pressed with a steady amount of pressure. If the pedal goes to the
floor, inspect the hydraulic system for leaks and repair any worn or damaged components. After repair,
bleed the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6-29.
Master Cylinder Inspection
• Inspect the exterior of the master cylinder. The presence of brake fluid on the exterior of the master cyl-
inder indicates a brake fluid leak. Replace any leaking components and bleed the hydraulic brake sys-
tem. See Bleeding the Hydraulic Brake System on page 6-29.
• Check the brake fluid level. See Brake Fluid, Section 10, Page 10-6.
• Remove the reservoir cap and inspect the brake fluid. The brake fluid should be clean with no residue
in the bottom of the reservoir or any other evidence of contamination. If brake fluid is contaminated,
purge the brake fluid and refill the hydraulic system. See Purging the Hydraulic System on page 6-
30. Also See Filling the Hydraulic System on page 6-31.
• Check the vent holes in the reservoir cap. The vent holes should be clean and open. If the vent holes
are not clean and open, clean or replace the cap.
• Check the diaphragm inside the reservoir cap. The diaphragm should not have holes or other damage.
If the diaphragm is damaged, replace it before placing the vehicle in service.
Brake Line and Hose Inspection
• Inspect the brake lines. The brake lines should not be kinked, dented or damaged in any way. There
should be no leakage from the brake lines or fittings. If a leak is discovered, replace the brake line. See
Hydraulic Line and Hose Replacement on page 6-24.
• Inspect the brake hoses at the front wheels. When turning the steering wheel all the way from left to
right and back again, the hoses should not come in contact with any component, especially the wheels
or tires.
• Inspect the brake hoses. Hoses must be flexible and free from leaks, cuts, cracks or bulges. If the
hoses do not pass inspection, replace as necessary. See Hydraulic Line and Hose Replacement on
page 6-24.
• Check the back side of each brake cluster backing plate. The backing plates should be free from brake
fluid and grease. If a brake hose or wheel cylinder shows signs of leaking, determine the cause of the
leak and replace the brake hose or wheel cylinder. See Wheel Cylinder Replacement on page 6-19.
Also See Hydraulic Line and Hose Replacement on page 6-24.
Park Brake Inspection
• Apply moderate pressure to the park brake handle. Tension should increase as the handle is pulled.
When latched, the park brake should lock the wheels and hold the vehicle stationary (on incline of 20%
or less). If the park brake does not function as described, adjust the park brake. See Park Brake
Adjustment on page 6-34.
• Check the park brake cables, equalizer and linkage. The cables should not be corroded, frayed or dam-
aged and should move freely within the cable sheathing. The cables should not come in contact with
either of the rear wheels or tires.
