BODY AND TRIM
Front Body Repair
Page 4-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
4
The front body is made of an ABS/DR acrylic material similar to the material used to manufacture hot tubs
and shower/tub units. Cleaning and repair techniques for the front body are the same as those used on con-
ventional acrylic sheet. Repair kits, cleaning and polishing products may be purchased at any hardware store
where ABS/DR acrylic (hot tubs and shower/tub units) are sold.
The seats of the vehicle will last longer with proper cleaning. Use a solution of 10% liquid soap and warm
water applied with a soft cloth. For imbedded dirt, a soft bristle brush may be used. For heavy soiling, difficult
stains, or scratches, blemishes, or other body damage, see Seat on page 4-5. See following NOTE.
NOTE: Dispose of waste water properly.
FRONT BODY REPAIR
Read WARNING and CAUTION on page 4-1.
LIGHT SCRATCHES, ABRASIONS AND HAZE
The original gloss can be restored by hand buffing with “Novus Plastic Polish”, “Mirror Glaze Professional
Formula Number 17” or similar polishing compounds. A buffing wheel with a small amount of tallow applied
to the pad may also be used. Remember to use a very light touch, as ABS/DR acrylic polishes easily.
Johnson’s “J-Wax” or “Kit” may be applied as a final treatment.
DEEPER SCRATCHES
Ajax cleanser applied dry and hand-rubbed will rapidly smooth moderate scratches. Use a soft polishing
compound to restore gloss.
Scratches (up to 10 mils) can be removed by light sanding. Start with wet silicone carbide abrasive paper
(320 grit or finer). Use progressively finer grits (i.e. 400, 600, 800) to reduce sanding marks. Use Ajax
cleanser (or equivalent) for final smoothing. A Micro Mesh acrylic polishing kit with abrasive papers from
1800 to 8000 grit will provide the best final finish. Restore gloss with soft polishing compound.
GOUGES, PUNCTURES, TEARS, LARGE SCRATCHES, AND ABRASIONS
Touch-up is not recommended. Replace the entire body part or have it repaired by a professional paint and
body repair shop with experience repairing ABS/DR acrylic bodies.
BRUSH GUARD
Read WARNING and CAUTION on page 4-1.
BRUSH GUARD REMOVAL
1. Remove the four truss head screws (14) and nuts (15) that secure the brush guard to the vehicle frame
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
