HYDRAULIC AND PARK BRAKE SYSTEMS
Brake Cluster Replacement
Page 6-18 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 REMOVAL
1. Perform the procedure for brake drum removal. See Rear Wheel Brake Drum Removal on page 6-8.
2. Remove the rear axle to remove rear brake cluster.
2.1. Using 90° internal snap ring pliers (.090 tip) (CCI 1012560), remove internal retaining ring from
axle tube (Figure 6-4, Page 6-9).
2.2. Carefully pull the axle shaft straight out of the axle tube.
2.3. Repeat steps 2.1 through 2.2 for the opposite rear wheel if necessary.
3. Remove park brake cable clip (1), hair spring cotter pin (2) and clevis pin (3) (Figure 6-15, Page 6-18).
4. Remove the cable from the cable support bracket (Figure 6-15, Page 6-18)Using a 3/8 inch flare nut
wrench, remove the brake hose from the rear brake cluster. To avoid spilling brake fluid, lift the hose
above the brake cluster assembly (Figure 6-16, Page 6-18).
5. To ensure that no debris enters the hydraulic system, place the hose fitting in a plastic bag and secure
to the vehicle frame as shown (Figure 6-17, Page 6-18)..
Figure 6-15 Park Brake Cable
Figure 6-16 Rear Brake Hose
Figure 6-17 Rear Brake Hose With Plastic Bag
CABLE
SUPPORT
BRACKET
1
3
2
WIRE TIE
PLASTIC
BAG
FLEX BRAKE
HOSE
