Club Car Pioneer 1200, Maintenance Service Manual

Page: 72 / 360

HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Bell Crank Replacement
Page 6-26 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
6
5. 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 CLUSTER HOSE 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 the brake hose from the rear brake cluster assembly (Figure 6-16,
Page 6-18).
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).
5. Remove the horseshoe clip (12) that secures the rear brake hose (9) to the I-beam of the vehicle frame
(Figure 6-20, Page 6-23).
6. Remove the brake hose (9) from the vehicle (Figure 6-20, Page 6-23).
REAR CLUSTER HOSE INSTALLATION
1. Install brake hose through the D-shaped hole in I-beam.
2. Install horseshoe clip.
3. Using a flare nut wrench, tighten the flare nut fitting to the rear brake cluster to 11 ft-lb (14.9 N·m).
4. 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).
5. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Filling the Hydraulic Sys-
tem on page 6-31.
6. 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.
MASTER CYLINDER AND BELL CRANK REPLACEMENT
Read WARNING on page 6-1.
BELL CRANK REMOVAL
1. Chock the wheels and release the park brake.
2. Remove the rod retaining bolt (6) and remove the clevis (16) from the bell crank assembly (13) (Figure
6-21, Page 6-27).
3. Remove the spring (18) from the bell crank (13) and master cylinder mounting bracket (19) (Figure 6-
21, Page 6-27).
4. Remove the bolt (20) and lock nut (21) from the bell crank (13) (Figure 6-21, Page 6-27).
5. Remove the bolt (9) and nylon lock nut (11) from the master cylinder mounting bracket (19) (Figure 6-
21, Page 6-27).