2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-1
6
SECTION 6 – MC012C-AS00 TRANSAXLE:
HYDRAULIC AND PARK BRAKE SYSTEMS
∆ DANGER
• See General Warning, Section 1, Page 1-1.
∆ WARNING
• See General Warning, Section 1, Page 1-1.
BRAKE SYSTEM INSPECTION
See General Warning, Section 1, Page 1-1.
The hydraulic brake system and park brake system should be inspected immediately after any service to
either of the brake systems.
Brake Pedal Inspection
• When driving the vehicle and pressing the brake pedal, the vehicle should come to a smooth, straight
stop.
• Apply and release the brake pedal several times. If noise or binding occurs, the brake pedal or hydrau-
lic brake system may be in need of service. Pedal movement should be smooth, and when the pedal is
released, it should return quickly and quietly.
• Move the brake pedal from side to side to check for worn parts. Excessive side movement indicates
loose or worn pedal mounting parts. If worn parts are found, replace the worn parts, then adjust the
brake pedal. See Brake Pedal Adjustment, Section 5, Page 5-3.
• Apply heavy pressure to the pedal and check for sponginess and excessive pedal travel. The pedal
should be firm, and the back of the brake pedal should be a minimum of 2 inches from the floor. If the
brake pedal feels “spongy”, perform the brake bleeding procedure. See Bleeding the Hydraulic Brake
System on page 6-31.
• Hold the brake pedal depressed with medium foot pressure (25 to 35 lb.) for 15 seconds. The pedal
should not continue dropping when pressed with a steady amount of pressure. If the pedal goes to the
floor, inspect the hydraulic system for leaks and repair any worn or damaged components. After repair,
bleed the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6-31.
Master Cylinder Inspection
• Inspect the exterior of the master cylinder. Replace any leaking components and bleed the hydraulic
brake system. See Bleeding the Hydraulic Brake System on page 6-31.
• Check the brake fluid level. See Brake Fluid, Section 10, Page 10-4.
• Remove the reservoir cap and inspect the brake fluid. If brake fluid is contaminated, purge the brake
fluid and refill the hydraulic system. See Filling the Hydraulic System on page 6-32.
• Check the vent holes in the reservoir cap and clean or replace as necessary.
• Check the diaphragm inside the reservoir cap and replace if damaged.
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