Front Suspension Components; Kingpin And Steering Spindle Removal; Kingpin And Steering Spindle Installation - Pioneer 1200 Maintenance Service Manual

7
STEERING AND FRONT SUSPENSION
Toe-in Adjustment, Continued:
7. Check the toe-in. If toe-in is not adjusted properly, repeat step 6.
8. Tighten nuts (12) to 20 ft-lb (27 N·m) and recheck toe-in. Repeat step 6 for further adjustment.
9. Install new cotter pins (18).
10. After toe-in adjustment is made and with wheels in the straight ahead position, the steering wheel should
be at the center of its travel. If not at the center of travel, remove and correct position. See Steering
Wheel Installation on page 7-3.

FRONT SUSPENSION COMPONENTS

See General Warning, Section 1, Page 1-1.

KINGPIN AND STEERING SPINDLE REMOVAL

1. Remove the front brake drum. See Front Wheel Brake Drum Removal, Section 6, Page 6-6.
2. Remove cotter pin (18), nut (24), and ball joint from the spindle assembly (Figure 7-20, Page 7-11).
3. Remove the four Torx-head bolts (18), washers (19) and lock nuts (20) securing the brake cluster to the
spindle assembly. See Figure 6-1, Section 6, Page 6-2.
4. Rest the brake cluster on the A-arm as shown (Figure 7-28, Page 7-15). Ensure that there is no strain
on the brake hose. See following WARNING.
∆
WARNING
• Strain on the brake hose or the brake hose fittings can result in damage to the hose or fittings,
causing a leak in the hydraulic system, diminished brake performance, or brake failure.
5. Remove the nut (22), washer (36) and kingpin (21) (Figure 7-29, Page 7-16).
6. Remove the thrust washer (32).
7. Remove the wave washer (33) and inspect it. If the washer is broken or has a wave bottom to wave crest
height dimension of less than 0.040 inch (0.10 cm), it must be replaced.
8. Slide the spindle assembly (20) off of the A-arm (13).
9. Repeat steps 1 through 8 for the opposite front wheel if necessary.

KINGPIN AND STEERING SPINDLE INSTALLATION

1. Inspect all parts and replace them as necessary.
2. Inspect the kingpin (21) and spindle (19). If either are worn or damaged, they must be replaced
(Figure 7-29, Page 7-16).
3. Inspect the kingpin bushings (16 and 18). If the bushings are worn or damaged, remove them and press
in new ones. See following NOTE.
Page 7-14 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Front Suspension Components