Pioneer 1200, Maintenance Service Manual

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MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder And Bell Crank Replacement
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-29
6
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 6-31.
1. Chock the wheels and release the park brake and access the master cylinder.
2. Place a pan below the vehicle to collect the brake fluid.
3. Remove the two wires from the master cylinder pressure switch (4) (Figure 6-22, Page 6-30).
4. Use a 7/16-inch flare nut wrench to remove the brake line (4) from the master cylinder (Figure 6-20,
Page 6-25 or Figure 6-21, Page 6-28).
5. Pioneer 1200:
5.1. Use a 3/8-inch flare nut wrench to remove the brake lines (10 and 11) from the master cylinder
(Figure 6-20, Page 6-25).
6. Pioneer 1200SE:
6.1. Use a 3/8-inch flare nut wrench to remove the brake line (15) from the master cylinder (Figure 6-21,
Page 6-28).
7. Cover the flare nut fittings on the brake lines with plastic bags and wire ties to keep any dirt or debris from
entering the hydraulic brake system.
8. Remove the two bolts (7) and nylon lock nuts (8) that secure the master cylinder (Figure 6-22,
Page 6-30).
9. Remove master cylinder (1) from mounting bracket (19), push rod (3) and rubber boot (2).
MASTER CYLINDER INSTALLATION
1. Install master cylinder (1) into mounting bracket (19) and insert push rod (3), then seat boot (2)
(Figure 6-22, Page 6-30).
2. Install two bolts (7) and nylon lock nuts (8) that secure the master cylinder (1) to the master cylinder
mounting bracket (19) and tighten to 14 ft-lb (19 N·m).
3. Attach brake line (4) to master cylinder and tighten flare nut fitting to 11 ft-lb (14.9 N·m) (Figure 6-20,
Page 6-25 or Figure 6-21, Page 6-28).
4. Pioneer 1200:
4.1. Attach brake lines (10 and 11) to master cylinder and tighten flare nut fittings to 11 ft-lb (14.9 N·m)
(Figure 6-20, Page 6-25).
5. Pioneer 1200SE:
5.1. Attach brake line (15) to master cylinder and tighten flare nut fittings to 11 ft-lb (14.9 N·m)
(Figure 6-21, Page 6-28).
6. Attach the two wires to the master cylinder pressure switch (4) (no particular orientation).
7. Adjust the brake pedal as instructed in Section 5. See Brake Pedal Adjustment, Section 5, Page 5-3.
8. Fill the reservoir of the master cylinder and bleed the entire hydraulic brake system. See Bleeding the
Hydraulic Brake System on page 6-31.
9. Perform all of the brake system inspections. See Brake System Inspection on page 6-1.