A-Arm Installation; Shock Absorber Removal - Pioneer 1200 Maintenance Service Manual

STEERING AND FRONT SUSPENSION
A-Arm Removal, Continued:
5. Remove the wave washer (33) 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 7-29, Page 7-16).
6. Slide the spindle assembly (20) off of the A-arm (13).
7. Remove the lower shock absorber mounting bolt (2), nut (3) and steering stop bracket (34).
8. Remove the two bolts (10), two nuts (11) and the A-arm (13) from the suspension mounting plate.
9. Repeat steps 1 through 8 for the opposite front wheel if necessary.

A-ARM INSTALLATION

1. Inspect the bushings (14) and sleeves (15) in the A-arm (13) and replace if necessary (Figure 7-29,
Page 7-16).
2. Inspect the bushings (16 and 18). If worn or damaged, remove and press in new ones. See following
NOTE.
NOTE: If the bushings are replaced, ream new bushings to .750-.752 (3/4-inch) (19.05-19.10 mm) in diam-
eter. The reamer should be long enough to ream both bushings from one direction.
3. Install the A-arm (13) to the front suspension mounting plate using bolt (10) and nut (11) and tighten to
20 ft-lb (27 N·m) (Figure 7-29, Page 7-16).
4. Install the spindle assembly (20) onto the A-arm (13).
5. Install the lower shock absorber mount to the A-arm with bolt (2), nut (3), and steering stop/brake hose
bracket (34) (Figure 7-29, Page 7-16). Align the bracket (34) with the shock absorber and tighten hard-
ware to 20 ft-lb (29.7 N·m) (Figure 7-30, Page 7-18).
6. Install the thrust washer (32), wave washer (33) and kingpin (21).
7. Install the washer (36) and a new lock nut (22) and tighten to 18 ft-lb (24.4 N·m).
8. Insert the ball joint (23) into the spindle assembly (Figure 7-20, Page 7-11).
9. Install the lock nut (24) to secure the ball joint to the spindle and tighten to 18 ft-lb (24.4 N·m).
10. Install a new cotter pin (18) and bend to secure it to the ball joint.
11. Use a grease gun and apply grease to the grease fitting (17) in the A-arm (13) (Figure 7-29, Page 7-16).
See Lubrication on page 7-12.
12. Install the brake cluster. See Front Brake Cluster Assembly Installation, Section 6, Page 6-17.
13. Install the wheel and tighten the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m).
14. Repeat steps 1 through 13 for the opposite front wheel if necessary.
15. Check toe-in adjustment and make adjustments if necessary. See Toe-in Adjustment on page 7-13.
16. 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.

SHOCK ABSORBER REMOVAL

1. Chock the rear wheels, set the park brake, and lift the front of the vehicle with a chain hoist or floor jack.
See WARNING "Lift only one end..." in General Warning, Section 1, Page 1-2.
2. Place jack stands under the outer front frame I-beams and lower onto jack stands. See Figure 5-2,
Section 5, Page 5-3.
3. Inspect shock absorbers for damage or fluid leakage on the body and replace if necessary.
4. Remove the bolt (2) and nut (3) attaching the upper shock absorber mount to the A-arm (Figure 7-29,
Page 7-16).
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Front Suspension Components
Page 7-17
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