Club Car Pioneer 1200 Maintenance Service Manual Download Page 52

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HYDRAULIC AND PARK BRAKE SYSTEMS

Brake System Troubleshooting

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

Vehicle pulls to one side,
Continued

Water on the brake shoe linings

Apply the brakes several times to dry the
brake shoe linings.

Sticking wheel cylinder piston

Replace the wheel cylinder. See Wheel
Cylinder Replacement on page 6-19.

Faulty suspension parts

See Section Section 7 – Steering and
Front Suspension or Section 9 – Rear
Suspension.

Pulsating brake pedal

Warped brake drums

Replace the brake drums. See Brake
Drum Removal on page 6-7.

Bent axle

Replace the axle. See Section 16 – Unit-
ized Transaxle with Differential Lock.

Worn or damaged front wheel bearings

Replace bearings. See Section 7 – Steer-
ing and Front Suspension.

Noise and chatter –
Squealing, clicking or scraping sound
upon brake application

Bent, damaged or incorrect brake shoes

Replace the brake shoes. See Brake
Shoe Removal on page 6-9.

Worn out brake shoes

Replace the brake shoes. See Brake
Shoe Removal on page 6-9.

Foreign material embedded in brake shoe
linings

Replace the brake shoes. See Brake
Shoe Removal on page 6-9.

Broken brake shoe return springs or hold
down springs

Replace damaged parts.

Rough, grooved or dry brake shoe ledges
or backing plate bosses

Lubricate the bosses of the brake cluster
backing plate, and/or replace the brake
shoes. See Brake Cluster Assembly
Inspection and Cleaning on page 6-10
and/or Brake Shoe Removal on page 6-9.

Brake drums are cracked or scored

Replace the brake drums. See Brake
Drum Removal on page 6-7.

Decreasing brake pedal travel

Weak or broken brake shoe return springs

Replace return springs.

Sticking wheel cylinder piston

Replace the wheel cylinder. See Wheel
Cylinder Replacement on page 6-19.

Overly adjusted brake adjusters

Adjust brake adjusters. See Brake Shoe
Adjuster Replacement on page 6-21.

Improperly adjusted park brake

Adjust park brake. See Park Brake
Adjustment on page 6-34.

All brakes drag

Binding brake pedal

Lubricate and adjust. See Section 5 of
this Maintenance and Service Manual.

Soft or swollen rubber parts caused by
incorrect or contaminated brake fluid

Replace master cylinder. See Master Cyl-
inder Removal on page 6-28.

Rear brakes drag

Binding park brake cables

Adjust or replace cables and adjust.

Improper brake adjustment

Adjust shoes and repair the brake shoe
adjusters if necessary. See Brake Clus-
ter Assembly Inspection and Cleaning
on page 6-10.

One brake drags

Weak or broken brake shoe return springs

Replace the return springs.

Sticking wheel cylinder pistons

Replace the wheel cylinder. See Wheel
Cylinder Replacement on page 6-19.

Loose or worn front wheel bearings

Adjust or replace front wheel bearings.
See Section 7 – Steering and Front
Suspension.

Troubleshooting Guide continued on next page...

SYMPTOM

POSSIBLE CAUSE(S)

CORRECTIVE ACTION

Summary of Contents for Pioneer 1200

Page 1: ...2001 MAINTENANCE SERVICE MANUAL 1200 Manual No 102190012 Edition Code 1000A00000...

Page 2: ......

Page 3: ...ub 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 It is the policy of Club Car Inc to...

Page 4: ...future editions of this manual Damage to a vehicle or component thereof not resulting from a defect or that occurs due to unrea sonable or unintended use overloading abuse or neglect including failur...

Page 5: ...1 Returning the Stored Vehicle to Service 3 2 SECTION 4 BODY AND TRIM Cleaning the Vehicle 4 1 Front Body Repair 4 2 Light Scratches Abrasions and Haze 4 2 Deeper Scratches 4 2 Gouges Punctures Tears...

Page 6: ...10 Receiver Hitch Removal 4 10 Receiver Hitch Installation 4 12 Floor Mat 4 12 Floor Mat Removal 4 12 Floor Mat Installation 4 12 SECTION 5 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal Adjustmen...

Page 7: ...Shoe Adjuster Installation 6 22 Hydraulic Line and Hose Replacement 6 24 Front Brake Line Removal 6 24 Front Brake Line Installation 6 24 Front Brake Cluster Hose Removal 6 24 Front Cluster Hose Insta...

Page 8: ...0 Rack and Pinion Installation 7 13 Front Suspension 7 13 Lubrication 7 13 Wheel Alignment 7 14 Front Suspension Components 7 16 Kingpin and Steering Spindle Removal 7 16 Kingpin and Steering Spindle...

Page 9: ...afety Checklist 10 2 Periodic Service Schedule 10 3 Periodic Lubrication Schedule 10 4 Master Cylinder 10 6 Brake Fluid 10 6 Engine Oil 10 6 Oil Viscosity 10 7 Fueling Instructions 10 7 Battery 10 8 S...

Page 10: ...ing Unit Circuit 11 19 Testing the Lighting Circuit 11 20 Test Procedures 11 20 Index of Test Procedures 11 20 SECTION 12 ELECTRICAL COMPONENTS Starter Generator 12 2 Voltage Regulator 12 13 Diode 12...

Page 11: ...er Head Removal 13 10 Valve Removal 13 11 Breather Valve Reed Valve 13 12 Cylinder Head Cleaning and Inspection 13 12 Valve Guides 13 13 Valve Seats 13 13 Valves 13 16 Rocker Arm and Rocker Shaft insp...

Page 12: ...ion 14 1 How the Carburetor Works 14 2 Main System 14 2 Slow Speed System 14 2 Choke and Fresh Air System 14 4 Float System 14 4 Carburetor 14 4 Main Jet Elevation Size Chart 14 5 Changing the Main Je...

Page 13: ...neral Information 14 24 Preparation for Extended Storage 14 24 Fuel Tank Removal 14 24 Fuel Tank Disposal 14 25 Fuel Tank Storage 14 25 Fuel Tank Installation 14 25 Fuel Lines 14 27 Fuel Shut Off Valv...

Page 14: ...or Gear Assembly 16 31 Differential Gear Lock Housing Assembly 16 31 Unitized Transaxle Assembly 16 32 Unitized Transaxle Installation 16 39 Forward Reverse F R Shifter Cable 16 47 F R Shifter Cable R...

Page 15: ...ne Vehicle Maintenance and Service Manual Page xiii 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 C...

Page 16: ......

Page 17: ...ians should become familiar with these general statements which can be found throughout this manual Also other specific warnings appear throughout this manual and on the vehicle DANGER Battery Explosi...

Page 18: ...Do not attempt to service hot engine or exhaust systems Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme...

Page 19: ...eering Self adjusting rack and pinion Suspension Front Independent A arms with coil over shocks Rear Semi independent rear suspension with multi leaf springs and dual hydraulic shocks Brakes Hydraulic...

Page 20: ...surface only 1200 lb 544 kg Bed Load Capacity level surface only 800 lb 363 kg Standard Seating Capacity 2 LIQUID CAPACITIES Engine Crankcase without filter 32 oz 95 liters Engine Crankcase with filt...

Page 21: ...E NOTE Always have the vehicle serial number at hand when ordering parts or making inquiries STORAGE GASOLINE VEHICLE See General Warning Section 1 Page 1 1 PREPARING THE VEHICLE FOR EXTENDED STORAGE...

Page 22: ...uretor and fuel lines is used up and the engine stalls Figure 3 2 Page 3 3 3 2 Loosen do not remove the carburetor drain screw and drain fuel remaining in bowl into a small container then pour the fue...

Page 23: ...l is pumped into the carburetor and fuel lines and the engine starts Turn the engine off See follow ing NOTE 3 Readjust tire pressure See Specifications Section 2 Page 2 2 NOTE Due to the oil added to...

Page 24: ...3...

Page 25: ...ine or exhaust system Failure to heed this warning can result in severe burns To avoid unintentionally starting the vehicle Disconnect the battery cables negative cable first Disconnect the spark plug...

Page 26: ...el 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 DEE...

Page 27: ...nect wiring to electrical components Dash Panel Installation 1 Reconnect wiring to electrical components 2 Reinstall the dash panel in reverse order of removal DASHBOARD INSTALLATION 1 Replace dashboa...

Page 28: ...ine Vehicle Maintenance and Service Manual 4 Figure 4 1 Front Body Assembly 10 11 TYPICAL 4 PLACES 5 TYPICAL 5 PLACES 7 TYPICAL 2 PLACES 6 2 12 9 9 FENDER SUPPORT 1 3 4 7 TYPICAL 6 PLACES TYPICAL 5 PL...

Page 29: ...ners insert into hole and push the head in SEAT Read WARNING and CAUTION on page 4 1 To preserve seat appearance clean regularly with mild soap or detergent applied with a sponge or soft cloth Use a s...

Page 30: ...CAUTION on page 4 1 SEAT SUPPORT REMOVAL 1 Completely remove both seats from the vehicle 2 Remove park brake cable from park brake lever See Equalizer Cable Removal Section 6 Page 6 31 3 Disconnect c...

Page 31: ...4 7 4 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...

Page 32: ...Hold bed at a slight angle front of bed lower than rear of bed to vehicle and place front edge of bed onto vehicle frame Bed latches 10 should be engaged with latch plates 11 Figure 4 3 Page 4 9 2 Lo...

Page 33: ...AND TRIM Tilt Bed 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 4 9 4 Figure 4 3 Tilt Bed 4 3 1 2 17 TYPICAL 2 PLACES 16 19 TYPICAL 2 PLACES 18 10 11 TYPICAL 2 PLACES 8 15 14...

Page 34: ...enger side of the vehicle The decal should be plainly visible when the cargo bed is raised TAILSKIRT Read WARNING and CAUTION on page 4 1 TAILSKIRT REMOVAL 1 Remove two thread forming screws 12 from t...

Page 35: ...aintenance and Service Manual Page 4 11 4 Figure 4 4 Rear Fender Tailskirt and Receiver Hitch 12 TYPICAL 2 PLACES 1 7 8 8 9 13 TYPICAL 2 PLACES 18 17 16 15 23 24 22 21 TYPICAL 2 PLACES 7 8 9 TYPICAL 2...

Page 36: ...MAT Read WARNING and CAUTION on page 4 1 FLOOR MAT REMOVAL 1 Remove the brake and accelerator pedals See Section 5 Accelerator and Brake Pedal Assem blies 2 Remove the top edge of the floor mat from t...

Page 37: ...ning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Turn the key switch to OFF rem...

Page 38: ...travel any further Figure 5 3 Page 5 3 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 dist...

Page 39: ...ment is not necessary but it must be a minimum of 1 8 inch so that the push rod does not contact the master cylinder piston when the pedal is at rest NOTE Brake pedal free play is the distance the pus...

Page 40: ...ck of the accelerator pedal is 5 3 4 inches 1 4 inch 14 6 cm 6mm Figure 5 7 Page 5 5 5 Adjust the accelerator rod DANGER Before servicing turn the key switch to OFF and place the Forward Reverse handl...

Page 41: ...and hold on to seat handle while moving Drive slowly in turns and straight up and down slopes Do not start vehicle until all occupa nts are seated One 1 person per seat maximu m Operate from driver si...

Page 42: ...ent Page 5 6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual 5 Figure 5 9 Accelerator Pedal Assembly FLOORBOARD REMOVED FOR CLARITY TYPICAL 4 PLACES 26 22 21 24 TYPICAL 4 PLACES 21 8...

Page 43: ...lectrical box cover and screw BRAKE PEDAL Read WARNING on page 5 1 BRAKE PEDAL REMOVAL 1 Make sure key switch is OFF and the Forward Reverse handle is in NEUTRAL then disconnect battery and spark plug...

Page 44: ...Pedal Adjustment on page 5 1 ACCELERATOR PEDAL Read WARNING on page 5 1 ACCELERATOR PEDAL REMOVAL 1 Make sure the key switch is OFF and the Forward Reverse handle is in NEUTRAL then disconnect the ba...

Page 45: ...ower hole in pedal and through pivot rod 6 Install two washers 25 and nut 23 onto bolt Finger tighten nut Figure 5 9 Page 5 6 3 Install plastic spacer 20 on pivot rod Figure 5 9 Page 5 6 4 Insert the...

Page 46: ...5...

Page 47: ...id unintentionally starting the vehicle Disconnect battery cables negative cable first Disconnect the spark plug wire from the spark plug Frame ground Do not allow tools or other metal objects to cont...

Page 48: ...e and pressing the brake pedal the vehicle should come to a smooth straight stop Apply and release the brake pedal several times If noise or binding occurs the brake pedal or hydrau lic brake system m...

Page 49: ...ic System on page 6 31 Check the vent holes in the reservoir cap The vent holes should be clean and open If the vent holes are not clean and open clean or replace the cap Check the diaphragm inside th...

Page 50: ...2 BRAKE SYSTEM TROUBLESHOOTING With normal scheduled maintenance and replacement of worn parts the hydraulic and park brake systems should provide trouble free operation In the event that a problem do...

Page 51: ...ce the brake drums See Brake Drum Removal on page 6 7 Clogged master cylinder lines or hoses Replace brake lines or hoses as required See Hydraulic Line and Hose Replace ment on page 6 24 Frozen maste...

Page 52: ...backing plate and or replace the brake shoes See Brake Cluster Assembly Inspection and Cleaning on page 6 10 and orBrakeShoeRemovalonpage 6 9 Brake drums are cracked or scored Replace the brake drums...

Page 53: ...hain hoist or floor jack Place jack stands under the front frame tubes to support the vehicle and lower the floor jack or chain hoist so that the vehicle is resting on the jack stands 2 Remove the lug...

Page 54: ...he brake shoe lining and the brake shoe drum Figure 6 3 Page 6 8 8 Repeat steps 1 through 7 for the opposite front wheel if necessary REAR WHEEL BRAKE DRUM REMOVAL 1 To remove the rear brake drums pla...

Page 55: ...DOT 5 brake fluid See Bleeding the Hydraulic Brake System on page 6 29 1 Brake drum removal is necessary prior to removing the brake shoes See Brake Drum Removal on page 6 7 2 Remove the rear axle to...

Page 56: ...ter components 3 Check the brake shoe adjusters in each brake cluster assembly for proper operation 3 1 With the brake drum removed gently rotate the adjusters with a torque wrench and hydraulic brake...

Page 57: ...An improperly installed C clip could result in a non functioning park brake Apply grease carefully when performing the following steps Do not allow any grease to get on the friction surfaces of the b...

Page 58: ...ake 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 sh...

Page 59: ...tallation on page 6 14 8 Install rear axle if required NOTE Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft 8 1 Clean the ax...

Page 60: ...r or damage If they are worn or pitted remove the cups by inserting a drift punch from the opposite end of the hub and tapping lightly around them Figure 6 2 Page 6 7 4 If bearing cups 7 were removed...

Page 61: ...ate the castle nut back until the next available notch allows the cotter pin to be installed 18 Install the dust cover 1 Figure 6 2 Page 6 7 19 With the brake drum properly seated and secured gently a...

Page 62: ...ust the clearance between the brake shoes and brake drum by turning each of the two adjusters on the brake cluster as shown Figure 6 13 Page 6 16 Use a hydraulic brake adjuster CCI 102169401 and torqu...

Page 63: ...cluster assembly Figure 6 1 Page 6 2 3 To ensure that no dirt or debris enters the hydraulic braking system place the hose fitting in a plastic bag and secure to the vehicle frame as shown Figure 6 1...

Page 64: ...le tube Figure 6 4 Page 6 9 2 2 Carefully pull the axle shaft straight out of the axle tube 2 3 Repeat steps 2 1 through 2 2 for the opposite rear wheel if necessary 3 Remove park brake cable clip 1 h...

Page 65: ...the splined bore of the differential side gear Continue advancing the shaft until the bearing seats against the axle tube shoulder 5 2 Install retaining ring in the axle tube Figure 6 4 Page 6 9 5 3...

Page 66: ...ose from the wheel cylinder 7 Figure 6 18 Page 6 20 See Hydraulic Line and Hose Replacement on page 6 24 4 Remove two bolts and lock washers 9 that secure the wheel cylinder to the brake cluster mount...

Page 67: ...ake System Inspection on page 6 2 BRAKE SHOE ADJUSTER REPLACEMENT Read WARNING on page 6 1 WARNING If at any point in this procedure the hydraulic system is opened the brakes must be bled after the co...

Page 68: ...e Cluster Replacement on page 6 17 5 Install brake shoes See Brake Shoe Installation on page 6 12 6 Install rear axle if required NOTE Clean any residual oil from the exposed end of the axle shaft and...

Page 69: ...Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6 23 6 Figure 6 20 Four Wheel Hydraulic Brake System TYPICAL 2 PLACES TYPICAL BOTH SIDES TYPICAL BOTH SIDES 5 7 8 9 2 1 3 6 12 4 10 1...

Page 70: ...o collect the brake fluid when the hydraulic system is opened in the fol lowing step 4 Using a flare nut wrench remove the flare nut of the front brake line 4 from the master cylinder Fig ure 6 20 Pag...

Page 71: ...m Figure 6 20 Page 6 23 6 Fill the reservoir of the master cylinder and bleed the hydraulic system See Filling the Hydraulic Sys tem on page 6 31 7 Perform all of the brake system inspections to ensur...

Page 72: ...ure 6 20 Page 6 23 6 Remove the brake hose 9 from the vehicle Figure 6 20 Page 6 23 REAR CLUSTER HOSE INSTALLATION 1 Install brake hose through the D shaped hole in I beam 2 Install horseshoe clip 3 U...

Page 73: ...r damage or wear and replace if necessary 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 Fi...

Page 74: ...lease the park brake 2 Place a pan below the vehicle to collect the brake fluid when the hydraulic system is opened in the fol lowing step 3 Remove the two wires from the master cylinder pressure swit...

Page 75: ...systems The front two wheels are connected to the smaller front portion of the brake fluid reservoir and the rear wheels are connected to the rear larger portion of the brake fluid reservoir Depending...

Page 76: ...eeder to start the vacuum 10 With the vacuum running open both of the brake bleeder valves 1 4 turn See Figure 6 1 Page 6 2 or Figure 6 18 Page 6 20 11 Monitor the fluid as it flows through the tubes...

Page 77: ...wheels and release the park brake 2 Remove the two screws 3 that secure the boot 2 to the seat support Figure 6 24 Page 6 32 3 Slide the boot 2 off of the park brake handle 1 Figure 6 24 Page 6 32 4 R...

Page 78: ...6 24 Park Brake Assembly ClubCar 18 23 11 4 5 TYPICAL 2 PLACES 1 28 5 6 TYPICAL 2 PLACES TYPICAL EACH SIDE OF VEHICLE 15 20 21 TYPICAL EACH SIDE OF VEHICLE 17 27 TYPICAL EACH SIDE OF VEHICLE 12 22 26...

Page 79: ...6 Remove the cable from the cable support bracket 17 or 18 7 Slide the cable through the hanger 15 and remove the cable from the vehicle 8 If necessary remove the other wheel brake cable in the same m...

Page 80: ...ng each of the two adjust ers on both rear brake clusters as shown Figure 6 13 Page 6 16 Use a hydraulic brake adjuster CCI 102169401 and torque wrench See following CAUTION CAUTION Do not apply more...

Page 81: ...ry cables negative cable first Disconnect the spark plug wire from the spark plug Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or electrica...

Page 82: ...Wheel Page 7 2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual 7 Figure 7 1 Steering Column 17 16 TYPICAL 4 PLACES 15 TYPICAL 4 PLACES 14 26 19 18 24 11 10 10 9 8 7 6 5 1 3 2 TYPICA...

Page 83: ...steering column Figure 7 3 Page 7 3 5 4 Using a 1 2 inch drive air impact wrench tighten the anvil screw 6 until the steering wheel breaks free from the steering shaft 5 5 Remove the steering wheel p...

Page 84: ...nt body See Front Body Removal Section 4 Page 4 3 6 Remove the upper bolt 2 and lock washer 3 from the universal joint 1 Figure 7 4 Page 7 4 7 Remove the nuts 17 bolts 15 and washers 16 from the steer...

Page 85: ...of wood on bearing seat and tap lightly on block until bearing seat 10 is fully seated in steering tube 14 Figure 7 5 Page 7 5 and Figure 7 6 Page 7 5 2 Press the bearing 9 all the way into the beari...

Page 86: ...le in the universal joint 1 before sliding the spline into the universal joint Figure 7 1 Page 7 2 4 Install the bolt 2 and lock washer 3 on the upper universal joint and finger tighten Figure 7 4 Pag...

Page 87: ...Page 7 11 5 Remove the four bolts 20 washers 21 and nuts 22 from the steering rack assembly mounting bracket Figure 7 7 Page 7 7 and Figure 7 20 Page 7 11 6 Remove the bolt 27 and lock washer Figure 7...

Page 88: ...ellows are secured with a metal clamp use a pair of pliers to remove the clamp Do not attempt to reuse the clamp when the rack and pinion is reassembled Use a plastic wire tie to secure the dust seal...

Page 89: ...ive wear If wear is excessive replace the steering box assembly CCI 102010101 Figure 7 20 Page 7 11 13 Inspect the ball joints 9 for wear Figure 7 20 Page 7 11 If one or both of the ball joints 9 are...

Page 90: ...ring onto pinion shaft exerting all pressure on the inner race Then install the c type stop ring 16 Figure 7 20 Page 7 11 3 Install pinion 3 and bearing 15 assembly into the housing 1 Figure 7 20 Page...

Page 91: ...Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7 11 7 Figure 7 20 Steering Gear 13 4 15 17 22 3 16 2 23 12 19 12 11 10 24 9 18 TYPICAL 4 PLACES TYPICAL 2 PLACES 20 21 5 6 8 7 TYPIC...

Page 92: ...ng 6 and screw 7 Figure 7 20 Page 7 11 The screw should be threaded in until it bottoms out and then backed out 1 4 turn Figure 7 22 Page 7 12 10 Insert a 3 8 inch deep well socket into the steering c...

Page 93: ...ly and to prevent corrosion apply a light coat of anti seize and lubricating com pound to the end of the steering column U joint 2 Align the flat portion of the compound joint shaft spline with the bo...

Page 94: ...at is oriented toward the rear of the vehicle The marks should be at the same height as the center of each hub 3 Measure the distance between the marks on the rear facing surfaces of the tires and the...

Page 95: ...eer 1200 Vehicle Front Suspension 17 TYPICAL 2 PLACES 16 TYPICAL 4 PLACES 20 34 35 24 37 1 2 TYPICAL 2 PLACES 4 TYPICAL 6 PLACES 3 6 TYPICAL 2 PLACES 15 22 7 TYPICAL 2 PLACES 10 TYPICAL 4 PLACES 19 3...

Page 96: ...tall new cotter pins 18 Figure 7 20 Page 7 11 10 After toe in adjustment is made and with wheels in the straight ahead position the steering wheel should be at the center of its travel If the steering...

Page 97: ...ge 7 15 5 Install the thrust washer 34 wave washer 35 and kingpin 23 Figure 7 28 Page 7 15 6 Install the washer 37 and a new lock nut 24 Tighten to 18 ft lb 24 4 N m Figure 7 28 Page 7 15 7 Insert the...

Page 98: ...e 7 28 Page 7 15 7 Insert the ball joint 23 into the spindle assembly Figure 7 20 Page 7 11 8 Install the lock nut 24 to secure the ball joint to the spindle and tighten to 18 ft lb 24 4 N m Figure 7...

Page 99: ...e shock absorber SHOCK ABSORBER INSTALLATION 1 Install the shock absorber by reversing the removal procedure 2 Tighten the nuts to 20 ft lb 27 N m 3 Inspect the brake hoses at the front wheels When tu...

Page 100: ...the wheel and hub on the spindle remove dust cap 1 and cotter pin 2 and then tighten the spindle nut 3 until the bearing 5 fully seats in the bearing cup 7 3 Loosen spindle nut one cotter pin positio...

Page 101: ...ry cables negative cable first Disconnect the spark plug wire from the spark plug Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other ele...

Page 102: ...until they are snug See following NOTE NOTE Traks Max II tires are directional For optimum performance on muddy terrain install all four tires as shown Figure 8 1 Page 8 2 2 Lower the vehicle and fin...

Page 103: ...8 2 Inflate the tire to the recom mended tire pressure 1 2 Immerse the tire in water and then mark the point where bubbles are formed by escaping air 1 3 Determine the cause of the air leak and repair...

Page 104: ...8...

Page 105: ...ve cable first Disconnect the spark plug wire from the spark plug Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring N...

Page 106: ...rs Page 9 2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual 9 Figure 9 1 Rear Suspension 7 8 8 7 6 1 14 12 24 23 18 13 19 23 24 23 17 22 REAR BRAKE CABLE 21 TYPICAL BOTH SIDES OF VEH...

Page 107: ...en installing shock absorbers make sure front shocks have identical part numbers and rear shocks have identical part numbers 1 To install reverse the removal procedure 2 On the upper shock absorber mo...

Page 108: ...shock mount bracket 14 Figure 9 1 Page 9 2 8 Remove bolt 16 and locknut 17 attaching the leaf spring 18 to the rear shackles 19 Figure 9 1 Page 9 2 9 Allow rear of leaf spring 18 to rest on the ground...

Page 109: ...m Figure 9 1 Page 9 2 6 Install shock absorber See Shock Absorber Installation on page 9 3 SNUBBER Read WARNING on page 9 1 SNUBBER REMOVAL 1 Support the powertrain with a floor jack under the engine...

Page 110: ...9...

Page 111: ...e vehicle or failure to properly maintain it could result in decreased vehicle performance or severe personal injury Any modification or change to the vehicle that affects the stability or handling of...

Page 112: ...vehicle GENERAL INFORMATION Read DANGER and WARNING on pages 10 1 and 10 2 To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program reg...

Page 113: ...nd lubrication schedules Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep the vehicle in optimum operating condition PERIODIC SERVICE SCHEDULE REGULAR...

Page 114: ...r damage Replace as required Check brake shoes and drums replace as required See Section 6 Hydraulic and Park Brake Systems Annual service by trained technician only every 100 hours of operation Engin...

Page 115: ...by trained technician only every 100 hours of operation Check fill unitized transaxle to plug level 5 31 oz 92 liters 80 90 Wt API class GL 3 or 80 90 Wt AGMA class 5 EP gear lubricant Inspect front...

Page 116: ...m top of reservoir Figure 10 3 Page 10 6 Also brake fluid should be clean with no residue in bottom of reservoir or other evidence of contamination See follow ing CAUTION CAUTION Use only DOT 5 silico...

Page 117: ...ricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation If the vehicle has an all weather e...

Page 118: ...fuel tank Avoid spilling fuel NOTE Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Vehicles to be stored for extended periods should be prepared for storage as...

Page 119: ...l repair Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those affixed to the vehicle Wear safety glasses or approve...

Page 120: ...nection at ignition coil or RPM limiter Section 11 Troubleshooting and Electrical System Test Procedures 14 15 and 16 Intermittent ignition coil failure Section 11 Troubleshooting and Electrical Syste...

Page 121: ...tion chamber Section 13 FE350 Engine Spark plug heat range is incorrect Section 13 FE350 Engine Unsuitable or contaminated fuel Section 14 Fuel System Loss of engine power Exhaust valve is restricted...

Page 122: ...em Starter Circuit on page 11 15 Starter generator failed Section 11 Troubleshooting and Electrical System Test Procedure 8 Starter solenoid failed Section 11 Troubleshooting and Electrical System Tes...

Page 123: ...ion Engine mounting nuts or bolts are loose Section 13 FE350 Engine Snubber on frame is worn or damaged Section 13 FE350 Engine Misaligned muffler mounting clamp Section 15 Exhaust System Damaged driv...

Page 124: ...ADLIGHT FUEL HOUR GAUGE MASTER CYLINDER OIL LIGHT REVERSE BUZZER KEY SWITCH LIGHT SWITCH BROWN SONIC WELD SONIC WELD YELLOW WHITE BLACK WHITE BLACK YELLOW BLUE BLUE BLUE RED WHITE YELLOW GREEN WHITE G...

Page 125: ...WITCH LOCKOUT CAM LIMIT SWITCH OPTIONAL TAIL LIGHT OPTIONAL TAIL LIGHT BATTERY RED BLACK GREEN WHITE BLACK WHITE BLACK BRAIDED GROUND SOLENOID WHITE RED SONIC WELD SONIC WELD SONIC WELD ORANGE RED WHI...

Page 126: ...g Circuit Lockout Cam Circuit Fuel Gauge and Sending Unit Circuit Hour Gauge Circuit Lighting Circuit Recognizing and understanding the function of each of these circuits will help to quickly isolate...

Page 127: ...the positive post of the battery and the F2 post of the starter generator The starter generator then turns and cranks the engine through belt driven pulleys NOTE Engine rotation clockwise is as viewe...

Page 128: ...spark plug therefore the proper way to stop the engine is to run this electrical power to ground bypassing the spark plug Figure 11 6 Page 11 11 The engine kill circuit consists of the key switch and...

Page 129: ...fuse fuse block and con necting wires Figure 11 7 Page 11 11 The battery supplies power through the fuse block and is controlled by the reverse buzzer limit switch which is activated by a cam located...

Page 130: ...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 NOT...

Page 131: ...to the 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 10 Lockout Ca...

Page 132: ...trical circuits to determine the source of an electrical problem test the vehicle battery to determine whether or not it is the source of the problem A hydrometer multimeter and 160 ampere load tester...

Page 133: ...ITCH TEST PROCEDURE 4 CHECK LOCKOUT CAM LIMIT SWITCH TEST PROCEDURE 7 VOLTAGE ABOVE 9 6 VOLTS CHECK STARTER GENERATOR TEST PROCEDURE 8 SOLENOID DOES CLICK TAKE VOLTAGE READING TEST PROCEDURE 24 VOLTAG...

Page 134: ...CEDURE 14 CHECK FUEL SYSTEM SEE SECTION 14 CHECK COMPRESSION SEE CYLINDER HEAD IN SECTION 13 IGNITION GAP TEST NOT GOOD DISCONNECT ENGINE KILL WIRE GOOD SPARK NO SPARK CHECK RPM LIMITER TEST PROCEDURE...

Page 135: ...TEST LIMIT SWITCH REVERSE BUZZER WILL NOT FUNCTION AND ENGINE WILL NOT CRANK CHECK BATTERY TEST PROCEDURE 1 CHECK FUSE TEST PROCEDURE 2 DETERMINE CAUSE OF THE BLOWN FUSE REPLACE FUSE CHECK GROUND STR...

Page 136: ...PROCEDURE 21 CHECK LOW OIL WARNING LIGHT TEST PROCEDURE 22 REPLACE OIL LEVEL SENSOR REPLACE OIL LEVEL SENSOR REPLACE LOW OIL WARNING LIGHT REPLACE YELLOW WIRE WIRES INCORRECTLY CONNECTED WIRES CORRECT...

Page 137: ...he following chart Figure 11 20 to begin troubleshooting the fuel gauge and sending unit circuit Figure 11 20 Testing the Fuel Gauge and Sending Unit Circuit CHECK FUEL LEVEL SENDING UNIT TEST PROCEDU...

Page 138: ...rcuit 5 Key Switch Accessory Terminal 6 Solenoid 7 Lockout Cam Limit Switch 8 Starter Generator Starter Function Figure 11 21 Testing the Lighting Circuit CHECK VOLTAGE AT HEADLIGHT SOCKET TEST PROCED...

Page 139: ...t TEST PROCEDURE 1 BATTERY Read DANGER and WARNING on page 11 1 DANGER Due to the danger of an exploding battery wear a full face shield and rubber gloves when working around a battery Battery Explosi...

Page 140: ...diately Performing the Hydrometer Test 1 Be sure that the battery has sufficient water to cover the plates by approximately 0 5 inch 12 7 mm and is fully charged prior to beginning the test If water m...

Page 141: ...may be a weak cell When the variations between cells reach 0 050 or more the battery should be replaced Voltage Test 1 Place the red probe of a multimeter set at Volts DC 20 volt range on the positiv...

Page 142: ...box 3 Check that wires are connected correctly and are tight If they are not rewire or tighten as necessary 4 Remove fuse to be tested from the fuse block See Fuse Removal Section 12 Page 12 18 The re...

Page 143: ...ire connects the negative battery post to the frame The frame connection should be clean and tight Visual inspection of the connection on the frame is very difficult The best check for tightness is to...

Page 144: ...ading is correct leave the probes connected and proceed to the next step 6 Insert the key and hold the key in the START position The reading should be continuity If the reading is incorrect replace th...

Page 145: ...Do not allow the wires to touch the frame or other components of the vehicle Figure 11 29 Page 11 27 6 Set the multimeter to 200 ohms Connect the red probe to one of the large posts of the solenoid a...

Page 146: ...t connections 3 Set the multimeter to 200 ohms Place the red probe of the multimeter on the common COM terminal of the limit switch Place the black probe on the normally open NO terminal of the switch...

Page 147: ...lems 1 a grounded A1 or A2 terminal 2 a grounded wire in the brush area or 3 a grounded armature commutator If the F1 or F2 reading is incorrect it indicates a possible grounded F1 or F2 terminal or a...

Page 148: ...arter Generator Removal Section 12 Page 12 2 TEST PROCEDURE 9 WIRE CONTINUITY Read DANGER and WARNING on page 11 1 1 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and disco...

Page 149: ...e 12 14 5 Reconnect the diode See Diode Installation Section 12 Page 12 15 See also followingWARNING WARNING Incorrect wiring could result in severe injury or death Diode and solenoid connections must...

Page 150: ...tting to ensure that it is adjusted correctly See Engine RPM Adjustment Section 14 Page 14 13 4 With the battery in good condition and fully charged run the engine for several minutes to bring the vol...

Page 151: ...s turned to the OFF position It will be necessary to pull and hold the choke handle until the engine stops running 6 If the engine does not run proceed to Test Procedure 14 Ignition Spark on page 11 3...

Page 152: ...nd test the engine for proper operation TEST PROCEDURE 15 RPM LIMITER Read DANGER and WARNING on page 11 1 1 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and disconnect th...

Page 153: ...Figure 11 41 Page 11 36 If the resistance is still not between 0 6 1 7 ohms replace the coil 3 Using a multimeter set to 20k ohms measure the secondary coil resistance 3 1 Remove the spark plug wire...

Page 154: ...ng should be NO continuity If either reading is incorrect replace the key switch Figure 11 43 Page 11 36 5 Reconnect the key switch to the wire harness Ensure that the connector is connected correctly...

Page 155: ...t switch is located on the Forward Reverse shifter red white and orange wires are connected to it 1 Place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Move the Forward Rev...

Page 156: ...chock the wheels and disconnect the bat tery cables negative cable first 2 Remove the center dash assembly See Key Switch Removal Section 12 Page 12 15 3 Ensure that the wires are connected correctly...

Page 157: ...esults are good and the voltage reading is zero there may be a broken or damaged 6 gauge white wire from the solenoid to the starter generator See Test Procedure 8 Starter Genera tor Starter Function...

Page 158: ...e wheels and disconnect the battery cables negative cable first 2 Remove the center dash assembly to gain access to the back of the fuel hour gauge See Key Switch Removal Section 12 Page 12 15 3 Place...

Page 159: ...r records in six minute increments See fol lowing DANGER DANGER Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless...

Page 160: ...Test Procedure 2 Fuse on page 11 24 If the headlight diode is functioning correctly the wires and fuse show continuity and the readings are still incorrect replace the switch See Light Switch Removal...

Page 161: ...e Removal Section 12 Page 12 30 7 With the Forward Reverse handle in the NEUTRAL position and the wheels chocked start the engine and depress the accelerator pedal to the floor 8 Push the light switch...

Page 162: ...20 volts DC attach using an alligator clip the black probe of multimeter onto the negative battery terminal and place the red probe into the blue wire terminal of the wiring harness If the multimeter...

Page 163: ...technicians should repair or service this vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Follow the procedures exactly as...

Page 164: ...hain 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 suppo...

Page 165: ...led could damage the brushes Lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the br...

Page 166: ...5 See following CAUTION CAUTION When checking brush spring tension do not push springs beyond the point they would normally be if there were new brushes installed Exerting excessive force or pushing b...

Page 167: ...all the commutator end cover 23 onto the armature shaft Align the locating pin with the pin hole in the cover Install two M6 x 180 mm bolts 20 and tighten to 100 in lb 11 3 N m Figure 12 3 Page 12 4 4...

Page 168: ...starter generator housing 24 Figure 12 3 Page 12 4 3 To separate armature 33 from output end cover 36 remove nut 41 lockwasher 40 pulley 39 shaft key 34 spacer 37 and bearing retainer screws 43 Figure...

Page 169: ...2 7 2 Discard the bearings 3 Slide the bearing retainer 32 off of the output end of the shaft Figure 12 8 Page 12 6 Field Coil Removal 1 Remove the retaining nut from each field coil terminal and slid...

Page 170: ...aid in diagnosing the original cause of the failure Items to look for are listed below Burned charred or cracked insulation Improperly cured varnish Thrown solder Flared armature windings Worn burned...

Page 171: ...wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars 1 Using a multimeter set on 200 ohms place the positive probe on the commutator bars and th...

Page 172: ...ugh the insulators 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 Figure 12 13 Armature Gr...

Page 173: ...brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from slidi...

Page 174: ...48 in lb 5 4 N m 7 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 Belt Tension Adjustment Belt ten...

Page 175: ...e following CAUTION CAUTION Remove pry bar before starting engine 8 Connect battery cables positive cable first and tighten the terminals to 20 ft lb 27 1 N m Coat termi nals with Battery Protector Sp...

Page 176: ...press down all corners Install screw and tighten to 18 in lb 2 N m 4 Connect battery cables positive cable first and tighten terminals to 20 ft lb 27 1 N m Coat terminals with Battery Protector Spray...

Page 177: ...terminals to 20 ft lb 27 1 N m Coat termi nals with Battery Protector Spray CCI 1014305 KEY SWITCH Read DANGER and WARNING on page 12 1 Testing the Key Switch See Section 11 Test Procedure 4 Page 11...

Page 178: ...oval procedures to install key switch in the dash Tighten the key switch nut firmly Reconnect the wire connector to the key switch 2 Install the dash panel 3 Connect battery cables positive cable firs...

Page 179: ...ns 2 Connect all wires as indicated 2 1 Connect the 6 gauge white wire from the starter generator and the 12 gauge white wire to the large post on the solenoid See Wiring Diagram Section 11 Page 11 6...

Page 180: ...e vehicle electrical system may occur 2 Install the snap on electrical box cover by firmly pressing down on all corners and install the screw tightening to 18 in lb 2 N m 3 Connect battery cables posi...

Page 181: ...ive cable first and tighten the terminals to 20 ft lb 27 1 N m Coat termi nals with Battery Protector Spray CCI 1014305 4 Check limit switch operation 4 1 Place the Forward Reverse handle in the NEUTR...

Page 182: ...is activated only when the Forward Reverse handle is in the NEUTRAL position 4 Connect battery cables positive cable first and tighten the terminals to 20 ft lb 27 1 N m Coat termi nals with Battery...

Page 183: ...age 11 37 Reverse Buzzer Limit Switch Removal 1 Disconnect the battery cables negative cable first Figure 12 1 Page 12 2 2 Disconnect the wires from the reverse buzzer limit switch 4 located on the ba...

Page 184: ...white wire to the normally open NO terminal of the reverse buzzer limit switch 4 Figure 12 20 Page 12 19 5 Connect battery cables positive cable first and tighten the terminals to 20 ft lb 27 1 N m C...

Page 185: ...DANGER and WARNING on page 12 1 Testing the Fuel Hour Gauge See Section 11 Test Procedure 26 Page 11 40 and Test Procedure 27 Page 11 41 With the key switch in the OFF position the fuel hour gauge fi...

Page 186: ...e cable first and tighten the terminals to 20 ft lb 27 1 N m Coat termi nals with Battery Protector Spray CCI 1014305 FUEL LEVEL SENDING UNIT Read DANGER and WARNING on page 12 1 The fuel level sendin...

Page 187: ...5 N m 4 Reconnect black wire at the bullet connector to the white black wire 5 Connect battery cables positive cable first and tighten the terminals to 20 ft lb 27 1 N m Coat termi nals with Battery...

Page 188: ...ing 9 Figure 12 26 Page 12 26 7 Loosen but do not remove three bolts 6 attaching the fan housing as shown 8 Remove the remaining four bolts 10 attaching the fan housing as shown Figure 12 26 Page 12 2...

Page 189: ...t off the wire Figure 12 28 Page 12 27 3 Remove the gasket 1 and protector tube 3 from the old coil NOTE Moisten the spark plug wire with water to make gasket removal and installation easier 4 Remove...

Page 190: ...the engine crankcase Tighten all seven mounting bolts to 90 in lb 10 2 N m Figure 12 26 Page 12 26 15 Install the stiffener with four hex head bolts and lock nuts Tighten the hardware to 23 ft lb 30...

Page 191: ...e retaining tabs on the connector 4 and remove halogen bulb assembly 6 Headlight Bulb Installation NOTE When handling halogen bulbs do not touch glass portion of bulb Oil from finger tips can cause pr...

Page 192: ...e 2 from the headlight diode and remove it from the vehicle Headlight Diode Installation 1 Mount the headlight diode to the frame using the mounting hardware Tighten to 25 in lb 2 8 N m Fig ure 12 31...

Page 193: ...ter nut Then turn the knob in the opposite direction until the headlight beams on the knob are horizontal to the ground Tighten the set screw to lock the knob to the shaft 4 Install the dash panel in...

Page 194: ...Protector Spray CCI 1014305 to prevent future corrosion 2 The battery should be kept clean and dry to prevent self discharge Any dirt grime or acid spillage should be removed Wash the battery with a...

Page 195: ...the fol lowing table See following NOTE NOTE Contact your local water department for mineral content analysis Battery Removal Read DANGER and WARNING on page 12 1 and DANGER on page 12 31 1 Chock the...

Page 196: ...ceed this 45 angle when lifting carrying or installing battery The battery acid could cause severe personal injury when accidentally coming in contact with the skin or eyes and could damage clothing C...

Page 197: ...gure 4 2 Page 4 7 4 Lower the bed and place both seats on the vehicle See following WARNING WARNING Do not disengage prop rod until all persons are clear of cargo bed area Do not drop tilt bed lower g...

Page 198: ...ecommended that the area be heated to at least 60 F 16 C prior to charging The battery will not charge effectively in cold temperatures for the same reasons that it does not discharge as rapidly in co...

Page 199: ...on while servicing vehicle Wear a full face shield and rubber gloves when working with batteries Turn key switch OFF place Forward Reverse handle in the NEUTRAL position and remove key before servicin...

Page 200: ...s before beginning engine service Diagrams DANGER WARNING CAUTION and NOTE statements and detailed descriptions have been included wherever necessary Nevertheless even a detailed account has limitatio...

Page 201: ...s Tightening Sequence Where there is a tightening sequence indicated in this Service Manual the bolts nuts or screws must be tightened in the order and by the method indicated When installing a part t...

Page 202: ...prevents severe stress on the balls and races and prevents damage Press on the inner race if the ball bearing is being pressed onto a shaft or on the outer race if the ball bearing is being pressed in...

Page 203: ...le color or two color and with only a few exceptions must be con nected to leads of the same color On any of the two color leads there is a greater amount of one color and a lesser amount of a second...

Page 204: ...lve begins to open at precisely the same time during each valve event However to ensure good seating there is a small amount of clearance present after the valve closes This clearance is eliminated by...

Page 205: ...between the electrode and base The electrode should not be eroded Black color excessive carbon and or a wet plug indicate a too rich condition White burned or melted elec trodes indicate a too lean c...

Page 206: ...er tight then tighten the spark plug to 20 ft lb 27 N m ENGINE MOUNTING PLATE See Engine Removal on page 13 23 CYLINDER HEAD Read DANGER and WARNING on page 13 1 GENERAL INFORMATION Prior to attemptin...

Page 207: ...15 Exhaust System 9 If the engine is to be totally disassembled drain oil and remove the oil filter If only the cylinder head is to be disassembled proceed without draining the oil or removing the oi...

Page 208: ...3 Figure 13 10 Page 13 10 2 Remove the E ring 1 and pull the rocker shaft 2 out of the cylinder head Figure 13 11 Page 13 10 3 Lift out the rocker arms 3 washer 4 and push rods 5 CYLINDER HEAD REMOVAL...

Page 209: ...10 4 Remove valve stem seal 11 with a screwdriver Figure 13 15 Page 13 11 See following CAUTION CAUTION To keep the screwdriver from damaging the cylinder head flange surface place a piece of heavy ca...

Page 210: ...e 3 Figure 13 16 Page 13 12 See page 13 20 for Breather Valve Installation CYLINDER HEAD CLEANING AND INSPECTION 1 Clean the head with a non flammable solvent and dry thoroughly 2 Bead blast or scrape...

Page 211: ...th the rocker arm side of the head facing up drive the new valve guide into the head with the valve guide arbor 3 until the snap ring 2 just seats on the head Figure 13 21 Page 13 14 5 Ream the guide...

Page 212: ...rfaced See Valve Seat Repair on page 13 14 Make sure to lap the valves to the seats after refacing Valve Seat Repair CAUTION If you are unfamiliar with the following procedures Club Car suggests that...

Page 213: ...take port cutter CCI 101655401 removing only enough material to produce a smooth and concentric seat Figure 13 26 Page 13 15 CAUTION Use care not to dull the cutter Do not turn the cutter counterclock...

Page 214: ...eat does not make proper contact lap the valve into the seat with a vacuum cup tool 4 1 Coat the surface of the valve sparingly with a fine lapping compound 4 2 Use the vacuum cup lapping tool 1 to gr...

Page 215: ...thickness of the valve head as shown Figure 13 29 Page 13 17 2 If the valve head thickness A Figure 13 29 Page 13 17 is less than 0 024 inch 0 610 mm replace the valve Valve Stem Bend 1 Support the v...

Page 216: ...at several points along its length Figure 13 33 Page 13 18 2 If the inside diameter is more than the service limit of 0 4803 inch 12 20 mm replace the rocker arm 3 Using a micrometer measure the diame...

Page 217: ...hown put the rocker shaft 2 into the posts through the rocker arm 3 and washer 4 Figure 13 36 Page 13 20 3 Slide the washer 4 against the exhaust rocker and fit the E ring 1 into the groove in the roc...

Page 218: ...tains a vacuum in the crankcase Oil laden air in the crankcase passes through the reed valve and expands into the rocker chamber In the rocker chamber most oil separates from the air and drains back t...

Page 219: ...e 13 39 Page 13 22 4 Connect muffler See Section 15 Exhaust System 5 Install carburetor 11 throttle spring 12 and the throttle spring bracket 13 Tighten to 50 in lb 5 6 N m Figure 13 40 Page 13 22 6 C...

Page 220: ...able Connection Figure 13 41 Check Engine Oil Level Figure 13 42 Oil Level Sensor Wire Figure 13 43 Crankcase Cover 1 7 6 5 2 3 4 8 11 10 9 12 13 Club Ca r 2 Low Level Safe Level 3 Full Level 1 Oil fi...

Page 221: ...s the engine must be removed from the vehicle CAUTION 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 Un...

Page 222: ...ightly with a plastic mallet on alternate sides near the dowel pins 5 Figure 13 43 Page 13 22 4 Remove the crankcase cover gasket completely It may stick to the flanged surface of the crankcase OIL LE...

Page 223: ...gh pressure chamber in the lifter Camshaft and Hydraulic Lifter Inspection If the engine typically remains noisy for two minutes after it starts the hydraulic lifter might be worn between the plunger...

Page 224: ...ocedure Figure 13 50 Page 13 26 As the engine is cranked the ACR opens and reduces com pression in the cylinder allowing the starter to turn the engine with a minimal amount of effort When the engine...

Page 225: ...rviceable part on the ACR The ACR is a component part of the camshaft assembly and as such if the ACR fails the camshaft assembly must be replaced PISTON AND CONNECTING ROD Read DANGER and WARNING on...

Page 226: ...e the piston 8 The oil ring is made of three pieces upper and lower rails and expander It is difficult to measure the ring groove clearance and thickness Inspect visually for wear or damage Piston Rin...

Page 227: ...ng rod and cap Replace parts if scored 2 Using a telescoping gauge measure the inside diameter of the connecting rod small bore at several points along its length Figure 13 57 Page 13 29 3 If the insi...

Page 228: ...nt parallel with the crankshaft and the second at right angles to the crankshaft at three different locations in the bore The first measurement location is 0 4 inch 10 mm from the top of the cylinder...

Page 229: ...soap warm water and clean rags 4 Dry the cylinder and coat with engine oil See following CAUTION CAUTION The cylinder must be thoroughly cleaned after honing to eliminate all grit IGNITION COIL AND FL...

Page 230: ...Coil Inspection and Repair See Test Procedure 16 Section 11 Page 11 35 Ignition Coil Installation 1 Installation is the reverse of removal 2 While tightening the two bolts 3 use a bronze feeler gauge...

Page 231: ...pump shaft bearing surface Replace both rotors as a set if the measurement is less than 0 4971 inch 12 627 mm Figure 13 67 Page 13 33 4 2 Using a micrometer measure the diameter of the outer rotor at...

Page 232: ...34 2 Inspect the relief valve spring 3 for pitting cracks rusting and burrs Replace if necessary 3 Measure free length of the spring 3 with a vernier caliper Figure 13 71 Page 13 34 If the free lengt...

Page 233: ...en tighten to 7 ft lb 9 5 N m in the sequence shown Figure 13 65 Page 13 33 After tightening bolts check the torque of the first bolt CRANKSHAFT AND COUNTERBALANCE Read DANGER and WARNING on page 13 1...

Page 234: ...cks positioned as close to the crankshaft as possible Figure 13 75 Page 13 36 4 Using a press push on the end of the crankshaft to pull the spur gear and the helical gear off the crank shaft Figure 13...

Page 235: ...e inside diameter of the large end is greater than 1 9726 inches 50 106 mm replace the link rod Figure 13 79 Page 13 37 See following NOTE NOTE Do not remove the link rod on the PTO power take off sid...

Page 236: ...river See following NOTE NOTE Install the new bearing with its oil hole aligned with the oil passage in the counterbalance weight 2 Clean the parts thoroughly in a high flash point solvent and wipe dr...

Page 237: ...inches 34 930 mm replace the crankshaft 4 Using a micrometer measure the connecting rod journal at several points along its length Figure 13 84 Page 13 39 5 If the journal diameter is less than 1 474...

Page 238: ...Page 13 40 2 The final finishing dimensions are as follows Figure 13 87 Page 13 40 A 1 4759 1 4763 inches 37 489 37 500 mm B 0 110 0 126 inch 2 80 3 20 mm C 1 1968 inches maximum 30 4 mm D 1 2775 1 2...

Page 239: ...Car Bearing Driver Kit Part No 1016416 drive out the ball bearing 3 as shown Ball Bearing Inspection 1 Clean the ball bearing thoroughly in high flash point solvent and dry it NOTE Never use compresse...

Page 240: ...e 1 97 inch 50 mm seal driver press the oil seal into the crankcase cover until it is 0 157 inch 4 mm below the outside surface Plain Bearing Surface Inspection Plain bearing surfaces are used for bot...

Page 241: ...the link rod onto the crankshaft and install the key Press the spur gear and helical gear onto the crank shaft Figure 13 94 Page 13 43 and Figure 13 95 Page 13 43 See following CAUTION and NOTE CAUTIO...

Page 242: ...ston rings should be facing up when installed 5 Tighten the two connecting rod bolts to 16 5 ft lb 23 N m CRANKSHAFT AXIAL PLAY ADJUSTMENT Read DANGER and WARNING on page 13 1 1 With the gasket instal...

Page 243: ...f removal See page 13 25 2 Apply a light film of engine oil to the camshaft journals and cam lobes Figure 13 98 Determine Crankshaft Shim Size Figure 13 99 Install Shim On Crankshaft Figure 13 100 Cra...

Page 244: ...face to the cam gear sur face 2 Record this measurement Figure 13 103 Page 13 46 2 Measure from the crankcase cover 3 mounting face to the camshaft bearing inner end 4 3 Locate the measurements on the...

Page 245: ...wear and damage 2 Install crankcase cover Using HANDS ONLY seat cover completely against the crankcase If the cover will not seat the camshaft is not installed correctly 3 Install and finger tighten e...

Page 246: ...rap wrench 3 to keep the flywheel and fan assembly 1 from turning while tightening the fly wheel nut to 63 ft lb 85 4 N m Figure 13 107 Page 13 48 See following CAUTION CAUTION The flywheel nut has ri...

Page 247: ...of a new oil filter and install the filter on the crankcase Fill the crankcase to the proper level with the cor rect type of oil This engine should be regarded as a new engine for next scheduled oil c...

Page 248: ...end bearing I D max 0 4746 in 12 057 mm Piston top ring groove clearance with new ring max 0 0063 in 0 16 mm Piston second ring groove clearance with new ring max 0 0055 in 0 14 mm Piston oil ring gro...

Page 249: ...907 mm Breather reed valve valve tip air gap max 0 008 in 0 2 mm Valve stem exhaust intake stem bend max 0 0012 in 0 03 mm Push rod rod bend max 0 0196 in 0 50mm Valve guide exhaust intake I D Standar...

Page 250: ...p standard 0 012 in 0 304 mm Oil pressure min at fast idle speed 45 5 psi 314 kPa Oil filter bypass valve opening pressure 11 4 to 17 0 psi 78 to 118 kPa Compression pressure min with automatic compre...

Page 251: ...when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Frame ground Do not allow tools or other metal objects to contact frame when disconn...

Page 252: ...der heavy load con ditions A dirty or clogged main jet will cause the mixture to become too lean An overly rich mixture could be caused by a clogged air passage clogged air holes in the main nozzle a...

Page 253: ...uel is supplied mainly through the pilot outlet Figure 14 3 Page 14 3 The air fuel mixture is adjusted by the pilot screw needle valve Figure 14 3 Page 14 3 Figure 14 3 Carburetor AIR FUEL AIR FUEL MI...

Page 254: ...ure 14 5 Page 14 4 Fuel is supplied to the carburetor float chamber by an external impulse pump that draws fuel from the fuel tank and through the fuel filters Figure 14 4 Page 14 4 The fuel then pass...

Page 255: ...ff valve on gas tank to the closed OFF position 1 3 Loosen the intake air hose clamp 22 and disconnect the intake air hose 23 at the carburetor end only 1 4 Remove the governor cable cotter pin 25 and...

Page 256: ...owl into the catch basin Figure 14 7 Page 14 7 Tighten the drain screw to 10 in lb 1 1 N m Return fuel to the gas tank or dispose of properly 4 Mark the body of the carburetor and the carburetor fuel...

Page 257: ...after removal of the main jet This is best accomplished by positioning the carburetor upside down during main jet removal Figure 14 7 Page 14 7 7 Select the proper size main jet See chart on page 14 5...

Page 258: ...on the engine Figure 14 6 Page 14 6 12 1 Attach the throttle return spring 11 to the carburetor and then to the throttle bracket 4 just before positioning the carburetor and securing it to the engine...

Page 259: ...Place chocks at the rear wheels and lift the front of the vehicle with a chain hoist or floor jack Place jack stands under the round frame cross tube to support the vehicle See preceding DANGER See al...

Page 260: ...rst at each end of the accelerator rod 10 After the accelerator pedal and rod are properly adjusted adjust the engine RPM setting See Engine RPM Adjustment on page 14 13 11 Install the electrical box...

Page 261: ...E Accelerator Cable Removal 1 Access the engine compartment See DANGER on page 14 1 1 1 Tilt the bed and ensure that the prop rod is engaged 2 Remove the electrical box cover and loosen the cable hous...

Page 262: ...Linkage Page 14 12 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual 14 Figure 14 11 Governor and Accelerator Cables 8 7 11 9 9 REFERENCE EXHAUST SECTION 6 10 7 12 13 14 15 1 2 17 3 4...

Page 263: ...d onto the spring end of the cable conduit Figure 14 11 Page 14 12 6 Before tightening the cable housing retaining nuts make sure the engine RPM adjustment is correct See Engine RPM Adjustment on page...

Page 264: ...YSTEM Read DANGER and WARNING on page 14 1 GENERAL INFORMATION The choke system is a simple mechanism requiring very little or no maintenance The system consists of a choke assembly that is attached t...

Page 265: ...Cable Installation on page 14 14 5 Test choke for proper operation INTAKE DUCT REMOVAL 1 Remove the front body See Front Body Removal Section 4 Page 4 3 2 Slightly loosen the lug nuts on the front dri...

Page 266: ...on the intake shield and remove the adhesive backing 4 Install the shield to the frame with the adhesive strip and a pop rivet 30 5 Install air box See Air Box Installation on page 14 15 6 Install st...

Page 267: ...tenance and Service Manual Page 14 17 14 Figure 14 14 Air Intake and Choke Assemblies 30 29 TYPICAL 3 PLACES 22 23 13 TYPICAL 2 PLACES 24 14 25 TYPICAL 2 PLACES 25 21 20 19 TYPICAL 3 PLACES REFERENCE...

Page 268: ...hose and remove hose from the air box assembly 4 Standing on driver side of vehicle grasp air hose mounting inlet and open box fully Remove filter ele ment 11 5 Using a clean cloth wipe away any dust...

Page 269: ...gure 14 15 Page 14 20 3 1 Remove the clamps 16 and fuel lines 1 and 2 from the filter and plug the fuel lines Figure 14 15 Page 14 20 4 Remove the secondary filter 22 Figure 14 15 Page 14 20 4 1 Remov...

Page 270: ...fuel filter to fuel pump Fuel pump to secondary fuel filter Secondary fuel filter to carburetor Vent tube Carburetor Vent tube Gas Tank Impulse line LENGTH 14 0 in 35 6 cm 6 0 in 15 2 cm 11 5 in 29 2...

Page 271: ...20 and impulse line 7 from fuel pump Figure 14 15 Page 14 20 4 Disconnect the fuel lines 2 and 3 from the pump and plug them to prevent gasoline leakage Figure 14 15 Page 14 20 See following WARNING...

Page 272: ...e valve assemblies 31 32 and 33 and all gaskets and diaphragms for damage Figure 14 16 Page 14 22 3 If a valve assembly is damaged the rubber retaining plug 33 and valve assembly must be replaced Figu...

Page 273: ...the pump Direction of fuel flow is indicated by the arrows on the fuel pump Figure 14 15 Page 14 20 See also Figure 14 17 Page 14 22 2 Connect to the output side of the fuel pump the fuel line 3 that...

Page 274: ...gine until fuel remaining in the carburetor fuel pump and fuel lines is used up and the engine stalls 6 Remove the four bolts 8 eight washers 9 and four lock nuts 10 from the seat support See Figure 4...

Page 275: ...s a spare 2 In a well ventilated area flush the fuel tank with water to remove any remaining gasoline 3 In a well ventilated area set the tank upside down so that the water can drain out of it To make...

Page 276: ...15 Page 14 20 5 Connect the fuel line 1 to the fuel tank shut off valve 15 Use a new clamp Figure 14 15 Page 14 20 6 Connect the black wire from the fuel gauge to one of the fuel level sending unit sc...

Page 277: ...of the fuel line clamps at the carburetor fuel filters fuel pump and fuel tank for leaks 15 2 Inspect each fuel line to ensure that the lines are not cracked cut or worn FUEL LINES Read DANGER and WAR...

Page 278: ...procedures Fully Open Position The valve s open position differs from standard valve configurations For the valve to be fully open it must be turned approximately 120 from the closed OFF position unt...

Page 279: ...le while it is running Do not wear loose clothing Remove jewelry such as rings watches chains etc before servicing vehicle Hot Do not attempt to service hot engine or exhaust system Failure to heed th...

Page 280: ...Figure 15 2 Page 15 3 1 Use the muffler clamp 6 to attach the muffler bracket 2 to the muffler as shown Figure 15 2 Page 15 3 Leave the muffler clamp loose enough to allow the muffler to move as the m...

Page 281: ...tery cables positive first and tighten terminals to 20 ft lb 27 1 N m Figure 15 1 Page 15 2 Coat terminals with Battery Protector Spray CCI 1014305 12 Place the Forward Reverse handle in the NEUTRAL p...

Page 282: ...15...

Page 283: ...ng of components or wiring Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring Never allow a positive wire to touch the...

Page 284: ...by a differential lock lever The lever is located between the driver and passenger seats Figure 16 3 Page 16 2 Lockout Cam The Pioneer 1200 vehicle has a lockout circuit that prevents a driver from st...

Page 285: ...new lubricant Tighten the plug to 20 ft lb 27 1 N m Use a funnel when filling the transaxle through the lubricant level indi cator hole Fill with 31 oz 92 liters 80 90 Wt API class GL 3 or 80 90 Wt A...

Page 286: ...or jack Then place jack stands under the axle tubes to support the vehicle 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...

Page 287: ...have not slipped and are still seated against the shoulder on the axle shaft Figure 16 4 Page 16 4 8 Inspect the bearing If the bearing is damaged or worn replace it AXLE BEARING Axle Bearing Removal...

Page 288: ...e pushed away from the bearing as the collar and bearing are pressed on If Loctite gets on or in the bearing the bearing must be replaced The collar should be removed no more than two times If a colla...

Page 289: ...ter rod against the retaining ring and tap lightly at four to five locations to ensure it is properly seated See following WARNING WARNING Be sure retaining ring is properly seated in its groove If ri...

Page 290: ...16 11 Air Intake Hose Figure 16 12 Impulse Line Figure 16 13 Differential Lock Cable Bracket Club Car CLAMP C lu b C a r CLAMP IMPULSE LINE CCI102046601 REDUCED STEERING CONTROL MAY CAUSE SERIOUS INJU...

Page 291: ...icle to disconnect the cable from the differ ential lock lever 1 Figure 16 14 Page 16 9 3 5 5 Remove wire tie 6 securing the cable to the vertical support Figure 16 117 Page 16 50 3 6 Remove the cover...

Page 292: ...ction and then disconnect the 6 gauge white wire F2 post 6 gauge black ground wire A2 post and 16 gauge yellow wire DF post from starter generator Figure 16 19 Page 16 10 3 13 Disconnect the engine oi...

Page 293: ...from the cable support bracket Figure 16 23 Page 16 11 4 3 Remove the upper shock mounting hardware from the rear shock absorber and remove the shock absorber 4 4 Using a 3 8 inch flare nut wrench rem...

Page 294: ...hardware from both rear shocks Figure 16 22 Page 16 11 6 Using a hydraulic jack placed under the transaxle Figure 16 28 Page 16 13 raise the vehicle and place jack stands set at approximately 17 1 2 i...

Page 295: ...resting on the floor 12 Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle Figure 16 31 Page 16 13 13 Place blocks under the engine pan so...

Page 296: ...ining bolt Remove the governor arm from the shaft Figure 16 35 Page 16 14 17 Remove screws securing the governor cable bracket to transaxle Figure 16 36 Page 16 15 18 Remove screws securing the accele...

Page 297: ...lowing information provides instructions for disassembling the unitized transaxle however the transaxle case can be separated and gears accessed without removing the axles or axle tubes from the case...

Page 298: ...he tran saxle case or differential lock housing 5 If necessary remove the brake cable brackets from the axle tubes 5 1 Remove the bolt 17 washers and lock nut from the bracket Figure 16 23 Page 16 11...

Page 299: ...loosen them in their seating CAUTION To prevent damage to the gears use extreme care when handling them 11 When all the gear assemblies are slightly loosened remove the differential gear case assembly...

Page 300: ...er shaft by pushing it through the case toward the interior of transaxle Figure 16 40 Page 16 16 16 3 Use a seal puller to remove the shifter shaft oil seal 18 from the case Figure 16 40 Page 16 16 17...

Page 301: ...16 1 DIFFERENTIAL GEAR LOCK HOUSING DISASSEMBLY 1 Rotate the arm 99 and remove the differential lock cog 104 Figure 16 47 Page 16 19 2 Loosen but do not remove the differential lock arm retaining nut...

Page 302: ...tenance and Service Manual 16 Figure 16 48 Unitized Transaxle with Differential Lock ClubCar REFERENCE PASSENGER SIDE CASE REFERENCE DRIVER SIDE CASE 67 66 65 69 68 69 61 62 60 59 41 54 53 48 44 46 55...

Page 303: ...to reinstall it into the tran saxle case 1 Secure the governor gear assembly in a vise as shown Wrap shaft in a cloth to prevent damage Fig ure 16 50 Page 16 21 2 Use two small screwdrivers to pry the...

Page 304: ...gear 81 from the differential gear carrier case Figure 16 48 Page 16 20 4 Remove the differential pin 79 Figure 16 48 Page 16 20 by pushing it through from one side Fig ure 16 52 Page 16 22 Remove the...

Page 305: ...ing off the input shaft as shown Fig ure 16 54 Page 16 23 See preceding CAUTION 2 Pull the spring washer 42 spur gear 43 dowel pin 53 thrust plate 44 input gear assembly 45 large needle bearing 46 sma...

Page 306: ...ATE GEAR DISASSEMBLY 1 Place bearing puller wedge attachment CCI 1012812 between bearing 41 and shaft gear 59 Fig ure 16 48 Page 16 20 then press bearing off shaft Figure 16 56 Page 16 24 See followin...

Page 307: ...e bearing off 2 Place a bearing puller wedge attachment CCI 1012812 between the bearing and the larger gear on the idler shaft then press the bearing off the shaft 68 Figure 16 48 Page 16 20 as shown...

Page 308: ...differential lock shaft Figure 16 47 Page 16 19 COMPONENT ASSEMBLY Read DANGER and WARNING on page 16 1 IDLER SHAFT ASSEMBLY 1 Press a new bearing 69 Figure 16 48 Page 16 20 onto each end of the idler...

Page 309: ...long end of the shaft install the synchronizer ring 48 Figure 16 48 Page 16 20 with the smooth collar of the ring towards the clutch hub Make sure the three notches in the collar mate with the synchr...

Page 310: ...zer ring should be oriented toward the clutch hub and the notches in it should mate with the synchronizer inserts as shown Figure 16 48 Page 16 20 11 Install the narrow bearing 47 wide bearing 46 and...

Page 311: ...78 Figure 16 48 Page 16 20 See following CAUTION CAUTION Apply pressure against the inner race of the bearing only Applying pressure anywhere else will damage the bearing 2 Install differential gear 8...

Page 312: ...16 30 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual 16 Figure 16 69 Second Idler Gear Figure 16 70 Carrier Case Figure 16 71 Ring Gear Figure 16 72 Retaining Bolts 80 79 76 78 81 7...

Page 313: ...shaft is installed into the case and then the rest of the governor gear assembly is installed on the shaft Pro ceed with unitized transaxle assembly DIFFERENTIAL GEAR LOCK HOUSING ASSEMBLY 1 If previ...

Page 314: ...ear shaft installation tool CCI 101933101 over the shaft bore in the inside of the left driver side case and insert the governor gear shaft into the tool long end from the groove first as shown Figure...

Page 315: ...bore but insert far enough that it will not fall out No gears mesh at this time Figure 16 82 Page 16 34 7 3 Install the oil guide with the baffle toward the case wall as shown Figure 16 83 Page 16 34...

Page 316: ...1200 Gasoline Vehicle Maintenance and Service Manual 16 Figure 16 81 Differential Gear Assembly Figure 16 82 Idler Gear Assembly Figure 16 83 Oil Guide Figure 16 84 Synchronizer Ring Gear SLOT TAB Cut...

Page 317: ...y kind and they are not scratched or damaged in any way 9 Apply a continuous bead of Three Bond No 1215 CCI 101928701 sealant to the mating surface around the complete profile of the right passenger s...

Page 318: ...r and governor gear mesh Shifter arm and the shifter fork slotted arm also mesh SHIFTER FORK The small gear on the intermediate gear assembly meshes with the differential ring gear DIFFERENTIAL RING G...

Page 319: ...assemblies if removed on the transaxle case Figure 16 4 Page 16 4 12 1 Make sure the mating surfaces of the axle tubes transaxle case and differential lock housing are clean and free of oil grease or...

Page 320: ...g ring as shown Figure 16 92 Page 16 38 12 6 Place a 1 4 to 3 8 inch 6 10 mm diameter rod against the retaining ring and tap lightly at four to five locations to ensure it is properly seated See follo...

Page 321: ...ing 1 to the differential lock arm on the differential lock housing Figure 16 94 Page 16 39 6 2 Install the two bolts 2 to secure the cable bracket to the transaxle case Figure 16 94 Page 16 39 Tighte...

Page 322: ...13 Install the drive belt See Section 17 Torque Converter 14 Remove the blocks from under the engine and roll the powertrain into position under the vehicle Then lift the front of the powertrain and...

Page 323: ...ransaxle Installation 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16 41 16 Figure 16 98 Driven Clutch Figure 16 99 Snubber Figure 16 100 Leaf Springs Figure 16 101 Leaf Spri...

Page 324: ...ing a flare nut wrench connect the brake hoses to the left rear and right rear brake clusters and bleed the air from the brake lines See Section 6 Hydraulic and Park Brake Systems 21 Check the brake s...

Page 325: ...druff key 9 on the shifter shaft Figure 16 40 Page 16 16 26 3 Place the shifter lever 6 aligned with the woodruff key onto the Forward Reverse shaft 15 26 4 Install the nut 3 washer 4 and bolt 7 on th...

Page 326: ...rburetor and secure with a hose clamp Figure 16 109 Page 16 44 30 Connect the impulse line to the fuel pump and secure it with the hose clamp Figure 16 110 Page 16 45 31 Connect air intake hose to car...

Page 327: ...3 4 Push the cable sheath toward the front of the vehicle to secure the cable to the bracket Figure 16 117 Page 16 50 33 5 Secure the cable to the vertical support with a wire tie 6 as shown Figure 16...

Page 328: ...hicle malfunction property damage or personal injury 37 Connect the spark plug wire 38 Connect the battery cables positive cable first and tighten to 20 ft lb 27 1 N m 39 Adjust the engine RPM setting...

Page 329: ...e and remove the wire tie Figure 16 116 Page 16 48 4 Remove cable from the vehicle F R SHIFTER CABLE INSTALLATION 1 From the F R shifter route the cable exactly as it was originally to the transaxle s...

Page 330: ...n vehicle malfunction property damage or personal injury F R SHIFTER CABLE ADJUSTMENT With the shifter lever of the unitized transaxle in the NEUTRAL position Figure 16 115 Page 16 47 the Forward Reve...

Page 331: ...The wheel should be fairly easy to rotate and the other rear wheel should rotate in the opposite direction indicating that the differential lock is not engaged If this is not the case the differential...

Page 332: ...ance and Service Manual 16 Figure 16 117 Differential Lock Cable Routing ClubCar WARNING 2 1 3 4 5 1 Rotate the cable connector toward the passenger side of the vehicle to connect the cable to the dif...

Page 333: ...e 16 50 3 Connect the differential lock cable spring end 1 to the differential lock arm 3 on the differential lock housing Figure 16 117 Page 16 50 4 Push the cable 5 toward the rear of the vehicle in...

Page 334: ...16...

Page 335: ...aution to avoid shorting of components or wiring Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot engine or exhaust system Failure to heed this...

Page 336: ...h the use of a torque sensing ramp device on the driven clutch This device overcomes the force of the centrifugal weights to close the driven clutch and open the drive clutch thus increasing axle torq...

Page 337: ...clutch does not solve the problem disassemble and thoroughly clean all parts of the drive clutch Be sure to clean the plastic drive buttons 10 Figure 17 5 Page 17 6 DRIVE BELT Read DANGER and WARNING...

Page 338: ...and replace it DRIVE CLUTCH REMOVAL 1 Remove the drive belt as instructed See Drive Belt Removal on page 17 3 2 Loosen the starter generator mounting and adjusting hardware and then remove the starter...

Page 339: ...mage the lubricating characteristics of the bushings 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 t...

Page 340: ...Drive Clutch Page 17 6 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual 17 Figure 17 5 Drive Clutch Assembly 20 21 17 19 2 1 3 13 4 5 6 7 11 12 12 16 15 14 10 TYPICAL 3 PLACES ONE SPR...

Page 341: ...sure the face of the puller plate is parallel to the face of the clutch Figure 17 7 Page 17 7 2 4 Unscrew the puller center bolt out of the clutch to pull clutch cover off 3 Remove the thrust washer 1...

Page 342: ...tainer can be removed from the spring if necessary Figure 17 5 Page 17 6 8 If necessary remove idler bearing Use a press to remove the bearing Figure 17 10 Page 17 9 See following NOTE NOTE Do not rem...

Page 343: ...yond specification and they must be replaced Figure 17 5 Page 17 6 6 Inspect the pins on the primary weights 2 There should be no measurable wear Replace them if they are worn scratched or damaged Fig...

Page 344: ...pin and push them against the outside sur faces of the weights Center the weights and washers on the mounting pin Figure 17 14 Page 17 11 11 Install the weight assemblies into the slots in the hub cas...

Page 345: ...8 17 Install the thrust washer 11 onto the moveable face assembly Figure 17 5 Page 17 6 18 Install the hub assembly 1 on the moveable face assembly and align the match marks made before disassembling...

Page 346: ...TORQUE CONVERTER Drive Clutch Page 17 12 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual 17 Figure 17 16 Driven Clutch Assembly 2 3 4 5 6 7 8 11 12 1 10 9 TYPICAL 3 PLACES...

Page 347: ...7 Drive the vehicle and check for proper operation DRIVEN CLUTCH Read DANGER and WARNING on page 17 1 DRIVEN CLUTCH REMOVAL 1 Remove the drive belt See Drive Belt Removal on page 17 3 2 Remove the bo...

Page 348: ...scratched or damaged DRIVEN CLUTCH ASSEMBLY 1 Place the three drive buttons 6 in position Apply one drop of Loctite 222 to each of the socket head cap screws and then install and tighten them to 8 in...

Page 349: ...can be reused if the O D does not exceed 1 607 inches 40 82 mm Otherwise it must be replaced with a new ring CCI 1014080 9 While holding onto the cam tap the end of the fixed face shaft lightly with...

Page 350: ...17...

Page 351: ...est 11 23 maintenance 12 32 mineral content 12 33 removal 12 33 self discharge 12 32 storage 12 35 testing 11 21 11 39 vibration damage 12 33 voltage test 11 23 water level 12 32 bed tilt see tilt bed...

Page 352: ...er troubleshooting 17 3 clutch drive see drive clutch clutch driven see driven clutch column steering see steering column commutator see starter generator connecting rod inspection 13 29 installation...

Page 353: ...circuit 11 9 headlights 11 20 hour gauge circuit 11 14 lighting circuit 11 14 lockout cam circuit 11 12 11 19 see also lockout cam low oil warning circuit 11 12 11 18 reverse buzzer circuit 11 11 11...

Page 354: ...ation 12 31 removal 12 31 testing 11 41 headlights see also lighting circuit testing 11 43 hitch receiver see receiver hitch hour gauge see fuel hour gauge hub front wheel see brakes drum hub hydrauli...

Page 355: ...inspection 13 37 lockout cam function 16 2 installation 12 20 limit switch 11 28 installation 12 19 removal 12 18 removal 12 20 testing 11 38 troubleshooting 11 19 lockout cam circuit function 11 12 l...

Page 356: ...10 reed valve see breather valve reverse buzzer installation 12 20 limit switch installation 12 21 removal 12 21 testing 11 37 removal 12 20 testing 11 37 reverse buzzer circuit operation 11 11 troubl...

Page 357: ...g 11 29 11 31 steering rack and pinion assembly 7 10 disassembly 7 8 installation 7 13 removal 7 6 steering column assembly 7 5 disassembly 7 4 installation 7 6 removal 7 4 steering wheel installation...

Page 358: ...ation 4 8 removal 4 8 tire installation 8 3 pressure 8 1 removal 8 3 repair 8 3 tools see service tools torque converter operation 17 1 troubleshooting 17 3 transaxle see unitized transaxle troublesho...

Page 359: ......

Page 360: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808...

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Club Car Pioneer 1200, Maintenance Service Manual

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