Brake Cluster Inspection And Cleaning - Pioneer 1200 Maintenance Service Manual

6
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS

BRAKE CLUSTER INSPECTION AND CLEANING

See General Warning, Section 1, Page 1-1.
∆
WARNING
• If at any point in this procedure the hydraulic system is opened, 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.
NOTE: Factory installed brake shoes have non-asbestos linings (CCI P/N 102050201). When replacing
brake shoes, Club Car, Inc., recommends non-asbestos replacement parts.
1. Remove the brake drum. See Front Wheel Brake Drum Removal on page 6-6, and Rear Wheel Brake
Drum Removal on page 6-8.
2. Remove the brake shoes. See Front Brake Shoe Removal on page 6-8, and Rear Brake Shoe
Removal on page 6-9.
3. Clean the brake cluster back plate and all of the brake cluster components.
4. Check the brake shoe adjusters in each brake cluster assembly for proper operation.
4.1. Locate the bolt heads of the two brake shoe adjusters on the back of each brake cluster assembly.
4.2. Use a torque wrench and a Torx #T-27 driver, or hydraulic brake adjuster (CCI P/N 102169401), and
gently rotate the adjuster bolts (Figure 6-3, Page 6-7). See following NOTE.
NOTE: If the adjusters require more than 65 in-lb (7.3 N·m) of force to rotate, they must be replaced. See
Brake Shoe Adjuster Replacement on page 6-21.
5. Check the wheel cylinder for signs of leakage and replace if necessary. See Wheel Cylinder Replace-
ment on page 6-19.
6. Check all springs for loss of compression, tension, or damage and replace if necessary.
7. Check each brake cluster assembly for signs of excessive wear or damage and replace if necessary. See
Brake Cluster Assembly Replacement on page 6-17.
PIN
STRUT
Figure 6-8 Park Brake Lever and Strut
8. Ensure that the park brake lever and strut assembly (14) can be easily moved by hand (Figure 6-19,
Page 6-21). If so proceed to step 10. If not proceed to step 9.
9. Clean and lubricate the rear park brake lever and strut.
9.1. Remove the park brake cable hair spring clip (1), hair spring cotter pin (2), and clevis pin (3) from
the cable clevis and strut (Figure 6-16, Page 6-18).
Page 6-10 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
LEVER
C-CLIP
Brake Cluster Inspection and Cleaning