Bleeding The Hydraulic Brake System - Pioneer 1200 Maintenance Service Manual

MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS

BLEEDING THE HYDRAULIC BRAKE SYSTEM

See General Warning, Section 1, Page 1-1.
The hydraulic system must be free of air. Air enters the hydraulic system whenever the system is opened and
will result in a "spongy" brake pedal.
The master cylinder controls two separate hydraulic sub-systems. The front two wheels are connected to the
smaller, front portion of the brake fluid reservoir, and the rear wheels to the larger portion. One or both sub-
systems may require bleeding, depending on where the hydraulic system was opened. To bleed both, use the
following procedure, front brakes first.
1. Check the brake pedal and master cylinder push rod for proper adjustment before proceeding. See
Brake Pedal Adjustment, Section 5, Page 5-3.
2. Chock front or rear wheels, release the park brake, and lift the vehicle with a chain hoist or floor jack. See
WARNING "Lift only one end..." in See General Warning, Section 1, Page 1-1.
3. Place jack stands under the outer front frame I-beam, or under the rear axle tubes and lower onto stands.
See Figure 5-2, Section 5, Page 5-3.
4. Remove the cap from the master cylinder reservoir and fill the reservoir with DOT 5 brake fluid.
5. Remove each wheel and gently adjust the clearance between the brake shoes and brake drum by turning
each of the two adjusters on the brake cluster (Figure 6-14, Page 6-16). Use a torque wrench and a Torx
#T-27 driver or hydraulic brake adjuster (CCI P/N 102169401). See following CAUTION.
∆
CAUTION
• Do not apply more than 65 in-lb (7.3 N·m) of torque to any of the adjuster bolts. Over-
tightening the adjuster bolts could result in damage to the brake cluster components or the
separation of the bolt (4) from the adjuster (3) (Figure 6-1, Page 6-2 or Figure 6-19, Page 6-21).
6. Place, but do not tighten, the cap onto the master cylinder reservoir.
7. Connect vacuum type brake bleeder (CCI P/N S0010702).
• Front Brakes Only: Connect the two hose fittings from a vacuum type brake bleeder to the brake
bleeder valves on the back of each of the front wheel brake cluster assemblies (Figure 6-23,
Page 6-32). Proceed to step 8.
• Rear Brakes Only: Connect the two hose fittings from a vacuum type brake bleeder to the brake
bleeder valves on the back of each of the rear wheel brake cluster assemblies. Proceed to step 8.
8. Connect an air hose to the vacuum brake bleeder. The air pressure must be regulated at 12 to 15 psi
(.827 to 1.034 Bars).
9. Press the handle on the brake bleeder to start the vacuum.
10. With the vacuum running, open both of the brake bleeder valves 1/4 turn. See Figure 6-1, Page 6-2 or
Figure 6-19, Page 6-21.
11. Monitor the fluid as it flows through the tubes of the vacuum bleeder tool. Continue to run the vacuum
until there are almost no air bubbles in the lines. See following NOTE.
NOTE: Do not allow the brake fluid in the master cylinder reservoir to drop below the "min" level mark at
any time during the brake bleeding procedure (Figure 6-24, Page 6-33).
12. With the vacuum still running, tighten the two brake bleeder valves.
13. Allow the handle on the brake bleeder tool to open, turning the vacuum system off.
14. Fill the master cylinder reservoir to the "MAX" level with DOT 5 brake fluid (Figure 6-24, Page 6-33).
15. Tighten the cap on the master cylinder reservoir.
16. Properly dispose of the brake fluid in the vacuum type brake bleeder tool.
17. Perform all of the brake system inspections. See Brake System Inspection on page 6-1.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Bleeding the Hydraulic Brake System
Page 6-31
6