HYDRAULIC AND PARK BRAKE SYSTEMS
Brake System Troubleshooting
Page 6-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
6
Brake Drum and Shoe Inspection
• Remove and inspect each brake drum. The drum should not be cracked or warped, or have excessive
scores or heat checks.
• Inspect the brake shoes. Shoes should not be distorted, cracked or have broken welds.
• Check the condition of the brake shoe linings. The brake shoe lining should not be glazed or soiled with
grease or brake fluid. There should be a minimum of 1/32 inch (0.8 mm) of usable lining remaining at
the thinnest point.
Brake Cluster Inspection
• Check each wheel cylinder (7) by pulling back the edge of each dust boot (Figure 6-1, Page 6-2) or
(Figure 6-18, Page 6-20). There should be no accumulation of brake fluid in the boot. Brake fluid in the
boot indicates a leaking wheel cylinder. If there is fluid in the boot, replace the wheel cylinder. See
Wheel Cylinder Replacement on page 6-19.
• Inspect the shoe hold-down parts and springs. Shoe hold-down pins, springs and cups must be prop-
erly installed and not damaged.
• Inspect the automatic brake adjuster parts. If the adjusters (3) are frozen (requiring more than 65 in-lb
(7.4 N·m) to turn freely), worn or loose, replace the adjuster assemblies in pairs (Figure 6-1, Page 6-2).
BRAKE SYSTEM TROUBLESHOOTING
With normal scheduled maintenance and replacement of worn parts, the hydraulic and park brake systems
should provide trouble-free operation. In the event that a problem does occur, the following troubleshooting
guide will be helpful in identifying operating difficulties. The guide includes the symptom, probable cause(s)
and suggested checks. The procedures used in making these checks can be found in the referenced sec-
tions of this Maintenance and Service Manual.
SYMPTOM
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
Low pedal – Pedal may go to the floor
Excessive clearance between the drums
and shoe linings
Front - Perform Step 19 of Front Wheel
Brake Drum Installation on page 6-14.
Rear - Perform Step 3 of Rear Wheel
Brake Drum Installation on page 6-16.
Automatic adjusters are not working
Make several forward and reverse brake
stops; if the pedal does not come up,
replace the automatic adjusters. See
Brake Shoe Adjuster Replacement on
page 6-21.
Bent or distorted brake shoes
Replace the brake shoes. See Brake
Shoe Removal on page 6-9.
Leak in the hydraulic system
Check the master cylinder, brake lines
and hoses for leaks. Replace all damaged
parts.
Air in the hydraulic system
See Bleeding the Hydraulic Brake Sys-
tem on page 6-29.
Weak (bulging) brake hose
Replace the worn hose. See Hydraulic
Line and Hose Replacement on page 6-
24.
Improperly adjusted master cylinder push
rod
See Brake Pedal Adjustment on
page 5-1.
Troubleshooting Guide continued on next page...
