Club Car Pioneer 1200 Maintenance Service Manual
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Club Car Pioneer 1200 Maintenance Service Manual

Club Car Pioneer 1200 Maintenance Service Manual

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1200
2001 MAINTENANCE & SERVICE MANUAL
Manual No. 10 219 0 01 2
Edition Code 1000A00000

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Summary of Contents for Club Car Pioneer 1200

  • Page 1 1200 2001 MAINTENANCE & SERVICE MANUAL Manual No. 10 219 0 01 2 Edition Code 1000A00000...
  • Page 3 If the technician does not have such knowledge and skills, attempted service or repairs to the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be performed by an authorized Club Car distributor/dealer representative or by a Club Car factory- trained technician.
  • Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is con- tinually working to further improve our vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    Dashboard Removal ........................Dashboard Installation ........................Front Body Removal ........................Front Fender Removal ........................Front Fender Installation ........................ Front Body Installation ........................Seat ..............................Seat Removal ..........................Seat Installation ..........................2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page iii...
  • Page 6 General Information ........................... Brake System Inspection ........................Brake System Troubleshooting ......................Brake Drum Removal ......................... Front Wheel Brake Drum Removal ....................Rear Wheel Brake Drum Removal ....................Brake Shoe Removal ......................... Page iv 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 7 Park Brake Cable Removal ......................6-31 Park Brake Cable Installation ......................6-33 Park Brake Handle Removal ......................6-33 Park Brake Handle Installation ...................... 6-34 Park Brake Adjustment ........................6-34 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page v...
  • Page 8 7-20 SECTION 8 – WHEELS AND TIRES General Information ........................... Wheels ............................... Wheel Removal ..........................Wheel Installation ........................... Tires ..............................Tire Removal ..........................Tire Repair ............................. Tire Installation ..........................Page vi 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 9 Reverse Buzzer Circuit ........................11-11 Low Oil Warning Circuit ......................... 11-12 Lockout Cam Circuit ........................11-12 Fuel Gauge and Sending Unit Circuit .................... 11-13 Hour Gauge Circuit ........................11-14 Lighting Circuit ..........................11-14 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page vii...
  • Page 10 RPM Limiter ............................12-24 Ignition Coil ............................12-25 Oil Level Sensor ..........................12-28 Headlights ............................12-29 Headlight Diode ..........................12-30 Light Switch ............................12-30 Battery ..............................12-31 Ground Straps ............................ 12-36 Page viii 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 11 Camshaft and Hydraulic Lifters ...................... 13-25 Piston and Connecting Rod ....................... 13-27 Cylinder Block ............................ 13-30 Ignition Coil and Flywheel ........................13-31 Oil Pump ............................13-32 Oil Pressure Relief Valve ....................... 13-34 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page ix...
  • Page 12 Air Box Removal ..........................14-15 Air Box Installation ......................... 14-15 Intake Duct Removal ........................14-15 Intake Duct Installation ........................14-16 Intake Duct Repair ......................... 14-18 Air Filter ............................14-18 Page x 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 13 Axle Shaft ............................16-3 Axle Shaft and Oil Seal Removal ....................16-4 Axle Bearing ..........................16-5 Axle Shaft Installation ........................16-7 Unitized Transaxle Removal ......................16-7 Unitized Transaxle Disassembly ......................16-15 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page xi...
  • Page 14 Drive Clutch Cleaning and Inspection .................... 17-5 Drive Clutch Disassembly ......................17-7 Inspection of Drive Clutch Parts ..................... 17-9 Drive Clutch Assembly ........................17-9 Drive Clutch Installation ......................... 17-13 Page xii 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 15 Driven Clutch ............................. 17-13 Driven Clutch Removal ........................17-13 Driven Clutch Disassembly ......................17-13 Driven Clutch Inspection ........................ 17-14 Driven Clutch Assembly ......................... 17-14 Driven Clutch Installation ....................... 17-15 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page xiii...

  • Page 17: Section 1 - Safety

    SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is impor- tant to note that throughout this manual there are statements labeled DANGER , WARNING , or CAUTION .
  • Page 18 AS SEEN FROM PASSENGER'S SIDE OF VEHICLE REMOVE NEGATIVE DISCONNECT BATTERY CABLES CABLE FIRST BEFORE WORKING ON VEHICLE Figure 1-1 Battery Page 1-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 19: Section 2 - Vehicle Specifications

    SECTION 2 – VEHICLE SPECIFICATIONS GENERAL INFORMATION Club Car, Inc. reserves the right to change specifications and design of the vehicle at any time without notice and without obligation to make these changes on units previously sold. SPECIFICATIONS POWER SOURCE Engine: 4 cycle, OHV, 351 cc, 11 hp rated, single cylinder, air cooled, with pressure lubrication system •...
  • Page 20 Rear: 14-18 psi (97-124 kPa) Front: 12-16 psi (83-110 kPa) Turf Tread Rear: 16-20 psi (110-138 kPa) Front: 14-16 psi (97-110 kPa) Traks Max II Tread Rear: 18-20 psi (124-138 kPa) Page 2-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 21: Section 3 - General Information

    • Warranties SERIAL NUMBER IDENTIFICATION The serial number of each Club Car vehicle is printed on a bar code decal mounted on the frame directly above the accelerator pedal (Example: AD0012-583947) (Figure 3-1, Page 3-1). There is also a second serial number decal mounted on the front body frame behind the dash panel.

  • Page 22: Returning The Stored Vehicle To Service

    9. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling. RETURNING THE STORED VEHICLE TO SERVICE 1. Connect the battery cables, positive cable (+) first. 2. Restore fuel system to operation. Page 3-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 23 SIDE OF VALVE Figure 3-2 Closed Fuel Shut-off Valve Figure 3-3 Open Fuel Shut-off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 3-4 Incorrect Fuel Shut-off Valve 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 3-3...

  • Page 25: Section 4 - Body And Trim

    fine grade (No. 00) steel wool. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.

  • Page 26: Front Body Repair

    1. Remove the four truss head screws (14) and nuts (15) that secure the brush guard to the vehicle frame (Figure 4-1, Page 4-4). BRUSH GUARD INSTALLATION 1. Installation is the reverse of removal. Tighten the four nuts (15) to 15 ft-lb (20.3 N·m) (Figure 4-1, Page 4-4). Page 4-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 27: Front Body Components

    3. Using a phillips head screwdriver, remove the six Tuflok fasteners (7) from sides and two from front of front body. 4. Disconnect light wiring harness from headlight assemblies. 5. Pull front body forward to clear dashboard and lift off vehicle (Figure 4-1, Page 4-4). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 4-3...
  • Page 28 5 PLACES TYPICAL 6 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES FENDER SUPPORT TYPICAL 5 PLACES TYPICAL 4 PLACES Figure 4-1 Front Body Assembly Page 4-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 29: Front Fender Removal

    • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat from the vehicle first. SEAT REMOVAL 1. Pull seat forward and lift up to remove from seat support (1). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 4-5...

  • Page 30: Seat Installation

    2. Reconnect differential lock cable end to the differential lock handle. See step 33 of Unitized Transaxle Installation, Section 16, Page 16-44. 3. Reinstall park brake cable. See Equalizer Cable Installation, Section 6, Page 6-33. Page 4-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 31: Armrest Removal

    1. Perform steps 1, 4 and 5 of Seat Support Removal on page 4-6. See also following WARNING. ∆ WARNING • Both armrests must be installed before operating the vehicle, unless the vehicle is fitted with a structural cab. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 4-7...

  • Page 32: Armrest Installation

    3. Adjust the two rear bumpers (18) by tightening or loosening the nut (19) until a 3/16 inch gap between the bottom of the bumper head and the frame weldment is achieved. These bumpers are not to be tight- ened completely down; they are designed to “float”. Page 4-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 33 BODY AND TRIM Tilt Bed TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 4-3 Tilt Bed 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 4-9...

  • Page 34: Rear Fender

    3. Where the hitch (14) is mounted to hitch brace (20), remove the nut (24), lock washer (23), washer (22) and bolt (21). 4. Remove hitch (14) from vehicle. Page 4-10 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 35 BODY AND TRIM Receiver Hitch TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 4-4 Rear Fender, Tailskirt, and Receiver Hitch 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 4-11...

  • Page 36: Receiver Hitch Installation

    FLOOR MAT INSTALLATION 1. Install the floor mat in the reverse order of removal. 2. Install the brake and accelerator pedals. See Section 5 – Accelerator and Brake Pedal Assemblies. Page 4-12 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 37: Section 5 - Accelerator And Brake Pedal Assemblies

    2. Remove the rod retaining bolt (8) and remove the clevis (16) from the bell crank assembly (11) (Figure 5-1, Page 5-2). 3. Loosen the brake stop jam nut (31) (Figure 5-2, Page 5-3). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 5-1...
  • Page 38 5. While holding the brake pedal in this position, measure the distance from the back of the brake pedal to the floorboard (Figure 5-3, Page 5-3). If the measured distance is between 6-3/8 inches (16.2 cm) and 6-7/8 inches (17.5 cm), proceed to step 9. Page 5-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 39: Accelerator Pedal Adjustment

    3. If using an accelerator pedal adjustment tool to make adjustment: 3.1. Clamp the accelerator pedal adjustment tool (CCI 101871001) to the accelerator pedal, with the end marked accelerator pedal height closest to the floorboard. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 5-3...
  • Page 40 • To prevent accidentally starting the vehicle, disconnect the battery as instructed in WARNING on page 5-1. This will prevent the possibility of the vehicle running over you when you are adjusting the accelerator rod. Page 5-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 41 • When loosening jam nuts on the accelerator rod with one end disconnected, hold the disconnected accelerator rod with locking pliers. • When tightening jam nuts on the accelerator rod, hold the disconnected ball joint with locking pliers. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 5-5...
  • Page 42 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal Adjustment FLOORBOARD REMOVED FOR CLARITY Figure 5-9 Accelerator Pedal Assembly Page 5-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 43: Brake Pedal

    floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position. Use approved jack stands of proper weight capacity to support the vehicle. 3. Remove the brake pedal assembly. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 5-7...

  • Page 44: Brake Pedal Installation

    (but do not remove) the four bolts (22) and lock nuts (15) to make installation of the pivot rod easier (Figure 5-9, Page 5-6). 11. Remove nylon spacer (20) (Figure 5-9, Page 5-6). Page 5-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 45: Accelerator Pedal Installation

    8. Install the accelerator rod assembly (17, 18 and 19) (Figure 5-9, Page 5-6). 9. Adjust the accelerator pedal and accelerator rod. See Accelerator Pedal Adjustment on page 5-3. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 5-9...

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

    GENERAL INFORMATION The Pioneer 1200 vehicle is equipped with two types of shoe drum braking systems: a hydraulic, four-wheel braking system for normal stopping, and a hand-activated mechanical rear-wheel park brake system for retaining the vehicle when it is stationary.

  • Page 48: Brake System Inspection

    • Apply and release the brake pedal several times. If noise or binding occurs, the brake pedal or hydrau- lic brake system may be in need of service. Pedal movement should be smooth, and when the pedal is released, it should return quickly and quietly. Page 6-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 49 • Check the park brake cables, equalizer and linkage. The cables should not be corroded, frayed or dam- aged and should move freely within the cable sheathing. The cables should not come in contact with either of the rear wheels or tires. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-3...

  • Page 50: Brake System Troubleshooting

    Weak (bulging) brake hose Line and Hose Replacement on page 6- Improperly adjusted master cylinder push See Brake Pedal Adjustment on page 5-1. Troubleshooting Guide continued on next page... Page 6-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 51 Tighten or replace the backing plate and/ plate or hardware. Replace the brake drums. See Brake Scored or warped brake drums Drum Removal on page 6-7. Troubleshooting Guide continued on next page... 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-5...
  • Page 52 Cylinder Replacement on page 6-19. Adjust or replace front wheel bearings. Loose or worn front wheel bearings See Section 7 – Steering and Front Suspension. Troubleshooting Guide continued on next page... Page 6-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 53: Brake Drum Removal

    floor jack or chain hoist so that the vehicle is resting on the jack stands. 2. Remove the lug nuts and remove the front wheel. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-7...

  • Page 54: Rear Wheel Brake Drum Removal

    (Figure 6-3, Page 6-8). 4. Removing tight brake drums: 4.1. On the back of each brake cluster assembly, locate the heads of the two brake shoe adjusters. Page 6-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 55: Brake Shoe Removal

    NOTE: The brake shoes are under spring pressure and can release suddenly when cup and spring assem- blies are removed. 4. Grasp both brake shoes and pull them, with the springs, out of brake cluster assembly (Figure 6-6, Page 6-10). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-9...

  • Page 56: Brake Cluster Assembly Inspection And Cleaning

    Use only DOT 5 brake fluid. See Bleeding the Hydraulic Brake System on page 6-29. NOTE: Factory installed brake shoes on the Pioneer 1200 have non-asbestos linings. When replacing brake shoes, Club Car recommends non-asbestos replacement parts.
  • Page 57 7. Use a small brush to carefully apply a liberal amount of white lithium NLGI Number 2 grease (Dow Corn- ing BR2-Plus or equivalent) on each of the six raised bosses on the brake cluster backing plate (Figure 6-8, Page 6-11). See preceding WARNING. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-11...

  • Page 58: Brake Shoe Installation

    DOT 5 brake fluid. See Bleeding the Hydraulic Brake System on page 6-29. NOTE: Unlike some other brake systems, the Pioneer 1200 vehicle uses a pair of identical brake shoes in each brake cluster. While a brake shoe may be installed on either the left-hand or right-hand side of the brake cluster assembly, the shoe must be positioned so that the adjuster pin is inserted into the slot of the brake shoe as illustrated (Figure 6-1, Page 6-2 or Figure 6-18, Page 6-20).
  • Page 59 • Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-13...

  • Page 60: Brake Drum Installation

    Rotation of the brake shoe adjusters may be necessary to create additional clearance between the brake shoes and the brake drum (Figure 6-3, Page 6-8). Use a hydraulic brake adjuster (CCI 102169401) to gently rotate the adjusters. 11. Fill cavity with grease. Page 6-14 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 61 See Brake System Inspection on page 6-2. 24. Check the front wheel free play. See Front Wheel Free Play Inspection, Section 7, Page 7-20. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-15...

  • Page 62: Rear Wheel Brake Drum Installation

    7. 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 6-2. Page 6-16 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 63: Brake Cluster Replacement

    3. Perform the procedure for front brake drum/hub installation. See Front Wheel Brake Drum Installation on page 6-14. 4. Bleed the front wheel brakes as instructed. See Bleeding the Hydraulic Brake System on page 6-29. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-17...

  • Page 64: Rear Brake Cluster Removal

    (Figure 6-17, Page 6-18).. CABLE SUPPORT BRACKET Figure 6-15 Park Brake Cable Figure 6-16 Rear Brake Hose WIRE TIE PLASTIC FLEX BRAKE HOSE Figure 6-17 Rear Brake Hose With Plastic Bag Page 6-18 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 65: Rear Brake Cluster Installation

    Use only DOT 5 brake fluid. See Bleeding the Hydraulic Brake System on page 6-29. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-19...

  • Page 66: Wheel Cylinder Removal

    REF BRAKE HOSE, PAGE 5.8 BLEEDER VALVE TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 6-18 Rear Hydraulic Brake Cluster Assembly Page 6-20 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 67: Wheel Cylinder Installation

    Figure 6-19 Remove Axle Retaining Ring 2.2. Carefully pull the axle shaft straight out of the axle tube. 2.3. Repeat steps 2.1 and 2.2 for the opposite rear wheel if necessary. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-21...

  • Page 68: Brake Shoe Adjuster Installation

    7. 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 6-2. Page 6-22 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 69 HYDRAULIC AND PARK BRAKE SYSTEMS Brake Shoe Adjuster Replacement TYPICAL BOTH SIDES TYPICAL 2 PLACES REFERENCE FRONT BRAKE ASSEMBLY TYPICAL BOTH SIDES REFERENCE REAR BRAKE ASSEMBLY Figure 6-20 Four-Wheel Hydraulic Brake System 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-23...

  • Page 70: Hydraulic Line And Hose Replacement

    floor jack. Place jack stands under the front frame tube to support the vehicle and lower the floor jack or chain hoist so that the vehicle is resting on the jack stands. Page 6-24 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 71: Front Cluster Hose Installation

    (Figure 6-20, Page 6-23). Tighten to 11 ft-lb (14.9 N·m). 4. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Filling the Hydraulic Sys- tem on page 6-31. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-25...

  • Page 72: Rear Brake Cluster Hose Removal

    4. Remove the bolt (20) and lock nut (21) from the bell crank (13) (Figure 6-21, Page 6-27). 5. Remove the bolt (9) and nylon lock nut (11) from the master cylinder mounting bracket (19) (Figure 6- 21, Page 6-27). Page 6-26 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 73 (Figure 6-21, Page 6-27). NOTE: The needle bearing (14) is press fitted to the bell crank. If replacement is necessary, the bearing must be pressed out and replaced (Figure 6-21, Page 6-27). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-27...

  • Page 74: Bell Crank Installation

    7. Perform all of the brake system inspections to ensure that both the hydraulic brake system and the park brake system are in correct adjustment and are operating correctly before placing the vehicle into ser- vice. See Brake System Inspection on page 6-2. Page 6-28 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 75: Bleeding The Hydraulic Brake System

    first bleed the two front brakes and repeat the procedure to bleed the two rear brakes. 1. Check the brake pedal and master cylinder push rod for proper adjustment before proceeding. See Brake Pedal Adjustment, Section 5, Page 5-1. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-29...

  • Page 76: Purging The Hydraulic System

    1. Perform steps 6 through 10 of the brake bleeding procedure on the two front wheels. See Bleeding the Hydraulic Brake System on page 6-29. 2. Allow 1 quart (0.95 liters) of the brake fluid to be pulled into the vacuum type brake bleeder tool. Page 6-30 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 77: Filling The Hydraulic System

    7. Remove the end of the park brake cable from handle (1) by pushing the equalizer cable in an upward direction and pulling the cable end toward the passenger side of the vehicle. 8. Remove the equalizer cable from the vehicle. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-31...
  • Page 78 EACH PULLEY 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL EACH SIDE OF VEHICLE TYPICAL EACH SIDE OF VEHICLE TYPICAL EACH SIDE OF VEHICLE Figure 6-24 Park Brake Assembly Page 6-32 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 79: Park Brake Cable Installation

    2. Remove the two bolts (4), four washers (5) and two lock nuts (6) from the park brake handle (Figure 6- 24, Page 6-32). 3. Remove the park brake handle (1) from the seat support. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-33...

  • Page 80: Park Brake Handle Installation

    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 6-2. Page 6-34 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 81: Section 7 - Steering And Front Suspension

    STEERING WHEEL REMOVAL 1. Disconnect battery and spark plug as instructed. See WARNING on page 7-1. 2. Remove the two mounting screws (24) and plate (19) (Figure 7-1, Page 7-2). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-1...
  • Page 82 STEERING AND FRONT SUSPENSION Steering Wheel TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-1 Steering Column Page 7-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 83: Steering Wheel Installation

    2. Install the steering wheel nut (18) and tighten to 13 ft-lb (17.6 N·m) (Figure 7-1, Page 7-2). 3. Install the steering wheel plate (19) and plate mounting screws (24) (Figure 7-1, Page 7-2). Tighten screws to 16 in-lb (1.8 N·m). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-3...

  • Page 84: Steering Column

    NOTE: Do not allow the steering shaft to slide out of the steering tube when removing the snap ring. 2. Remove the washer (6), spring (7), and wedge (8) (Figure 7-1, Page 7-2). Page 7-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 85: Steering Column Assembly

    3. Install the wedge (8), spring (7), washer (6) and snap ring (5) onto the bottom end of the steering shaft (11) (Figure 7-5, Page 7-5). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-5...

  • Page 86: Steering Column Installation

    floor jack or chain hoist so that the vehicle is resting on the jack stands. 2. Remove the lug nuts from the front wheels. 3. Remove the cotter pins (18) and ball joint retaining nuts (24) (Figure 7-20, Page 7-11). Page 7-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 87 6. Remove the bolt (27) and lock washer (Figure 7-1, Page 7-2) from the universal joint, then remove the rack assembly and universal joint from the vehicle (Figure 7-8, Page 7-7). Figure 7-8 Remove Rack and Pinion 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-7...

  • Page 88: Rack And Pinion Disassembly

    6. Remove the universal joint assembly from the pinion (3) by fully removing the bolt and then sliding off the universal joint (Figure 7-20, Page 7-11). 7. Remove the dust seal (Figure 7-14, Page 7-9). 8. Using snap ring pliers, remove the snap ring (Figure 7-15, Page 7-9). Page 7-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 89 13.3. Using a wrench, remove the ball joint (9) from the rack (2) (Figure 7-20, Page 7-11). 14. Remove the rack (2) from housing (1) (Figure 7-20, Page 7-11). Figure 7-14 Remove Dust Seal Figure 7-15 Pinion Snap Rings 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-9...

  • Page 90: 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. Page 7-10 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 91 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 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-11...
  • Page 92 12. If measured resistance is not 7 to 15 in-lb (.8 to 1.7 N·m), adjust the screw (7) until correct setting is achieved. Tighten the nut (8) to 28 ft-lb (38 N·m) (Figure 7-22, Page 7-12). See following NOTE. Page 7-12 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 93: Rack And Pinion Installation

    See Periodic Lubrication Schedule, Section 10, Page 10-4. ∆ CAUTION • To ensure proper lubrication of the front suspension, raise front of vehicle to lubricate. See WARNING on page 7-1. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-13...

  • Page 94: Wheel Alignment

    Proper toe-in is 11/16 inch ± 3/8 of an inch (18 mm ± 10 mm). Both drag links should be adjusted to an equal distance. Figure 7-27 Adjust Toe-in Page 7-14 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 95 2 PLACES TYPICAL 4 PLACES TYPICAL TYPICAL 2 PLACES 4 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-28 Pioneer 1200 Vehicle Front Suspension 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-15...

  • Page 96: Front Suspension Components

    4. Rest the brake cluster on the A-arm as shown (Figure 7-29, Page 7-16). Ensure that there is no strain on the brake hose.See following WARNING. Figure 7-29 Rest Brake Cluster on A-arm Page 7-16 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 97: Kingpin And Steering Spindle Installation

    5. Remove the wave washer (35) and inspect it. If the washer is broken or has a wave bottom to wave crest height dimension of less than .040 inch (0.10 cm), it must be replaced (Figure 7-28, Page 7-15). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-17...

  • Page 98: A-Arm Installation

    3. Remove the bolt (2) and nut (9) attaching the shock absorber to the A-arm (Figure 7-30, Page 7-19). 4. Remove the steering stop weldment (38) and brake hose support bracket from the A-arm (Figure 7-30, Page 7-19). Page 7-18 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 99: Shock Absorber Installation

    Figure 7-30 Shock Absorber Removal Figure 7-31 Front Wheel Bearings and Hub 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-19...

  • Page 100: Front Wheel Bearings And Hubs

    FRONT WHEEL BEARINGS AND HUB REMOVAL See Front Wheel Brake Drum Removal, Section 6, Page 6-7. FRONT WHEEL BEARINGS AND HUB INSTALLATION See Front Wheel Brake Drum Installation, Section 6, Page 6-14. Page 7-20 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 101: Section 8 - Wheels And Tires

    Front: 14-16 psi (97-110 kPa) Traks Max II Tread Rear: 18-20 psi (124-138 kPa) • Keep lug nuts properly tightened. • Keep the front end properly aligned and adjusted. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 8-1...

  • Page 102: Wheels

    4. Check the park brake cables. The cables should not come in contact with either of the rear wheels or tires. Page 8-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 103: Tires

    2. Adjust air pressure in the tire to the recommended pressure and immerse the wheel and tire assembly in water to make sure there are no leaks. 3. Install the wheel. See Wheel Installation on page 8-2. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 8-3...

  • Page 105: Section 9 - Rear Suspension

    GENERAL INFORMATION The rear suspension and powertrain of the Pioneer 1200 vehicle move independently from the vehicle frame. The suspension includes two multi-leaf springs controlled by two hydraulic shock absorbers mounted between the spring mounting plate and the frame.
  • Page 106 REAR SUSPENSION Shock Absorbers TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE AXLE SADDLE Figure 9-1 Rear Suspension Page 9-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 107: Shock Absorber Installation

    Read WARNING on page 9-1. MULTI-LEAF SPRING REMOVAL 1. Remove shock absorbers. See Shock Absorber Removal and Inspection on page 9-1. 2. Loosen the lug nuts on wheel(s) to be removed. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 9-3...

  • Page 108: Multi-Leaf Spring Installation

    Install locknut (22) and tighten to 15 ft-lb (20.3 N·m) (Figure 9-1, Page 9-2). ∆ CAUTION • Use only grade eight bolts for the front mounts of the leaf springs. Page 9-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 109: 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 9-5, Page 9-5). SNUBBER MOUNTING BRACKET SNUBBER BRACKET Figure 9-5 Snubber Brackets 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 9-5...

  • Page 111: Section 10 - Periodic Maintenance

    - Disconnect battery cables, negative cable (–) first (Figure 10-1, Page 10-2). - Disconnect the spark plug wire from the spark plug. - Turn fuel shut-off valve to closed (OFF) (Figure 10-5, Page 10-7). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 10-1...

  • Page 112: General Information

    Owner’s Manual as a guide to check the following items. • Vehicle warning decals • Brake system • Park brake • Reverse warning buzzer • Steering and linkages • Proper acceleration and maximum speed Page 10-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 113: Periodic Service Schedule

    Front wheel alignment and toe-in See Section 7 – Steering and Front Suspension. Electrical wiring and connections Check for tightness and damage. Periodic Service Schedule continued on next page... 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 10-3...

  • Page 114: Periodic Lubrication Schedule

    RECOMMENDED LUBRICANT PLACE Semiannually by owner or trained technician Brake pedal shaft bearings Dry Moly Lube (CCI 1012151) (every 50 hours of operation) Periodic Lubrication Schedule continued on next page... Page 10-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 115 Change engine oil and oil filter liters) with filter operation or annually, See Oil Viscosity on page 10-7. whichever comes first *(Figure 10-2, Page 10-5). FLOORBOARD Figure 10-2 Lubrication Points 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 10-5...

  • Page 116: Master Cylinder

    The vehicle should be on a level surface when checking oil. Do not overfill with oil. ∆ CAUTION • Do not remove dipstick while engine is running. Page 10-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 117: Oil Viscosity

    • If the vehicle has an all-weather enclosure installed, the gas tank must be properly vented as shown (Figure 10-5, Page 10-7). • To avoid the possibility of fire, clean up any spilled gasoline before operating the vehicle. 1. Remove the passenger seat. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 10-7...

  • Page 118: Battery

    4. Replace passenger seat. See following WARNING. ∆ WARNING • Make sure seat hinges and latch are securely engaged before operating vehicle. BATTERY For periodic battery maintenance, see Battery, Section 12, Page 12-31. Page 10-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 119: Section 11 - Troubleshooting And Electrical System

    (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position. Use approved jack stands of proper weight capacity to support the vehicle. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-1...

  • Page 120: General Information

    Section 14 – Fuel System Fouled spark plug Section 13 – FE350 Engine Spark plug wire damaged or loose Section 13 – FE350 Engine Troubleshooting Guide continued on next page... Page 11-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 121 Unsuitable fuel, or incorrect (rich) fuel Section 14 – Fuel System mixture Section 11 – Troubleshooting and Electrical Ignition coil failed System Test Procedures 14, 15, and 16 Troubleshooting Guide continued on next page... 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-3...
  • Page 122 Generator field coil is shorted System Test Procedure 11 Section 12 – Electrical Components Brushes are worn or commutator is dirty Starter/Generator on page 12-2 Troubleshooting Guide continued on next page... Page 11-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 123 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 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-5...

  • Page 124: Wiring Diagram

    TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagram WIRING DIAGRAM PASSENGER SIDE HEADLIGHT DRIVER SIDE HEADLIGHT SONIC WELD SONIC WELD LIGHT SWITCH Figure 11-1 Wiring Diagram for Pioneer 1200 (Front) Page 11-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 125 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagram SONIC WELD SONIC WELD SONIC WELD Wiring Diagram for Pioneer 1200 (Rear) 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-7...

  • Page 126: Electrical System

    For a complete wiring diagram, see page 11-6. AS SEEN FROM PASSENGER SIDE OF VEHICLE REMOVE NEGATIVE CABLE FIRST DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE Figure 11-2 Battery Disconnect Page 11-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 127: 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. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-9...

  • Page 128: 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 11-12. Page 11-10 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 129: Reverse Buzzer Circuit

    Forward/Reverse shifter. When the Forward/Reverse handle is placed in REVERSE, a cam depresses the reverse limit switch, closing the circuit. The reverse buzzer sounds. Figure 11-7 Reverse Buzzer Circuit for Pioneer 1200 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-11...

  • Page 130: Low Oil Warning Circuit

    LOCKOUT CAM CIRCUIT The Pioneer 1200 is equipped with a lockout cam that allows the engine to be started only when the For- ward/Reverse handle is in the NEUTRAL position. The lockout cam (yellow) is located on the back of the For- ward/Reverse handle, inside the engine compartment.

  • Page 131: Fuel Gauge And Sending Unit Circuit

    ON position. The power goes through the gauge to the sending unit at the fuel tank. The send- ing unit tells the gauge how much fuel is in the tank (Figure 11-11, Page 11-13). Figure 11-11 Fuel Gauge and Sending Unit Circuit 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-13...

  • Page 132: Hour Gauge Circuit

    A hydrometer, multimeter, and 160 ampere load tester will be required. See Test Procedure 1 – Battery on page 11-21. Page 11-14 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 133: 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 11-15 Testing the Generator Circuit 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-15...

  • Page 134: 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 11-17 Testing the Engine Kill Circuit Page 11-16 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 135: 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 11-18 Testing the Reverse Buzzer Circuit 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-17...

  • Page 136: 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 11-19 Testing the Low Oil Warning Circuit Page 11-18 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 137: 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 11-20 Testing the Fuel Gauge and Sending Unit Circuit 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-19...

  • Page 138: 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) Page 11-20 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 139 - Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable oil. Call a physician immediately. - Eyes: Flush with water for 15 minutes. Call a physician immediately. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-21...
  • Page 140 5. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the bottom of the rubber bulb. Remove the hydrometer from the cell and release the pressure from the bulb. Page 11-22 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 141 Load Test 1. Using a 160 ampere load tester, connect the load tester to the battery posts. 2. Turn the switch on the load tester to the ON position. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-23...
  • Page 142 Read DANGER and WARNING on page 11-1. 1. Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels and disconnect the bat- tery cables, negative cable (–) first. 2. Check the starter/generator ground strap. Page 11-24 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 143 The reading should be continuity. If the reading is incorrect, check that terminal connections are clean and tight. If the connections are good and the reading is incorrect, repair or replace the wire. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-25...
  • Page 144 2. Remove the center dash assembly. See Key Switch Removal, Section 12, Page 12-15. 3. Ensure that the connector is connected correctly and is tight. If it is not, repair or replace as necessary. Page 11-26 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 145 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 11-31, Page 11-28). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-27...
  • Page 146 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. Page 11-28 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 147 The starter/ generator will need to be removed from the vehicle and disassembled by a qualified technician. See Starter/Generator Removal, Section 12, Page 12-2. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-29...
  • Page 148 1. Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and disconnect the battery cables, negative cable (–) first. 2. Disconnect the two wires from the diode assembly, which is located on the I-beam close to the battery. Page 11-30 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 149 1. Place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. 2. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as neces- sary. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-31...
  • Page 150 3. With the wheels chocked, connect the 6 gauge red wire to the positive post on the battery, then connect the 6 gauge black wire to the negative post. Page 11-32 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 151 1. Place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. ® 2. Remove the plug wire from the spark plug. Using an ignition spark gap test tool (Thexton 404 equivalent), check for correct spark (Figure 11-38, Page 11-34). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-33...
  • Page 152 Another method of testing is to replace the RPM Limiter and then run the engine. If the engine runs properly, keep the new RPM Limiter in the circuit. Page 11-34 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 153 Another method of testing is to replace the coil and then run the engine. If the engine runs properly, keep the new coil in the circuit. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-35...
  • Page 154 If it is not, repair or replace as necessary. WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Reading with key switch in the OFF position Figure 11-43 Test Key Switch – Engine Kill Circuit Page 11-36 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 155 3. Check for proper wiring and tight connections. Using a multimeter, individually check for continuity through each wire that connects to the reverse buzzer (Figure 11-7, Page 11-11). If the buzzer will not function when properly wired, replace the buzzer. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-37...
  • Page 156 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. Page 11-38 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 157 240 ± 20 Ω (ohms) Empty Lower Position (Tank Empty) 120 ± 20 Ω (ohms) Half Full Center Position (Tank Half Full) 60 ± 20 Ω (ohms) Full Upper Position (Tank Full) 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-39...
  • Page 158 8. Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded earlier. If not, check the continuity of the blue and black wires (Figure 11-45, Page 11-41). Page 11-40 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 159 3. Using a multimeter set on 20 volts DC, place alligator clips on the multimeter probes. Connect the red (+) probe to the light switch terminal with the blue wire connected to it (Figure 11-47, Page 11-42). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-41...
  • Page 160 Place black (–) probe on the connector (Figure 11-48, Page 11-43). See following CAUTION. Page 11-42 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 161 1. Place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. 2. Inspect wires at the light bulb socket. Make sure wires are securely fastened to the contacts inside socket. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 11-43...
  • Page 162 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 11-49 Check Voltage to Headlight Socket Page 11-44 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 163: Section 12 - Electrical Components

    • If wires are removed or replaced, make sure wiring is properly routed and secured to vehicle frame. Failure to properly route and secure wiring could result in vehicle malfunction, property damage or personal injury. WARNING CONTINUED ON NEXT PAGE... 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-1...

  • Page 164: Starter/Generator

    2. Disconnect the battery cables, negative cable (–) first (Figure 12-1, Page 12-2). 3. Disconnect the wires from the starter/generator (1). Mark wires before disconnecting. Loosen the pivot nuts (7) and bolts (5) (Figure 12-2, Page 12-3). Page 12-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 165 2. Check the wear line on the side of the brush. If the end of the brush is within 1/16 of an inch (1.6 mm) of the wear line, replace all four brushes (Figure 12-5, Page 12-4). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-3...
  • Page 166 1. Connect the brush wires to the holders using four lockwashers (26) and four screws (25), making sure the crossover leads are connected also. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12-4, Page 12-4). Page 12-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 167 (29) in the openings in the commutator end cover (23) (Figure 12-4, Page 12-4). BRUSH BEING HELD BY BRUSH SPRING Figure 12-7 Pull Brushes Away From Center of the Commutator End Cover 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-5...
  • Page 168 Bearings should be replaced if there is extensive wear or pitting on the balls or on the rolling surfaces. Do not remove the bearings unless they are to be replaced. Page 12-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 169 Remove the four pole piece screws from the housing. Remove the four pole pieces from inside the housing. Remove the field coils from the inside of the housing (Figure 12-11, Page 12-8). See following NOTE. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-7...
  • Page 170 Check for loose or raised commutator bars. Slight roughness of the commuta- tor can be polished away with 400 grit (or finer) sandpaper. See following CAUTION. Page 12-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 171 If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings. Be sure the insulators are tight in the housing. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-9...
  • Page 172 Install a flat washer, lockwasher 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 12-8). Page 12-10 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 173 Position the starter/generator in the mounting bracket so that the bolts will go through the starter/generator before going through the bracket. Install a locknut (7) onto each bolt. Tighten to finger tight (Figure 12-14, Page 12-12). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-11...
  • Page 174 4. Push the starter/generator down so it is at the lowest point of its adjustment travel. With the starter/gen- erator belt fully in place around the drive clutch pulley, install the starter/generator belt (3) around the pulley (10) on the end of the starter/generator. Page 12-12 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 175: Voltage Regulator

    4. Remove the voltage regulator mounting screw (8) and remove the voltage regulator (9). TO KILL LIMIT SWITCH TO BATTERY FRAME GROUND TO BULLET ELECTRICAL TO SOLENOID CONNECTOR COMPONENT BOX Figure 12-16 Voltage Regulator 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-13...

  • Page 176: Diode

    2. Disconnect wires from the diode (1) (Figure 12-17, Page 12-14). 3. Remove the mounting hardware (2) from the diode and remove it from the vehicle. Figure 12-17 Diode Page 12-14 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 177: Key Switch

    4. Remove the key switch: 4.1. Remove the key switch nut (1) (Figure 12-18, Page 12-15). 4.2. Remove key switch (2) from back side of dash panel. Figure 12-18 Key Switch Removal 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-15...
  • Page 178 2. Install the dash panel. 3. Connect battery cables, positive cable first and tighten the terminals to 20 ft-lb (27.1 N·m). Coat termi- nals with Battery Protector Spray (CCI 1014305). Page 12-16 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 179: Solenoid

    18 in-lb (2 N·m). 5. Connect battery cables, positive cable first and tighten the terminals to 20 ft-lb (27.1 N·m). Coat termi- nals with Battery Protector Spray (CCI 1014305). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-17...

  • Page 180: Fuse

    (Figure 12-20, Page 12-19). 3. Remove two nuts (2) and washers (6) from the lockout cam limit switch (5) and slide the lockout cam limit switch off of the screws. Page 12-18 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 181: Lockout Cam

    Read DANGER and WARNING on page 12-1. 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. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-19...

  • Page 182: Reverse Warning Buzzer

    1. Install the screw (3) through the buzzer (2) bracket tab and secure with nut (4). Tighten to 14 in-lb (1.6 N·m) (Figure 12-22, Page 12-21). NOTE: The reverse warning buzzer is secured at one hole only. Page 12-20 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 183: Reverse Buzzer Limit Switch

    1. Install the reverse buzzer limit switch (4), and then install two spacers (9) against the limit switch. 2. Install the lockout cam limit switch (5) with two washers (6) and two nuts (2). Tighten to 5 in-lb (0.6 N·m). See following CAUTION. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-21...

  • Page 184: Oil Warning Light

    Figure 12-23 Fuel/Hour Gauge and Oil Warning Light Installation OIL WARNING LIGHT Read DANGER and WARNING on page 12-1. Testing the Oil Warning Light See Test Procedure 22, Section 11, Page 11-38. Page 12-22 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 185: Fuel/Hour Gauge

    4. Remove the two hex nuts (3) and lock washers (4) from the threaded studs on the back of the gauge. Remove the mounting bracket (5) from the back side of the gauge and remove the gauge from the dash. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-23...

  • Page 186: Fuel Level Sending Unit

    4. Disconnect the other black wire at the other bullet connector near the RPM limiter. 5. Remove the flange head bolts from the RPM limiter band and remove the RPM limiter and damper (Figure 12-24, Page 12-25). Page 12-24 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 187: Ignition Coil

    1.1. Tilt the bed and ensure that the prop rod is engaged. 2. Disconnect the battery cables, negative cable (–) first (Figure 12-1, Page 12-2). 3. Unplug spark plug wire from the spark plug. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-25...
  • Page 188 9. Disconnect the 18 gauge black wire (12) from the spade terminal on the ignition coil (11) and remove the coil by removing two bolts (10) (Figure 12-27, Page 12-26). Figure 12-25 Remove Stiffener REMOVE Figure 12-26 Remove Fan Housing Figure 12-27 Remove Ignition Coil Page 12-26 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 189 8. Install the gasket (1) on the cap (2). 9. Position the ignition coil (7) onto the cast mounting bosses on the engine crankcase and tighten the two mounting bolts (6) to finger tight at this time. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-27...

  • Page 190: Oil Level Sensor

    See Test Procedure 21, Section 11, Page 11-38. Oil Level Sensor Removal See Oil Level Sensor Removal, Section 13, Page 13-24. Oil Level Sensor Installation See Oil Level Sensor Installation, Section 13, Page 13-24. Page 12-28 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 191: Headlights

    3. Turn the wire harness/halogen bulb assembly (4 and 6) counterclockwise one-quarter turn. 4. Connect battery cables, positive cable first and tighten the terminals to 20 ft-lb (27.1 N·m). Coat termi- nals with Battery Protector Spray (CCI 1014305). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-29...

  • Page 192: Headlight Diode

    4. Connect battery cables, positive cable first and tighten the terminals to 20 ft-lb (27.1 N·m). Coat termi- nals with Battery Protector Spray (CCI 1014305). LIGHT SWITCH Read DANGER and WARNING on page 12-1. Testing the Light Switch See Test Procedure 28, Section 11, Page 11-41. Page 12-30 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 193: Battery

    - Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable oil. Call a physician immediately. - Eyes: Flush with water for 15 minutes. Call a physician immediately. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-31...
  • Page 194 Club Car recommends a group 70, side-post battery (CCI 1012328), with a 650 cranking amp rating at 32 °F (0 °C) (500 CCA at 0 °F (-17.8 °C)) and a reserve capacity of at least 105 minutes. The group 70 classifica- tion indicates battery size: 8-1/4 inches W x 6-1/2 inches D x 7-1/4 inches H (21.0 cm W x 16.5cm D x 18.4...
  • Page 195 7. Carefully lift and rotate the seat support (1) 90° clockwise and allow it to rest on the vehicle body as illustrated (Figure 12-33, Page 12-34). See following NOTE. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-33...
  • Page 196 3. Attach the negative charger cable (–) to the negative (–) battery post. 4. The battery may be charged with a slow charge (3-10 amps) or a fast charge (20-30 amps). Charge until the specific gravity reaches 1.250. See following WARNING. Page 12-34 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 197 5. Check the state of charge periodically. A battery that is discharged and left in a cold environment can freeze and crack. If the specific gravity drops below 1.220, the battery should be recharged. See fol- lowing WARNING. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-35...

  • Page 198: 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 11-24. Page 12-36 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 199: Section 13 - Fe350 Engine

    (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position. Use approved jack stands of proper weight capacity to support the vehicle. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-1...

  • Page 200: General Information

    GENERAL INFORMATION Read DANGER and WARNING on page 13-1. All Club Car gasoline vehicles are powered by 4-cycle, overhead valve, single cylinder, air-cooled engines. The 4-cycle engine has an oil reservoir (crankcase) similar to automobiles, trucks, aircraft, heavy equipment, machinery and other applications designed for reliable heavy-duty service. The engine has two major com- ponent assemblies: the cylinder assembly and the crankcase assembly.
  • Page 201 A part installed using a press or driver, such as a seal, should first be coated with oil on its outer or inner cir- cumference (contact surface) so that it will go into place smoothly. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-3...

  • Page 202: Electrical System

    See also Section 11 – Troubleshooting and Electrical System and Section 12 – Electrical Compo- nents. 1. Always minimize shock hazards when working on electrical equipment. Work in a clean, dry environ- ment with dry hands. Page 13-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 203: Lubrication System

    (Figure 13-1, Page 13-5 and Figure 13-3, Page 13-6): • Inlet filter screen (2) • Trochoid pump (3) • Cartridge filter (5) • Pressure relief valve (8) 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-5...

  • Page 204: Hydraulic Lifters

    Spark plugs are selected to suit specific engine design and vehicle operating conditions. The spark plug (CCI 101881101) is designed to give maximum life and efficient combustion of fuel. The spark gap is 0.027 to 0.031 in. (0.69 to 0.79 mm). Page 13-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 205 Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible. Spark should be blue and strong and able to jump a 5/16 inch (8 mm) gap. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-7...

  • Page 206: Engine Mounting Plate

    3. Loosen air intake hose clamp (7) from intake pipe (5) and remove hose (6) (Figure 13-6, Page 13-9). 4. Disconnect the fuel line (9) and vent tube (10) from the carburetor (4) (Figure 13-7, Page 13-9). Page 13-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 207 11. Remove the nine bolts (14) and two-ended bolt (11) (Figures 13-8 and 13-9, Page 13-10). 12. Take off the head shroud (13), the upper shroud (23) and the bracket (22). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-9...

  • Page 208: Rocker Arm And Push Rod Removal

    1. Remove the six bolts (1) and take off the cylinder head assembly (2) (Figure 13-12, Page 13-11). 2. Remove head gasket (3). Note the position of the two dowels (4) as shown (Figure 13-13, Page 13-11). Page 13-10 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 209: Valve Removal

    • The valve stem seal cannot be reused. Replace valve stem seal with a new one. 5. Remove spring seat (9) (Figure 13-15, Page 13-11). PADDING Figure 13-14 Valve Removal Figure 13-15 Spring Seat Removal 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-11...

  • Page 210: Breather Valve (Reed Valve)

    Do not remove any more material than is necessary or change the shape of the combustion chamber (Figure 13-18, Page 13-13). • Do not grind the valve seats or the gasket surface. Page 13-12 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 211: Valve Guides

    2. Using Prussian Blue, coat the valve seat. 3. Push the valve into the guide. 4. Rotate the valve against the seat with a lapping tool (1) (Figure 13-23, Page 13-14). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-13...
  • Page 212 Valve Seat Repair ∆ CAUTION • If you are unfamiliar with the following procedures, Club Car suggests that the cylinder head be taken to a professional engine machine shop for reconditioning. 1. Clean the cylinder head thoroughly. See Cylinder Head Cleaning and Inspection on page 13-12.
  • Page 213 2.6. Turn the seat cutter (1) clockwise one turn at a time while pressing down very lightly. Recheck the width after each cutter revolution. See following CAUTION and NOTE. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-15...

  • Page 214: Valves

    Figure 13-28 Valve Head Seating Area VALVES Visual Inspection of Valves 1. Inspect the valve head seating area (1) for erosion, nicks and warping, etc. (Figure 13-28, Page 13- 16). See following NOTE. Page 13-16 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 215 1. Using a micrometer, measure the diameter of the stem at several points along its length (Figure 13-31, Page 13-18). 2. If the outside diameter is less than the service limit of 0.2728 inch (6.930 mm) intake, 0.2722 inch (6.915 mm) exhaust, replace the valve. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-17...

  • Page 216: Rocker Arm And Rocker Shaft Inspection

    4. If the outside diameter is less than the service limit of 0.4704 inch (11.949 mm), replace the shaft. Measure each position in two places 90° apart. Figure 13-32 Measure Valve Spring Length Figure 13-33 Measure Rocker Arm Bearing I.D. Page 13-18 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 217: Push Rod Inspection

    7. Increase the torque in four increments of 50 in-lb (6 N·m) and then tighten to final torque of 220 in-lb (25 N·m). See following CAUTION. ∆ CAUTION • Do not turn any one bolt down completely before tightening the others. Doing so may cause the cylinder head to warp. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-19...

  • Page 218: Valve Clearance Check And Adjustment

    NOTE: Place the reed valve on the seat so there is a slight gap (2) 0.008 inch maximum (0.203 mm) between the valve and the seat (Figure 13-38, Page 13-21). Page 13-20 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 219: Installation Of Remaining Engine Components

    2/3 turn after gasket contact. Fill crankcase with the correct level of oil (Figure 13-41, Page 13-22). See Section 2 – Vehicle Specifications. 10. Run the engine for three minutes to check for leaking oil. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-21...
  • Page 220 Oil must be in is located under the passenger seat. the safe level. Figure 13-41 Check Engine Oil Level Figure 13-42 Oil Level Sensor Wire Figure 13-43 Crankcase Cover Page 13-22 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 221: Crankcase

    • Before removal and disassembly, clean the engine. 1. Remove the powertrain by performing steps 1 through 14, pages 16-7 through 16-14 in Section 16 – Unitized Transaxle with Differential Lock. See following NOTE. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-23...

  • Page 222: Crankcase Cover Removal

    3. Connect sensor wire (2) to cord connector (1) (Figure 13-45, Page 13-25). 4. Install screw (3) through wire clamp and into crankcase cover. Tighten to 30 in-lb (3.4 N·m). Page 13-24 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 223: Camshaft And Hydraulic Lifters

    Page 13-26) and (Figure 13-49, Page 13-26). 6. If the camshaft journal diameter is less than 0.9026 inch (22.927 mm) at either end of the shaft, replace the camshaft. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-25...
  • Page 224 The engine cranks at 550 to 650 RPM and the ACR closes at approximately 700 RPM After the engine starts, it will idle at 1050 to 1150 RPM. Page 13-26 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 225: Piston And Connecting Rod

    1. Remove two retaining rings holding the piston pin in place. 2. Remove the piston pin. Piston Inspection and Repair 1. Remove all deposits from the piston. 2. Clean the carbon from the piston ring grooves. See following CAUTION. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-27...
  • Page 226 NOTE: It is difficult to measure exactly the oil ring thickness. Replace the oil ring whenever the compression rings (top and second) are replaced. Figure 13-53 Measure Ring End-Gap Figure 13-54 Measure Piston Ring Thickness Page 13-28 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 227 4. Remount the connecting rod cap to the connecting rod at the large bore end, aligning the pilot groove on the rod. Screw in the connecting rod bolts and tighten them to 16.5 ft-lb (23 N·m). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-29...

  • Page 228: Cylinder Block

    Always resize the bore to exactly 0.020 inches (0.50 mm) over standard size. 1. The bore size 0.020 inches over standard size is 3.2858 - 3.2866 inches (83.460 - 83.480 mm). See Specifications for Resizing Cylinder Bore on page 13-51. Page 13-30 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 229: Ignition Coil And Flywheel

    3. Hold the flywheel (4), not the fan (7), with a strap wrench (5) and, using a 25 mm socket, remove the flywheel nut (and flat washer) by turning it counterclockwise (Figure 13-63, Page 13-32). See following CAUTION. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-31...

  • Page 230: Oil Pump

    1. Remove the six screws (1 - 6) and remove the oil pump cover (7) (Figure 13-65, Page 13-33). 2. Peel off the oil pump cover gasket (8). 3. Remove the pump gear cover plate (9) and filter screen (10). Page 13-32 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 231 4.5. If the rotor thickness is less than 0.3905 inch (9.920 mm), replace both rotors. Measure two Measure two places 90° apart. places 90° apart. Figure 13-67 Measure Pump Shaft Bearing Surface Figure 13-68 Measure Outer Rotor O.D. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-33...

  • Page 232: Oil Pressure Relief Valve

    Oil Pressure Relief Valve Installation 1. Installation is the reverse of removal. If necessary, put the ball in position and lightly tap with a plastic hammer to form a perfect seat. Page 13-34 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 233: Crankshaft And Counterbalance

    2. Pull out the crankshaft and the counterbalance together as an assembly (Figure 13-74, Page 13-35). Figure 13-73 Counterbalance Guide Shaft Figure 13-74 Crankshaft and Counterbalance and O-Ring Removal 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-35...
  • Page 234 • Use a press when removing the spur gear and helical gear from, or installing them on the crankshaft. 5. Remove the woodruff key. 6. Slide the remaining link rod off the crankshaft. Page 13-36 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 235 Figure 13-77 Inspect Link Rod Figure 13-78 Measure Link Rod Small Bore I.D. Measure each position in 2 places 90° apart. Figure 13-79 Measure Link Rod Large Bore I.D 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-37...

  • Page 236: Counterbalance Weight

    3. If the outside diameter is smaller than 1.0199 inches (25.907 mm), or the shaft shows signs of wear or damage, replace the guide shaft. 4. Check the O-ring seal to make sure the O-ring is not damaged. Replace if necessary. Page 13-38 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 237 Figure 13-83 Measure Crankshaft Journals Measure each position Measure each position in 2 places 90° apart. in 2 places 90° apart. Figure 13-84 Measure Connecting Rod Journal Figure 13-85 Measure Link Rod Journals 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-39...

  • Page 238: Oil Screen

    2. Clean the oil screen thoroughly with a high flash-point solvent, then dry the screen. Oil Screen Installation 1. To install the oil screen, reverse the removal procedure. 2. Tighten bolts (1) to 30 in-lb (3.4 N·m). Page 13-40 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 239: Ball Bearing

    2. Place the crankcase cover (1) on a bench with its outside up (gasket surface against bench) (Figure 13- 89, Page 13-41). 3. Using a bearing driver (2) (Part of Club Car Bearing Driver Kit, Part No. 1016416), drive out the ball bearing (3) as shown.

  • Page 240: Oil Seals

    If the inside diameter is greater than 1.1841 inch (30.075 mm), replace the crankcase (Figure 13-91, Page 13-41). Figure 13-92 Inspect Camshaft Bearing Surface Figure 13-93 Crankshaft Assembly in Crankcase Cover Page 13-42 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 241 SPUR GEAR (CHAMFERED INSIDE (NOTE DIAMETER FACING DOWN) TIMING PRESS RAM MARK) PRESS TABLE LINK ROD Figure 13-94 Crankshaft Installation Figure 13-95 Press on Spur Gear and Helical Gear 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-43...

  • Page 242: Crankshaft Axial Play Adjustment

    The correct crankshaft shim is 1.53 mm (Figure 13-100, Page 13-45). See following NOTE. 5. Install the shim (5) on the crankshaft (6) (Figure 13-99, Page 13-45). NOTE: Crankshaft shim sizes for FE350 engines range from 1.11 to 1.81 mm. Page 13-44 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 243 1. Installation is the reverse of removal. See page 13-25. 2. Apply a light film of engine oil to the camshaft journals and cam lobes. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-45...
  • Page 244 5. Install the shim (1) on the camshaft (2) (Figure 13-104, Page 13-46). Figure 13-103 Measurements to be Recorded Figure 13-104 Shim Installation on Camshaft for Camshaft Shim Table Page 13-46 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 245: Crankcase Cover Installation

    130 in-lb (14 N·m). Then, repeating the sequence, tighten them to 250 in-lb (28.2 N·m). 5. Connect the yellow jumper wire (11) to the cord connector (12) (Figure 13-42, Page 13-22). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-47...

  • Page 246: Engine Assembly

    4. Install ignition coil. See Ignition Coil Installation on page 13-32. 5. Install cylinder head shrouds. Installation is the reverse of removal. See Cylinder Shroud Removal, Steps 11 and 12, Page 13-9. Page 13-48 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 247 17. Connect the battery cables, positive first and tighten to 20 ft-lb (27.1 N·m). 18. Adjust the engine RPM setting. See Engine RPM Adjustment, Section 14, Page 14-13. 19. Test-drive vehicle to ensure all systems are functional and correctly adjusted. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-49...

  • Page 248: Service Specifications

    0.0197 to 0.0433 in. Valve seat width Standard (0.50 to 1.10mm) Valve seat width max. 0.075 in. (1.9 mm) Valve face angle (exhaust, intake) Standard 45° (Ex.), 30° (In.) Page 13-50 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 249: Specifications For Resizing Cylinder Bore

    90 in-lb (10 N·m) Fan shroud screws 25 in-lb (2.8 N·m) 130 in-lb (15 N·m) Bolts marked with “4” (when used with nuts) 50 in-lb (5.9 N·m) 30 in-lb (3.4 N·m) 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 13-51...

  • Page 250: Adjustments And Settings

    1.18 in. (30 mmHg) Cylinder head-gasket surface flatness (max.) 0.002 in. (0.05 mm) ACR lift (standard) 0.059 in. (1.5 mm) ACR lift (min.) 0.0354 in. (0.9 mm) Engine rpm 3800 (±30) RPM Page 13-52 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 251: Section 14 - Fuel System

    The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The car- buretor atomizes the fuel, mixes it with air, and feeds the combustible mixture into the cylinder. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-1...

  • Page 252: How The Carburetor Works

    The throttle valve (Figure 14-3, Page 14-3) is almost closed when this is the case, and as high negative pressure is created on the back side of the throttle valve, intake air is drawn in and Page 14-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 253 CARBURETOR BORE TO ENGINE MAIN AIR JET MIXTURE MIXTURE INTAKE CYLINDER CYLINDER THROTTLE VALVE MAIN NOZZLE BLEED PIPE FLOAT MAIN JET FUEL INLET FUEL INLET FLOAT CHAMBER Figure 14-3 Carburetor 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-3...

  • Page 254: Choke And Fresh Air System

    • Choke and air intake system (for restriction of air flow). See Choke and Air Intake System on page 14-14. • Fuel pump. See Fuel Pump on page 14-21. Page 14-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 255: Main Jet Elevation/Size Chart

    The carburetor must be kept upright during removal. 2. Position the carburetor with the drain screw (11) over a catch basin (Figure 14-7, Page 14-7). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-5...
  • Page 256 4. Mark the body of the carburetor and the carburetor fuel bowl with an indelible ink marker so that, after removal, the bowl can be installed again in the same position (Figure 14-7, Page 14-7). Page 14-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 257 7. Select the proper size main jet. See chart on page 14-5. Check the size designation on the jet to make sure it is the correct part. 8. Install the new main jet and tighten it to 12 in-lb (1.4 N·m). See following CAUTION and NOTE. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-7...

  • Page 258: Engine Control Linkage

    Read DANGER and WARNING on page 14-1. GENERAL INFORMATION For proper vehicle operation, it is important the accelerator pedal, governor linkage, and throttle adjustments are done correctly and in the proper sequence. See following CAUTION. Page 14-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 259: Accelerator Rod

    2. Install the ball joint on the ball stud at the accelerator pedal (Figure 14-8, Page 14-9). 3. Access the engine compartment. See DANGER on page 14-1. 3.1. Tilt the bed and ensure that the prop rod is engaged. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-9...

  • Page 260: Governor Cable

    3. Install governor cable end into carburetor throttle clevis and install clevis pin (8) and cotter pin (9) (Fig- ure 14-11, Page 14-12). 4. Install governor cable clevis over governor lever arm and install clevis pin (8) and cotter pin (9) (Figure 14-11, Page 14-12). Page 14-10 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 261: Accelerator Cable

    Page 14-12). Pull the cable housing out of the bracket. 5. Disconnect the spring (16) from the engine governor arm by rotating the arm counterclockwise one-half turn. Remove the cable assembly from the vehicle (Figure 14-11, Page 14-12). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-11...
  • Page 262 FUEL SYSTEM Engine Control Linkage TYPICAL 2 PLACES REFERENCE EXHAUST SECTION Figure 14-11 Governor and Accelerator Cables Page 14-12 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 263: Closed Throttle Or Idle Adjustment

    1. If the governor is adjusted, proceed to step 2; otherwise, adjust the governor. See Governor Cable Installation and Adjustment on page 14-10. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-13...

  • Page 264: Choke And Air Intake System

    1. Insert choke cable through hole in body until choke lever assembly seats against body. 2. Install three screws (19), washers (20), and locknuts (21) as shown and tighten to 18 in-lb (2.0 N·m) (Figure 14-14, Page 14-17). Page 14-14 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 265: Air Box Removal

    13. Drill out the two pop rivets (24) securing the intake duct to the floorboard (Figure 14-14, Page 14-17). 14. Remove three screws (23) and flat washers (22) from the bottom of the air box assembly (Figure 14- 14, Page 14-17). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-15...

  • Page 266: Intake Duct Installation

    (Figure 14-14, Page 14-17). Tighten the two bolts (28) and nuts to 20 ft-lb (27 N·m) (Figure 14-14, Page 14-17). 9. Tighten the two bolts (26) and locknuts to 20 ft-lb (27 N·m) (Figure 14-14, Page 14-17). Page 14-16 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 267 Choke and Air Intake System REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 14-14 Air Intake and Choke Assemblies 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-17...

  • Page 268: Intake Duct Repair

    • If air box is extremely dirty, remove air box from vehicle and clean thoroughly. • Use only Club Car replacement air filters (CCI 1015426). The use of other air filters could result in engine damage. If the air filter is too thin, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.

  • Page 269: Fuel Filters

    6. Place the Forward/Reverse handle in the NEUTRAL position and chock the wheels. Start the engine and check for fuel leaks. See following DANGER. ∆ DANGER • Repair any fuel leaks before operating the vehicle. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-19...
  • Page 270 2.5 in. (6.4 cm) Vent tube (Carburetor) 17.0 in. (43.2 cm) Vent tube (Gas Tank) 17.0 in. (43.2 cm) Impulse line 14.0 in. (35.6 cm) Figure 14-15 Fuel and Vent Lines Page 14-20 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 271: Fuel Pump

    FUEL PUMP DISASSEMBLY NOTE: A fuel pump rebuild kit is available from Club Car (CCI 1014524). This kit includes all gaskets, dia- phragms, and valves. 1. Remove four screws (24) and lock washers (25) from front of the fuel pump (Figure 14-16, Page 14- 22).

  • Page 272: Fuel Pump Cleaning And Inspection

    Figure 14-16 Fuel Pump Figure 14-17 Fuel Pump Orientation ∆ CAUTION • If the valve assembly is not installed exactly as shown, the impulse fuel pump will not operate properly. Page 14-22 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 273: Fuel Pump Installation

    • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure. ∆ CAUTION • Add only unleaded gasoline to the tank. Do not put oil into the fuel tank. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-23...

  • Page 274: General Information

    10. Using a siphon with a suction device, siphon all fuel out of the tank and into an approved container. See following DANGER and WARNING. Page 14-24 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 275: Fuel Tank Disposal

    2.1. Position the straps in the indentions on the tank. 2.2. Install the screws (12 and 14) into the speed nuts (11). Tighten screws to 25 in-lb (2.8 N·m) (Fig- ure 14-15, Page 14-20). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-25...
  • Page 276 (Figure 14-19, Page 14-26) and install the flat washer, lock washer and nut. Tighten to 18 in-lb (2.0 N·m). 7. Slide the rubber boot over the stud (Figure 14-19, Page 14-26). Page 14-26 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 277: Fuel Lines

    Small spring steel band clamps are used on all hose connections except at the carburetor. A screw band clamp should be used at the carburetor (Figure 14-15, Page 14-20). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 14-27...

  • Page 278: Fuel Shut-Off Valve

    SIDE OF VALVE Figure 14-21 Closed Fuel Shut-off Valve Figure 14-22 Open Fuel Shut-off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 14-23 Incorrect Fuel Shut-off Valve Page 14-28 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 279: Section 15 - Exhaust System

    GENERAL INFORMATION The exhaust system is designed to provide quiet vehicle operation. If the muffler should ever need to be removed for repairs or replacement, follow the instructions below. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 15-1...

  • Page 280: Muffler

    4. Install the hex nuts (10) and lock washers (11). Tighten the nuts fingertight. 5. Install the hex head cap screw (7), lock washer (8), and flat washer (9). Tighten the cap screw finger- tight. Page 15-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 281 • 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 15-2 Exhaust System 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 15-3...

  • Page 283: Section 16 - Unitized Transaxle With Differential Lock

    GENERAL INFORMATION The Pioneer 1200 gasoline-powered vehicle is equipped with a heavy-duty, fully-synchronized Unitized Tran- saxle with Differential Lock. The unitized transaxle utilizes fully-synchronized internal gearing to change vehi- cle direction. Because the unitized transaxle is used to reverse vehicle direction, the engine, drive clutch, belt, and driven clutch rotate in the same direction;...
  • Page 284 Figure 16-3 Differential Lock Lever Lockout Cam The Pioneer 1200 vehicle has a lockout circuit that prevents a driver from starting the vehicle when it is in gear. The engine can be started only when the Forward/Reverse handle is in the NEUTRAL position. See Lockout Cam Circuit, Section 11, Page 11-12.

  • Page 285: Lubrication

    If the unitized transaxle is to be removed from the vehicle, then do not remove the wheels, axle shafts, or axle tubes first. Instructions for removing the unitized transaxle from the vehicle begin on page 16-7. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-3...

  • Page 286: Axle Shaft And Oil Seal Removal

    See WARNING on page 16-1. 3. Remove the rear wheel and brake drum. 4. Using 90° internal snap ring pliers (.090 tip), remove internal retaining ring from axle tube (Figure 16-5, Page 16-5). Page 16-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 287: Axle Bearing

    flange and the bearing. See following CAUTION. ∆ CAUTION • Do not tighten the bearing puller wedge attachment against the axle shaft. This could damage the axle shaft when pressing the bearing and collar off. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-5...
  • Page 288 6. Place the bearing puller wedge attachment against collar and press both bearing and collar onto shaft. Install the retaining ring (88) (Figure 16-4, Page 16-4). See following CAUTION. Page 16-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 289: Axle Shaft Installation

    3.4. Loosen the hose clamp and then disconnect the fuel line from the carburetor. To prevent spilling fuel, the disconnected end of the line can be pushed onto the impulse line fitting of the fuel pump (Figure 16-15, Page 16-9). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-7...
  • Page 290 Figure 16-12 Impulse Line 1. Apply pressure to locking tabs of the cable. 2. Pull cable sheath toward rear of vehicle to disconnect from the bracket. Figure 16-13 Differential Lock Cable Bracket Page 16-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 291 Disconnect the cable from the actuator cam and remove it from the box (Figure 16-16, Page 16-9). 3.7. Disconnect the engine ground wire from the oil filler tube mounting bracket (Figure 16-17, Page 16-10). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-9...
  • Page 292 3.15. Cut away the wire ties securing the kill switch wire at the lower right front of the engine (below the exhaust header), the wire harness at the governor cable bracket, and the wire harness to the plate beneath the muffler. Page 16-10 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 293 fluid, lift the hose above the brake cluster assembly (Figure 16-24, Page 16-11). WHITE/BLACK WIRE BLACK WIRE Figure 16-21 Engine Kill Switch Wire Figure 16-22 Shock Absorbers CABLE SUPPORT BRACKET Figure 16-23 Park Brake Cable Figure 16-24 Brake Hose 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-11...
  • Page 294 9. Remove the bolts that secure the leaf springs to the shackles (Figure 16-27, Page 16-12). WIRE TIE PLASTIC FLEX BRAKE HOSE Figure 16-25 Cover Brake Hose Fitting Figure 16-26 Spring Retainer Bolts Figure 16-27 Rear Shackles Page 16-12 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 295 OF FLOOR JACK OF JACK STANDS APPROX. 17-1/2" (44.5 cm) Figure 16-28 Raise Vehicle Figure 16-29 Position Jack Stands SNUBBER SNUBBER BRACKET Figure 16-30 Snubber Figure 16-31 Remove Powertrain 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-13...
  • Page 296 Figure 16-32 Position Powertrain Figure 16-33 Remove Drive Belt GOVERNOR ARM RETAINING BOLT RETAINING BOLT Leave cable connected. Leave cable connected. Figure 16-34 Driven Clutch Figure 16-35 Governor Arm Page 16-14 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 297: Unitized Transaxle Disassembly

    2. Using 90° (.090 tip) internal snap ring pliers, remove the internal retaining rings (Figure 16-5, Page 16- 5) from the axle tubes. 3. Pull the axles (82 and 83) out of the axle tubes (Figure 16-4, Page 16-4). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-15...
  • Page 298 8. Remove the fifteen bolts (28) that hold the transaxle housing together (Figure 16-40, Page 16-16). TYPICAL 15 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 16-40 Transaxle Gear Casing and Brackets Page 16-16 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 299 (Figure 16-44, Page 16-18). 15. Remove the oil flow guide from the case (Figure 16-45, Page 16-18). DIFFERENTIAL GEAR CASE ASSEMBLY Figure 16-41 Loosen Gears Figure 16-42 Remove Differential Gear Case 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-17...
  • Page 300 ASSEMBLY Figure 16-43 Remove Intermediate Gear Figure 16-44 Input Shaft Oil Seal SHIFTER SHAFT SLOT OIL FLOW GUIDE Figure 16-45 Oil Flow Guide Figure 16-46 Pivot Arm Oil Seal Page 16-18 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 301: Component Disassembly

    (94) (Figure 16-47, Page 16-19). 6. If necessary, gently pry the O-ring from the groove in the differential lock shaft with a small screwdriver (Figure 16-73, Page 16-31). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-19...
  • Page 302 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Disassembly REFERENCE PASSENGER SIDE CASE REFERENCE DRIVER SIDE CASE Figure 16-48 Unitized Transaxle with Differential Lock Page 16-20 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 303: Governor Gear Disassembly

    2. Use two small screwdrivers to pry the gear and flyweight off the shaft as shown (Figure 16-50, Page 16-21). Figure 16-49 Remove Governor Gear Figure 16-50 Pry Gear from Shaft Remove retaining bolts. Tap around ring gear to loosen. Figure 16-51 Remove Ring Gear 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-21...

  • Page 304: Differential Gear Case Disassembly

    • Do not tighten the bearing puller wedge attachment against the shaft. This could damage the shaft. PRESS ARBOR WEDGE ATTACHMENT Figure 16-52 Differential Pin Figure 16-53 Remove Bearing Page 16-22 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 305: Shifter Fork Disassembly

    (44), and synchronizer ring (48) from the input shaft (Figure 16-48, Page 16-20). PRESS PRESS RAM ARBOR BEARING PULLER WEDGE ATTACHMENT WEDGE ATTACHMENT Figure 16-54 Remove Bearing Figure 16-55 Remove Bearing 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-23...

  • Page 306: Intermediate Gear Disassembly

    Page 16-20) and the small gear on the idler shaft (68) (Figure 16-48, Page 16-20), then press the bearing off the shaft as shown (Figure 16-57, Page 16-24). See following CAUTION. Page 16-24 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 307 Figure 16-58 Remove Idler Shaft Figure 16-59 Inspect Bearings Press bearing onto idler shaft. Turn idler shaft over and press bearing on other end. Figure 16-60 Synchro. Ring Figure 16-61 Idler Shaft 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-25...

  • Page 308: Unitized Transaxle Component Inspection

    flush with the machined lip of the shaft at the ends of the shaft splines (Figure 16-62, Page 16-27). Page 16-26 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 309 CLUTCH HUB SYNCHRONIZER Notched SLEEVE surfaces of synchro. LONG END TOP VIEW inserts face OF SHAFT out. SPRINGS TOP AND BOTTOM Figure 16-64 Synchronizer Inserts Figure 16-65 Synchronizer Clutch Hub 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-27...
  • Page 310 See following CAUTION. ∆ CAUTION • Apply pressure against the inner race of the bearing only. Applying pressure anywhere else will damage the bearing. Page 16-28 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 311: Shifter Fork Assembly

    flush with the sides of the car- rier case (Figure 16-69, Page 16-30). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-29...
  • Page 312 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Component Assembly Figure 16-69 Second Idler Gear Figure 16-70 Carrier Case DOWEL PIN TIGHTENING SEQUENCE DOWEL HOLE Figure 16-71 Ring Gear Figure 16-72 Retaining Bolts Page 16-30 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 313: Governor Gear Assembly

    6. Place the differential lock arm (99) on the shaft (95) and place the hooked end of the spring (98) on the arm (Figure 16-74, Page 16-31). 7. Tighten the differential lock arm retainer nut (101) to 60 in-lb (6.8 N·m) (Figure 16-74, Page 16-31). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-31...

  • Page 314: Unitized Transaxle Assembly

    (Figure 16-79, Page 16-33). Bend the legs of the cotter pin. SHAFT TOOL Press oil seal into right side case. Figure 16-75 Install Seals Figure 16-76 Governor Gear Shaft Page 16-32 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 315 (43) is meshed with the governor gear (66) (Figure 16-48, Page 16-20), and the shifter lever (19) (Figure 16-40, Page 16-16) is positioned in the bracket on the shifter fork. See also Figure 16-85, Page 16-36. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-33...
  • Page 316 Figure 16-82 Idler Gear Assembly Cutaway view of shifter SLOT fork and synchronizer gear assembly being inserted as a unit into casing. Figure 16-83 Oil Guide Figure 16-84 Synchronizer Ring Gear Page 16-34 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 317 (Figure 16-74, Page 16-31). 11.5. Using the alignment pin as a guide, position the differential lock housing onto the driver side of the transaxle case (Figure 16-90, Page 16-37). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-35...
  • Page 318 Large idler gear and synchronizer SHIFTER gear mesh. FORK Shifter arm and the shifter fork slotted arm also mesh. Figure 16-87 Gear Alignment Figure 16-88 Prepare Mating Surfaces Page 16-36 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 319 Figure 16-89 Casing Torque Sequence Dowell Pin will help hold Differential Locking Assembly to Transaxle casting until axle bolts are inserted. Figure 16-90 Axle Tube Surface 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-37...
  • Page 320 13.2. Install the bolt (17), washers, and lock nut on the bracket and tighten to 23 ft-lb (31.2 N·m) (Figure 16-23, Page 16-11). TIGHTENING SEQUENCE Figure 16-91 Install Axle Tubes Figure 16-92 Retaining Ring Page 16-38 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 321: Unitized Transaxle Installation

    (Figure 16-97, Page 16-40). TRANSAXLE MOUNTING BOLT AND NUT (TYPICAL 4 PLACES) WOODEN BLOCKS TRANSAXLE MOUNTING NUTS (TYPICAL 2 PLACES) Figure 16-93 Transaxle Mounting Figure 16-94 Differential Lock Bracket Installation 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-39...
  • Page 322 1. Install the governor arm 4. Tighten the on the governor shaft. retaining nut. 2. Turn shaft counterclockwise. 3. Pull governor arm rearward. Figure 16-96 Governor Cable Bracket Figure 16-97 Governor Arm Page 16-40 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 323 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Installation SNUBBER SNUBBER BRACKET Figure 16-98 Driven Clutch Figure 16-99 Snubber Figure 16-100 Leaf Springs Figure 16-101 Leaf Springs and Shackles 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-41...
  • Page 324 24. Connect the oil level sensor wire (18 gauge yellow) to the jumper wire (Figure 16-104, Page 16-43). Figure 16-102 Shock Absorber Page 16-42 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 325 106, Page 16-44). 27. Attach the ground wire to the mounting screw on the oil filler tube mounting bracket and tighten to 50 in-lb (5.7 N·m) (Figure 16-107, Page 16-44). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-43...
  • Page 326 TOP VIEW SPRING RELEASE NUTS Figure 16-106 Connect Shifter Cable Figure 16-107 Engine Ground TOP VIEW CLAMP ACCELERATOR CABLE Figure 16-108 Connect Cable to Cam Figure 16-109 Connect Fuel Line Page 16-44 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 327 Install and tighten the level indicator hole plug to 21 ft-lb (28.5 N·m). CLAMP IMPULSE LINE Figure 16-110 Impulse Line Figure 16-111 Air Intake Hose CLAMP Figure 16-112 Carburetor Vent Tube 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-45...
  • Page 328 39. Adjust the engine RPM setting. See Engine RPM Adjustment, Section 14, Page 14-13. Step 1. Step 2. Step 3. Figure 16-113 Differential Cable End Installation Push cable into the bracket. Figure 16-114 Differential Cable Installation Page 16-46 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 329: Forward/Reverse (F&R) Shifter Cable

    5. Install the ball joint socket (2) on the F&R shifter assembly ball stud (3) (Figure 16-116, Page 16-48). 6. Install wire tie (8) to secure wire harness to cable at the support bracket near the F&R shifter assembly (Figure 16-116, Page 16-48). See following WARNING. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-47...

  • Page 330: F&R Shifter Cable Adjustment

    (1) may be loosened and the ball joint socket (2) rotated to get the proper adjustment (Figure 16-116, Page 16-48). See following CAUTION. REFERENCE TRANSMISSION SHIFTER LEVER REFERENCE TRANSMISSION CABLE SUPPORT BRACKET Figure 16-116 F&R Shifter Cable Page 16-48 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 331: Differential Lock System

    5. With the cable disconnected from the bracket, rotate the cable connector toward the driver side of the vehicle to disconnect the cable from the differential lock lever (1) (Figure 16-14, Page 16-9). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-49...
  • Page 332 2. Push plastic cable retainer toward the front of the vehicle to secure the cable to the bracket. Figure 16-117 Differential Lock Cable Routing Page 16-50 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 333: Differential Lock Cable Installation

    5.5. Secure the cable to the vertical support as shown with a wire tie (6) (Figure 16-117, Page 16-50). 6. Inspect the differential lock system for proper operation. See Differential Lock System Inspection on page 16-49. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-51...

  • Page 335: Section 17 - Torque Converter

    (smaller diameter) on the drive clutch. The driven clutch is mounted on the transaxle. It is in the closed position, and the drive belt is riding at a high position (large diameter) on it when the engine is at idle. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 17-1...
  • Page 336 DRIVEN CLUTCH DRIVEN CLUTCH CAM PULLER PULLER PLUG (CCI 1014508) (CCI 1014507) DRIVE CLUTCH HOLDER TOOL DRIVE (CCI 1015524) CLUTCH PULLER (CCI 1014496) Figure 17-1 Torque Converter Tool Kit Page 17-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 337: Troubleshooting

    Maintaining proper adjustment of the engine and governor, as well as the torque converter, is essential to the troubleshooting process. If these adjustments are within Club Car specifications and, when climbing a steep hill, the engine begins to lose RPM before the drive belt reaches the top of the driven clutch, there is a torque converter problem.

  • Page 338: Drive Belt Installation

    6. Support the drive clutch assembly in your hand and back the clutch puller tool out of the crankshaft. ∆ CAUTION • Do not hit or tap the clutch with a hammer. Do not pry the clutch. These actions will damage the clutch. Page 17-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 339: 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. 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 17-5...
  • Page 340 TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES (ONE SPRING PER CLUTCH) Figure 17-5 Drive Clutch Assembly Page 17-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 341: Drive Clutch Disassembly

    HUB PULLER TOOL (CLUB CAR PART NO. 1014497) Mark the clutch cover and its corresponding position on the moveable casting. Figure 17-6 Mark Clutch Cover Figure 17-7 Remove Clutch Cover 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 17-7...
  • Page 342 9. Use a scribe or small pick to remove the spiral backup rings (12) from each end of the bore in the fixed face assembly (Figure 17-5, Page 17-6 and Figure 17-11, Page 17-9). Discard the rings. Page 17-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 343: Inspection Of Drive Clutch Parts

    4. Install the spacer (13) onto the shaft of the fixed face (Figure 17-5, Page 17-6). 5. Install a new spiral backup ring (12) in each end of the bore of the moveable face assembly (14) (Figure 17-5, Page 17-6). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 17-9...
  • Page 344 (Figure 17-15, Page 17-11). 14. While compressing the take-up spring, install the drive button over the rib and take-up spring as shown (Figure 17-8, Page 17-8). Page 17-10 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 345 Pin should protrude an equal amount on both sides. Figure 17-14 Install White Washers DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED Figure 17-15 Correct Orientation of Drive Button Take-up Spring 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 17-11...
  • Page 346 TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES Figure 17-16 Driven Clutch Assembly Page 17-12 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 347: Drive Clutch Installation

    3. Remove the spring (5) (Figure 17-16, Page 17-12). 4. Retain the key (3). 5. Slide the moveable face (7) off the fixed face shaft (8) (Figure 17-16, Page 17-12). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 17-13...

  • Page 348: Driven Clutch Inspection

    Rotate the cam until the keyway is aligned with the key (3) on the fixed face assembly, and then start the cam onto the shaft approximately 1/4 to 3/8 inch (6.3 to 9.5 mm). Page 17-14 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...

  • Page 349: Driven Clutch Installation

    1. To install the driven clutch, reverse the removal procedure. Before tightening the center bolt (11) to 14 ft-lb (19.0 N·m), make sure the mounting washer (12) is installed between the center bolt and the clutch (yellow side facing out) (Figure 17-16, Page 17-12). 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 17-15...
  • Page 351 ..........12-32 installation ........... 6-12 mineral content ..........12-33 removal ............6-9 removal ............12-33 system inspection ..........6-2 self-discharge ..........12-32 storage ............12-35 troubleshooting ..........6-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page i-1...
  • Page 352 ..........11-6 clutch, driven differential see driven clutch see unitized transaxle column, steering differential gear case see steering column commutator assembly ............16-29 see starter/generator disassembly ...........16-22 Page i-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 353 ......11-12, 11-18 assembly ............14-22 reverse buzzer circuit ......11-11, 11-17 starter and generator circuit ......11-15 cleaning and inspection ......... 14-22 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page i-3...
  • Page 354 ............12-31 oil pump ............13-33 removal ............12-31 park brake ............6-3 testing ............11-41 piston .............13-27 headlights piston pin ...........13-29 see also lighting circuit pre-operation safety checklist (daily) ....10-2 Page i-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 355 ............13-34 installation ..........12-19 oil pump removal ............. 12-18 cover removal ..........13-32 removal ............12-20 inspection ............13-33 testing ............11-38 troubleshooting ..........11-19 installation ............. 13-35 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page i-5...
  • Page 356 ............9-1 installation .............9-3 installation ..........12-21 removal ............9-1 removal ............. 12-21 testing ............11-37 snubber removal ............12-20 installation ............9-5 testing ............11-37 removal ..............9-5 Page i-6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 357 ..........7-8 headlight diode ..........11-42 installation ..........7-13 headlight switch ..........11-41 removal ............7-6 steering column hour gauge ............ 11-41 assembly ............7-5 ignition coil ............ 11-35 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page i-7...
  • Page 358 ............. 6-4 torque converter ..........17-3 wire continuity testing ........11-30 vehicle troubleshooting guide ......11-2 wiring diagram ............ 11-6 Page i-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual...
  • Page 360 Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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