STEERING AND FRONT SUSPENSION
Front Suspension Components
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-17
7
∆ WARNING
• Strain on the brake hose or the brake hose fittings can result in damage to the hose or fittings,
causing a leak in the hydraulic system, diminished brake performance, or brake failure.
5. Remove the nut (24) and washer (37) from kingpin (23) and remove the kingpin (Figure 7-28, Page 7-15).
6. Remove the thrust washer (34) (Figure 7-28, Page 7-15).
7. Remove the wave washer (35) and inspect it. If the washer is broken or has a wave bottom to wave crest
height dimension of less than .040 inch (0.10 cm), it must be replaced (Figure 7-28, Page 7-15).
8. Slide the spindle (21) off of the A-arm (14) (Figure 7-28, Page 7-15).
9. Repeat the procedure for the other front wheel if necessary.
KINGPIN AND STEERING SPINDLE INSTALLATION
1. Inspect all parts and replace them as necessary.
2. Inspect the kingpin (23) and spindle (21). If either are worn or damaged, it must be replaced (Figure 7-
3. Inspect the bushings (18 and 20) (Figure 7-28, Page 7-15). If the bushings are worn or damaged, remove
them and press in new ones. See following NOTE.
NOTE: If the bushings are replaced, ream new bushings to .750-.752 of an inch (19.05-19.10 mm) in diame-
ter. The reamer should be long enough to ream both bushings from one direction.
4. Install the spindle (21) onto the A-arm (14) (Figure 7-28, Page 7-15).
5. Install the thrust washer (34), wave washer (35) and kingpin (23) (Figure 7-28, Page 7-15).
6. Install the washer (37) and a new lock nut (24). Tighten to 18 ft-lb (24.4 N·m) (Figure 7-28, Page 7-15).
7. Insert the ball joint (23) into the spindle assembly (Figure 7-20, Page 7-11).
8. Install the lock nut (24) and tighten to 18 ft-lb (24.4 N·m) (Figure 7-20, Page 7-11).
9. Install a new cotter pin (18) and bend it to secure it to the ball joint (Figure 7-20, Page 7-11).
10. Using a grease gun, apply grease to the grease fitting (19) in the A-arm (14) (Figure 7-28, Page 7-15).
11. Install the brake cluster. See Front Brake Cluster Installation, Section 6, Page 6-17.
12. Repeat the procedure for the other front wheel if necessary.
13. Check toe-in adjustment and make adjustments if necessary. See Toe-in Adjustment on page 7-14.
14. Inspect the brake hoses at the front wheels. When turning the steering wheel all the way from left to right
and back again, the hoses should not come in contact with any component, especially the wheels or tires.
A-ARM REMOVAL
1. Remove the front brake cluster. See Front Brake Cluster Removal, Section 6, Page 6-17.
2. Remove cotter pin (18) and nut (24), then remove the ball joint from the spindle assembly (Figure 7-20,
3. Remove the nut (24) and washer (37) from the kingpin (23) and remove the kingpin (Figure 7-28, Page
4. Remove the thrust washer (34) (Figure 7-28, Page 7-15).
5. Remove the wave washer (35) and inspect it. If the washer is broken or has a wave bottom to wave crest
height dimension of less than .040 inch (0.10 cm), it must be replaced (Figure 7-28, Page 7-15).
