Club Car Pioneer 1200, Maintenance Service Manual

Page: 44 / 360

ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal
Page 5-8 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
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3.1. Remove the bolt (9) and nut (19) from the brake pedal weldment (Figure 5-1, Page 5-2).
3.2. Remove nuts (4), retaining plates (6), bolts (7), and mounting blocks (5). If the mounting blocks (5)
show signs of excessive wear, or are damaged, they must be replaced with new ones before
installing pedal assembly (Figure 5-1, Page 5-2).
3.3. Remove the nut (3) and brake stop (2) (Figure 5-1, Page 5-2).
3.4. Lift pedal assembly (1) through the floorboard (Figure 5-1, Page 5-2 and Figure 5-10, Page 5-7).
BRAKE PEDAL INSTALLATION
1. From the top side of the floorboard, insert the brake pedal weldment assembly (1) (Figure 5-1, Page 5-
2) through the opening in the floor as shown (Figure 5-10, Page 5-7) and install the pedal stop (2) and
nut (3) (Figure 5-1, Page 5-2) on the weldment.
2. Attach the equalizer rod (10) to the brake pedal weldment assembly (1) as shown (Figure 5-1, Page 5-
2). Tighten to 17 in-lb (23 N·m).
3. Position and attach brake pedal assembly and mounting blocks (5) to vehicle frame as shown. Tighten
to 50 in-lb (6.5 N·m) (Figure 5-1, Page 5-2).
4. Pull the brake pedal toward the rear of the vehicle until the brake stop bumper will not allow the pedal to
travel any further (Figure 5-3, Page 5-3).
5. To adjust the brake pedal, perform steps 4 through 11 of Brake 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
battery and spark plug as instructed in the WARNING on page 5-1.
2. Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack.
Place jack stands under front cross tube of the vehicle frame and lower the vehicle onto the jack
stands.
3. Remove the nut (23), two washers (25), and bolt (4) securing the accelerator pedal (1) to the pivot rod
(6) (Figure 5-9, Page 5-6).
4. Disconnect the accelerator rod assembly (17, 18 and 19) (Figure 5-9, Page 5-6) at the front and rear
ball studs and remove it from the vehicle.
5. Remove the nut (10) and ball stud (16) from the accelerator pivot rod assembly (6) (Figure 5-9, Page
5-6).
6. Slide the spring retainer (11) off of the accelerator pivot rod (Figure 5-9, Page 5-6).
7. Remove lock nut (26) from the accelerator pivot shaft (Figure 5-9, Page 5-6).
8. Depress brake pedal slightly and then slide the spacer (24) toward end of accelerator pivot rod. Rotate
the spacer (26) and remove from the pivot rod (6) (Figure 5-9, Page 5-6).
9. Remove pivot rod (6) from accelerator pivot rod supports (21).
10. Inspect the accelerator pivot rod supports (21) for wear or damage and replace as necessary. If the
pivot rod supports do not require replacement, loosen (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).