HYDRAULIC AND PARK BRAKE SYSTEMS
Bleeding the Hydraulic Brake System
Page 6-30 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
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2. Turn the key switch to the OFF position, place the Forward/Reverse handle in the NEUTRAL position,
chock the front wheels and release the park brake.
3. Remove the cap from the master cylinder reservoir and fill the reservoir with DOT 5 brake fluid.
4. Remove each wheel and gently adjust the clearance between the brake shoes and brake drum by turn-
ing each of the two adjusters on the brake cluster as shown (Figure 6-13, Page 6-16). Use a hydraulic
brake adjuster (CCI 102169401) and torque wrench. See following CAUTION.
∆ CAUTION
• Do not apply more than 65 in-lb (7.3 N·m) of torque to any of the adjuster bolts. Over-tightening the
adjuster bolts could result in damage to the brake cluster components or the separation of the bolt (4)
from the adjuster (3) (Figure 6-1, Page 6-2 or Figure 6-18, Page 6-20).
5. Place, but do not tighten, the cap onto the master cylinder reservoir.
6. Front Brakes Only: Connect the two hose fittings to a vacuum type brake bleeder to the brake bleeder
valves on each of the front brake clusters (Figure 6-22, Page 6-29). Proceed to step 8.
7. Rear Brakes Only: Connect the two hose fittings to a vacuum type brake bleeder to the brake bleeder
valves on each of the rear brake clusters(Figure 6-22, Page 6-29). Proceed to step 8.
8. Connect an air hose to the vacuum brake bleeder. The air pressure must be regulated at 12 to 15 psi
(82.7 to 103.4 kPa).
9. Press the handle on the brake bleeder to start the vacuum.
10. With the vacuum running, open both of the brake bleeder valves 1/4 turn. See Figure 6-1, Page 6-2 or
11. Monitor the fluid as it flows through the tubes of the vacuum bleeder tool. Continue to run the vacuum
until there are almost no air bubbles in the lines. See following NOTE.
NOTE: Do not allow the brake fluid in the master cylinder reservoir (Figure 6-23, Page 6-31) to drop below
the “MIN” level mark at any time during the brake bleeding procedure. Add brake fluid as necessary
while performing step 11.
12. With the vacuum still running, tighten the two brake bleeder valves. See Figure 6-1, Page 6-2 or Figure
13. Allow the handle on the brake bleeder tool to open, turning the vacuum system off.
14. Fill the master cylinder reservoir to the “MAX” level with DOT 5 brake fluid (Figure 6-23, Page 6-31).
15. Repeat procedure for both front and rear brakes.
16. Tighten the cap on the master cylinder reservoir.
17. Properly dispose of the brake fluid in the vacuum type brake bleeder tool.
18. 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.
PURGING THE HYDRAULIC SYSTEM
In some cases it may be necessary to completely drain the front, rear or entire hydraulic brake system of
brake fluid. To completely purge the hydraulic system, perform the following procedure.
1. Perform steps 6 through 10 of the brake bleeding procedure on the two front wheels. See Bleeding the
Hydraulic Brake System on page 6-29.
2. Allow 1 quart (0.95 liters) of the brake fluid to be pulled into the vacuum type brake bleeder tool.
