Pioneer 1200 Maintenance Service Manual page 61

MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS
9. If the brake drum is difficult to push over the brake shoes, use the following procedure:
9.1. Locate the bolt heads of the two brake shoe adjusters on the back of the brake cluster plates.
9.2. Use a torque wrench and a Torx #27 driver, or hydraulic brake adjuster (CCI P/N 102169401), and
gently rotate the adjuster bolts to increase the clearance between the brake shoe lining and the
brake drum (Figure 6-14, Page 6-16). 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.
10. Fill the brake drum hub cavity with grease.
11. Install the outside bearing (5) onto the spindle (Figure 6-2, Page 6-7).
12. Install the flat washer (4) up against the bearing race.
13. Install the castle nut (3) onto the spindle finger-tight.
14. Rotate the brake drum slowly while gently tightening the castle nut (3) until the drum hub and bearings
are properly seated.
15. Tighten the castle nut (3) to 10 ft-lb (13.6 N·m) to fully seat the bearing and cup.
16. Loosen the castle nut 1/2 turn and retighten the nut to 14 in-lb (1.6 N-m).
17. Install a new cotter pin (2), bending the split ends of the pin to secure the castle nut (Figure 6-2,
Page 6-7). See following WARNING, CAUTION, and NOTE.
∆
WARNING
• Make sure to install and bend the cotter pin. Failure to bend the cotter pin could result in the
separation of the wheel from the spindle. Loss of vehicle control could result, causing severe
personal injury.
∆
CAUTION
• Use a new cotter pin when installing the drum/hub assembly.
NOTE: If the cotter pin does not line up with the hole in the spindle when the castle nut is properly tight-
ened, rotate the castle nut back until the next available notch allows the cotter pin to be installed.
18. Install the dust cover (1).
19. With the brake drum properly seated and secured, use a torque wrench with a Torx #T-27 driver, or
hydraulic brake adjuster (CCI P/N 102169401) and gently adjust the clearance between the brake shoes
and brake drum by turning each of the two adjuster bolt heads on the back of the brake cluster plate
(Figure 6-14, Page 6-16). 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).
20. Install the wheel and finger-tighten the lug nuts (21).
21. Repeat steps 1 through 20 for the opposite front wheel if necessary.
22. Lower the vehicle and finish tightening the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m).
23. Check the front wheel free play. See Front Wheel Free Play Inspection, Section 7, Page 7-18.
24. 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
Brake Drum Installation
Page 6-15
6