Pioneer 1200, Maintenance Service Manual

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ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal Adjustment
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 5-3
5
3. Loosen, but do not remove, the brake stop jam nut (31) (Figure 5-4, Page 5-3).
4. Pull the brake pedal toward the rear of the vehicle until the brake stop bumper will not allow the pedal to
travel any further (Figure 5-5, Page 5-3).
5. Holding the brake pedal in this position, measure the distance from the back of the brake pedal to the
floorboard. If it is between 6-3/8 inches (16.2 cm) and 6-7/8 inches (17.5 cm), proceed to step 7.
6. Adjust the brake stop bumper (22) up to decrease the distance between the pedal and the floorboard, or
down to increase (Figure 5-4, Page 5-3). Proper brake pedal height is 6-5/8 inches ± 1/4-inch (16.8 cm
± 6 mm) (Figure 5-5, Page 5-3).
7. Tighten the jam nut (31) to 8 ft-lb (9.5 N·m) (Figure 5-4, Page 5-3).
8. Adjust the clevis (16) by rotating it so that the rod retaining bolt (8) can be placed through the clevis (16)
and the bottom hole in the bell crank assembly (11) (Figure 5-1, Page 5-2). See following NOTE.
NOTE: The spring (17) should not be under tension while the brake pedal is at rest.
9. Install the rod retaining bolt (8) through the clevis (16) and the bell crank (11). Tighten the bolt to 14 ft-
lb (19 N·m).
10. There should be at least 1/8-inch (3.2 mm) of free play (at the push rod) before the push rod begins to
depress the master cylinder piston (Figure 5-6, Page 5-4). See following NOTE.
Figure 5-2 Jack Stand Location on I-Beam Figure 5-3 Brake Pedal Weldment Through Floor
Figure 5-4 Adjust Brake Pedal Height Figure 5-5 Measure Brake Pedal Height
Club Car
STOP
Installation
Removal
22
31
STOP
1 2
3
4
5
6
7
8
9
10 11
12
Correct pedal position
is 6-5/8-inch
±
1/4-inch
(16.8 cm
±
6 mm) from
floormat to back of
brake pedal.