STEERING AND FRONT SUSPENSION
Front Suspension Components
Page 7-18 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
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6. Slide the spindle (21) off of the A-arm (14) (Figure 7-28, Page 7-15).
7. Remove the lower shock absorber mounting bolt (2) and nut (3) from the A-arm (Figure 7-28, Page 7-15).
8. Remove the two bolts (10) and two nuts (11) securing the A-arm to the front suspension mounting plate
9. Remove the A-arm from the suspension mounting plate.
10. Repeat the procedure for the other front wheel if necessary.
A-ARM INSTALLATION
1. Prior to installation, inspect the bushings (16) and sleeves (17) in the A-arm and replace them if neces-
sary (Figure 7-28, Page 7-15).
2. Inspect the bushings (18 and 20) (Figure 7-28, Page 7-15). If the bushings are worn or damaged, remove
them and press in new ones. See following NOTE.
NOTE: If the bushings are replaced, ream new bushings to .750-.752 (3/4 inch) (19.05/19.10 mm) in diame-
ter. The reamer should be long enough to ream both bushings from one direction.
3. Install the A-arm in the reverse order of removal. Tighten the A-arm nuts (11) to 20 ft-lb (27 N·m) (Figure
4. Install the spindle (21) onto the A-arm (14) (Figure 7-28, Page 7-15).
5. Install the thrust washer (34), wave washer (35) and kingpin (23) (Figure 7-28, Page 7-15).
6. Install the washer (37) and a new lock nut (24). Tighten to 18 ft-lb (24.4 N·m) (Figure 7-28, Page 7-15).
7. Insert the ball joint (23) into the spindle assembly (Figure 7-20, Page 7-11).
8. Install the lock nut (24) to secure the ball joint to the spindle and tighten to 18 ft-lb (24.4 N·m) (Figure 7-
9. Install a new cotter pin (18) and bend it to secure it to the ball joint (Figure 7-20, Page 7-11).
10. Using a grease gun, apply grease to the grease fitting (19) in the A-arm (14)(Figure 7-28, Page 7-15).
11. Install the brake cluster. See Front Brake Cluster Installation, Section 6, Page 6-17.
12. Repeat the procedure for the other front wheel if necessary.
13. Check toe-in adjustment and make adjustments if necessary. See Toe-in Adjustment on page 7-14.
14. 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.
SHOCK ABSORBER REMOVAL AND INSPECTION
1. Place chocks at the rear wheels, set the park brake, and lift the front of the vehicle with a chain hoist or
floor jack. Place jack stands under the front frame tubes to support the vehicle and lower the floor jack
or chain hoist so that the vehicle is resting on the jack stands.
2. Inspect the shock absorbers for damage or fluid leakage on the shock absorber body. Leaking or dam-
aged shock absorbers should be replaced.
3. Remove the bolt (2) and nut (9) attaching the shock absorber to the A-arm (Figure 7-30, Page 7-19).
4. Remove the steering stop weldment (38) and brake hose support bracket from the A-arm (Figure 7-30,
