ACCELERATOR AND BRAKE PEDAL ASSEMBLIES
Accelerator Pedal Adjustment
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 5-3
5
6. Adjust the brake stop bumper (22) up or down (Figure 5-2, Page 5-3). Adjusting the bumper upward
decreases the distance between the pedal and the floorboard. Adjusting the bumper downward
increases the distance between the pedal and the floorboard. Proper brake pedal height is 6-5/8 inches
± 1/4 inch (16.8 cm ± 6 mm) (Figure 5-3, Page 5-3).
7. Tighten the jam nut (31) to 8 ft-lb (9.5 N·m) (Figure 5-2, Page 5-3).
8. Adjust the clevis (16) by rotating it clockwise or counterclockwise so that the rod retaining bolt (8) can
easily be placed through the clevis (16) and the bottom hole in the bell crank assembly (11) (Figure 5-
1, Page 5-2).
NOTE: The spring (17) should not be under tension while the brake pedal is at rest (Figure 5-1, Page 5-2).
9. Install the rod retaining bolt (8) through the clevis (16) and the bell crank (11). Tighten the bolt to 14 ft-
lb (19 N·m) (Figure 5-1, Page 5-2).
10. While observing the push rod, press the brake pedal. There should be at least 1/8 inch of free play (at
the push rod) before the push rod begins to depress the master cylinder piston (Figure 5-4, Page 5-4).
An accurate measurement is not necessary, but it must be a minimum of 1/8 inch so that the push rod
does not contact the master cylinder piston when the pedal is at rest.
NOTE: Brake pedal free play is the distance the push rod (12) travels before the master cylinder piston (18)
is depressed (Figure 5-1, Page 5-2). See also Figure 5-4, Page 5-4.
11. Perform all of the brake system inspections in Section 6 to ensure that both the hydraulic brake system
and the park brake system are adjusted correctly and are operating correctly before placing the vehicle
into service. See Brake System Inspection, Section 6, Page 6-2.
ACCELERATOR PEDAL ADJUSTMENT
Read WARNING on page 5-1.
1. Measure the distance from the top of the accelerator pedal to the floorboard. If the distance is within
the range of 5-3/4 inches ±1/4 inch (14.6 cm ± 6mm) (Figure 5-5, Page 5-4), adjusting the accelerator
pedal is not necessary. Proceed to Step 5.
2. Loosen the nut and bolt securing the accelerator pedal to the pivot plate (Figure 5-6, Page 5-4).
3. If using an accelerator pedal adjustment tool to make adjustment:
3.1. Clamp the accelerator pedal adjustment tool (CCI 101871001) to the accelerator pedal, with the
end marked
accelerator pedal height closest to the floorboard.
Figure 5-2 Adjust Brake Pedal Height
Figure 5-3 Measure Brake Pedal Height
22
31
STOP
1 2
3
4
5
6
7
8
9
10 11
12
Correct pedal position
is 6-5/8 in.
±
1/4 in.
(16.8 cm
±
6 mm) from
floormat to back of
brake pedal.
