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Pioneer 1200 Maintenance Service Manual

2003
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1200/1200SE
2003 MAINTENANCE & SERVICE MANUAL
Manual No. 10 2 3 1 8 8 1 3
Edition Code 0503A00000

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Summary of Contents for Pioneer 1200

  • Page 1 1200/1200SE 2003 MAINTENANCE & SERVICE MANUAL Manual No. 10 2 3 1 8 8 1 3 Edition Code 0503A00000...
  • Page 3 This manual provides detailed information for the maintenance and repair of the Pioneer 1200 and Pioneer 1200SE vehicles, and should be thoroughly reviewed prior to servicing the vehicles. The procedures provided must be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.
  • Page 4 There are no warranties expressed or implied in this manual. See the limited warranty found in the vehicle owner’s manual or write to Club Car, Inc., P.O. Box 204658, Augusta, GA 30917-4658 USA, Attention: Warranty Department. Page ii 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 5: Table Of Contents

    Seat Adjustment ........................... Front Seat Support ........................... Front Seat Support Removal ......................Front Seat Support Installation ..................... Rear Seat Support ..........................Rear Seat Support Removal ......................Rear Seat Support Installation ...................... 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page iii...
  • Page 6 Rear Brake Shoe Removal ......................Brake Cluster Inspection and Cleaning .................... 6-10 Brake Shoe Installation ........................6-11 Front Brake Shoe Installation ....................... 6-12 Rear Brake Shoe Installation ....................... 6-12 Page iv 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 7 Park Brake Cable Removal ......................6-33 Park Brake Cable Installation ....................... 6-34 Park Brake Handle Removal ......................6-35 Park Brake Handle Installation ..................... 6-35 Park Brake Adjustment ......................... 6-35 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page v...
  • Page 8 SECTION 9 – REAR SUSPENSION Shock Absorbers ..........................Shock Absorber Removal and Inspection ..................Shock Absorber Installation ......................Multi-Leaf Springs ..........................Multi-Leaf Spring Removal ......................Multi-Leaf Spring Installation ......................Page vi 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 9 Testing the Low Oil Warning Circuit ..................... 11-17 Testing the Lockout Cam Circuit ....................11-18 Testing the Fuel Gauge and Sending Unit Circuit ................ 11-18 Testing the Lighting Circuit ......................11-19 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page vii...
  • Page 10 Breather Valve (Reed Valve) ....................... 13-3 Valve Clearance Check and Adjustment ..................13-3 Crankcase ............................13-3 Engine Removal ........................... 13-3 Crankcase Cover Removal ......................13-4 Oil Level Sensor ........................... 13-4 Page viii 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 11 Fuel Pump Assembly ........................14-20 Fuel Pump Installation ........................14-20 Fuel Tank ............................14-21 Fuel Tank Removal ........................14-21 Fuel Tank Storage or Disposal ..................... 14-25 Fuel Tank Installation ........................14-25 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page ix...
  • Page 12 Drive Clutch Cleaning and Inspection ..................17-5 Drive Clutch Disassembly ......................17-6 Inspection of Drive Clutch Parts ....................17-7 Drive Clutch Assembly ......................... 17-9 Drive Clutch Installation ....................... 17-12 Page x 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 13 Driven Clutch Removal ......................... 17-13 Driven Clutch Disassembly ......................17-13 Driven Clutch Inspection ....................... 17-13 Driven Clutch Assembly ........................ 17-15 Driven Clutch Installation ......................17-17 SECTION i – INDEX 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page xi...

  • Page 15: Section 1 - Safety

    Service only in a well-ventilated area. • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 1-1...
  • Page 16 • Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance, severe personal injury, or death. • Do not leave children unattended on vehicle. Page 1-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 17 SAFETY General Warning AS SEEN FROM PASSENGER SIDE OF VEHICLE REMOVE NEGATIVE CABLE FIRST DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE Figure 1-1 Battery 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 1-3...

  • Page 19: Section 2 - Vehicle Specifications

    Turning radius (per SAE J 695) 139.6 in. (355 cm) 15 ft. 6 in. (472.4 cm) Intersecting aisle clearance 112.2 in. (285 cm) 120 in. (304 cm) Specifications continued on next page... 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 2-1...
  • Page 20 (1.10-1.38 Bars) (1.10-1.38 Bars) Front: 14-16 psi Front: 14-16 psi (.97-1.10 Bars) (.97-1.10 Bars) Traks Max II tread (optional) Rear: 18-20 psi Rear: 18-20 psi (1.24-1.38 Bars) (1.24-1.38 Bars) Page 2-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 21: Section 3 - General Information

    P O BOX 204658 AUGUSTA GA 30917 Figure 3-1 STORAGE ∆ DANGER • Read General Warning, Section 1, Page 1-1. ∆ WARNING • Read General Warning, Section 1, Page 1-1. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 3-1...

  • Page 22: Preparing The Vehicle For Extended Storage

    NOTE: Due to the oil added to the engine in preparation for storage,engine may smoke excessively for a short while when running it for the first time after storage. 7. Adjust tires to recommended tire pressure. See General Information, Section 8, Page 8-1. Page 3-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 23 SIDE OF VALVE Figure 3-4 Fuel Valve – Open Figure 3-5 Fuel Valve – Closed PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 3-6 Fuel Valve – Partially Closed 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 3-3...

  • Page 25: Section 4 - Body And Trim

    Each vehicle is equipped with an ABS/DR acrylic cap front body and an aluminum rear body and frame. The cargo bed on the Pioneer 1200 is powder-coated steel. The Pioneer 1200SE has an aluminum cargo bed. For regular front body cleaning, use automotive cleaning solutions with a sponge or soft cloth, or use Club Car’s Vehicle Care Kit (CCI P/N AM10021).

  • Page 26: Light Scratches

    3. Tighten Torx-head screws (3) with plastic washers (4) to 45 in-lb (5.1 N·m). 4. Install five caps (1). 5. Install the dash panel and connect wiring to panel components. 6. Install steering wheel. See Steering Wheel Installation, Section 7, Page 7-3. Page 4-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 27: Front Body Removal

    2. Pull back floor mat to access rivets securing front fender (9) to frame. Drill out two 3/16 x 5/8 pop rivets (10) and remove two washers (11). 3. Use a 3/8 hex-head socket to remove two screws (12) from fender frame support and remove fender. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 4-3...

  • Page 28: Front Fender Installation

    3. Adjust seat to prefered position. Align holes in seat panel (3) with holes in seat (2) and secure with four bolts (4) and lock washers (5). Tighten bolts to 96 in-lb (10.8 N·m). ∆ WARNING • Make sure seat hinges and latch are securely engaged before operating vehicle. Page 4-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 29 5 PLACES TYPICAL 6 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES FENDER SUPPORT TYPICAL 5 PLACES TYPICAL 2 PLACES Figure 4-2 Front Body Assembly 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 4-5...

  • Page 30: Front Seat Support

    2. Remove park brake equalizer cable from park brake handle. See Equalizer Cable Removal, Section 6, Page 6-33. 3. Disconnect cable from differential lock control. See step 5 in Unitized Transaxle Removal, Section 16, Page 16-6. TYPICAL 4 PLACES Figure 4-3 Front Seat Support Page 4-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 31: Front Seat Support Installation

    2. Install the seat back support (22) in reverse order of removal. Tighten hardware to 15 ft-lb (20.34 N·m). 3. Install a new seat bottom rear trim using new barrel connectors. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 4-7...
  • Page 32 6. Install bottom bench seat, aligning the front edge of the seat against the inside edge of the front trim, and push down into place. TYPICAL 4 PLACES TYPICAL 10 PLACES TYPICAL 4 PLACES Figure 4-4 Pioneer 1200SE Rear Seat Support Page 4-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 33: Cargo Bed

    1.6. Lift bed from bed latch and with prop rod in a slot notch, place prop rod (1) or (25) in bed mounting hole and install flat washer (4) and a new cotter pin (3) onto prop rod. 1.7. Proceed to Bed Stop Bumper Adjustment on page 4-11. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 4-9...
  • Page 34 BODY AND TRIM Cargo Bed TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 4-5 Pioneer 1200 Cargo Bed Page 4-10 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 35: Bed Stop Bumper Adjustment

    (Figure 4-6, Page 4-11). 2.2. Tighten lock nuts (8) to 20 in-lb (2.3 N·m). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 4-11...

  • Page 36: Rear Fender Removal

    3. Remove two 5/16-18 hex nuts (13), lock washers (12), flat washers (11) and 5/16-18 x 1-inch bolts (18) where the hitch frame (10) mounts to the vehicle frame and remove the hitch. Page 4-12 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 37: Receiver Hitch Installation

    2. Install tailskirt. See Tailskirt Installation on page 4-12. TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 4-7 Rear Fender, Tailskirt, and Hitch – with MC012C-AS00 Transaxle 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 4-13...

  • Page 38: Floor Mat

    2.1. Begin at the corners of where the rear seat frame meets the floorboard, and slide each corner under the frame, sliding each side under the angle supports and lastly lapping the edge against the back of the front seat support. Page 4-14 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 39: Section 5 - Accelerator And Brake Pedal Assemblies

    4. Adjust the brake pedal. See Brake Pedal Adjustment on page 5-3. 5. Connect the battery cables, positive (+) post first, and tighten terminals to 20 ft-lb (27.1 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 5-1...

  • Page 40: Brake Pedal Adjustment

    1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Remove the key. Chock the wheels. 2. Remove the rod retaining bolt (8) and clevis (16) from the bell crank assembly (11) (Figure 5-1, Page 5-2). Page 5-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 41 10. There should be at least 1/8-inch (3.2 mm) of free play (at the push rod) before the push rod begins to depress the master cylinder piston (Figure 5-6, Page 5-4). See following NOTE. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 5-3...

  • Page 42: Accelerator Pedal

    6. Remove the nut (10) and ball stud (16) from the accelerator pivot rod (6) and spring retainer (11) assem- bly. 7. Slide the spring retainer (11) off of the accelerator pivot rod boss. Page 5-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 43: Accelerator Pedal Installation

    5-3/4 inches ±1/4-inch (14.6 cm ± 6 mm) (Figure 5-7, Page 5-7), adjusting the accelerator pedal is not necessary. Tighten the nylon locknut (23) to 26 ft-lb (35.3 N·m) (Figure 5-11, Page 5-8) and proceed to step 7. If adjustment is necessary, proceed to step 2. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 5-5...
  • Page 44 9.3. Connect the spark plug wire. 10. Connect the battery cables, positive (+) cable first and tighten terminals to 20 ft-lb (27.1 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 5-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 45 ADJUSTMENT TOOL (CCI P/N 101871001) RUBBER STRAP Figure 5-9 Accelerator Pedal Height Adjustment RETAINING PARALLEL NUTS WITH TOP VIEW OF THE ELECTRICAL COMPONENT Figure 5-10 Accelerator Cable and Electrical Box 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 5-7...
  • Page 46 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment FLOORBOARD REMOVED FOR CLARITY Figure 5-11 Accelerator Pedal Assembly Page 5-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 47: Section 6 - Mc012C-As00 Transaxle: Hydraulic And Park Brake Systems

    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. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-1...
  • Page 48 Park Brake Adjustment on page 6-35. • Check the park brake cables, equalizer and linkage for damage. The cables should not come in contact with either of the rear wheels or tires. Page 6-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 49: Brake System Troubleshooting

    Leak in the hydraulic system and hoses for leaks. Replace all damaged parts. See Bleeding the Hydraulic Brake Air in the hydraulic system System on page 6-31. Troubleshooting Guide continued on next page... 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-3...
  • Page 50 Accelerator and Brake Pedal Assemblies. Vehicle pulls to one side Replace the brake shoes. See Brake Incorrect or distorted brake shoes Shoe Removal on page 6-8. Troubleshooting Guide continued on next page... Page 6-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 51 Assemblies. Soft or swollen rubber parts caused by Replace master cylinder. See Master incorrect or contaminated brake fluid Cylinder Removal on page 6-29. Troubleshooting Guide continued on next page... 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-5...

  • Page 52: Brake Drum Removal

    4.1. Remove the dust cover (1) and cotter pin (2) (Figure 6-2, Page 6-7). 4.2. Remove the castle nut (3), large flat washer (4), wheel bearing (5) and drum (8). If the brake drum was easily removed, proceed to step 6. Page 6-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 53 Rotate adjuster bolts Rotate adjuster bolts to tighten brake shoes. to loosen brake shoes. Hex-Head Bolt Wrench Torx-Head Bolt Wrench Torx Torx Figure 6-3 Loosen or Tighten Brake Adjusters 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-7...

  • Page 54: Rear Wheel Brake Drum Removal

    3. Pull brake shoes and tensioning springs from the brake cluster assembly (Figure 6-7, Page 6-9). 4. Repeat steps 1 and 3 for the opposite front wheel if necessary. Page 6-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 55: Rear Brake Shoe Removal

    7. Repeat steps 1 through 6 for the opposite rear wheel if necessary. Figure 6-4 Rotate Front Spring Cups Figure 6-5 Rear Wheel Bolt Flange Assembly Figure 6-6 Rotate Rear Spring Cups Figure 6-7 Remove Brake Shoes 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-9...

  • Page 56: Brake Cluster Inspection And Cleaning

    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...

  • Page 57: Brake Shoe Installation

    Use only DOT 5 brake fluid. See Bleeding the Hydraulic Brake System on page 6-31. See following NOTE. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-11...

  • Page 58: Front Brake Shoe Installation

    3. Attach the tensioning springs onto the shoe with the smaller spring on top and the larger spring on the bottom (Figure 6-11, Page 6-12). Smaller spring on top Lever is present on rear brake clusters only Larger spring on bottom Figure 6-11 Brake Shoe Tensioning Springs Page 6-12 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 59 flange from the splined end of the axle. Loss of vehicle control could result, causing severe personal injury. 8.6. Install the rubber boot (26) onto the large washer (23). See following NOTE. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-13...

  • Page 60: Brake Drum Installation

    7. Carefully apply grease around the seal (6) inner lip before installation. Do not allow grease to touch the brake shoe linings nor the brake shoe surface of the drum hub. 8. Place the brake drum hub (8) onto the spindle and brake cluster assembly. Page 6-14 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 61 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 Page 6-15...

  • Page 62: Rear Wheel Brake Drum Installation

    (4) from the adjuster (3) (Figure 6-1, Page 6-2 or Figure 6-19, Page 6-21). Page 6-16 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 63: Brake Cluster Assembly Replacement

    1. Install the back plate to the front spindle flange with four new Torx-head bolts (18), washers (19) and lock nuts (20). Tighten all four bolts to 76 in-lb (8.6 N·m) (Figure 6-1, Page 6-2). See following CAUTION. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-17...

  • Page 64: Rear Brake Cluster Assembly Removal

    flange (Figure 6-19, Page 6-21). 9. Repeat steps 1 through 8 for the opposite rear wheel if necessary. CABLE SUPPORT BRACKET Figure 6-16 Park Brake Cable Figure 6-17 Rear Brake Hose Flare Nut Page 6-18 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 65: Rear Brake Cluster Assembly Installation

    FRONT WHEEL CYLINDER REMOVAL 1. Remove front brake drum. See Front Wheel Brake Drum Removal on page 6-6. 2. Remove front brake shoes. See Front Brake Shoe Removal on page 6-8. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-19...

  • Page 66: Front Wheel Cylinder Installation

    6. Bleed the rear wheel brakes. See Bleeding the Hydraulic Brake System on page 6-31. 7. Perform all of the brake system inspections. See Brake System Inspection on page 6-1. Page 6-20 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 67: Brake Shoe Adjuster Replacement

    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. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-21...

  • Page 68: Front Brake Shoe Adjuster Removal

    REAR BRAKE SHOE ADJUSTER INSTALLATION NOTE: The adjusters must be replaced as pairs using new hardware. 1. Install bolt (4) and flat washer (2) to the back plate (1) (Figure 6-19, Page 6-21). Page 6-22 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 69: Hydraulic Line And Hose Replacement

    3. Secure the brake line to the vehicle frame with the P-clamp (7), using a new 3/6 x 3/4-inch aluminum pop rivet (8) and two 3/16-inch rivet washers (14). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-23...

  • Page 70: Front Brake Hose Assembly Removal

    1.3. Place a pan below the vehicle to collect the brake fluid. 1.4. Use a 3/8-inch flare nut wrench to remove brake line (10 or 11) from the master cylinder (Figure 6-20, Page 6-25). Page 6-24 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 71 floor jack. See WARNING "Lift only one end..." in General Warning, Section 1, Page 1-1. 2.2. Place jack stands under the rear axle tubes and lower onto stands. See Figure 5-2, Section 5, Page 5-3. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-25...

  • Page 72: Rear Brake Line Installation

    6. Remove the horseshoe clip (12) that secures the rear brake hose (9) to the I-beam frame and remove brake hose (9) through the oval-shaped hole in the vehicle I-beam. 7. Repeat steps 4 through 6 for the opposite rear brake hose if necessary. Page 6-26 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 73: Rear Brake Hose Installation

    5. Adjust the brake pedal as instructed. See Brake Pedal Adjustment, Section 5, Page 5-3. 6. 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 Page 6-27...
  • Page 74 BOTH SIDES TYPICAL 2 PLACES REFERENCE FRONT SUSPENSION REFERENCE MASTER CYLINDER REFERENCE FRONT BRAKE ASSEMBLY TYPICAL BOTH SIDES REFERENCE REAR BRAKE ASSEMBLY Figure 6-21 Pioneer 1200SE Four-Wheel Hydraulic Brake System Page 6-28 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 75: Master Cylinder Removal

    8. Fill the reservoir of the master cylinder and bleed the entire hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6-31. 9. 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 Page 6-29...
  • Page 76 2 PLACES PIONEER 1200SE PLUG TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 6-22 Master Cylinder Page 6-30 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 77: Bleeding The Hydraulic Brake System

    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 Page 6-31...

  • Page 78: Purging The Hydraulic System

    After purging the brake system and making any necessary repairs, bleed the brakes, adding DOT 5 brake fluid until the system is full and virtually no air bubbles are present in the brake bleeder vacuum tubes. See Bleed- ing the Hydraulic Brake System on page 6-31. Page 6-32 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 79: Park Brake System

    5. Remove the cable from the cable support bracket (16 or 24). 6. Slide the cable through the frame hanger (15) and remove the cable from the vehicle. 7. Remove the remaining wheel brake cable if necessary. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-33...

  • Page 80: Park Brake Cable Installation

    4. Attach the opposite end of cable (22) through a frame bracket notch (25) and secure with a wire clip (26). 5. Pull the end of the brake cable (8) up and into a keyhole opening in the park brake equalizer bracket (10). Page 6-34 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 81: Park Brake Handle Removal

    5. With the park brake released (down), tighten the conical nut (23) until significant resistance is observed in the equalizer cable in order to fully lock the brakes (Figure 6-27, Page 6-37). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-35...
  • Page 82 10. Perform all of the brake system inspections to ensure that both the hydraulic brake system and the park brake system are adjusted and operating correctly before placing the vehicle into service. See Brake System Inspection on page 6-1. Page 6-36 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 83 TYPICAL 4 PLACES TYPICAL EACH PULLEY 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL EACH SIDE OF VEHICLE TYPICAL EACH SIDE OF VEHICLE Figure 6-27 Park Brake System 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-37...

  • Page 85: Section 7 - Steering And Front Suspension

    7.5. Remove the steering wheel nut (18) and the steering wheel from the steering column (13). Figure 7-1 Steering Wheel Puller Figure 7-2 Steering Wheel Puller 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-1...
  • Page 86 STEERING AND FRONT SUSPENSION Steering Wheel TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-3 Steering Column Page 7-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 87: Steering Wheel Installation

    6. Insert a flat blade screwdriver between the bottom of the outer race of the bearing (9) and the bottom lip of the bearing seat (10) and remove the bearing (9). NOTE: Use new retaining rings and bearings for reassembly. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-3...

  • Page 88: Steering Column Assembly

    1. Install boot (14) (if previously removed) (Figure 7-3, Page 7-2). 2. To minimize corrosion, apply a light coat of anti-seize lubricant to both splined ends of the steering shaft. Page 7-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 89: Rack And Pinion

    floor jack. See WARNING "Lift only one end..." in General Warning, Section 1, Page 1-1. 2. Place jack stands under the outer front frame I-beams and lower onto stands. See Figure 5-2, Section 5, Page 5-3. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-5...

  • Page 90: Rack And Pinion Disassembly

    11. If the ball bearing (15) (Figure 7-20, Page 7-11) has been damaged, remove the c-type stop ring (16) (Figure 7-15, Page 7-8) and press the bearing off (Figure 7-13, Page 7-8). Page 7-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 91 13.2. Tap the flange out of the notch in the rack (Figure 7-19, Page 7-9). 13.3. Remove the ball joint (9) from the rack (2) (Figure 7-20, Page 7-11). 14. Remove the rack (2) from housing (1). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-7...
  • Page 92 Figure 7-11 Dust Bellows Clamp PRESS RAM PINION GEAR BEARING Figure 7-12 Remove Pinion from Housing Figure 7-13 Remove Bearing from Pinion Figure 7-14 Remove Dust Seal Figure 7-15 Pinion Snap Rings Page 7-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 93: Rack And Pinion Assembly

    See following CAUTION. CAUTION • Do not force the pinion-bearing assembly into the housing. The gear teeth or the small bearing could be damaged. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-9...

  • Page 94: Rack And Pinion Installation

    4. Install remaining bolt and lock washer on the upper universal joint and tighten to 15 ft-lb (20 N·m). 5. Check all universal joint bolts for proper torque of 15 ft-lb (20 N·m). 6. Adjust the toe-in. See Toe-in Adjustment on page 7-13. Page 7-10 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 95 STEERING AND FRONT SUSPENSION Rack and Pinion TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-20 Steering Gear 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-11...

  • Page 96: Front Suspension

    Wheel alignment is limited to adjusting the toe-in of the front wheels. See Toe-in Adjustment on page 7-13. See following NOTE. NOTE: Prior to making any front suspension adjustments, inspect components for wear or damage and repair or replace as necessary. Page 7-12 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 97 6.4. Tighten the lock nuts (24) to 18 ft-lb (24.4 N·m) (Figure 7-20, Page 7-11). Both drag links should be adjusted to an equal distance. Figure 7-27 Adjust Toe-in 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-13...

  • Page 98: Front Suspension Components

    (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...

  • Page 99: A-Arm Removal

    2. Remove cotter pin (18), nut (24) and ball joint from the spindle assembly (Figure 7-20, Page 7-11). 3. Remove the nut (22), washer (36) and kingpin (21) (Figure 7-29, Page 7-16). 4. Remove the thrust washer (32). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-15...
  • Page 100 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL TYPICAL 4 PLACES TYPICAL 2 PLACES 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-29 Front Suspension Page 7-16 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 101: A-Arm Installation

    3. Inspect shock absorbers for damage or fluid leakage on the body and replace if necessary. 4. Remove the bolt (2) and nut (3) attaching the upper shock absorber mount to the A-arm (Figure 7-29, Page 7-16). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-17...

  • Page 102: Shock Absorber Installation

    floor jack. See WARNING "Lift only one end..." in General Warning, Section 1, Page 1-2. 2. Place jack stands under the outer front frame I-beams and lower onto jack stands. See Figure 5-2, Section 5, Page 5-3. Page 7-18 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 103: Front Wheel Bearings And Hub Removal

    FRONT WHEEL BEARINGS AND HUB REMOVAL See Front Wheel Brake Drum Removal, Section 6, Page 6-6. FRONT WHEEL BEARINGS AND HUB INSTALLATION See Front Wheel Brake Drum Installation, Section 6, Page 6-14. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-19...

  • Page 105: Section 8 - Wheels And Tires

    Traks Max II tires are directional. For optimum performance on muddy terrain, install all four tires as shown (Figure 8-1, Page 8-1). DIRECTION TRAKS MAX II OF FORWARD TREAD ROTATION Figure 8-1 Tire Rotation 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 8-1...

  • Page 107: Section 9 - Rear Suspension

    3. Chock the front wheels and lift rear of vehicle with a chain hoist or floor jack. If using floor jack, place jack under transaxle as shown (Figure 9-2, Page 9-3). See WARNING "Lift only one end..." in General Warning, Section 1, Page 1-2. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 9-1...
  • Page 108 REAR SUSPENSION Multi-Leaf Springs TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE AXLE SADDLE Figure 9-1 Rear Suspension for MC012C-AS00 Transaxle Page 9-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 109: Multi-Leaf Spring Installation

    Attach lock nut (22) and tighten to 15 ft-lb (20.3 N·m). See following CAUTION. ∆ CAUTION • Use only grade-eight bolts for the front leaf spring mounts. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 9-3...

  • Page 110: Snubber

    1. Install in the reverse order of removal. 2. Tighten snubber bracket mounting nuts (1) to 13 ft-lb (17.6 N·m) (Figure 9-4, Page 9-4). SNUBBER MOUNTING BRACKET SNUBBER BRACKET Figure 9-4 Snubber Brackets Page 9-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 111: Section 10 - Periodic Maintenance

    Check park brake cables for damage. Replace if necessary. Brake system Check brake shoes and drums; replace if necessary. See Brake Cluster Inspection and Cleaning, Section 6, Page 6-10. Periodic Service Schedule continued on next page... 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 10-1...

  • Page 112: Periodic Lubrication Schedule

    32 oz. (.95 liter) without filter; 38 oz. every 200 hours of Change engine oil and oil filter (1.12 liters) with filter operation or annually, whichever comes first Page 10-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 113: Master Cylinder

    PERIODIC MAINTENANCE Master Cylinder FLOORBOARD Figure 10-1 Pioneer 1200 and Pioneer 1200SE Lubrication Points MASTER CYLINDER The master cylinder is located under the passenger seat toward the center of the vehicle (Figure 10-2, Page 10-3). Raise or remove the seat to check the brake fluid level.

  • Page 114: Brake Fluid

    Full Level Safe Level Level Oil fill tube is located behind and under passenger seat. Figure 10-3 Pioneer 1200 Oil Level Check Figure 10-4 Pioneer 1200SE Oil Level Check Page 10-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 115: Engine Oil And Filter Change

    9. Remove the engine oil filter, turning it counterclockwise, allowing the residual oil in the filter port and filter to drain into the oil drain pan. See following NOTE. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 10-5...
  • Page 116 filter to the oil mounting bracket. See following NOTE. NOTE: Use only Club Car oil filters (CCI P/N 1016467) designed for this engine. Coat Rubber Seal Figure 10-8 Replace Engine Oil Filter Figure 10-9 Add Engine Oil Page 10-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 117: Oil Viscosity

    • To avoid the possibility of fire, clean up any spilled gasoline before operating the vehicle. ∆ CAUTION • To allow for expansion, do not fill higher than one inch from the top of the fuel tank. Avoid spilling fuel. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 10-7...

  • Page 118: Battery

    Call a physician immediately. - Eyes: Flush with water for 15 minutes. Call a physician immediately. ∆ WARNING • Do not jump-start a dead battery using another battery and jumper cables. Page 10-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 119 If battery appears weak, have it charged by a trained technician. The battery should never be left discharged any longer than absolutely necessary (do not leave discharged overnight). For specific battery testing procedures, see Battery, Section 12, Page 12-28. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 10-9...

  • Page 121: Section 11 - Troubleshooting And Electrical System: Fe400 Engine

    Section 14 – Fuel System dirty or clogged fuel filter Fuel pump malfunction; fuel pressure to Section 14 – Fuel System carburetor too low Troubleshooting Guide continued on next page... 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-1...
  • Page 122 Section 13 – FE400 Engine Unsuitable fuel, or incorrect (rich) fuel Section 14 – Fuel System mixture Dirt entering combustion chamber Section 13 – FE400 Engine Troubleshooting Guide continued on next page... Page 11-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 123 Generator field coil is shorted Electrical System: FE400 Engine Test Procedure 11 See Starter/Generator, Section 12, Brushes are worn or commutator is dirty Page 12-1. Troubleshooting Guide continued on next page... 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-3...
  • Page 124 Test Procedures 4 and 17 Carburetor is too lean; check main and Section 14 – Fuel System pilot jet sizes Carburetor throttle stop screw out of Section 14 – Fuel System adjustment Page 11-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 125: Electrical System

    For a complete wiring diagram, see pages 11-6 and 11-7. AS SEEN FROM PASSENGER SIDE OF VEHICLE REMOVE NEGATIVE CABLE FIRST DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE Figure 11-1 Battery Disconnect 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-5...

  • Page 126: Wiring Diagram

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400 ENGINE Wiring Diagram WIRING DIAGRAM PASSENGER SIDE HEADLIGHT DRIVER SIDE HEADLIGHT SONIC WELD SONIC WELD LIGHT SWITCH Figure 11-2 Wiring Diagram for FE400 Key-Start Vehicles (Front) Page 11-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 127 TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400 ENGINE Wiring Diagram SONIC WELD SONIC WELD SONIC WELD Figure 11-3 Wiring Diagram for FE400 Key-Start Vehicles (Rear) 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-7...

  • Page 128: Electrical Circuits

    To prevent battery overcharging, the voltage regulator senses battery voltage, and by opening and closing an electronic switch, controls the amount of charge going to the battery. Page 11-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 129: Engine Ignition Circuit

    The engine kill circuit consists of the key switch and connecting wires. The engine can be stopped by turning the key switch to the OFF position. See Lockout Cam Circuit on page 11-11. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-9...

  • Page 130: Reverse Buzzer Circuit

    The light receives power through the key switch when the key switch is turned to the ON position. When the oil level in the crankcase is low, the oil level sensor closes the circuit to ground and illuminates the low oil warning light. Page 11-10 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 131: Lockout Cam Circuit

    The lockout cam circuit consists of the connecting wires and a limit switch that is located on the Forward/ Reverse shifter assembly and is activated by the lockout cam (Figure 11-11, Page 11-12). NEUTRAL SERVICE POSITION Figure 11-10 Correct Position for Lockout Cam 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-11...

  • Page 132: Fuel Gauge And Sending Unit Circuit

    ON position. The power goes through the gauge to the sending unit at the fuel tank. The sending unit tells the gauge how much fuel is in the tank (Figure 11-12, Page 11-12). Figure 11-12 Fuel Gauge and Sending Unit Circuit Page 11-12 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 133: Hour Meter Circuit

    Test the vehicle battery to determine whether or not it is the source of the problem before testing the electrical circuits. A hydrometer, multimeter, and 160-ampere load tester will be required. See Test Procedure 1 – Bat- tery on page 11-20. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-13...

  • Page 134: Testing The Starter Circuit And Generator Circuit

    CHECK DIODE (TEST PROCEDURE 10) CHECK STARTER/GENERATOR (GENERATOR FUNCTION) (TEST PROCEDURE 11) CHECK VOLTAGE REGULATOR (TEST PROCEDURE 12) CHECK WIRE CONTINUITY (TEST PROCEDURE 9) Figure 11-16 Testing the Generator Circuit Page 11-14 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 135: Testing The Engine Ignition Circuit

    OF CIRCUIT WIRING WIRES CORRECTLY WIRES INCORRECTLY CONNECTED CONNECTED CONNECT WIRES CORRECTLY CHECK CONTINUITY OF CIRCUIT WIRES (TEST PROCEDURE 9) NO CONTINUITY REPLACE WIRE Figure 11-18 Testing the Engine Kill Circuit 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-15...

  • Page 136: Testing The Reverse Buzzer Circuit

    WIRES INCORRECTLY CONNECTED CONNECTED CHECK CONTINUITY RECONNECT WIRES OF CIRCUIT WIRES TO REVERSE BUZZER CONTINUITY NO CONTINUITY REPLACE REVERSE BUZZER REPLACE WIRE Figure 11-19 Testing the Reverse Buzzer Circuit Page 11-16 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 137: Testing The Low Oil Warning Circuit

    LOW OIL WARNING LIGHT LOW OIL WARNING LIGHT ILLUMINATES DOES NOT ILLUMINATE REPLACE CONTINUITY OIL LEVEL SENSOR REPLACE LOW OIL WARNING LIGHT Figure 11-20 Testing the Low Oil Warning Circuit 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-17...

  • Page 138: Testing The Lockout Cam Circuit

    GAUGE (TEST PROCEDURE 26) (TEST PROCEDURE 26) VOLTAGE READINGS VOLTAGE READINGS INCORRECT INCORRECT REPLACE FUEL GAUGE REPLACE FUEL GAUGE Figure 11-21 Testing the Fuel Gauge and Sending Unit Circuit Page 11-18 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 139: Testing The Lighting Circuit

    INDEX OF TEST PROCEDURES 1. Battery 2. Fuse 3. Ground Straps 4. Key Switch (Starter Circuit) 5. Key Switch (Accessory Terminal) 6. Solenoid 7. Lockout Cam Limit Switch 8. Starter/Generator (Starter Function) 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-19...
  • Page 140 NOTE: The battery must be properly maintained and fully charged in order to perform the following test procedures. Battery maintenance procedures, including watering information and allowable min- eral content, can be found in Section 12 of this manual. See Battery, Section 12, Page 12-28. Page 11-20 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 141 (Figure 11-23, Page 11-21). 7. Record the reading. 8. Return the electrolyte to the cell from which it was taken. Replace vent cap. 9. Repeat steps 2 through 8 on all cells. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-21...
  • Page 142 70 °F (20 °C and above) 9.6 V 60 °F (16 °C) 9.5 V 50 °F (10 °C) 9.4 V 40 °F (4 °C) 9.3 V 30 °F (-1 °C) 9.1 V Page 11-22 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 143 The reading should be continuity. If the reading is incorrect, clean and tighten wire connections. If the connections are good but the reading is incorrect, repair or replace the wire. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-23...
  • Page 144 If the reading is incorrect, check that terminal connections are clean and tight. If the connections are good but the reading is incorrect, repair or replace the wire. Page 11-24 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 145 3. Remove the center dash assembly. See Key Switch Removal, Section 12, Page 12-14. 4. Ensure that the connector is connected correctly and is tight. If it is not, repair or replace as necessary. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-25...
  • Page 146 Turn key switch to the START position and listen for the solenoid click. While holding the key in the START position, the meter should read full battery voltage. If the reading is incorrect, replace the solenoid (Figure 11-32, Page 11-27). Page 11-26 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 147 Reverse shifter is in the NEUTRAL position only. The limit switch should make an audible click as it is depressed. If it does not, check for wear on the cam lobe. If the cam lobe will not activate the limit switch, replace the cam. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-27...
  • Page 148 0.1 and 0.3 Ω (ohms). If the reading is incorrect, a possible open field coil or bad connections at terminals may be the cause. The starter/generator will need to be removed from the vehicle and disassembled by a qualified technician. See Starter/Generator Removal, Section 12, Page 12-1. Page 11-28 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 149 3.2. Remove the cover retaining screw (5) and electrical component box cover (6) (Figure 11-36, Page 11-30). 3.3. Remove the lock nuts (7) from the two large solenoid posts and disconnect the diode wires from the solenoid. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-29...

  • Page 150: Starter/Generator

    • Incorrect wiring could result in severe injury or death. • Diode and solenoid connections must have correct polarity. • Keep all persons clear of engine belts when making final connections. Page 11-30 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 151 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Check that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-31...
  • Page 152 3. Turn the key switch to the START position and release if the engine starts. If the engine starts and con- tinues to idle, check the kill-wire for grounding, the kill limit switch, and the key switch. See Testing the Engine Kill Circuit on page 11-15. See following WARNING. Page 11-32 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 153 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Disconnect the battery cables as instructed (Figure 11-1, Page 11-5). See WARNING "To avoid unin- tentionally starting..." in General Warning, Section 1, Page 1-1. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-33...
  • Page 154 (Figure 11-43, Page 11-35). 3.2. If the resistance is not between 0.6 - 1.7 Ω (ohms), bench test the ignition coil. See Ignition Coil – Bench Test on page 11-37. Page 11-34 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 155 (Figure 11-47, Page 11-37). If the resistance is not between 4.5k - 6.0k Ω (ohms), the cap has failed and must be replaced. Proceed to the next step with the spark plug cap still removed. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-35...
  • Page 156 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11-44 Secondary Coil Test – In Vehicle Test Figure 11-45 Ignition Coil and Cap Figure 11-46 Spark Plug Cap Removal Page 11-36 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 157 6 on page 11-39. If the resistance is not between 12.0k - 14.0k Ω (ohms), the spark plug cap and secondary coil must be tested independently from each other. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-37...
  • Page 158 200nA 1000 --- FUSED 750V Ω 200nA 1000 --- FUSED 750V Figure 11-49 Primary Coil Resistance – Bench Test Figure 11-50 Secondary Coil and Cap Resistance – Bench Test Page 11-38 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 159 General Warning, Section 1, Page 1-2. 3. Remove the center dash assembly. See Key Switch Removal, Section 12, Page 12-14. 4. Remove the connector from the key switch. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-39...
  • Page 160 The reverse buzzer limit switch is located on the Forward/Reverse shifter; red/white and orange wires are con- nected to it. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. Page 11-40 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 161 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Disconnect the battery cables as instructed (Figure 11-1, Page 11-5). See WARNING "To avoid unin- tentionally starting..." in General Warning, Section 1, Page 1-2. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-41...
  • Page 162 See General Warning, Section 1, Page 1-1. ∆ WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure. Page 11-42 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 163 See Test Procedure 26 – Fuel Gauge on page 11-44. WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V TANK CONNECTION SENDING UNIT FRAME CONNECTION Figure 11-53 Test Fuel Level Sending Unit 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-43...
  • Page 164 3. Turn the key past the ON position to the START position and hold until the engine is running smoothly. Release the key and it will return to the ON position and the engine should idle. Page 11-44 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 165 5. Connect the battery cables, positive (+) cable first, and tighten terminals to 20 ft-lb (27 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 6. Connect the black (–) probe of the multimeter to the negative (–) post of the battery. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-45...
  • Page 166 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Inspect wires at the light bulb socket. Make sure wires are securely fastened to the contacts inside socket. Page 11-46 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 167 12 volts, the black wire has continuity. BLACK WIRE WAVETEK BLUE WIRE 1000 WIRE HARNESS 2000 200k Ω Ω 200nA 1000 --- FUSED 750V LEFT HEADLIGHT Figure 11-58 Check Voltage to Headlight Socket 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 11-47...
  • Page 169 5. Support the starter/generator so that when the pivot bolts are removed the starter/generator will not fall to the ground. Remove the two pivot nuts (7) and bolts (5) from the mounting bracket. 6. Remove the starter/generator. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-1...
  • Page 170 Page 12-3). Test brush spring tension with a spring scale. If any spring has a tension less than 24 ounces (6.67 N), replace all four springs (Figure 12-6, Page 12-3). See following CAUTION. Page 12-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 171 STARTER/GENERATOR BRUSH BRUSH HOLDER WEAR LINE Figure 12-5 Inspect Brushes Replace springs that apply a force of less than 24 ounces (6.67 N). Figure 12-6 Brush Spring Tension Test 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-3...
  • Page 172 Replace if there is extensive wear or pitting on the balls or rolling surfaces. Do not remove bearings unless they are to be replaced. Page 12-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 173 NOTE: Do not remove the insulators or the field coils unless an electrical test indicates that it is necessary (Figure 12-11, Page 12-6). See Test Procedure 8, Section 11, Page 11-28. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-5...
  • Page 174 • Worn, burned, or glazed commutator • Loose or raised commutator bars • Bruised or damaged armature core laminations • Worn armature bearing or shaft • Dirty or oily commutator Page 12-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 175 Burned, blackened, charred, or scorched coil insulation indicates the starter/generator has overheated due to overloads, grounding, or shorted coil windings and should be replaced. Be sure the insulators are tight in the housing. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-7...
  • Page 176 Install a flat washer, lock washer and nut onto each threaded terminal on the outside of the housing. Tighten nuts to 47.5 in-lb (5.4 N·m) (Figure 12-11, Page 12-6). See following CAUTION. Page 12-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 177 5. Connect the yellow wire from the voltage regulator to the DF terminal on the starter/generator. Install a flat washer, lock washer, and nut onto the terminal and tighten the nut to 31 in-lb (3.5 N·m). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-9...
  • Page 178 • Remove pry bar before starting engine. 8. Connect the battery cables, positive (+) cable first, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12-10 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 179: Voltage Regulator

    See Test Procedure 12, Section 11, Page 11-31. TO KILL LIMIT SWITCH TO BATTERY FRAME GROUND TO BULLET ELECTRICAL TO SOLENOID CONNECTOR COMPONENT BOX Figure 12-16 Voltage Regulator 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-11...

  • Page 180: Diode

    2. Peel the protective film from both sides of the new thermal pad (1) (Figure 12-18, Page 12-13). See fol- lowing CAUTION. PIONEER 1200SE PIONEER 1200 ANGLED I-BEAM OUTER I-BEAM Figure 12-17 Location of Diodes Page 12-12 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 181 90 in-lb (10.2 N·m). 5. Replace the electrical component box cover (6) and screw (5) and tighten the screw to 18 in-lb (2.0 N·m). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-13...

  • Page 182: Key Switch

    3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Figure 12-19 Key Switch Removal Page 12-14 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 183: Solenoid

    See Test Procedure 2, Section 11, Page 11-23. Fuse Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-15...
  • Page 184 18 in-lb (2 N·m). 3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12-16 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 185: Lockout Cam Limit Switch

    If the cam lobes have worn to the point where they will no longer actuate the lockout cam limit switch, the cam must be replaced. Testing the Lockout Cam See Test Procedure 23, Section 11, Page 11-42. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-17...

  • Page 186: Reverse Warning Buzzer

    4. Disconnect the wires from the reverse warning buzzer (2) (Figure 12-23, Page 12-19). 5. Remove the screw (3), nut (4), flat washer (6), and lock wassher (5) securing the buzzer to the vertical frame support. Page 12-18 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 187: Reverse Buzzer Limit Switch

    Do not disconnect the wires. 5. Remove the spacers (9) from the reverse buzzer limit switch (4) and slide the reverse buzzer limit switch off the screws. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-19...

  • Page 188: Low Oil Warning Light

    3. Install the dash in reverse order of removal. See Key Switch Removal on page 12-14. 4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12-20 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 189: Fuel Gauge/Hour Meter

    Tighten to 2.5 in-lb (.28 N·m). Place one drop of Loctite™ on each hex nut. Do not allow Loctite to come into contact with the gauge/meter casing. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-21...

  • Page 190: Fuel Level Sending Unit

    5. Connect other female bullet of the black coil wire to the ignition coil bullet terminal. 6. Connect the battery cables, positive (+) cable first, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 12-22 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 191: Ignition Coil

    5. Slide the engine away from the transaxle housing and lift the engine from the mounting plate. 6. Place the engine on a solid, flat surface, preferably on a sturdy work bench. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-23...
  • Page 192 16. Place the engine onto the engine mounting plate and slide the two washers (3) onto the two engine body bolts, then slide the bolts through the mounting plate and transaxle housing. Loosely attach the two nuts (6) finger-tight. See Figure 13-5, Section 13, Page 13-6. Page 12-24 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 193 Figure 12-26 Remove Fan Housing Figure 12-27 Black Wire And Ignition Coil SPARK PLUG 0.012 Inch (0.304 mm) Figure 12-28 Clean Grommet Figure 12-29 Mount Ignition Coil Using Feeler Gauge 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-25...

  • Page 194: Oil Level Sensor

    1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. 2. Disconnect the battery cables as instructed (Figure 12-1, Page 12-1). See WARNING "To avoid unin- tentionally starting..." in General Warning, Section 1, Page 1-2. Page 12-26 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 195: Voltage Limiter

    3. Remove the center dash panel. See Key Switch Removal on page 12-14. 4. Disconnect wires from the voltage limiter (1) (Figure 12-31, Page 12-27). 5. Remove the mounting hardware (2) from the voltage limiter and remove. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-27...

  • Page 196: Light Switch

    Ventilate when charging or using in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries. For added protection, cover top of the battery when servicing the vehicle. DANGER CONTINUED ON NEXT PAGE... Page 12-28 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 197: General Information

    Check the water level more frequently in hot weather or when the battery becomes old. See Figure 11-24, Section 11, Page 11-21. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-29...
  • Page 198 4.1. Remove the rear seat. 4.2. Remove the choke cable and bracket from the air filter box. 5. Remove the battery hold-down clamp from the battery and remove. See following WARNING. Page 12-30 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 199 • If the charger must be stopped, disconnect the AC supply cord from the wall outlet before disconnecting the DC leads from the battery. Allow the battery to cool to room temperature and resume charging battery at a lower amp rate. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-31...
  • Page 200 The vehicle is equipped with a starter/generator. The generator is not designed to charge a dead battery. If the vehicle battery has become discharged, it must be charged using a properly rated automotive type charger. See following WARNING. Page 12-32 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 201: Ground Straps

    ∆ WARNING • Do not jump-start a dead battery using another battery and jumper cables. GROUND STRAPS Testing the Ground Straps See Test Procedure 3, Section 11, Page 11-23. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 12-33...

  • Page 203: Section 13 - Fe400 Engine

    • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The Pioneer 1200 and 1200SE vehicles are powered by the FE400, 4-cycle, overhead valve, single-cylinder, air-cooled engine. See following NOTE. NOTE: Engine rotation is clockwise as viewed from the clutch side of the engine.
  • Page 204 5/16-inch (8 mm) gap. Setting the Spark Gap 1. Pass a contact point file between the electrodes to produce flat, parallel surfaces to facilitate accurate gauging. Page 13-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 205: Cylinder

    See General Warning, Section 1, Page 1-1. ENGINE REMOVAL To perform repairs on crankcase components, remove engine from the vehicle. See following CAUTION. CAUTION • Before removal and disassembly, clean the engine. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 13-3...

  • Page 206: Crankcase Cover Removal

    2. Disconnect the oil level sensor wire (2) from the cord connection (1) (Figure 13-4, Page 13-5). 3. Remove the two mounting screws (8) from inside of the crankcase cover and remove the oil level sensor and bracket. Page 13-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 207: Ignition Coil And Flywheel

    • Do not damage the fan blades with the strap wrench. Do not place screwdriver or pry bar in the fan blades. 5. Remove the flywheel with a puller. 6. Remove the flywheel key from its groove. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 13-5...
  • Page 208 FE400 ENGINE Ignition Coil and Flywheel TYPICAL 4 PLACES TYPICAL 2 PLACES SHROUD TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 13-5 Engine Mounting Plate – with MC012C-AS00 Transaxle Page 13-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 209 3. Tighten the two ignition coil bolts to 30 in-lb (3.4 N·m). Loosen Remove. Remove. Figure 13-6 Flywheel Housing Figure 13-7 Ignition Coil 0.012 inch (0.304 mm) Figure 13-8 Flywheel Nut Removal Figure 13-9 Adjust Ignition Coil Air Gap 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 13-7...

  • Page 210: Crankcase Cover Installation

    4. Install the fan housing and tighten the seven screws to 90 in-lb (10 N·m). 5. Install the fan shroud and tighten the four screws to 25 in-lb (2.8 N·m). Page 13-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 211: Engine Installation

    Battery Terminal Protector Spray (CCI P/N 1014305). 11. Adjust the engine RPM setting. See Engine RPM Adjustment, Section 14, Page 14-10. 12. Test-drive vehicle to ensure all systems are functional and correctly adjusted. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 13-9...

  • Page 212: Torque Specifications

    0.027 to 0.031 in. (0.69 to 0.79 mm) Ignition coil air gap (standard) 0.012 in. (0.304 mm) Compression pressure (min.) 71 psi (4.83 Bars) (with automatic compression release) Engine RPM 3850 (±30) RPM Page 13-10 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 213: Section 14 - Fuel System

    MAIN JET ELEVATION/SIZE CHART FE400 ENGINE ALTITUDE MAIN JET SIZE 0-3280 ft. (0-1000 m) 3280-6562 ft. (1000-2000 m) 6562 ft. and over (2000 m and over) 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-1...

  • Page 214: Changing The Main Jet

    5. Remove the carburetor fuel bowl retaining screw and washer (12) and fuel bowl (10) and clean it with a nonflammable solvent. See following NOTE. Page 14-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 215 18. Install carburetor vent line (14) and clamp (13). 19. Install the governor cable clevis pin (24) and cotter pin (25). 20. Install the intake hose (23) and secure with hose clamp. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-3...
  • Page 216 FUEL SYSTEM Carburetor Changing the Main Jet, Continued: TYPICAL 2 PLACES Figure 14-2 Carburetor Installation Page 14-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 217: Engine Control Linkage

    See General Warning, Section 1, Page 1-1. GENERAL INFORMATION It is important that the accelerator pedal, governor linkage, and throttle adjustments are done correctly and in the proper sequence. See following CAUTION. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-5...

  • Page 218: Accelerator Rod

    2. Adjust accelerator pedal position. See Accelerator Pedal Adjustment, Section 5, Page 5-5. 3. Install the ball joint on the ball stud at the accelerator pedal (Figure 14-4, Page 14-6). 4. Remove the electrical box screw and cover. Page 14-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 219: Governor Cable

    6. Hold the arm and shaft in the fully counterclockwise position and tighten the governor arm lever nut to 36 in-lb (4.0 N·m). 7. Check engine RPM adjustment. See Engine RPM Adjustment on page 14-10. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-7...

  • Page 220: Accelerator Cable

    7. Install the electrical box cover, and tighten the retaining screw to 18 in-lb (2.0 N·m). 8. Connect the battery cables, positive (+) post first, and tighten terminals to 20 ft-lb (27 N·m). Coat termi- nals with Battery Terminal Protector Spray (CCI P/N 1014305). Page 14-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 221 FUEL SYSTEM Engine Control Linkage TYPICAL 2 PLACES REFERENCE EXHAUST SECTION Figure 14-7 Governor and Accelerator 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-9...

  • Page 222: Closed Throttle Or Idle Adjustment

    1. With the engine running and the Forward/Reverse handle in NEUTRAL, position a tachometer (CCI P/ N 1016112) close to the spark plug wire and plug, and adjust the low idle screw on the carburetor until the tachometer reads 1200 to 1250 RPM (Figure 14-8, Page 14-10). ENGINE RPM ADJUSTMENT ∆...

  • Page 223: Choke And Air Intake System

    2.2. Place hose (16) onto air box top (4) and secure with wire clamp (15). 2.3. Attach choke cable (18) to the air box top (4). See Choke Cable Installation on page 14-11. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-11...

  • Page 224: Intake Duct Repair

    It’s best to have one person hold the front brake drum assembly while a second person removes each bolt from their respective shock and shock tower, and gently allow the A-arm assembly to rest in a suspended condition. Page 14-12 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 225 3.3. Cut the wire tie holding Forward/Reverse cable and choke cable to the air duct under the vehicle. 3.4. Slide the air duct toward the front of the vehicle and down until it clears the chassis plate. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-13...

  • Page 226: Intake Duct Installation

    1.8. Lower the vehicle and tighten the wheel lug nuts, using a crisscross pattern, to 55 ft-lb (75 N·m). 1.9. Install front body. See Front Body Installation, Section 4, Page 4-4. Page 14-14 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 227: Air Filter

    8. Install hose (16) and hose clamp (15) and make sure clamp ends are located in the 12:00 o’clock position (Figure 14-10, Page 14-17 or Figure 14-11, Page 14-18). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-15...

  • Page 228: Fuel Filter Removal

    • Make sure the air vent on the fuel pump is not clogged with dirt. See following NOTE. NOTE: To clean the air vent, the fuel pump must be disassembled. Page 14-16 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 229 FUEL SYSTEM Fuel Pump REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 14-10 Pioneer 1200 Air Intake and Choke Assemblies 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-17...
  • Page 230 FUEL SYSTEM Fuel Pump REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 14-11 Pioneer 1200SE Air Intake and Choke Assemblies Page 14-18 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 231: Fuel Pump Removal

    2. Inspect the valve assemblies (31, 32, and 33), gaskets and diaphragms for damage (Figure 14-12, Page 14-20). 3. If a valve assembly is damaged, the rubber retaining plug (33) and valve assembly must be replaced. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-19...

  • Page 232: Fuel Pump Assembly

    IMPULSE LINE BACK COVER Figure 14-12 Pioneer 1200 and 1200 SE Fuel Pump Figure 14-13 Pioneer 1200 and 1200 SE Pump Mount FUEL PUMP ASSEMBLY 1. Install the fuel gasket (35) and diaphragm (34) on the back cover (36) (Figure 14-12, Page 14-20).

  • Page 233: Fuel Tank

    (Figure 14-14, Page 14-22). See following NOTE. NOTE: It is not necessary to remove the park brake cable or differential lock cable to service or remove the fuel tank. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-21...
  • Page 234 13. Pioneer 1200 SE: 13.1. Loosen the strap (13) by removing nut (12) from J-bolt (8) (Figure 14-16, Page 14-24). 14. Lift the fuel tank out of the vehicle. Page 14-22 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 235 Vent tube (Fuel Tank) 17.0 in. (43.2 cm) Impulse line 14.0 in. (35.6 cm) Total 35.0 in. (88.9 cm) 34.0 in. (86.36 cm) Figure 14-15 Pioneer 1200 Fuel and Vent Lines 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-23...
  • Page 236 Vent tube (Fuel Tank) 17.0 in. (43.2 cm) Impulse line 14.0 in. (35.6 cm) Total 75.65 in. (192.2 cm) 34.0 in. (86.36 cm) Figure 14-16 Pioneer 1200 SE Fuel and Vent Lines Page 14-24 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 237: Fuel Tank Storage Or Disposal

    4. Connect fuel line (1) to the fuel tank shut-off valve (15) and secure with a new clamp (16). ORANGE WIRE FRAME TANK CONNECTION CONNECTION Figure 14-17 Fuel Level Sending Unit 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-25...

  • Page 238: Fuel Lines

    Fuel line no. 4 runs from the outlet of the secondary fuel filter (22) to the carburetor. Arrow indicates flow. A screw band clamp should be used at the carburetor. Page 14-26 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 239: Fuel Shut-Off Valve

    WITH OFF MARKINGS ON THE SIDES OF VALVE) VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE Figure 14-20 Closed Fuel Shut-off Valve Figure 14-21 Open Fuel Shut-off Valve 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-27...
  • Page 240 FUEL SYSTEM Fuel Shut-Off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 14-22 Incorrect Fuel Shut-off Valve Page 14-28 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 241: Section 15 - Exhaust System

    10. Connect the spark plug wire. 11. Connect the battery cables, positive (+) cable first, and tighten terminals to 20 ft-lb (27.1 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 15-1...
  • Page 242 • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation. TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 15-1 Exhaust System – FE400 Engine Page 15-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 243: Section 16 - Mc012C-As00 Unitized Transaxle With Differential Lock

    (Figure 16-1, Page 16-1) . Components for this transaxle are identified in the respective illustrated parts list manual. RUBBER DUST IDENTIFICATION DECAL Figure 16-1 MC012C-AS00 Transaxle 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-1...

  • Page 244: Lubrication

    5 EP gear lubricant Tighten the plug to 20 ft-lb (27.1 N·m). Differential Lock Lever The differential lock lever is located between the driver and passenger seats (Figure 16-4, Page 16-2) . Figure 16-4 Differential Lock Lever Page 16-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 245: Axle Shaft

    See WARNING "Lift only one end of the vehicle..." in General Warning, Section 1, Page 1-1. 2. Remove the wheel from the vehicle. 3. Remove the brake drum. If the brake drum was easily removed, proceed to step 5. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-3...
  • Page 246 (Figure 16-7, Page 16-4) . Discard the oil seal. See following CAUTION. Insert prybar under seal, then pull seal out of its axle tube seat. Figure 16-7 Axle Seal Page 16-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 247: Axle Bearing Removal

    • Make sure to install and bend the cotter pin. Failure to bend the cotter pin could result in the separation of the wheel bolt flange from the splined end of the axle. Loss of vehicle control could result, causing severe personal injury. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-5...

  • Page 248: Unitized Transaxle Removal

    2. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in General Warning, Section 1, Page 1-1. 3. Close the fuel shut-off valve on fuel tank. See Fuel Shut-Off Valve, Section 14, Page 14-27. Page 16-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 249 Page 16-8) . 5.3. Rotate the cable connector toward the driver side of the vehicle to disconnect the cable from the dif- ferential lock lever (1) (Figure 16-13, Page 16-8) . 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-7...
  • Page 250 (Figure 16-15, Page 16-9) . 5.7. Disconnect the engine ground wire from the oil filler tube mounting bracket (Figure 16-16, Page 16-9) . Page 16-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 251 6. Remove the lower shock mounting hardware from both rear shocks (Figure 16-24, Page 16-12) . 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-9...
  • Page 252 7.4. Use a 3/8-inch flare nut wrench and remove the brake hose from the rear brake cluster. To avoid spilling brake fluid, lift the hose above the brake cluster assembly (Figure 16-22, Page 16-11). Page 16-10 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 253 10. Remove the bolts securing the leaf springs to their front mounts (Figure 16-27, Page 16-13). 11. Remove the bolts that secure the leaf springs to the shackles (Figure 16-28, Page 16-13). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-11...
  • Page 254 16.1. Grasp belt midway between drive and driven clutch and pull up on belt to force the driven clutch sheaves apart. Roll the belt counterclockwise while pulling it off driven clutch (Figure 16-32, Page 16-14). Page 16-12 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 255 17-1/2" (44.5 cm) Figure 16-25 Raise Vehicle Figure 16-26 Position Jack Stands REMOVE BOLTS, THEN ROTATE SHACKLES UP AND AWAY FROM SPRINGS Figure 16-27 Spring Retainer Bolts Figure 16-28 Rear Shackles 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-13...
  • Page 256 22.1. Remove four transaxle mounting bolts (one at each corner of the transaxle mounting plate) as shown (Figure 16-38, Page 16-15). 22.2. Remove two middle transaxle mounting nuts as shown (Figure 16-38, Page 16-15). 23. Remove leaf springs, wheels and brake assemblies from transaxle. Page 16-14 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 257 Figure 16-36 Forward/Reverse Shifter Bracket TRANSAXLE MOUNTING BOLT AND NUT (TYPICAL 4 PLACES) WOODEN BLOCKS TRANSAXLE MOUNTING NUTS (TYPICAL 2 PLACES) Figure 16-37 Differential Lock Arm and Bracket Figure 16-38 Transaxle Mounting 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-15...

  • Page 258: Unitized Transaxle Installation

    9. Loosely install governor lever arm on governor shaft (Figure 16-43, Page 16-17). Turn the governor arm shaft counterclockwise until it stops. Pull the governor lever arm rearward until the carburetor throttle is in the “wide open throttle” (WOT) position. Page 16-16 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 259 1. Install the governor arm 4. Tighten the on the governor shaft. retaining nut. 2. Turn shaft counterclockwise. 3. Pull governor arm rearward. Figure 16-42 Governor Cable Bracket Figure 16-43 Governor Arm 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-17...
  • Page 260 • 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. See Bleeding the Hydraulic Brake System, Section 6, Page 6-31. Page 16-18 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 261 24. Connect the oil level sensor wire (18-gauge yellow) to the jumper wire (Figure 16-50, Page 16-21). Figure 16-46 Leaf Springs Figure 16-47 Leaf Springs and Shackles WHITE/BLACK WIRE BLACK WIRE Figure 16-48 Ignition Kill Wire 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-19...
  • Page 262 Page 16-21). Install electrical box cover and tighten cover screw to 18 in-lb (2.0 N·m). 29. Pull fuel line from impulse line fitting of the fuel pump and connect it to the carburetor and secure with a hose clamp (Figure 16-55, Page 16-21). Page 16-20 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 263 TOP VIEW SPRING RELEASE NUTS Figure 16-52 Connect Shifter Cable Figure 16-53 Engine Ground TOP VIEW CLAMP ACCELERATOR CABLE Figure 16-54 Connect Cable to Cam Figure 16-55 Connect Fuel Line 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-21...
  • Page 264 38. Connect the battery cables, positive (+) cable first and tighten terminals to 20 ft-lb (27.1 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 39. Adjust the engine RPM setting. See Engine RPM Adjustment, Section 14, Page 14-10. Page 16-22 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 265 Unitized Transaxle Installation CLAMP Figure 16-58 Carburetor Vent Tube Step 1 Step 2 Step 3 Figure 16-59 Differential Cable End Installation Push cable into the bracket. Figure 16-60 Differential Cable Installation 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-23...

  • Page 266: Forward/Reverse Shifter Cable

    5. Install the ball joint socket (2) on the Forward/Reverse shifter assembly ball stud (3). 6. Install wire tie (8) to secure wire harness to cable at the support bracket near the Forward/Reverse shifter assembly. See following WARNING. Page 16-24 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 267: Forward/Reverse Shifter Cable Adjustment

    Place the shift lever in the NEUTRAL position (straight up) (Figure 16-62, Page 16-25). For minor adjust- ments, the nut (1) may be loosened and the ball joint socket (2) rotated to get the proper adjustment (Figure 16-62, Page 16-25). See following CAUTION. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-25...

  • Page 268: Differential Lock System

    DIFFERENTIAL LOCK CABLE REMOVAL 1. Place the differential lock handle in the unlocked position. 2. Remove wire tie (6) securing the cable to the vertical support (Figure 16-63, Page 16-28). Page 16-26 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 269: Differential Lock Cable Installation

    5.5. Secure the cable to the vertical support with a wire tie (6) (Figure 16-63, Page 16-28). 6. Inspect the differential lock system for proper operation. See Differential Lock System Inspection on page 16-26. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 16-27...
  • Page 270 2. Push plastic cable retainer toward the front of the vehicle to secure the cable to the bracket. Figure 16-63 Differential Lock Cable Routing Page 16-28 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 271: Section 17 - Torque Converter

    To properly assemble and disassemble the torque converter, the following tools should be used: • Torque Converter Tool Kit (CCI P/N 1014510) (Figure 17-1, Page 17-2) • Scribe or small pick (not included in torque converter tool kit) 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 17-1...
  • Page 272 PULLER PLUG (CCI P/N 1014507) DRIVE CLUTCH HOLDER TOOL (CCI P/N 1015524) DRIVE CLUTCH PULLER (CCI P/N 1014496) CAM INSTALLATION TOOL (CCI P/N 101808401) Figure 17-1 Torque Converter Tool Kit Page 17-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 273: Drive Belt

    2. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in General Warning, Section 1, Page 1-2. 3. Disconnect the spark plug. See WARNING "To avoid unintentionally starting..." in General Warning, Section 1, Page 1-2. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 17-3...

  • Page 274: Drive Belt Installation

    8. Use a 1/2-inch socket to tighten the clutch puller tool. The drive clutch will release free of the crankshaft (Figure 17-4, Page 17-5). 9. Support the drive clutch assembly in your hand and back the clutch puller tool out of the crankshaft. Page 17-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 275: Drive Clutch Cleaning And Inspection

    2. Inspect the belt contact surfaces of the clutch sheaves for wear. If any area of a sheave contact surface has wear of 0.060-inch (1.52-mm) or more, the clutch should be replaced. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 17-5...

  • Page 276: Drive Clutch Disassembly

    5.3. Remove the plastic washers, weights and wave washer from the pins. Before removing, note the orientations of the wave washer and of the primary and secondary weights to one another (Figure 17-12, Page 17-10 and Figure 17-13, Page 17-10). Retain all parts. Page 17-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 277: Inspection Of Drive Clutch Parts

    3. Inspect the steel shaft (7) on the fixed face assembly. There should be no noticeable wear anywhere on the shaft. Replace the shaft if it is worn, scratched, or damaged. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 17-7...
  • Page 278 TORQUE CONVERTER Drive Clutch Inspection of Drive Clutch Parts, Continued: TYPICAL 3 PLACES Figure 17-7 Drive Clutch Assembly Page 17-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...

  • Page 279: Drive Clutch Assembly

    4. Install the spacer (13) onto the shaft of the fixed face. 5. Install a new spiral backup ring (12) in each end of the bore of the moveable face assembly (14). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 17-9...
  • Page 280 6.1. Rotate the moveable face assembly clockwise while installing it onto the shaft. 6.2. Install the retaining ring (3) (Figure 17-7, Page 17-8). 7. Install the primary weights on the mounting pins (Figure 17-12, Page 17-10). Page 17-10 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 281 17. Install the hub assembly (1) on the moveable face assembly and align the match marks made before dis- assembling the clutch. Press the hub assembly on by hand. 18. Replace the plastic ring (22) hole protector. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 17-11...

  • Page 282: Drive Clutch Installation

    6. Connect the battery cables, positive (+) cable first, and tighten terminals to 20 ft-lb (27 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 7. Place the Forward/Reverse handle in the NEUTRAL position. 8. Drive the vehicle and check for proper operation. Page 17-12 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 283 (35.15-mm), the entire moveable face assembly must be replaced. 5. Inspect the shaft of the fixed face assembly. There should be no noticeable wear. Replace the shaft if it is worn, scratched or damaged. 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 17-13...
  • Page 284 TORQUE CONVERTER Driven Clutch TYPICAL 3 PLACES Figure 17-16 Driven Clutch Assembly Page 17-14 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 285 The retaining ring can be reused if the O.D. does not exceed 1.607-inches (40.82-mm). Otherwise it must be replaced with a new ring (CCI P/N 1014080). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 17-15...
  • Page 286 NOTE: The cam has an interference fit with the keyed shaft and should remain in position when the cam installation tool is removed, providing for the assembly of the retaining ring. Page 17-16 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 287 3. Connect the spark plug. 4. Connect the battery cables, positive (+) cable first, and tighten terminals to 20 ft-lb (27 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 17-17...
  • Page 289 ............. 6-1 see drive belt installation ............. 5-1 body, front removal ............5-1 components ............4-2 shoe, front installation ............4-4 installation ........... 6-12 removal ............. 4-2 removal ............6-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page i-1...
  • Page 290 ......11-14 DANGER starter circuit ............11-8 definition of ............1-1 engine dashboard general information ..........13-1 installation ............4-2 identification ............3-1 removal .............. 4-2 ignition circuit ...........11-9 Page i-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 291 ........ 14-19 brake line and hose ........... 6-2 disassembly ..........14-19 brake pedal ............6-1 installation ............. 14-20 brake system ............. 6-1 removal ............14-19 differential lock ..........16-26 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page i-3...
  • Page 292 ...........6-35 troubleshooting ..........11-18 removal ............6-35 lockout cam circuit inspection ............6-2 function ............11-11 pulley low oil warning circuit installation ...........6-34 function ............11-10 troubleshooting ..........11-17 removal ............6-33 Page i-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 293 ............7-5 shock absorber steering column assembly ............7-4 see suspension, front and suspension, rear snubber disassembly ............7-3 installation ............9-4 installation ............7-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page i-5...
  • Page 294 ........... 11-40 voltage regulator kill wire, engine ..........11-40 installation ............12-11 lockout cam removal ............12-11 cam ............11-42 limit switch ..........11-27 testing ............11-31 Page i-6 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 295 INDEX WARNING definition of ............1-1 wheel see tire wheel cylinder see brakes, wheel cylinder wire continuity testing ........11-29 wiring diagram ........... 11-5 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page i-7...
  • Page 297 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual...
  • Page 300 Club Car, Inc. www.clubcar.com Phone 1.706.863.3000 P.O. Box 204658 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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