Club Car Pioneer 1200, Maintenance Service Manual

Page: 71 / 360

HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-25
6
2. Place a pan below the vehicle to collect the brake fluid when the hydraulic system is opened in the fol-
lowing step.
3. Remove the banjo bolt (15) and copper washers (16) from each of the front brake cluster assemblies
(Figure 6-1, Page 6-2).
4. Remove the bolt, lock nut, steering weldment stop and front hose bracket from where the bottom of the
shock connects to each of the front A-arms.
5. Using a flare nut wrench, remove the brake line (4) from the Y-adapter block (1) (Figure 6-20, Page 6-
23).
6. Remove the bolt (2), two washers (13) and lock nut (3) that secure the Y-adapter (1) to the shock tower
(Figure 6-20, Page 6-23).
7. Remove the Y-adapter and front hose assembly (1) from the vehicle (Figure 6-20, Page 6-23).
FRONT CLUSTER HOSE INSTALLATION
1. Installation is the reverse of removal.
2. Tighten the nut (3) to 76 in-lb (8.6 N·m) (Figure 6-20, Page 6-23).
3. Connect the brake hose assembly to each brake cluster assembly with new copper washers (16).
Tighten the banjo bolts (15) to 13 ft-lb (17.6 N·m) (Figure 6-1, Page 6-2).
4. Tighten the lower shock absorber mounting hardware to 20 ft-lb (27 N·m).
5. Connect the flare fitting to the Y-adapter (1) with a flare nut wrench and tighten to 11 ft-lb (14.9 N·m)
(Figure 6-20, Page 6-23).
6. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Filling the Hydraulic Sys-
tem on page 6-31.
7. Perform all of the brake system inspections to ensure that both the hydraulic brake system and the park
brake system are adjusted and operating correctly before placing the vehicle into service. See Brake
System Inspection on page 6-2.
REAR BRAKE LINE REMOVAL
1. Place chocks at the rear wheels, release the park brake and lift the rear of the vehicle with a chain hoist
or floor jack. Place jack stands under the rear axle tubes to support the vehicle and lower the floor jack
or chain hoist so that the vehicle is resting on the jack stands.
2. Place a pan below the vehicle to collect the brake fluid when the hydraulic system is opened in the fol-
lowing step.
3. Using a flare nut wrench, remove brake line (10 or 11) from master cylinder (Figure 6-20, Page 6-23).
4. Using a flare nut wrench, remove the brake line (10 or 11) from the rear brake hose at the I-beam of the
vehicle frame (Figure 6-20, Page 6-23).
REAR BRAKE LINE INSTALLATION
1. Installation is the reverse of removal.
2. Using a flare nut wrench, tighten the flare nut fittings to the master cylinder to 11 ft-lb (14.9 N·m).
3. Using a flare nut wrench, install the brake line (10 or 11) to the rear brake hose at the I-beam of the
vehicle frame (Figure 6-20, Page 6-23). Tighten to 11 ft-lb (14.9 N·m).
4. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Filling the Hydraulic Sys-
tem on page 6-31.