HYDRAULIC AND PARK BRAKE SYSTEMS
Master Cylinder and Bell Crank Replacement
Page 6-28 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
6
BELL CRANK INSTALLATION
1. Install the bolt (9), spacers (12) and inner bearing race (15). Tighten nut (11) to 25 ft-lb (40 N·m) (Fig-
2. Install push rod (3) into bell crank clevis.
3. Install the bolt (20) and locknut (21) and tighten to 14 ft-lb (19 N·m) (Figure 6-21, Page 6-27).
4. Install spring (18) as shown (Figure 6-21, Page 6-27).
5. Adjust the brake pedal as instructed in Section 5. See Brake Pedal Adjustment, Section 5, Page 5-1.
6. 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.
MASTER CYLINDER REMOVAL
∆ WARNING
• To perform this procedure, the hydraulic system must be opened. As a result, the brakes must
be bled after the correct reinstallation of the brake components. Failure to bleed the brakes
could result in decreased braking performance due to air being trapped in the hydraulic
system. Use only DOT 5 brake fluid. See Bleeding the Hydraulic Brake System on page 6-29.
1. Chock the wheels and release the park brake.
2. Place a pan below the vehicle to collect the brake fluid when the hydraulic system is opened in the fol-
lowing step.
3. Remove the two wires from the master cylinder pressure switch (4) (Figure 6-21, Page 6-27).
4. Using a flare nut wrench, remove the three brake lines from the master cylinder.
5. Cover the flare nut fittings of the three brake lines with plastic bags and wire ties to keep any dirt or
debris from entering the hydraulic system.
6. Remove the two bolts (7) and nylon lock nuts (8) that secure the master cylinder (1) to the master cylin-
der mounting bracket (19) (Figure 6-21, Page 6-27).
7. Remove the master cylinder from the master cylinder mounting bracket.
MASTER CYLINDER INSTALLATION
1. Installation is the reverse of removal.
2. Insert push rod (3) and seat boot (2).
3. Install bolts (7) and nuts (8) and tighten to 14 ft-lb (19 N·m) (Figure 6-21, Page 6-27).
4. Tighten the three flare nut fittings at the master cylinder to 11 ft-lb (14.9 N·m).
5. Adjust the brake pedal as instructed in Section 5. See Brake Pedal Adjustment, Section 5, Page 5-1.
6. Fill the reservoir of the master cylinder and bleed the entire hydraulic system. See Filling the Hydraulic
7. Perform all of the brake system inspections to ensure that both the hydraulic brake system and the park
brake system are in correct adjustment and are operating correctly before placing the vehicle into ser-
