FUEL SYSTEM
Choke and Air Intake System
Page 14-16 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
14
Intake Duct Removal, Continued:
15. Lift air box assembly off the intake duct. Be careful that the intake seal on the bottom of the air box
assembly is not dislodged in the process.
16. Pull the intake duct forward and out of the vehicle.
INTAKE DUCT INSTALLATION
The intake duct assembly is installed from the front of the vehicle.
1. Slide the intake duct between the round crossmember and the floorboard, moving it to the rear along
the underside of the floorboard. Insert the end of the intake duct through the slot in the front of the air
box mounting plate.
2. Secure the front of the duct to the underside of the floorboard with two pop rivets (24) and flat washers
(25) (Figure 14-14, Page 14-17).
3. Place a piece of double-sided adhesive tape on the intake shield and remove the adhesive backing.
4. Install the shield to the frame with the adhesive strip and a pop rivet (30).
5. Install air box. See Air Box Installation on page 14-15.
6. Install steering joint assembly. See following NOTE.
NOTE: Make sure steering wheel and front wheels are properly aligned before installing steering joint.
6.1. Position steering joint assembly (1) on vehicle as shown. Install three lock washers and three
bolts and tighten to 15 ft-lb (20.3 N·m) (Figure 14-13, Page 14-16). Make sure all of the steering
joint bolts are properly tightened to 15 ft-lb (20.3 N·m).
7. Position the strap plate (27) on the frame and install two bolts (26), flat washers and locknuts. Finger
tighten (Figure 14-14, Page 14-17).
8. Connect the strap plate (27) and upper shock absorber mounts to the shock tower with two bolts (28)
and nuts (Figure 14-14, Page 14-17). Tighten the two bolts (28) and nuts to 20 ft-lb (27 N·m) (Figure
14-14, Page 14-17).
9. Tighten the two bolts (26) and locknuts to 20 ft-lb (27 N·m) (Figure 14-14, Page 14-17).
Figure 14-13 Compound Steering Joint
1
