HYDRAULIC AND PARK BRAKE SYSTEMS
Brake Cluster Replacement
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-17
6
BRAKE CLUSTER REPLACEMENT
Read WARNING on page 6-1.
∆ WARNING
• To perform this procedure, the hydraulic system must be opened. As a result, the brakes must
be bled after the correct reinstallation of the brake components. Failure to bleed the brakes
could result in decreased braking performance due to air being trapped in the hydraulic
system. Use only DOT 5 brake fluid. See Bleeding the Hydraulic Brake System on page 6-29.
• Worn or damaged brake drums MUST NOT be machined. Replace as necessary.
FRONT BRAKE CLUSTER REMOVAL
1. Perform the procedure for brake drum removal. See Brake Drum Removal on page 6-7.
2. Remove the banjo bolt (15) and copper washers (16) from the brake cluster assembly. To avoid spilling
brake fluid, lift the hose above the brake cluster assembly (Figure 6-1, Page 6-2).
3. To ensure that no dirt or debris enters the hydraulic braking system, place the hose fitting in a plastic bag
and secure to the vehicle frame as shown (Figure 6-14, Page 6-17).
4. Remove the four Torx head bolts (17), washers (18) and lock nuts (19) that secure the brake cluster to
the spindle assembly (Figure 6-1, Page 6-2).
FRONT BRAKE CLUSTER INSTALLATION
1. Use only new hardware for this step. Install the brake cluster mounting plate to the spindle assembly
with four Torx head bolts (17), washers (18) and lock nuts (19). Tighten all four bolts to 76 in-lb (8.6
N·m) (Figure 6-1, Page 6-2).
2. Connect the brake hose to the brake cluster assembly with two new copper washers (16) and the banjo
bolt (15). Tighten the banjo bolt to 13 ft-lb (17.6 N·m) (Figure 6-1, Page 6-2).
3. Perform the procedure for front brake drum/hub installation. See Front Wheel Brake Drum Installation
4. Bleed the front wheel brakes as instructed. See Bleeding the Hydraulic Brake System on page 6-29.
Figure 6-14 Front Brake Hose With Plastic Bag
WIRE TIE
PLASTIC
BAG
FLEX BRAKE
HOSE
