Intake Duct Repair; Intake Duct Removal - Pioneer 1200 Maintenance Service Manual

14
FUEL SYSTEM
Air Box Installation, Continued:
3. Pioneer 1200SE:
3.1. Place air box assembly into vehicle and install three flat washers (24) and screws (25) from under-
side of air box mounting plate into air box (12) (Figure 14-11, Page 14-18). Tighten to 33 in-lb (3.7
N·m).
3.2. Place hose (16) onto air box top (4) and secure with wire clamp (15).
3.3. Attach choke cable (18) to the air box top (4). See Choke Cable Installation on page 14-11.
4. Test choke for proper operation.

INTAKE DUCT REPAIR

If the air intake duct has a crack of 1/16-inch (1.5 mm) or less, and does not exceed 11 inches (27.5 cm) in
length, or has a round shaped hole no greater than 1/2-inch (13 mm) in diameter, it may be repairable with an
Air Duct Repair Kit (CCI P/N 101971001). The kit includes repair materials and procedures for small cracks
and holes. If the intake duct is badly torn or has larger holes, it will need to be replaced.

INTAKE DUCT REMOVAL

NOTE: This procedure is best accomplished using two people.
1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Pioneer 1200:
2.1. Remove the front body. See Front Body Removal, Section 4, Page 4-3.
2.2. Slightly loosen the lug nuts on both front wheels.
2.3. Raise the front of the vehicle with a floor jack.
2.4. Place jack stands under the vehicle outer front frame I-beam and lower onto the jack stands.
See Figure 5-2, Section 5, Page 5-3. See WARNING "Lift only one end..." in General Warning,
Section 1, Page 1-1.
2.5. Remove the front wheels.
2.6. Remove the bolt (1) that connects the steering joint to the steering column shaft (Figure 14-9,
Page 14-13). See following NOTE.
NOTE: The bolt must be removed completely before the splined coupling can be separated.
Make an alignment mark on the steering column shaft and the steering joint for use during replace-
ment.
2.7. Remove the four bolts and lock nuts (2) from the rack and pinion assembly mount and gently dis-
connect the steering joint from steering column shaft at the bolt (1) location (Figure 14-9,
Page 14-13). Gently allow both the rack and pinion assembly and the steering column shaft to drop
down, remaining suspended between both rod ball joint ends.
2.8. Remove the two bolts (26), lock nuts and flat washers that secure the top of the strap plate (27) to
the vehicle frame (Figure 14-10, Page 14-17).
2.9. Remove the two bolts (28) and nuts that connect the upper shock mounts to the shock tower and
bottom of the strap plate (27). Remove the strap plate (27). See following CAUTION.
∆
CAUTION
• When removing the two bottom bolts (28) from the strap plate and shock tower, the A-arm
assemblies will drop. It's best to have one person hold the front brake drum assembly while a
second person removes each bolt from their respective shock and shock tower, and gently
allow the A-arm assembly to rest in a suspended condition.
Page 14-12 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Choke and Air Intake System