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2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual

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Figure 3-2 P1200 Fuel Tank

Figure 3-3 P1200SE Fuel Tank

Figure 3-4 Fuel Valve – Open

Figure 3-5 Fuel Valve – Closed

Figure 3-6 Fuel Valve – Partially Closed

TO CARBURETOR

VENT TUBE

VENT

FUEL
TANK

FUEL
SHUT-OFF
VALVE

VENT

VENT
TUBE

FUEL
TANK

FUEL SHUT-OFF VALVE

FUEL PUMP

(under rear
seat)

FUEL FILTER
(under rear seat)

FULL OPEN (ON)

POSITION

VIEWED FROM SELECTOR

SIDE OF VALVE

CLOSED (OFF) POSITION

(SELECTOR IS ALIGNED

WITH OFF MARKINGS ON THE SIDES OF VALVE)

OFF

VIEWED FROM SELECTOR

SIDE OF VALVE

VIEWED FROM SELECTOR

SIDE OF VALVE

PARTIALLY CLOSED

POSITION

Summary of Contents for 1200

Page 1: ...2003 MAINTENANCE SERVICE MANUAL 1200 1200SE Manual No 102318813 Edition Code 0503A00000 ...

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Page 3: ...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 It is the policy of Club Car Inc to assist its distributors and dealers in continually updating their service knowl edge and facilities so they can provide prompt and efficient service for vehicle owners Regional technical rep ...

Page 4: ...pear in 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 failure to provide reasonable or necessary maintenance as instructed in the vehicle owner s manual accident or alteration including increasing vehicle speed beyond factory specifications or modificat...

Page 5: ...3 2 SECTION 4 BODY AND TRIM Cleaning the Vehicle 4 1 Front Body Repair 4 1 Abrasions and Haze 4 1 Light Scratches 4 2 Large Scratches and Abrasions 4 2 Front Body Components 4 2 Dashboard Removal 4 2 Dashboard Installation 4 2 Front Body Removal 4 3 Front Fender Removal 4 3 Front Fender Installation 4 4 Front Body Installation 4 4 Seat 4 4 Seat Adjustment 4 4 Front Seat Support 4 6 Front Seat Supp...

Page 6: ...KE PEDAL ASSEMBLIES Brake Pedal 5 1 Brake Pedal Removal 5 1 Brake Pedal Installation 5 1 Brake Pedal Adjustment 5 2 Accelerator Pedal 5 4 Accelerator Pedal Removal 5 4 Accelerator Pedal Installation 5 5 Accelerator Pedal Adjustment 5 5 SECTION 6 MC012C AS00 TRANSAXLE HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Inspection 6 1 Brake System Troubleshooting 6 3 Brake Drum Removal 6 6 Front Wheel Bra...

Page 7: ...Adjuster Installation 6 22 Rear Brake Shoe Adjuster Removal 6 22 Rear Brake Shoe Adjuster Installation 6 22 Hydraulic Line and Hose Replacement 6 23 Front Brake Line Removal 6 23 Front Brake Line Installation 6 23 Front Brake Hose Assembly Removal 6 24 Front Brake Hose Assembly Installation 6 24 Rear Brake Line Removal 6 24 Rear Brake Line Installation 6 26 Rear Brake Hose Removal 6 26 Rear Brake ...

Page 8: ...ension 7 12 Lubrication 7 12 Wheel Alignment 7 12 Front Suspension Components 7 14 Kingpin and Steering Spindle Removal 7 14 Kingpin and Steering Spindle Installation 7 14 A Arm Removal 7 15 A Arm Installation 7 17 Shock Absorber Removal 7 17 Shock Absorber Installation 7 18 Front Wheel Bearings and Hubs 7 18 Front Wheel Free Play Inspection 7 18 Front Wheel Bearings and Hub Removal 7 19 Front Whe...

Page 9: ...ctrical System 11 5 Wiring Diagram 11 6 Electrical Circuits 11 8 Starter Circuit 11 8 Generator Circuit 11 8 Engine Ignition Circuit 11 9 Engine Kill Circuit 11 9 Reverse Buzzer Circuit 11 10 Low Oil Warning Circuit 11 10 Lockout Cam Circuit 11 11 Fuel Gauge and Sending Unit Circuit 11 12 Hour Meter Circuit 11 13 Lighting Circuit 11 13 Circuit Testing 11 13 Testing the Starter Circuit and Generato...

Page 10: ...t 12 20 Fuel Gauge Hour Meter 12 21 Fuel Level Sending Unit 12 22 RPM Limiter 12 22 Ignition Coil 12 23 Oil Level Sensor 12 26 Headlights 12 26 Voltage Limiter 12 27 Light Switch 12 28 Testing the Light Switch 12 28 Battery 12 28 General Information 12 29 Ground Straps 12 33 SECTION 13 FE400 ENGINE General Information 13 1 Special Engine Service Tools Available From Club Car 13 1 Before Servicing ...

Page 11: ...ccelerator Cable 14 8 Closed Throttle or Idle Adjustment 14 10 Engine RPM Adjustment 14 10 Choke and Air Intake System 14 11 Choke Cable Removal 14 11 Choke Cable Installation 14 11 Air Box Removal 14 11 Air Box Installation 14 11 Intake Duct Repair 14 12 Intake Duct Removal 14 12 Intake Duct Installation 14 14 Air Filter 14 15 Fuel Filter Removal 14 16 Fuel Filter Installation 14 16 Fuel Pump 14 ...

Page 12: ... Transaxle Installation 16 16 Forward Reverse Shifter Cable 16 24 Forward Reverse Shifter Cable Removal 16 24 Forward Reverse Shifter Cable Installation 16 24 Forward Reverse Shifter Cable Adjustment 16 25 Differential Lock System 16 26 Differential Lock System Inspection 16 26 Differential Lock Cable Removal 16 26 Differential Lock Cable Installation 16 27 SECTION 17 TORQUE CONVERTER General Info...

Page 13: ...Vehicle Maintenance and Service Manual Page xi Driven Clutch 17 13 Driven Clutch Removal 17 13 Driven Clutch Disassembly 17 13 Driven Clutch Inspection 17 13 Driven Clutch Assembly 17 15 Driven Clutch Installation 17 17 SECTION i INDEX ...

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Page 15: ...e GENERAL WARNING The following safety procedures must be followed whenever the vehicle is being operated repaired or ser viced Service technicians 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 Explosive gases Do not smoke Keep sparks and flames away from th...

Page 16: ...vere burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Check the vehicle owner s manual for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read Any modification or change to the vehicle that affects the stability or handling of the vehicle or incre...

Page 17: ...oneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual Page 1 3 1 Figure 1 1 Battery FRONT OF VEHICLE AS SEEN FROM PASSENGER SIDE OF VEHICLE REMOVE NEGATIVE CABLE FIRST DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE ...

Page 18: ...1 ...

Page 19: ...and dual hydraulic shocks Brakes Hydraulic brake system self adjusting drum brakes on each wheel with separate hand operated park brake BODY CHASSIS Frame Chassis Twin I Beam welded aluminum Side and rear body All aluminum with a powder coated steel cargo bed Side and rear body All aluminum with an aluminum cargo bed Front body ABS DR acrylic cap Tires 23 x 10 50 12 tubeless 4 ply rated load range...

Page 20: ... 227 kg Standard seating capacity 2 4 LIQUID CAPACITIES Engine crankcase without filter 32 oz 95 liters Engine crankcase with filter 38 oz 1 12 liters Unitized transaxle MC012C AS00 29 oz 85 liters Master cylinder 8 oz 240 ml Fuel tank unleaded gasoline only 7 gallons 26 5 liters 6 5 gallons 24 6 liters TIRE PRESSURE All terrain tread standard Front 7 11 psi 48 76 Bars Rear 14 18 psi 97 1 24 Bars ...

Page 21: ...RIAL NUMBER IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted on the frame directly above the accelerator pedal Example AD0301 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 The dashboard must be removed to view this number See following NOTE NOTE Have the vehicle serial number availa...

Page 22: ... baking soda per 1 gallon 3 8 L of water Rinse solution off batteries Do not allow this solution to enter the bat teries 12 Remove spark plug and pour 1 2 ounce of SAE 10 weight oil into the engine through the spark plug hole Rotate engine crankshaft by hand several times then install spark plug and tighten to 20 ft lb 27 N m 13 Adjust tires to rated capacities See General Information Section 8 Pa...

Page 23: ... 6 Fuel Valve Partially Closed TO CARBURETOR VENT TUBE VENT FUEL TANK FUEL SHUT OFF VALVE VENT VENT TUBE FUEL TANK FUEL SHUT OFF VALVE FUEL PUMP under rear seat FUEL FILTER under rear seat A A FULL OPEN ON POSITION VIEWED FROM SELECTOR SIDE OF VALVE CLOSED OFF POSITION SELECTOR IS ALIGNED WITH OFF MARKINGS ON THE SIDES OF VALVE OFF OFF VIEWED FROM SELECTOR SIDE OF VALVE VIEWED FROM SELECTOR SIDE O...

Page 24: ...3 ...

Page 25: ...r discoloration from aluminum use a commercially available aluminum cleaner paste and fine grade No 00 steel wool Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains Club Car does not recommend any type of pressure washing or steam cleaning Both can create water dam age to electrical components and subsequent component failur...

Page 26: ...ic bodies FRONT BODY COMPONENTS See General Warning Section 1 Page 1 1 DASHBOARD REMOVAL 1 Make sure the key switch is OFF and the Forward Reverse handle is in NEUTRAL Remove the key Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 Remove the dash panel 3 1 Loosen the seven Tuflok screws shown in De...

Page 27: ... body 6 4 Use a phillips head screwdriver to remove the six Tuflok fasteners 7 from sides and two 7 from front of body 6 5 Disconnect light wiring harness from each headlight assembly 6 Lift the back edge of the body up and pull forward to remove from vehicle FRONT FENDER REMOVAL 1 Remove front body 6 Figure 4 2 Page 4 5 See Front Body Removal on page 4 3 2 Pull back floor mat to access rivets sec...

Page 28: ...liquid dish soap and warm water applied with a soft damp cloth is rec ommended A soft bristle brush may be used if necessary Wipe off any residue with a water dampened cloth Difficult Stains Dampen a soft white cloth with a solution of 10 household bleach sodium hypochlorite and 90 water Rub gently to remove stain then rinse with a water dampened cloth to remove bleach concentration Use Club Car s...

Page 29: ...aintenance and Service Manual Page 4 5 4 Figure 4 2 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 PLACES 11 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES 12 15 14 ...

Page 30: ...AT SUPPORT REMOVAL 1 Completely remove both front seats 2 from the vehicle Figure 4 3 Page 4 6 2 Remove park brake equalizer cable from park brake handle See Equalizer Cable Removal Section 6 Page 6 33 3 Disconnect cable from differential lock control See step 5 in UnitizedTransaxle Removal Section 16 Page 16 6 Figure 4 3 Front Seat Support 4 5 TYPICAL 4 PLACES 8 9 9 10 11 1 12 2 3 ...

Page 31: ...move eight 1 4 20 flange lock nuts 21 and eight 1 4 20 x 3 4 inch carriage bolts 20 and remove arm rests 10 and 11 Figure 4 4 Page 4 8 3 Remove four 1 4 20 x 1 inch phillips drive truss head machine screws 19 and lock washers 18 from seat back support 22 and remove seat back 16 and seat back cap 17 4 Remove four 5 16 18 flange lock nuts 24 and four 5 16 18 x 3 4 inch carriage bolts 23 and remove s...

Page 32: ...n hardware to 65 in lb 7 345 N m 5 Install seat back 16 and seat back cap 17 in reverse order of removal Tighten hardware to 6 ft lb 8 136 N m 6 Install bottom bench seat aligning the front edge of the seat against the inside edge of the front trim and push down into place Figure 4 4 Pioneer 1200SE Rear Seat Support 14 12 13 17 10 16 TYPICAL 4 PLACES 18 19 11 22 TYPICAL 10 PLACES 20 21 TYPICAL 4 P...

Page 33: ...late 11 and lift bed from vehicle 2 Pioneer 1200SE 2 1 Remove two 3 8 16 nylon lock nuts 2 from left and right cargo bed hinge bolt assemblies Figure 4 6 Page 4 11 2 2 Apply slight upward pressure by hand on the rear of the bed to relieve pressure on the hinges and remove the 3 8 x 3 3 8 inch hinge bolts 1 from the hinge assemblies 2 3 Raise rear edge of bed approximately 6 inches 15 2 cm and pull...

Page 34: ...o Bed Page 4 10 2003 Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual 4 Figure 4 5 Pioneer 1200 Cargo Bed 4 4 3 3 25 11 2 17 TYPICAL 4 PLACES 16 1 2 19 TYPICAL 2 PLACES 18 10 TYPICAL 2 PLACES 8 15 14 9 ...

Page 35: ...two front bumpers 16 by loosening the 1 4 20 nylon lock nuts 17 and position so that when the cargo bed is lowered both bumpers are centered on the bed frame weldments Figure 4 5 Page 4 10 1 2 Tighten lock nuts 17 to 20 in lb 2 3 N m 1 3 Adjust the two rear bumpers 18 loosening the 1 4 20 nylon lock nuts 19 until a 1 8 inch gap between the bottom of the bumper head and the frame weldment is achiev...

Page 36: ... following NOTE NOTE Use new nylon lock nuts when performing this assembly procedure The rear fender with the warning decal should be installed on the passenger side of the vehicle The decal should be plainly visible when the cargo bed is raised TAILSKIRT See General Warning Section 1 Page 1 1 TAILSKIRT REMOVAL 1 Remove the two thread forming screws 7 and flat washers 8 from the tailskirt 6 and sl...

Page 37: ...ver hitch removal process and tighten bolts to 15 ft lb 20 3 N m Figure 4 7 Page 4 13 2 Install tailskirt See Tailskirt Installation on page 4 12 Figure 4 7 Rear Fender Tailskirt and Hitch with MC012C AS00 Transaxle 7 8 TYPICAL 2 PLACES 2 5 4 4 3 6 TYPICAL 2 PLACES 10 9 11 1 5 4 3 TYPICAL 4 PLACES 3 5 TYPICAL 4 PLACES 4 12 13 14 15 TYPICAL 2 PLACES 14 15 12 13 ...

Page 38: ...ame meets the floorboard and roll the mat corner toward the center of the vehicle from under the side support angle pulling it diagonally from the vehicle FLOOR MAT INSTALLATION 1 Pioneer 1200 1 1 Install the floor mat in the reverse order of removal 1 2 Install the brake and accelerator pedals See Brake Pedal Installation Section 5 Page 5 1 Also See Accelerator Pedal Installation Section 5 Page 5...

Page 39: ...d vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 5 Remove the brake pedal assembly 5 1 Remove the bolt 9 and nut 19 Figure 5 1 Page 5 2 5 2 Remove nuts 4 washers 6 bolts 7 and mounting blocks 5 If th...

Page 40: ...nd not on public roads Keep entire body inside vehicle while moving Do not use differen tial lock on paved surface s Do not operate while under the influen ce of alcoho l or drugs OFF ON Read Owner s Manua Study and underst and controls To start engine Place shift lever in N Neutral position Depress brake pedal Turn key switch to START position and release To operat e vehicle Make sure wheels are ...

Page 41: ... 5 Page 5 3 7 Tighten the jam nut 31 to 8 ft lb 9 5 N m Figure 5 4 Page 5 3 8 Adjust the clevis 16 by rotating it so that the rod retaining bolt 8 can be placed through the clevis 16 and the bottom hole in the bell crank assembly 11 Figure 5 1 Page 5 2 See following NOTE NOTE The spring 17 should not be under tension while the brake pedal is at rest 9 Install the rod retaining bolt 8 through the c...

Page 42: ...e wheels See following WARNING WARNING Disconnect both battery cables negative cable first 2 Disconnect the spark plug SeeWARNING To avoid unintentionally starting in GeneralWarning Section 1 Page 1 2 3 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 the outer front I beam of the vehicle frame and lower the vehicle o...

Page 43: ... 3 Tighten bolts 22 to 75 in lb 8 5 N m 4 Install spacer 24 aligning the splined parts and tighten the nylon lock nut 26 to 18 ft lb 24 5 N m 5 Insert bolt 4 through a washer 25 and through the lower hole in the pedal then through the adjacent slotted hole in the pivot rod 6 Attach the remaining washer 25 and nut 23 Finger tighten nut See Accelerator Pedal Adjustment on page 5 5 6 Insert pivot sup...

Page 44: ...7 2 Loosen the jam nuts 18 and disconnect the accelerator rod 17 at the accelerator pedal Figure 5 11 Page 5 8 Adjust the length of the rod so the indicated cam edge is parallel with the edge of the electrical component box Figure 5 10 Page 5 7 See following CAUTION CAUTION After accelerator rod adjustment make sure approximately the same amount of thread is exposed at each end of the rod If lever...

Page 45: ...roads Keep entire body inside vehicle while moving Do not use differen tial lock on paved surface s Do not operate while under the influenc e of alcohol or drugs OFF ON Read Owner s Manual and safety warnings located on dash panel prior to driving Study and understa nd controls To start engine Place shift lever in N Neutral position Depress brake pedal Turn key switch to START position and release...

Page 46: ... Page 5 8 2003 Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual 5 Figure 5 11 Accelerator Pedal Assembly FLOORBOARD REMOVED FOR CLARITY TYPICAL 4 PLACES 26 22 21 24 TYPICAL 4 PLACES 21 8 15 20 19 4 25 1 18 17 16 9 11 10 23 6 25 14 5 7 17 19 18 13 12 ...

Page 47: ...avy pressure to the pedal and check for sponginess and excessive pedal travel The pedal should be firm and the back of the brake pedal should be a minimum of 2 inches from the floor If the brake pedal feels spongy perform the brake bleeding procedure See Bleeding the Hydraulic Brake System on page 6 31 Hold the brake pedal depressed with medium foot pressure 25 to 35 lb for 15 seconds The pedal sh...

Page 48: ...ing plate for signs of brake fluid leakage If so deter mine the cause of the leak and replace the brake hose or wheel cylinder See Wheel Cylinder Replacement on page 6 19 Also See Hydraulic Line and Hose Replacement on page 6 23 Park Brake Inspection Apply moderate pressure to the park brake handle When latched the park brake should lock the wheels and hold the vehicle stationary on incline of 20 ...

Page 49: ...springs Replace damaged items If the brake adjusters 3 are frozen requiring more than 65 in lb 7 4 N m to turn freely worn or loose replace the adjuster assemblies in pairs Figure 6 1 Page 6 2 See Brake Shoe Adjuster Replacement on page 6 21 BRAKE SYSTEM TROUBLESHOOTING The procedures used in making the checks provided in the following troubleshooting guide can be found in the referenced sections ...

Page 50: ...xle seal and replace the brake shoes See Brake Shoe Removal on page 6 8 Glazed brake shoe linings Replace the brake shoes See Brake Shoe Removal on page 6 8 Damaged or distorted brake shoes Replace the brake shoes See Brake Shoe Removal on page 6 8 Scored or barrel shaped brake shoe drums Replace the brake drums See Brake Drum Removal on page 6 6 Clogged master cylinder lines or hoses Replace brak...

Page 51: ...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 35 Noise and chatter Squealing clicking or scraping sound upon brake application Bent damaged or incorrect br...

Page 52: ... 7 4 2 Remove the castle nut 3 large flat washer 4 wheel bearing 5 and drum 8 If the brake drum was easily removed proceed to step 6 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 Cluster Inspection and Cleaning on page 6 10 One brake drags Weak or broken brake shoe ret...

Page 53: ...ster bolts to increase the clearance between the brake shoe lining and the brake drum Figure 6 3 Page 6 7 See following NOTE NOTE If the adjusters require more than 65 in lb 7 3 N m of force to rotate they must be replaced See Brake Shoe Adjuster Replacement on page 6 21 6 Repeat steps 1 through 5 for the opposite front wheel if necessary Figure 6 2 Front Spindle and Brake Drum Assembly Figure 6 3...

Page 54: ...See following NOTE NOTE If the adjusters require more than 65 in lb 7 3 N m of force to rotate they must be replaced See Brake Shoe Adjuster Replacement on page 6 21 5 3 Rotate the brake drum slightly to remove it 6 Repeat steps 3 through 5 for the opposite rear wheel if necessary BRAKE SHOE REMOVAL See General Warning Section 1 Page 1 1 WARNING If at any point in this procedure the hydraulic syst...

Page 55: ...arge flat washer 23 from the axle end 4 Slide the wheel bolt flange 22 off of the splined axle end 5 Use pliers or a brake tool to rotate the cup washer and compression spring assembly 90 and remove the cup and spring from each brake shoe Figure 6 6 Page 6 9 NOTE The brake shoes are under spring tension and can release suddenly when cup and spring assem blies are removed 6 Pull brake shoes and ten...

Page 56: ...eck the brake shoe adjusters in each brake cluster assembly for proper operation 4 1 Locate the bolt heads of the two brake shoe adjusters on the back of each brake cluster assembly 4 2 Use a torque wrench and a Torx T 27 driver or hydraulic brake adjuster CCI P N 102169401 and gently rotate the adjuster bolts Figure 6 3 Page 6 7 See following NOTE NOTE If the adjusters require more than 65 in lb ...

Page 57: ...sibly resulting in property damage or severe personal injury 10 Brush a light coat of white lithium NLGI Number 2 grease Dow Corning BR2 Plus or equivalent on each of the six raised bosses on the back plate Figure 6 9 Page 6 11 See preceding WARNING 11 Brush a light coat of white lithium NLGI Number 2 grease Dow Corning BR2 Plus or equivalent to each end of both brake shoes and into the slots in t...

Page 58: ...e remaining spring and cup washer 12 onto the pin of the adjuster 3 Figure 6 1 Page 6 2 and rotate 90 to secure the brake shoe Figure 6 4 Page 6 9 6 After the shoes are installed move them together up and down approximately 1 4 to 3 8 inch 6 3 to 9 5 mm to make sure that they will slide easily without binding Figure 6 13 Page 6 13 7 Install the front wheel brake drum See Front Wheel Brake Drum Ins...

Page 59: ... BR2 Plus or equivalent to both prior to assembly 8 1 Slide wheel bolt flange 22 onto splined axle Figure 6 5 Page 6 9 8 2 Slide the large flat washer 23 onto the end of the axle and up against the wheel bolt flange See following NOTE NOTE It is recommended that a light film of white lithium NLGI Number 2 grease Dow Corning BR2 Plus or equivalent be applied to both surfaces of the large washer 23 ...

Page 60: ...E Prior to installing the brake drum inspect the brake lines hoses drums and brake cluster assem blies See Brake System Inspection on page 6 1 Clean any residual grease from the friction area of the brake drum prior to installation 1 Clean the wheel bearings 5 Figure 6 2 Page 6 7 See following NOTE NOTE Do not use compressed air to dry wheel bearings after cleaning Spinning the wheel bearings at a...

Page 61: ...llowing WARNING CAUTION and NOTE WARNING Make sure to install and bend the cotter pin Failure to bend the cotter pin could result in the separation of the wheel from the spindle Loss of vehicle control could result causing severe personal injury CAUTION Use a new cotter pin when installing the drum hub assembly NOTE If the cotter pin does not line up with the hole in the spindle when the castle nu...

Page 62: ...ter bolts to increase the clearance between the brake shoe lining and the brake drum Figure 6 14 Page 6 16 See following NOTE NOTE If the adjusters require more than 65 in lb 7 3 N m of force to rotate they must be replaced See Brake Shoe Adjuster Replacement on page 6 21 3 Rotate and gently press the brake drum to ensure that the drum is properly seated 4 With the brake drum properly seated and s...

Page 63: ...the Hydraulic Brake System on page 6 31 Worn or damaged brake drums must not be machined Replace as necessary Use only approved replacement brake drums designed for your vehicle For MC012C AS00 transaxles use CCI P N 102264701 FRONT BRAKE CLUSTER ASSEMBLY REMOVAL 1 Remove front wheel brake drum See Front Wheel Brake Drum Removal on page 6 6 2 Remove the banjo bolt 16 and copper washers 17 Figure 6...

Page 64: ...ar brake drum See Rear Wheel Brake Drum Removal on page 6 8 2 Remove rear brake shoes See Rear Brake Shoe Removal on page 6 9 3 Remove park brake cable clip 1 hair spring cotter pin 2 and clevis pin 3 Figure 6 16 Page 6 18 4 Remove the cable from the cable support bracket 5 Slide the cable so that the coiled spring wire covering the cable wire can be fed through the slot in the support bracket and...

Page 65: ...3 and hair spring cotter pin 2 5 Install rear brake shoes See Rear Brake Shoe Installation on page 6 12 6 Install rear wheel brake drum See Rear Wheel Brake Drum Installation on page 6 16 7 Repeat steps 1 through 6 for the opposite rear wheel if necessary 8 Bleed the rear wheel brakes See Bleeding the Hydraulic Brake System on page 6 31 9 Perform all of the brake system inspections See Brake Syste...

Page 66: ...aulic Brake System on page 6 31 7 Perform all of the brake system inspections See Brake System Inspection on page 6 1 REAR WHEEL CYLINDER REMOVAL 1 Remove rear wheel brake drum See Rear Wheel Brake Drum Removal on page 6 8 2 Remove rear brake shoes See Rear Brake Shoe Removal on page 6 9 3 Use a 3 8 inch flare nut wrench and remove the brake hose fitting from the rear wheel cylinder Figure 6 17 Pa...

Page 67: ...st be bled after the correct reinstallation of the brake components Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic system Use only DOT 5 brake fluid See Bleeding the Hydraulic Brake System on page 6 31 Figure 6 19 Rear Hydraulic Brake Cluster Assembly 6 16 17 11 7 13 15 21 12 1 FRONT OF VEHICLE TYPICAL 2 PLACES 13 20 19 9 18 TYPI...

Page 68: ...g post is to the top of the back plate 4 Grip adjuster arm 3 with a pair of locking pliers and tighten the bolt 4 to 115 in lb 13 N m 5 Repeat steps 1 through 4 for the remaining adjuster 6 Install front brake cluster assembly See Front Brake Cluster Assembly Installation on page 6 17 7 Install front brake shoes See Front Brake Shoe Installation on page 6 12 8 Install front wheel brake drum See Fr...

Page 69: ...aulic system must be opened As a result the brakes must be bled after the correct reinstallation of the brake components Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic system Use only DOT 5 brake fluid See Bleeding the Hydraulic Brake System on page 6 31 Prior to servicing hydraulic brakes thoroughly clean the vehicle paying part...

Page 70: ...t wrench to remove the brake line 4 from the T manifold block 1 Figure 6 20 Page 6 25 7 Remove the bolt 2 washer 13 and lock nut 3 that secure the T manifold block 1 to the shock tower FRONT BRAKE HOSE ASSEMBLY INSTALLATION 1 Install the 1 4 20 x 1 1 4 inch hex head bolt 2 and nylon lock nut 3 washer 13 T manifold block 1 to frame bracket Tighten to 76 in lb 8 6 N m Figure 6 20 Page 6 25 2 Connect...

Page 71: ...necessary 2 Pioneer 1200SE 2 1 Chock the front wheels release the park brake and lift the rear of the vehicle with a chain hoist or floor jack See WARNING Lift only one end in General Warning Section 1 Page 1 1 2 2 Place jack stands under the rear axle tubes and lower onto stands See Figure 5 2 Section 5 Page 5 3 Figure 6 20 Pioneer 1200 Four Wheel Hydraulic Brake System TYPICAL 2 PLACES TYPICAL B...

Page 72: ... 4 20 x 3 4 inch bolt 18 and tighten to 65 in lb 7 345 N m Figure 6 21 Page 6 28 2 2 Install brake line 10 or 11 to rear brake hose at the I beam of the vehicle frame and tighten to 11 ft lb 14 9 N m 2 3 Install the opposite end of the brake line to the brake tee 17 and tighten to 11 ft lb 14 9 N m 2 4 Repeat steps 2 2 and 2 3 for the opposite rear brake line if necessary 2 5 Install rear brake li...

Page 73: ... park brake and access the master cylinder bell crank 2 Remove the brake rod clevis bolt 6 and clevis 16 from the bell crank assembly 13 Figure 6 22 Page 6 30 3 Remove the spring 18 from the bell crank 13 and master cylinder mounting bracket 19 4 Remove the push rod clevis bolt 20 and lock nut 21 from the bell crank 13 5 Remove the bell crank bolt 9 and nylon lock nut 11 from the master cylinder m...

Page 74: ...0SE Gasoline Vehicle Maintenance and Service Manual 6 Figure 6 21 Pioneer 1200SE Four Wheel Hydraulic Brake System TYPICAL 2 PLACES TYPICAL BOTH SIDES TYPICAL BOTH SIDES 5 7 8 14 14 9 2 18 17 10 11 1 3 6 12 REFERENCE MASTER CYLINDER 4 15 16 REFERENCE FRONT SUSPENSION REFERENCE REAR BRAKE ASSEMBLY REFERENCE FRONT BRAKE ASSEMBLY 13 ...

Page 75: ...on the brake lines with plastic bags and wire ties to keep any dirt or debris from entering the hydraulic brake system 8 Remove the two bolts 7 and nylon lock nuts 8 that secure the master cylinder Figure 6 22 Page 6 30 9 Remove master cylinder 1 from mounting bracket 19 push rod 3 and rubber boot 2 MASTER CYLINDER INSTALLATION 1 Install master cylinder 1 into mounting bracket 19 and insert push r...

Page 76: ...oneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual 6 Figure 6 22 Master Cylinder 1 5 4 7 TYPICAL 2 PLACES 8 18 19 20 11 8 TYPICAL 2 PLACES 3 6 13 2 8 12 TYPICAL 2 PLACES 15 14 16 17 6 TYPICAL 2 PLACES TYPICAL 2 PLACES 7 TYPICAL 2 PLACES TYPICAL 2 PLACES 7 TYPICAL 2 PLACES 10 9 8 8 PIONEER 1200SE PLUG ...

Page 77: ...y of the adjuster bolts Over tightening the adjuster bolts could result in damage to the brake cluster components or the separation of the bolt 4 from the adjuster 3 Figure 6 1 Page 6 2 or Figure 6 19 Page 6 21 6 Place but do not tighten the cap onto the master cylinder reservoir 7 Connect vacuum type brake bleeder CCI P N S0010702 Front Brakes Only Connect the two hose fittings from a vacuum type...

Page 78: ...ke System on page 6 31 2 Allow 1 qt 0 9464 l of the brake fluid to be pulled into the vacuum type brake bleeder tool 3 With the vacuum still running tighten the two brake bleeder valves 4 Allow the handle on the brake bleeder tool to open turning the vacuum system off 5 Repeat steps 1 through 4 for the two rear wheels FILLING THE HYDRAULIC SYSTEM After purging the brake system and making any neces...

Page 79: ...e Cable Removal on page 6 33 2 Remove the four 10 24 x 3 4 inch socket head screws 14 lock nuts 18 and washers 17 from frame and remove the assembly Figure 6 27 Page 6 37 Wheel Brake Cable Removal 1 Loosen the equalizer jam nut 11 and the conical nut 23 to provide slack in the wheel brake cables Figure 6 27 Page 6 37 2 Pull a wheel brake cable to the side and remove the cable end 8 from the keyhol...

Page 80: ... the threaded end of the equalizer cable 9 3 Attach the conical nut 23 and equalizer jam nut 11 to the threaded end of the equalizer cable 4 Attach the equalizer spring 21 from the equalizer cable to the frame 5 Slide the boot shield 27 around the park brake handle 6 Slide the boot 2 over the handle and down around the boot shield and onto the seat support 7 Attach the boot 2 using two 5 16 18 phi...

Page 81: ...on on page 6 1 PARK BRAKE ADJUSTMENT CAUTION Perform the following procedure only on level surface To avoid injury or property damage ensure that the path of the vehicle is clear before pushing vehicle 1 Ensure that the brake pedal is adjusted correctly See Brake Pedal Adjustment Section 5 Page 5 3 2 Chock the wheels release the park brake and place the Forward Reverse handle in the NEUTRAL posi t...

Page 82: ...hicle can no longer be pushed 7 Loosen the conical nut two full revolutions 8 Tighten the equalizer jam nut 11 against the conical nut 23 using the double wrench method to 55 in lb 6 3 N m 9 The park brake should now be adjusted so that the vehicle will not roll when pushed with the park brake latched in the fourth notch four clicks from the bottom of its travel 10 Perform all of the brake system ...

Page 83: ... Service Manual Page 6 37 6 Figure 6 27 Park Brake System ClubCar 23 11 4 5 TYPICAL 2 PLACES 1 27 5 6 TYPICAL 2 PLACES TYPICAL EACH SIDE OF VEHICLE 15 20 TYPICAL EACH SIDE OF VEHICLE 12 19 26 10 8 9 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES EACH PULLEY 14 18 TYPICAL 2 PLACES 13 3 TYPICAL 2 PLACES 2 7 22 25 21 17 16 16 24 ...

Page 84: ...6 ...

Page 85: ...teering column shaft 11 for installment positioning 6 Loosen the steering wheel nut 18 and back it off approximately 1 4 inch 6 mm Do not remove the nut 7 Use the steering wheel puller CCI P N 102061201 to remove steering wheel 7 1 Place the puller anvil 4 through the top opening of the steering wheel Figure 7 1 Page 7 1 7 2 Insert the anvil feet through the two slots in the base plate marked B 5 ...

Page 86: ...heel Page 7 2 2003 Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual 7 Figure 7 3 Steering Column 17 16 TYPICAL 4 PLACES 15 TYPICAL 4 PLACES 13 14 19 18 24 11 10 10 9 8 7 6 5 1 3 2 TYPICAL 3 PLACES 25 12 8 9 23 22 21 20 4 27 ...

Page 87: ...he steering wheel See Steering Wheel Removal on page 7 1 4 Remove dashboard See Dashboard Removal Section 4 Page 4 2 5 Remove the front body See Front Body Removal Section 4 Page 4 3 6 Remove the upper bolt 2 and lock washer 3 from the steering universal joint 1 Figure 7 4 Page 7 4 7 Remove the nuts 17 bolts 15 and washers 16 from the steering column mount 13 Figure 7 3 Page 7 2 8 Disconnect the s...

Page 88: ... ring 5 onto the bottom end of the steering shaft 11 Figure 7 5 Page 7 5 4 Insert the shaft 11 from the bottom of the steering tube 13 Figure 7 3 Page 7 2 5 Turn the assembly over and place the shaft 11 on a bench Install the wedge 8 and retaining ring 12 onto the top of the shaft Be sure the prongs on the retaining ring face up and away from the wedge Use a steering column retaining ring tool CCI...

Page 89: ...e front body See Front Body Installation Section 4 Page 4 4 9 Install dashboard and dash panel See Dashboard Installation Section 4 Page 4 2 10 Install the steering wheel See Steering Wheel Installation on page 7 3 11 Connect the spark plug 12 Connect the battery cables positive cable first and tighten terminals to 20 ft lb 27 N m Coat ter minals with Battery Terminal Protector Spray CCI P N 10143...

Page 90: ... plastic wire ties Figure 7 11 Page 7 8 NOTE If the dust seal bellows are secured with a metal clamp remove the clamp Do not reuse the clamp when the rack and pinion is reassembled Use a plastic wire tie to secure the dust seal bellows 4 Remove the two hex nuts 12 and slide off both of the dust seal bellows 10 Figure 7 20 Page 7 11 5 Remove rack screw nut 8 rack guide screw 7 rack guide pressure s...

Page 91: ...ints 9 for wear If one or both of the ball joints 9 are excessively worn remove and replace the ball joint from the rack 13 1 Secure the rack in a vise Figure 7 18 Page 7 9 Use wood blocks between the rack and the jaws of the vise to protect the rack from damage 13 2 Tap the flange out of the notch in the rack Figure 7 19 Page 7 9 13 3 Remove the ball joint 9 from the rack 2 Figure 7 20 Page 7 11 ...

Page 92: ...er 1200 1200SE Gasoline Vehicle Maintenance and Service Manual 7 Figure 7 11 Dust Bellows Clamp Figure 7 12 Remove Pinion from Housing Figure 7 13 Remove Bearing from Pinion Figure 7 14 Remove Dust Seal Figure 7 15 Pinion Snap Rings PRESS RAM PINION GEAR BEARING 4 16 ...

Page 93: ...n Press new bearing onto pinion shaft exerting all pressure on the inner race Then install the c type stop ring 16 See previous CAUTION 3 Install pinion 3 and bearing 15 assembly into the housing 1 Make sure the rack gear teeth will mesh with the gear teeth on the pinion The rack may need to be rotated slightly while lightly tapping on the pin ion bearing assembly with a rubber mallet See followin...

Page 94: ...ge 7 12 14 Install the ball joints 23 to each end of the drag links 19 Tighten to 20 ft lb 27 N m Figure 7 20 Page 7 11 15 Install the two dust seal bellows 10 16 Install new bellows clamps wire ties 11 17 To minimize corrosion apply a light coat of anti seize lubricating compound to the ball joint threads 18 Install the two nuts 12 and drag links 19 Tighten drag link 19 against nut 12 to 20 ft lb...

Page 95: ...oneer 1200 1200SE 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 TYPICAL 4 PLACES 1 14 TYPICAL 2 PLACES TYPICAL 2 PLACES ...

Page 96: ...lubrication of the front suspension raise front of vehicle to lubricate See General Warning Section 1 Page 1 1 WHEEL ALIGNMENT Wheel alignment is limited to adjusting the toe in of the front wheels See Toe in Adjustment on page 7 13 See following NOTE NOTE Prior to making any front suspension adjustments inspect components for wear or damage and repair or replace as necessary Figure 7 21 Press In ...

Page 97: ...the distance between the marks on the forward facing surfaces of the tires Figure 7 25 Page 7 13 See following NOTE NOTE The front measurement must be less than the rear measurement 5 Subtract the measurement on the front of the tires from the measurement on the rear of the tires The dif ference is the toe in Proper toe in is 11 16 inch 3 8 of an inch 18 mm 10 mm 6 If adjustment is necessary 6 1 R...

Page 98: ...ts 20 securing the brake cluster to the spindle assembly See Figure 6 1 Section 6 Page 6 2 4 Rest the brake cluster on the A arm as shown Figure 7 28 Page 7 15 Ensure that there is no strain on the brake hose See following WARNING WARNING Strain on the brake hose or the brake hose fittings can result in damage to the hose or fittings causing a leak in the hydraulic system diminished brake performa...

Page 99: ... cotter pin 18 and bend it to secure it to the ball joint 10 Use a grease gun and apply grease to the grease fitting 17 in the A arm 13 Figure 7 29 Page 7 16 See Lubrication on page 7 12 11 Install the brake cluster See Front Brake Cluster Assembly Installation Section 6 Page 6 17 12 Install the wheel and tighten the lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 13 Repeat steps 1 throug...

Page 100: ...pension 15 TYPICAL 2 PLACES 14 TYPICAL 4 PLACES 16 32 33 2 34 22 1 35 2 TYPICAL 2 PLACES 4 TYPICAL 4 PLACES 3 6 TYPICAL 2 PLACES TYPICAL 2 PLACES 13 13 7 TYPICAL 2 PLACES TYPICAL 2 PLACES 10 TYPICAL 4 PLACES 17 3 12 TYPICAL 2 PLACES 18 TYPICAL 2 PLACES 11 TYPICAL 4 PLACES 8 TYPICAL 4 PLACES 5 9 30 31 TYPICAL 4 PLACES 26 37 23 19 21 24 28 25 24 29 29 27 22 13 20 36 ...

Page 101: ...re to 20 ft lb 29 7 N m Figure 7 30 Page 7 18 6 Install the thrust washer 32 wave washer 33 and kingpin 21 7 Install the washer 36 and a new lock nut 22 and tighten to 18 ft lb 24 4 N m 8 Insert the ball joint 23 into the spindle assembly Figure 7 20 Page 7 11 9 Install the lock nut 24 to secure the ball joint to the spindle and tighten to 18 ft lb 24 4 N m 10 Install a new cotter pin 18 and bend ...

Page 102: ...the steering wheel all the way from left to right and back again the hoses should not come in contact with any component especially the wheels or tires 4 Connect the spark plug wire 5 Connect the battery cables positive cable first and tighten terminals to 20 ft lb 27 N m Coat ter minals with Battery Terminal Protector Spray CCI P N 1014305 FRONT WHEEL BEARINGS AND HUBS See General Warning Section...

Page 103: ...re 7 31 Page 7 19 4 Loosen spindle nut one cotter pin position If the hub does not turn freely loosen spindle nut one more cotter pin position 5 Install a new cotter pin 2 If movement continues replace the wheel bearings 5 as required 6 Finger tighten the wheel lug nuts and lower the vehicle Tighten the lug nuts in a crisscross pattern to 55 ft lb 74 6 N m FRONT WHEEL BEARINGS AND HUB REMOVAL See ...

Page 104: ...7 ...

Page 105: ...heels should not come in contact with the brake hoses NOTE An air leak could be due to a punctured tire faulty valve core improperly seated valve stem or improperly seated tire bead Small holes in the tire can be plugged using a standard automotive tubeless tire repair kit available at auto supply stores Tire must be removed or installed from the valve stem side of the rim Traks Max II tires are d...

Page 106: ...8 ...

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 Tighten nut 2 until rubber bushings 4 expand to the same diameter as the cup washers 3 Figure 9 1 Page 9 2 3 Install mounting hardware and tighten the nut 6 until the rubber bushings 8 expand to the same diam eter as the cup washe...

Page 108: ... Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual 9 Figure 9 1 Rear Suspension for MC012C AS00 Transaxle 7 8 8 7 6 1 14 12 24 23 18 13 25 19 23 24 23 17 22 REAR BRAKE CABLE 21 TYPICAL BOTH SIDES OF VEHICLE 16 3 4 4 3 2 AXLE SADDLE ...

Page 109: ...13 to the shock mount bracket 14 Figure 9 1 Page 9 2 8 Remove bolt 16 and lock nut 17 attaching the leaf spring 18 to the rear shackles 19 9 Allow rear of leaf spring 18 to rest on the ground and remove the bolt 21 and lock nut 22 attaching the front of the spring to the vehicle frame Remove spring from vehicle 10 Inspect the rubber bushings 23 and steel sleeves 24 in the spring eyes and replace t...

Page 110: ...5 ft lb 47 5 N m 6 Install shock absorber See Shock Absorber Installation on page 9 1 SNUBBER See General Warning Section 1 Page 1 1 SNUBBER REMOVAL 1 Support the powertrain with a floor jack under the engine mounting plate so that the snubber is raised slightly and does not rest on the vehicle frame 2 Working from above remove the two bolts 2 and two lock nuts 1 securing the snubber bracket to th...

Page 111: ...vel change if necessary See Periodic Lubrication Schedule on page 10 2 Check engine cooling air intake visually inspect unshrouded area around engine exhaust for grass and debris and clean if necessary Tires Check air pressure and adjust if necessary See Section 8 Wheels and Tires General vehicle Wash engine compartment and underside of vehicle Do not wash engine when hot Semiannual service by tra...

Page 112: ...ion Fuel filters Replace PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE LUBRICATION POINT RECOMMENDED LUBRICANT Semiannually by owner or trained technician every 50 hours of operation Brake pedal shaft bearings Dry Moly Lube CCI P N 1012151 Accelerator push rod pivots mounts and shifter cable pivots Dry Moly Lube CCI P N 1012151 Front suspension 2 fittings Chassis Lube EP NLGI Grade 2 Chec...

Page 113: ... brake fluid on the exterior surface of the master cylinder indicates a leak The vent holes in the reservoir cover should be clean and open The reservoir diaphragm should not have holes or other damage Figure 10 1 Pioneer 1200 and Pioneer 1200SE Lubrication Points Figure 10 2 Master Cylinder 2 5 1 7 4 2 2 3 6 3 6 2 2 1 FLOORBOARD W A R N I N G U S E O N L Y D O T 3 F L U I D F R O M A S E A L E D ...

Page 114: ...should be checked monthly The vehicle should be on a level surface when checking oil Do not overfill with oil ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil from the stick Figure 10 3 Page 10 4 or Figure 10 4 Page 10 4 See following CAUTION CAUTION Do not remove dipstick while engine is running 2 Check oil by fully inserting the dipstick into the oil f...

Page 115: ...ty glasses or approved eye protection when servicing the vehicle Wear rubber gloves when handling oil drain plug oil filter and oil drain pan 5 Clean the oil drain plug threads with solvent to remove oil and oil residue Make sure that the compres sion washer remains on the drain plug 6 Use a 14 mm socket or wrench and replace the front oil drain plug turning it clockwise and tighten to 18 ft lb 24...

Page 116: ...to direct the filter port oil into the drain pan Dispose of used oil according to the environmental laws and regulations for your area 10 Use a clean rag and wipe the oil filter mounting bracket surface clean where the oil filter gasket seats 11 Install a new oil filter CCI P N 1016467 Apply a light coat of white lithium NLGI Number 2 grease Dow Corning BR2 Plus or equivalent or new engine oil to ...

Page 117: ...rect the problem 17 Stop the engine and remove the dip stick to check the engine oil as a final step OIL VISCOSITY Choose the viscosity according to the temperature as shown Figure 10 10 Page 10 7 See following NOTE NOTE Using multi grade oils 5W 20 10W 30 and 10W 40 will increase oil consumption Check oil level more frequently when using multi grade oils FUELING INSTRUCTIONS See General Warning S...

Page 118: ...e and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Tools wires and metal objects can cause sparks when shorted across a battery Follow all instructions carefully when working with batteries Charge battery in a well ventilated area only Battery Poison Contains acid Causes severe burns Avoid ...

Page 119: ...inals should be washed off with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off the battery Do not allow this solution to enter the battery Be sure terminals are tight battery terminals should be tightened to 20 ft lb 27 1 N m Let the terminals dry and then spray them with Battery Terminal Protector Spray CCI P N 1014305 See following CAU...

Page 120: ...10 ...

Page 121: ...roubleshooting and Electrical System FE400 Engine Test Procedures 14 15 and 16 Intermittent ignition coil failure Section 11 Troubleshooting and Electrical System FE400 Engine Test Procedures 14 15 and 16 Low cylinder compression Section 13 FE400 Engine Water or dirt in the fuel system and or carburetor dirty or clogged fuel filter Section 14 Fuel System Carburetor improperly adjusted Section 14 F...

Page 122: ... too lean check main jet size Section 14 Fuel System Engine pre ignites Excessive carbon deposits on piston head or in combustion chamber Section 13 FE400 Engine Spark plug heat range is incorrect Section 13 FE400 Engine Unsuitable or contaminated fuel Section 14 Fuel System Loss of engine power Exhaust valve is restricted with carbon deposit Section 13 FE400 Engine Muffler or exhaust pipe restric...

Page 123: ... Section 11 Troubleshooting and Electrical System FE400 Engine Starter Circuit on page 11 14 Starter generator failed Section 11 Troubleshooting and Electrical System FE400 Engine Test Procedure 8 Starter solenoid failed Section 11 Troubleshooting and Electrical System FE400 Engine Test Procedure 6 Key switch failed Section 11 Troubleshooting and Electrical System FE400 Engine Test Procedure 4 Loc...

Page 124: ...ection 13 FE400 Engine Snubber on frame is worn or damaged Section 13 FE400 Engine Misaligned muffler mounting clamp Section 15 Exhaust System Damaged drive belt or starter belt Section 17 Torque Converter Damaged drive clutch Section 17 Torque Converter Damaged driven clutch Section 17 Torque Converter Damaged starter generator pulley See Starter Generator Removal Section 12 Page 12 1 RPM setting...

Page 125: ...g Unit Circuit Hour Meter Circuit Lighting Circuit This key start vehicle uses the ignition key to activate the electrical system and start the engine It allows the engine to run at idle or advanced RPM using the accelerator pedal when the Forward Reverse handle is in NEUTRAL See Section 13 FE400 Engine Use the troubleshooting flow charts in the Circuit Testing section to find the proper test proc...

Page 126: ...DRIVER SIDE HEADLIGHT FUEL GAUGE HOUR METER MASTER CYLINDER OIL LIGHT REVERSE BUZZER KEY SWITCH BROWN SONIC WELD SONIC WELD YELLOW WHITE BLACK WHITE BLACK YELLOW BLUE BLUE BLUE RED WHITE YELLOW GREEN WHITE GREEN WHITE WHITE YELLOW YELLOW BLUE B L U E BLUE BLUE BLUE BLACK BLUE BLACK BLACK BLUE BLUE BLACK BLACK WHITE BLUE BLACK B L A C K BLACK WHITE BLACK BLUE RED RED BLACK BLACK BLUE YELLOW Y E L L...

Page 127: ...VERSE BUZZER LIMIT SWITCH 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 WHITE WHITE BLACK YELLOW BLUE BLUE YELLOW RED WHITE YELLOW GREEN WHITE YELLOW RED ORANGE WHITE BLACK BLACK BLACK BLACK BLAC K BLAC K BLACK BLACK YELLOW BROWN BROWN BROWN BROWN BLACK B...

Page 128: ...ry 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 when viewed from the clutch side of the engine GENERATOR CIRCUIT The generator circuit consists of the starter generator voltage regulator diode solenoid battery and con necting wires Figure 11 5 Page 11 9 When battery power is first supplied...

Page 129: ...ark plug therefore the proper way to stop the engine is to run this electrical power to ground bypassing the spark plug Figure 11 7 Page 11 10 The engine kill circuit consists of the key switch and connecting wires The engine can be stopped by turning the key switch to the OFF position See Lockout Cam Circuit on page 11 11 Figure 11 5 Key Start Generator Circuit Figure 11 6 Ignition Circuit F2 DF ...

Page 130: ...everse handle is placed in REVERSE a cam depresses the reverse limit switch closing the circuit and activating the reverse buzzer LOW OIL WARNING CIRCUIT The low oil warning circuit consists of an oil level sensor in the engine a dash mounted low oil warning light key switch and connecting wires Figure 11 9 Page 11 11 The light receives power through the key switch when the key switch is turned to...

Page 131: ...nt on this vehicle NOTE Be sure the cam is in the correct position The cam should activate the limit switch only when the Forward Reverse handle is in the NEUTRAL position Figure 11 10 Page 11 11 The lockout cam circuit consists of the connecting wires and a limit switch that is located on the Forward Reverse shifter assembly and is activated by the lockout cam Figure 11 11 Page 11 12 Figure 11 9 ...

Page 132: ...ch is turned to the ON position The power goes through the gauge to the sending unit at the fuel tank The sending unit tells the gauge how much fuel is in the tank Figure 11 12 Page 11 12 Figure 11 11 Lockout Cam Circuit Figure 11 12 Fuel Gauge and Sending Unit Circuit 2 M L B G S KEY SWITCH FUSE BLOCK FRAME GROUND BATTERY FORWARD REVERSE ASSEMBLY LIMIT SWITCH 1 RED RED RED RED RED BLUE BLUE BLACK...

Page 133: ...Page 1 1 Test the vehicle battery to determine whether or not it is the source of the problem before testing the electrical circuits A hydrometer multimeter and 160 ampere load tester will be required See Test Procedure 1 Bat tery on page 11 20 Figure 11 13 Key Start Hour Meter Circuit Figure 11 14 Key Start Lighting Circuit 2 3 4 M L B G S FUEL GAUGE HOUR METER BLACK FRAME GROUND KEY SWITCH FUSE ...

Page 134: ...CHECK KEY SWITCH 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 VOLTAGE LESS THAN 9 6 VOLTS SOLENOID DOES CLICK CHECK BATTERY TEST PROCEDURE 1 CHECK SOLENOID TEST PROCEDURE 6 CHECK GROUND STRAPS TEST PROCEDURE 3 NO VOLTAGE READING CHECK SOLENOID TEST PROCEDU...

Page 135: ...ON GAP TEST TEST PROCEDURE 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 15 CHECK KEY SWITCH TEST PROCEDURE 17 CHECK PLUG GAP SEE SETTING THE SPARK PLUG GAP IN SECTION 13 CHECK COIL TEST PROCEDURE 16 ENGINE RUNS ENGINE DOES NOT RUN CHECK FOR GROUNDED W...

Page 136: ... USE MULTIMETER TO 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 STRAPS TEST PROCEDURE 3 REVERSE BUZZER WILL NOT FUNCTION AND ENGINE WILL CRANK CHECK WIRE CONNECTION TO THE REVERSE BUZZER TEST PROCEDURE 20 INCORRECT CONTINUITY READING CORRECT CONTINU...

Page 137: ...LEVEL SENSOR TEST 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 CORRECTLY CONNECTED LOW OIL WARNING LIGHT ILLUMINATES LOW OIL WARNING LIGHT ILLUMINATES LOW OIL WARNING LIGHT DOES NOT ILLUMINATE LOW OIL WARNING LIGHT DOES NOT ILLUMINATE OVERRIDE OIL LEVE...

Page 138: ... 1 Use the following chart Figure 11 21 Page 11 18 to begin troubleshooting the fuel gauge and sending unit circuit Figure 11 21 Testing the Fuel Gauge and Sending Unit Circuit CHECK FUEL LEVEL SENDING UNIT TEST PROCEDURE 25 VOLTAGE READING ABOVE 8 VOLTS VOLTAGE READING BELOW 8 VOLTS VOLTAGE READINGS CORRECT VOLTAGE READINGS INCORRECT REPLACE SENDING UNIT VOLTAGE READINGS INCORRECT REPLACE FUEL GA...

Page 139: ...h Starter Circuit 5 Key Switch Accessory Terminal 6 Solenoid 7 Lockout Cam Limit Switch 8 Starter Generator Starter Function Figure 11 22 Testing the Lighting Circuit CHECK VOLTAGE AT HEADLIGHT SOCKET TEST PROCEDURE 30 VOLTAGE READING 12 VOLTS NO VOLTAGE READING CONTINUITY OK REPLACE FUSE NO CONTINUITY NO LIGHTS WORK CHECK FUSE TEST PROCEDURE 2 CONTINUITY OK REPLACE LIGHT SWITCH NO CONTINUITY CHEC...

Page 140: ... wear a full face shield and rubber gloves when working around a battery Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or using in an enclosed space Wear a full face shield and rubber gloves when working on or near batteries For added protection cover top of the battery when servicing the vehicle Battery Poison Contains a...

Page 141: ...approximately 1 2 inch 13 mm and is fully charged prior to beginning the test If water must be added recharge the battery before perform ing the hydrometer test Figure 11 24 Page 11 21 2 Remove the vent cap 3 Record the electrolyte temperature of a center cell using a battery thermometer CCI P N 1011767 4 Draw electrolyte into the hydrometer 5 When the float rises off the bottom adjust the electro...

Page 142: ...volts or if the lowest specific gravity reading from the hydrometer test is less than 1 225 recharge the battery If battery voltage is greater than 12 4 volts and specific gravity is greater than 1 225 the prob lem is not with the battery If the battery does not reach 12 4 volts or if the specific gravity of a cell is still less than 1 225 after charging replace the battery See following NOTE NOTE...

Page 143: ... the fuse terminals The reading should be con tinuity If not determine fuse failure repair and replace the fuse with a properly rated new one TEST PROCEDURE 3 GROUND STRAPS See General Warning Section 1 Page 1 1 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed Figure 11 1 Page 11 5 See WARNING To...

Page 144: ... 2 Set the multimeter to 200 Ω ohms Place the red probe on the unconnected end of the 6 gauge black wire and the black probe on the vehicle frame Figure 11 27 Page 11 24 The reading should be continuity If the reading is incorrect check that terminal connections are clean and tight If the connections are good but the reading is incorrect repair or replace the wire Figure 11 25 Test Starter Generat...

Page 145: ...he reading is correct leave the probes connected and proceed to the next step 7 Insert the key and hold the key in the START position The reading should be continuity If the reading is incorrect replace the key switch Figure 11 29 Page 11 25 With the red probe of the multimeter on the B terminal and the black probe on the L terminal of the key switch the reading should be con tinuity If either rea...

Page 146: ...s replace the solenoid 6 Remove the 6 and 12 gauge white wires and the 18 gauge red wire from the large post of the solenoid Do not allow the wires to touch the frame or other components of the vehicle Figure 11 30 Page 11 26 7 Set the multimeter to 200 Ω ohms Connect the red probe to one of the large posts of the solenoid and connect the black probe to the other large post Figure 11 31 Page 11 27...

Page 147: ...ral Warning Section 1 Page 1 2 3 Check for proper wiring and tight connections 4 Set the multimeter to 200 Ω ohms Place the red probe of the multimeter on the common COM ter minal of the limit switch Place the black probe on the normally open NO terminal of the switch With out the lever depressed the reading should be no continuity Depress the lever and the reading should be continuity If either r...

Page 148: ...1 or F2 terminal or a grounded field coil If the DF reading is incorrect it indicates a possible grounded DF terminal or a grounded field coil 5 Disconnect the ground wire from the A2 terminal and the green wire from the A1 terminal on the starter generator 6 Use a multimeter set to 200 Ω ohms and place the red probe on the A1 terminal and the black probe on the A2 terminal The reading should be c...

Page 149: ...be on the terminal at one end of the wire Place the black probe on the other terminal end of the wire The reading should be continuity If the reading is incorrect repair or replace the wire TEST PROCEDURE 10 DIODE GENERATOR CIRCUIT See General Warning Section 1 Page 1 1 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the batter...

Page 150: ...tely 450 mV however a range of 400 500 mV is acceptable Figure 11 38 Page 11 31 6 Connect either the black or red lead of the multimeter to the diode body case Connect the other multimeter lead to both the red and white lead terminals of the diode The multimeter should indicate an overload no continuity If continuity reading does occur it indicates that one or both of the diode leads are grounded ...

Page 151: ... it at full governed speed The reading should show the voltage rising on the meter If the voltage rises see Test Procedure 12 Voltage Regulator on page 11 31 If the voltage does not rise and the diode was found to be functioning properly in Test Procedure 10 a tear down inspection of the starter generator will be necessary See Starter Generator Removal Section 12 Page 12 1 5 Reconnect the yellow w...

Page 152: ...er than 14 7 volts but rising steadily check battery condition See HydrometerTest on page 11 21 If the reading is lower than 14 7 volts and not rising and the starter generator is good or if the reading is over 15 3 volts and continues to rise replace voltage regulator See Voltage Regulator Removal Section 12 Page 12 11 TEST PROCEDURE 13 GROUNDED KILL WIRE See General Warning Section 1 Page 1 1 NO...

Page 153: ...18 000 volts 18 Kv setting SE Small Engine Setting on the Thexton 404 tool Connect the tester to the spark plug wire and connect the alligator clip to a solid engine ground 2 2 Start the engine There should be a strong blue spark between the probes of the spark gap tester If there is no spark or if the spark is a faint yellow or red color test components of the ignition circuit 3 If the spark gap ...

Page 154: ...il has tested okay in the vehicle and on the bench but fails to operate reliably replace the coil with a known good coil and operate the engine for several minutes to ensure that the coil functions at normal operating tempera ture If the new coil functions properly keep the new coil in the circuit Ignition Coil In Vehicle Test 1 Turn the key switch OFF and remove the key Place the Forward Reverse ...

Page 155: ...tly from each other 5 Test the spark plug cap separately from the secondary coil 5 1 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the spark plug wire 3 Figure 11 45 Page 11 36 5 2 Remove the cap from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire Figure 11 46 Page 11 36 5 3 Use a multimeter set to 20k Ω oh...

Page 156: ...nce and Service Manual 11 Test Procedure 16 Ignition Coil Continued Figure 11 44 Secondary Coil Test In Vehicle Test Figure 11 45 Ignition Coil and Cap Figure 11 46 Spark Plug Cap Removal 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k Ω Ω 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED CAP 7 4 3 1 2 5 ...

Page 157: ...the engine See Ignition Coil Removal Section 12 Page 12 23 2 Use a multimeter set to 200 Ω ohms and measure the primary coil resistance 2 1 Place the black probe of the meter on the terminal on the ignition coil 1 and place the red probe on the core 2 Figure 11 49 Page 11 38 2 2 If the resistance is not between 0 6 1 7 Ω ohms replace the ignition coil 3 Use a multimeter set to 20k Ω ohms and measu...

Page 158: ...Bench Test Figure 11 50 Secondary Coil and Cap Resistance Bench Test 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k Ω Ω 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k Ω Ω 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 1 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k Ω Ω 1000 ...

Page 159: ...se a multimeter set to 20k Ω ohms and place the red probe of the meter into the end of the spark plug wire and place the black probe on the core 2 Figure 11 51 Page 11 39 If the resistance is between 6 0k 11 0k Ω ohms the secondary coil is within acceptable limits If the resistance is not between 6 0k 11 0k Ω ohms the ignition coil has failed and must be replaced 6 If the preceding procedures indi...

Page 160: ...or located at the engine RPM limiter Figure 11 41 Page 11 33 4 Connect red probe of multimeter to the male bullet terminal on the white black wire and connect the black probe to the vehicle frame 5 With the Forward Reverse handle in the NEUTRAL position turn the key switch to the ON position and note the multimeter reading Turn the key and hold it in the START position while noting the multimeter ...

Page 161: ...ng a multimeter Figure 11 8 Page 11 10 If the buzzer will not function after wiring checks replace the buzzer TEST PROCEDURE 21 OIL LEVEL SENSOR See General Warning Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the spark plug wire See WARN...

Page 162: ...ll not activate the limit switch replace the cam TEST PROCEDURE 24 BATTERY TEST UNDER LOAD See General Warning Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Set a multimeter to 20 volts and place the red probe on the F2 white wire terminal on the sta...

Page 163: ...ns listed above the fuel level sending unit is working properly If the readings are incorrect the fuel level sending unit has failed and the fuel tank must be replaced See Fuel Tank Removal Section 14 Page 14 21 7 If the readings are correct and the fuel gauge does not function correctly check the continuity of the orange wire from the fuel level sending unit to the fuel gauge hour meter Leave the...

Page 164: ...tighten to 20 ft lb 27 1 N m 9 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 54 Page 11 44 10 The orange wire should remain disconnected for this step With the black probe still on the 3 terminal of the fuel gauge hour meter place the red probe of the multimeter on the ...

Page 165: ...d unin tentionally starting in General Warning Section 1 Page 1 2 3 Remove the center dash assembly See Key Switch Removal Section 12 Page 12 14 4 Use a multimeter set on 20 volts DC with alligator clips on the meter probes Connect the red probe to the light switch terminal with the blue wire connected to it Figure 11 56 Page 11 45 CAUTION Before connecting battery cables make sure none of the ele...

Page 166: ...e metal terminal in the connector Place black probe on the connector Figure 11 57 Page 11 47 See following CAUTION CAUTION Before connecting battery cables make sure no electrical components touch the front body trim or other parts of the vehicle frame Place a dry towel between the body trim and the center dash to prevent an electrical short circuit 6 Connect the battery cables positive cable firs...

Page 167: ...ace the red probe into the blue wire terminal of the wiring harness If the multimeter reading is approximately 12 volts the blue wire has continuity 7 Check continuity of the 16 gauge black wire from the headlight to the ground terminal Use a multimeter set to 20 volts DC and place the black probe of multimeter into the black wire terminal of the wiring harness and attach the red probe onto the po...

Page 168: ...11 ...

Page 169: ...Figure 12 1 Page 12 1 See WARNING To avoid unin tentionally starting in General Warning Section 1 Page 1 1 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 2 4 Remove the mounting adjustment nut 12 lock washer 9 and bolt 11 Lower the starter generator and slip the belt 4 off the pulley 10 5 Support the start...

Page 170: ... inspect the armature commutator and the bearings see Disassembly of the Starter Generator to Service the Armature Commutator on page 12 4 Brush Inspection and Replacement 1 Visually inspect brushes Replace brushes that are cracked or severely chipped 2 Check the wear line on the side of the brush If the end of the brush is within 1 16 inch 1 6 mm of the wear line replace all four brushes Figure 1...

Page 171: ...alled Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs Figure 12 3 Commutator End Cover Figure 12 4 Brush Covers and Brushes Figure 12 5 Inspect Brushes Figure 12 6 Brush Spring Tension Test 20 23 24 26 27 29 23 TYPICAL 3 PLACES 25 TYPICAL 4 PLACES 30 28 0 1 1 2 1 2 STARTER GENERATOR BRUSH WEAR LINE BRUSH HOLDER Replace springs that ...

Page 172: ... cover 23 Figure 12 4 Page 12 3 Disassembly of the Starter Generator to Service the Armature Commutator 1 Remove the two bolts 20 and pull commutator end cover 23 free of the starter generator housing 24 Figure 12 3 Page 12 3 See following NOTE NOTE Brushes must be removed to avoid damage from commutator removal Lift the brush springs out of the notches in the brushes and pull the brushes back fro...

Page 173: ...0 Page 12 6 2 Discard the bearings 3 Slide the bearing retainer 32 off of the output end of the shaft Figure 12 8 Page 12 5 Field Coil Removal 1 Remove the retaining nut from each field coil terminal and slide the insulator out of the slots in the hous ing 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 o...

Page 174: ...nsulation Improperly cured varnish Thrown solder Flared armature windings Worn burned or glazed commutator Loose or raised commutator bars Bruised or damaged armature core laminations Worn armature bearing or shaft Dirty or oily commutator Figure 12 10 Bearing Removal Figure 12 11 Field Coil Assembly USE A 1 2 INCH SOCKET OR PIPE PRESS RAM USE A 1 2 INCH SOCKET OR PIPE SUPPORT INNER RACE OF BEARIN...

Page 175: ...mutator diameter is less than 1 535 inches 39 mm at any of the four loca tions replace the armature assembly and bearings Figure 12 12 Page 12 7 Armature Ground Test CAUTION Do not submerge armature in solvent NOTE Before testing wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars 1 Use a multimeter set on 200 Ω ohms and place the positive p...

Page 176: ...gh the insulators Install a flat washer lock washer and nut onto each threaded terminal on the outside of the housing Tighten nuts to 47 5 in lb 5 4 N m Figure 12 11 Page 12 6 See following CAUTION Figure 12 13 Armature Ground Test ITEM SERVICE LIMIT Commutator diameter minimum 1 535 in 39 mm Concentric with armature shaft within 0 002 in 0 051 mm Limit depth of cut when machining commutator 0 007...

Page 177: ... armature shaft Align the locating pin and hole in the cover Install the two M6 x 180 mm bolts 20 and tighten to 100 in lb 11 3 N m Figure 12 3 Page 12 3 10 Push the brushes down into the holders Place springs into the notches in the brushes Install the brush cover 30 that has the drain hole in it next to the A2 terminal Install the remaining three brush covers 29 onto the openings in the commutat...

Page 178: ... bolts 5 on the mounting bracket carriage bolt 11 and hex nut 12 are finger tight Figure 12 14 Page 12 10 4 Push the starter generator down to it s lowest point of adjustment travel With the starter generator belt in place around the drive clutch pulley install the starter generator belt 3 5 Place a pry bar 13 between the top of the starter generator mounting bracket 2 and the underside of the sta...

Page 179: ...e regulator 9 Voltage Regulator Installation 1 Position the voltage regulator 9 in the electrical component box and install the mounting screw 8 and tighten screw to 23 in lb 2 6 N m Figure 12 16 Page 12 11 2 Connect the voltage regulator red wire 1 at the large post on the solenoid with the other red wires the yellow wire 4 at the bullet connector and the black wire 7 to the wire harness and the ...

Page 180: ...7 from the two large solenoid posts and disconnect the diode wires from the solenoid 5 1 Observe color orientation of the wires with the terminal locations on the solenoid The 12 gauge red wire from the diode should be attached to the same terminal as the red wire from the fuse block and the red wire from the battery The 12 gauge white wire should be attached to the other large solenoid post along...

Page 181: ...ollowing WARNING WARNING Incorrect wiring could result in severe injury or death Diode and solenoid connections must have correct polarity Keep all persons clear of engine belts when making final connections 4 1 Connect the 12 gauge red wire from the diode to the solenoid post with the fuse block and battery red wires and tighten lock nut to 90 in lb 10 2 N m Figure 12 18 Page 12 13 4 2 Connect th...

Page 182: ...e 12 1 See WARNING To avoid unin tentionally starting in General Warning Section 1 Page 1 1 3 Remove the dash panel 3 1 Loosen seven Tuflok screws but do not remove screws completely as shown in Detail A Figure 12 20 Page 12 16 3 2 Remove Tuflok screws from dash panel as shown in Detail B 3 3 Pull forward on top of dash panel to access back side of key switch 3 4 Disconnect the wire connector from...

Page 183: ...ed 2 1 Connect the 6 gauge white wire from the starter generator 18 gauge red wire from the voltage reg ulator and the 12 gauge white wire from the diode to the large post on the solenoid See Wiring Diagram Section 11 Page 11 6 2 2 Connect the 6 gauge red wire from the battery the 10 gauge red wire from the fuse block and the 12 gauge red wire from the diode to the other large post on the solenoid...

Page 184: ... fuse See following WARNING WARNING If a fuse is blown determine the cause of the failure and make necessary repairs before installing a new fuse Use the appropriately rated fuse if a fuse with a higher amp rating is used damage to the vehicle electrical system may occur 2 Install the snap on electrical box cover by firmly pressing down on all corners and install the screw and tighten to 18 in lb ...

Page 185: ...e 12 21 Page 12 18 Place the Forward Reverse handle in REVERSE to make sure that both switches actuate See following CAUTION CAUTION Do not overtighten the retaining nuts If the nuts are overtightened limit switches could be damaged 2 Connect the black wire to the common COM terminal and the green wire to the normally open NO ter minal of the lockout cam limit switch See Wiring Diagram Section 11 ...

Page 186: ...s positive cable first and tighten the terminals to 20 ft lb 27 1 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 REVERSE WARNING BUZZER See General Warning Section 1 Page 1 1 Testing the Reverse Warning Buzzer See Test Procedure 20 Section 11 Page 11 41 Reverse Warning Buzzer Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL ...

Page 187: ...rminals with Battery Terminal Protector Spray CCI P N 1014305 REVERSE BUZZER LIMIT SWITCH See General Warning Section 1 Page 1 1 Testing the Reverse Buzzer Limit Switch See Test Procedure 19 Section 11 Page 11 40 Reverse Buzzer Limit Switch Removal 1 Turn the key switch OFF and remove the keyl Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructe...

Page 188: ...o the ON position With the Forward Reverse handle in REVERSE the buzzer should sound LOW OIL WARNING LIGHT See General Warning Section 1 Page 1 1 Testing the Low Oil Warning Light See Test Procedure 22 Section 11 Page 11 41 Low Oil Warning Light Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instr...

Page 189: ...ward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed Figure 12 1 Page 12 1 See WARNING To avoid unin tentionally starting in General Warning Section 1 Page 1 2 3 Remove the dash panel See Key Switch Removal on page 12 14 4 Disconnect the wires from the fuel gauge hour meter 2 Figure 12 24 Page 12 21 Do not allow wires to touch 5 Remove the two hex nuts 3 an...

Page 190: ...emove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed Figure 12 1 Page 12 1 See WARNING To avoid unin tentionally starting in General Warning Section 1 Page 1 2 3 Disconnect the white black wire from the black wire at the bullet connector located near the RPM limiter Figure 12 25 Page 12 23 4 Disconnect the other black wire at the ...

Page 191: ...ized transaxle See Unitized Transaxle Removal Section 16 Page 16 6 See following CAUTION CAUTION Before removal and disassembly clean the engine 1 Remove the starter gererator See Starter Generator Removal on page 12 1 See following NOTE NOTE The crankshaft has left hand threads at the clutch mounting hole 2 Remove the muffler See Muffler Removal Section 15 Page 15 1 3 Remove the engine mounting h...

Page 192: ...and place it on the new spark plug wire 5 5 Install the protector tube 3 onto the new wire 6 Slide the gasket 1 onto the end of the new spark plug wire 7 Install the cap 2 on the new coil spark plug wire by rotating it clockwise three or four revolutions while applying light pressure on the cap 8 Install the gasket 1 on the cap 2 9 Position the ignition coil 7 onto the cast mounting bosses on the ...

Page 193: ...ge 13 6 18 Tighten the two engine body bolt nuts 6 to 17 ft lb 23 1 N m 19 Install the engine and transaxle assembly See Unitized Transaxle Installation Section 16 Page 16 16 See following CAUTION CAUTION Make sure wire harness is routed and secured away from the muffler Figure 12 26 Remove Fan Housing Figure 12 27 Black Wire And Ignition Coil Figure 12 28 Clean Grommet Figure 12 29 Mount Ignition...

Page 194: ...L LEVEL SENSOR See General Warning Section 1 Page 1 1 Testing the Oil Level Sensor See Test Procedure 21 Section 11 Page 11 41 Oil Level Sensor Removal See Oil Level Sensor Removal Section 13 Page 13 4 Oil Level Sensor Installation See Oil Level Sensor Installation Section 13 Page 13 5 HEADLIGHTS See General Warning Section 1 Page 1 1 Testing the Headlight Bulb and Socket See Test Procedure 30 Sec...

Page 195: ...arness halogen bulb assembly 4 and 6 into the headlight lens 7 3 Turn the wire harness halogen bulb assembly 4 and 6 counterclockwise one quarter turn 4 Connect the battery cables positive cable first and tighten the terminals to 20 ft lb 27 1 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 VOLTAGE LIMITER See General Warning Section 1 Page 1 1 Testing the Voltage Limiter ...

Page 196: ... outer nut 2 from the light switch 3 and remove Figure 12 32 Page 12 27 Light Switch installation 1 Connect the wires to the light switch See Wiring Diagram Section 11 Page 11 6 2 Thread the check nut 4 onto the switch until an equal number of threads show on both sides Install to the dash panel with nut 2 on the outside of the dash and tighten the nut to 14 in lb 1 6 N m Figure 12 32 Page 12 27 3...

Page 197: ...should be clean and tight Any frayed or worn wires should be replaced After all cables have been con nected and properly tightened to 20 ft lb 27 1 N m coat terminals with Battery Terminal Protector Spray CCI P N 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 bristle ...

Page 198: ...NGER on page 12 28 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed Figure 12 1 Page 12 1 See WARNING To avoid unin tentionally starting in General Warning Section 1 Page 1 2 3 Pioneer 1200 3 1 Remove the four bolts 8 eight washers 9 and four lock nuts 10 from the armrests 11 and 12 See Figure 4 ...

Page 199: ...er manufacturer 2 Attach the charger positive cable to the positive and negative cable to the negative battery post 3 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 WARNING If the battery case feels hot approximately 125 F 52 C or more emits gases or fluid boils from vents stop charging immed...

Page 200: ...ger The battery can be left in the vehicle Disconnect the negative cable first See WARNING To avoid unin tentionally starting in General Warning Section 1 Page 1 2 3 Fully charge the battery prior to storage 4 Store in a cool dry area The colder the area in which the battery is stored the less the battery will self discharge A battery stored at 0 F 17 8 C will discharge very little over a four mon...

Page 201: ...2003 Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual Page 12 33 12 WARNING Do not jump start a dead battery using another battery and jumper cables GROUND STRAPS Testing the Ground Straps See Test Procedure 3 Section 11 Page 11 23 ...

Page 202: ...12 ...

Page 203: ...ervice should have knowledge and experience in small engine service and repair Molybdenum Disulfide MoS2 Grease NOTE This manual makes reference to molybdenum disulfide grease in the assembly of certain engine and chassis parts Always refer to manufacturer s recommendations printed on the container before using such special lubricants Engine Rotation When turning the crankshaft by hand always turn...

Page 204: ...t be eroded Black color excessive carbon and or a wet plug indicate the fuel is too rich White burned or melted electrodes indi cate the fuel is too lean or pre igniting Oily deposits on the plug electrode are an indication of worn rings valve guides cylinder wall etc Also examine the spark plug wire Remove rubber boot and inspect internal spring for damage Inspect spark plug wire for damage and b...

Page 205: ...l cranking RPM resulting in lower compression At a normal crank ing speed of 550 600 RPM the compression should be typically 71 psi This value could vary slightly depending on wear of components affecting compression See Transaxles and Engines Manual for inspection and repair BREATHER VALVE REED VALVE The function of the breather is to create a vacuum in the crankcase which prevents oil from being...

Page 206: ...CRANKCASE COVER REMOVAL 1 Remove yellow jumper wire 11 from cord connector 12 Figure 13 2 Page 13 4 2 Remove nuts and clamps at two ended bolts 1 and 2 Figure 13 3 Page 13 4 3 Remove eight bolts 3 and remove the crankcase cover 4 See following NOTE NOTE If the crankcase cover sticks tap lightly with a plastic mallet on alternate sides near the dowel pins 5 Figure 13 3 Page 13 4 4 Remove the crankc...

Page 207: ...Figure 13 5 Page 13 6 2 Loosen three screws and remove the remaining four screws attaching the flywheel housing as shown then remove the fan housing Figure 13 6 Page 13 7 3 Disconnect the ignition coil 1 from its primary lead wire at the connector 2 Remove the two bolts 3 and take out the ignition coil Figure 13 7 Page 13 7 4 Hold the flywheel 4 not the fan 7 with a strap wrench 5 and use a 25 mm ...

Page 208: ...3 6 2003 Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual 13 Figure 13 5 Engine Mounting Plate with MC012C AS00 Transaxle ClubCar ClubCar TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES 3 1 4 5 2 TYPICAL 2 PLACES 6 FAN SHROUD ...

Page 209: ... 34 Ignition Coil Installation 1 Installation is the reverse of removal 2 Tighten the two bolts 3 and use a bronze feeler gauge to adjust the ignition coil air gap to 0 012 inch 0 304 mm Figure 13 9 Page 13 7 3 Tighten the two ignition coil bolts to 30 in lb 3 4 N m Figure 13 6 Flywheel Housing Figure 13 7 Ignition Coil Figure 13 8 Flywheel Nut Removal Figure 13 9 Adjust Ignition Coil Air Gap Loos...

Page 210: ...4 N m Then repeating the sequence tighten them to 250 in lb 28 2 N m FLYWHEEL INSTALLATION See General Warning Section 1 Page 1 1 1 Connect the yellow jumper wire 11 to the cord connector 12 Figure 13 2 Page 13 4 CAUTION Before assembly make sure parts are clean 2 Insert the flywheel key into the keyway in the crankshaft and align the flywheel keyway Push the flywheel and fan onto the crankshaft u...

Page 211: ...Install oil drain plug in the crankcase and tighten to 20 ft lb 27 1 N m Apply a light film of oil on the seal 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 Figure 13 13 Page 13 10 See Periodic Lubrication Schedule Section 10 Page 10 2 8 Check all hardware for proper torque tightness 9 Check engine oil level Figure ...

Page 212: ...rankcase cover to block bolts M8 22 ft lb 31 N m Starter Generator bracket to block bolts M8 16 5 ft lb 23 N m Oil drain plug M14 16 5 ft lb 23 N m Fan housing screws M6 90 in lb 10 N m Fan shroud screws M6 25 in lb 2 8 N m ITEM SERVICE LIMIT FE400 ENGINE Spark plug gap standard 0 027 to 0 031 in 0 69 to 0 79 mm Ignition coil air gap standard 0 012 in 0 304 mm Compression pressure min with automat...

Page 213: ...dition See Spark Plug Section 13 Page 13 1 Air filter element See Air Filter on page 14 15 Fuel filters See Fuel Filters on page 14 16 Choke and air intake system for restriction of air flow See Choke and Air Intake System on page 14 11 Fuel pump See Fuel Pump Removal on page 14 19 Fuel lines from fuel tank to filter to pump to filter to carburetor See Fuel Lines on page 14 26 Exhaust system for r...

Page 214: ... engine until the front bracket snubber is fully compessed This will allow the carburetor to pass the electrical box assembly Figure 14 1 Page 14 2 1 9 Remove the carburetor retaining nuts 19 intake pipe 17 and carburetor 12 See following NOTE NOTE Note the orientation of the gasket 16 between the carburetor intake pipe 17 and the carburetor body 12 so that it can be replaced in the same orientati...

Page 215: ...y 9 Install the fuel bowl and position with aligning marks made in step 4 See following CAUTION CAUTION Make sure the fuel bowl is properly seated against the carburetor fuel bowl gasket and the gasket is not pinched 10 Install the fuel bowl retaining screw and tighten to 61 in lb 6 9 N m 11 Write the size of the main jet on the fuel bowl with an indelible ink marker in a location that will be vis...

Page 216: ...ge 14 4 2003 Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual 14 Changing the Main Jet Continued Figure 14 2 Carburetor Installation 1 2 3 4 13 15 12 25 21 26 10 21 11 19 TYPICAL 2 PLACES 18 22 23 14 16 17 24 ...

Page 217: ...ENERAL INFORMATION It is important that the accelerator pedal governor linkage and throttle adjustments are done correctly and in the proper sequence See following CAUTION Figure 14 3 Changing the Main Jet Drain carburetor over a catch basin by turning bowl drain screw 11 counterclockwise 2 to 3 turns STEPS 2 AND 3 STEP 4 A Mark carburetor and corresponding position of fuel bowl B Check for coil l...

Page 218: ...ft the front of the vehicle with a chain hoist or floor jack Place jack stands under the outer front frame I beam of the vehicle and lower onto stands See Figure 5 2 Section 5 Page 5 3 See preceding DANGER See WARNING Lift only one end in General Warning Section 1 Page 1 1 2 Disconnect the ball joint 1 from the ball stud 2 on the accelerator pedal Figure 14 4 Page 14 6 and from the bell crank at t...

Page 219: ...PM Adjustment on page 14 10 11 Install the electrical component box cover and tighten retaining screw to 18 in lb 2 0 N m GOVERNOR CABLE Governor Cable Removal 1 Turn the key switch to OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Remove the cotter pin 25 and clevis pin 24 at the carburetor throttle bracket Figure 14 2 Page 14 4 3 Remove the E ring 7 at the ...

Page 220: ...ccelerator Cable Installation 1 Connect the cable to the cam 17 in the electrical box Figure 14 7 Page 14 9 2 Insert the cable housing into the mounting slot in the wall of the electrical box with approximately the same number of threads visible between the jam nuts as are visible from the nut inside the box to the end of the cable housing Figure 14 5 Page 14 8 Tighten the nuts finger tight 3 Conn...

Page 221: ...ol Linkage 2003 Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual Page 14 9 14 Figure 14 7 Governor and Accelerator 8 7 11 9 6 10 9 7 7 6 5 16 3 1 4 2 REFERENCE EXHAUST SECTION 12 13 14 TYPICAL 2 PLACES 17 15 ...

Page 222: ... the high speed RPM Press the accelerator pedal to the floor the tachometer should read 2 1 After the accelerator pedal and rod are adjusted the final governed engine RPM should be set to FE400 Engine 3850 30 RPM See Engine RPM Adjustment Section 14 Page 14 10 3 To reduce RPM loosen the accelerator cable retaining nut on the outside of the electrical box wall and tighten the retaining nut on the i...

Page 223: ... 17 to secure cable to air box Tighten screw to 18 in lb 2 0 N m 5 Pioneer 1200SE 5 1 Attach a new wire tie 23 around the cable and air duct Figure 14 11 Page 14 18 AIR BOX REMOVAL 1 Turn the key switch to OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Remove choke cable bracket screw 17 and cable 18 from air box top 4 Figure 14 10 Page 14 17 or Figure 14 11 ...

Page 224: ...le with a floor jack 2 4 Place jack stands under the vehicle outer front frame I beam and lower onto the jack stands See Figure 5 2 Section 5 Page 5 3 SeeWARNING Lift only one end in GeneralWarning Section 1 Page 1 1 2 5 Remove the front wheels 2 6 Remove the bolt 1 that connects the steering joint to the steering column shaft Figure 14 9 Page 14 13 See following NOTE NOTE The bolt must be removed...

Page 225: ...ecuring the top of the intake duct to the floorboard Figure 14 10 Page 14 17 2 14 Remove the air box assembly See Air Box Removal on page 14 11 2 15 Lift air box assembly off the intake duct Be careful that the intake seal on the bottom of the air box assembly is not dislodged in the process 2 16 Pull the intake duct forward and out of the vehicle 3 Pioneer 1200SE 3 1 Remove the air box assembly F...

Page 226: ... NOTE This procedure is best accomplished using two people 1 6 1 Attach each of the front A arms to the to the shock tower at the top shock mount and bot tom hole locations of the strip plate 27 using bolts 28 and lock nuts Do not tighten Figure 14 10 Page 14 17 1 6 2 Position the top edge of the strap plate 27 onto the frame and install the two bolts 26 flat washers and lock nuts Do not tighten 1...

Page 227: ...o latches 3 on the side of the air box Figure 14 10 Page 14 17 or Figure 14 11 Page 14 18 3 Remove the hose clamp 15 from the air hose and remove hose from the air box assembly 4 Stand on the driver side of vehicle grasp air hose mounting inlet and open and remove filter element 11 5 Wipe away any dust or dirt from inside the air box with a clean cloth Remove all dirt build up around the inside li...

Page 228: ...emove the filter and plug the fuel lines 3 and 4 FUEL FILTER INSTALLATION CAUTION Fuel filters are marked with flow direction arrows Make sure that filters are installed with arrows pointing in the direction of fuel flow from tank to carburetor 1 Install the primary fuel filter 17 in reverse of removal Use new clamps 16 Figure 14 15 Page 14 23 or Figure 14 16 Page 14 24 2 Install the secondary fue...

Page 229: ... Service Manual Page 14 17 14 Figure 14 10 Pioneer 1200 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 CARBURETOR 16 15 15 3 2 1 12 11 18 4 17 5 6 10 9 8 7 TYPICAL 2 PLACES 27 26 28 ...

Page 230: ...ehicle Maintenance and Service Manual 14 Figure 14 11 Pioneer 1200SE Air Intake and Choke Assemblies 14 28 27 26 21 20 19 TYPICAL 3 PLACES 23 TYPICAL 3 PLACES 24 25 13 REFERENCE CARBURETOR 16 15 15 3 2 1 18 4 5 6 10 9 8 7 TYPICAL 2 PLACES 12 11 17 22 28 TYPICAL 2 PLACES ...

Page 231: ...perly FUEL PUMP DISASSEMBLY NOTE A fuel pump rebuild kit is available from Club Car CCI P N 1014524 1 Remove four screws 24 and lock washers 25 from front of the fuel pump Figure 14 12 Page 14 20 2 Remove the front cover of the fuel pump while holding the rest of the pump intact 3 Note the orientations of the impulse gasket 27 the diaphragm 28 and the gasket 29 then remove them from the pump See f...

Page 232: ... fuel inlet to the fuel outlet Figure 14 13 Page 14 20 Tighten the screws to 26 in lb 3 0 N m FUEL PUMP INSTALLATION 1 Connect the fuel line 2 that comes from the fuel tank filter 17 to the fuel pump 18 Install a new clamp 16 Figure 14 15 Page 14 23 or Figure 14 16 Page 14 24 See same figures for proper routing of fuel lines See following NOTE NOTE Be sure to connect the fuel line 2 that comes fro...

Page 233: ...maged 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 FUEL TANK REMOVAL 1 Turn the key switch to OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Turn fuel shut off valve to the closed OFF position Figure 14 20 Page 14 27 3 Run the engin...

Page 234: ...vice Never attempt to siphon fuel using your mouth 9 Disconnect the black wire and orange wire from the fuel level sending unit on the tank Figure 14 17 Page 14 25 Do not remove the lower nut on the center stud of the sending unit See following WARN ING WARNING Make sure the key switch is OFF and key removed before disconnecting wiring 10 Loosen clamp 16 and remove the fuel line 1 from fuel tank s...

Page 235: ... pump Fuel pump to secondary fuel filter Secondary fuel filter to carburetor Vent tube Carburetor Vent tube Fuel Tank Impulse line Solid Color Clear 14 0 in 35 6 cm 6 0 in 15 2 cm 11 5 in 29 2 cm 2 5 in 6 4 cm 17 0 in 43 2 cm 17 0 in 43 2 cm 14 0 in 35 6 cm LENGTH Total 35 0 in 88 9 cm 34 0 in 86 36 cm 13 12 11 16 SEE ABOVE FUEL TANK FUEL PICKUP TUBE TYPICAL 2 PLACES 1 16 11 12 14 6 15 10 7 16 5 3...

Page 236: ...r to fuel pump Fuel pump to secondary fuel filter Secondary fuel filter to carburetor Vent tube Carburetor Vent tube Fuel Tank Impulse line Solid Color Clear 2 5 in 6 4 cm 46 5 in 118 1 cm 10 15 in 25 8 cm 2 5 in 6 4 cm 17 0 in 43 2 cm 17 0 in 43 2 cm 14 0 in 35 6 cm LENGTH Total 75 65 in 192 2 cm 34 0 in 86 36 cm 12 16 SEE ABOVE GAS TANK FUEL PICKUP TUBE TYPICAL 2 PLACES 1 16 6 13 8 15 7 16 5 3 7...

Page 237: ... and 10 and install the fuel tank Figure 14 15 Page 14 23 1 1 1 Position the straps in the indentions on the tank 1 2 Install the screws 12 and 14 into the speed nuts 11 and tighten screws to 25 in lb 2 8 N m Figure 14 15 Page 14 23 2 Pioneer 1200 SE 2 1 Position the retaining strap 13 and install the fuel tank Figure 14 16 Page 14 24 2 2 Install the nut 12 onto the J bolt 8 and tighten to 25 in l...

Page 238: ...er ventilation After installing the fuel tank and adding gasoline carefully check all fuel lines and connections for leaks Repair any leaks before using the vehicle 12 Allow the engine to run for a few minutes to ensure that the fuel lines are full of fuel 13 Inspect each fuel line connection for leaks 13 1 Check all clamps at the carburetor fuel filters fuel pump and fuel tank for leaks 13 2 Insp...

Page 239: ...ned approximately 120 from the closed OFF position until it can not be turned any further Figure 14 21 Page 14 27 If the valve becomes partially closed the engine will not run properly due to fuel starvation Figure 14 22 Page 14 28 Figure 14 18 Pioneer 1200 Fuel Tank Figure 14 19 Pioneer 1200 SE Fuel Tank Figure 14 20 Closed Fuel Shut off Valve Figure 14 21 Open Fuel Shut off Valve TO CARBURETOR V...

Page 240: ...M Fuel Shut Off Valve Page 14 28 2003 Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual 14 Figure 14 22 Incorrect Fuel Shut off Valve VIEWED FROM SELECTOR SIDE OF VALVE PARTIALLY CLOSED POSITION ...

Page 241: ...FFLER INSTALLATION NOTE Any time the muffler is removed from the vehicle install a new muffler clamp 6 CCI P N 1017689 and muffler gasket 12 Figure 15 1 Page 15 2 1 Use the muffler clamp 6 to attach the muffler bracket 2 to the muffler Figure 15 1 Page 15 2 Leave the muffler clamp loose 2 Place a new gasket 12 on the exhaust manifold mounting flange as shown 3 Position the muffler and bracket asse...

Page 242: ...e handle in NEUTRAL start the engine and check for exhaust leaks and proper engine operation See following DANGER DANGER The engine produces carbon monoxide which is an odorless deadly poison Do not operate the engine in an enclosed area without proper ventilation Figure 15 1 Exhaust System FE400 Engine 6 7 8 9 1 2 TYPICAL 2 PLACES 12 10 11 13 5 TYPICAL 2 PLACES 3 4 ...

Page 243: ...rection the engine drive clutch belt and driven clutch rotate in the same direction therefore the engine and clutches are not subjected to reversing loads This reduces mainte nance requirements on the engine and clutches With the unitized transaxle power is transferred from the engine through the drive clutch the drive belt the driven clutch and then through the unitized transaxle to the wheels Th...

Page 244: ...er plug is used for draining When draining lubricant both plugs should be removed to allow the lubricant to drain faster Be sure the drain plug and gas ket are cleaned and installed before filling the transaxle with new lubricant Use a funnel when filling the tran saxle through the lubricant fill hole Fill with 29 oz 85 liters 80 90 WT API class GL 3 or 80 90 WT AGMA class 5 EP gear lubricant Tigh...

Page 245: ...g axle shafts axle bearings or axle shaft oil seals 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 6 AXLE SHAFT BEARING AND OIL SEAL REMOVAL 1 Chock the front wheels and lift the rear of the vehicle with a floor jack Then place jack stands un...

Page 246: ...le Figure 16 5 Page 16 4 5 1 Remove rubber boot 26 from large flat washer 23 5 2 Remove and discard cotter pin 25 from locking nut cap 27 5 3 Remove the locking nut cap 27 from the flanged nut 24 5 4 Remove the flanged nut 24 and large flat washer 23 from the axle end 5 5 Remove the wheel bolt flange 22 from the splined axle end 6 Use a 90 internal snap ring pliers 0 090 inch tip to remove interna...

Page 247: ... 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 5 Install the wheel bolt flange 22 on the MC012C transaxle Figure 16 5 Page 16 4 See following NOTE NOTE Clean splined components before axle installation Use a small brush and carefully apply a light coat of white lithium NLG...

Page 248: ...cedure the hydraulic system must be opened As a result the brakes must be bled after the correct reinstallation of the brake components Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic system Use only DOT 5 brake fluid See Bleeding the Hydraulic Brake System Section 6 Page 6 31 1 Turn the key switch OFF and remove the key Place the...

Page 249: ...ne onto the impulse line fitting of the fuel pump Figure 16 14 Page 16 9 5 Remove the differential lock cable 5 1 Place differential lock handle in the disengaged direction 5 2 Use a pair of pliers and apply pressure to the locking tabs of the cable end 1 where it attaches to the differential lock handle mounting bracket Figure 16 12 Page 16 8 Pull the differential lock cable toward the rear of th...

Page 250: ...age 16 9 5 7 Disconnect the engine ground wire from the oil filler tube mounting bracket Figure 16 16 Page 16 9 Figure 16 12 Differential Lock Cable Bracket Figure 16 13 Differential Lock Cable Removal CCI102046601 REDUCED STEERING CONTROL MAY CAUSE SERIOUS INJURY OR DEATH Disengage differential lock on paved surfaces WARNING 1 2 1 Apply pressure to locking tabs of the cable 2 Pull cable sheath to...

Page 251: ... gauge yellow wire DF post from starter generator Figure 16 18 Page 16 10 5 13 Disconnect the engine oil level sensor wire 18 gauge yellow at the bullet connector just to the rear of the starter generator Figure 16 19 Page 16 10 5 14 Disconnect the engine kill switch wire 18 gauge white black from the bullet connector at the lower right front of the engine Figure 16 20 Page 16 10 5 15 Cut away the...

Page 252: ...he cable from the cable support bracket Figure 16 21 Page 16 11 7 3 Remove the upper shock mounting hardware from the rear shock absorber and remove the shock absorber 7 4 Use a 3 8 inch flare nut wrench and remove the brake hose from the rear brake cluster To avoid spilling brake fluid lift the hose above the brake cluster assembly Figure 16 22 Page 16 11 Figure 16 18 Generator Wires Figure 16 19...

Page 253: ... 13 and raise the vehicle Place jack stands set at approximately 17 1 2 inches 44 5 cm in height under the frame Figure 16 26 Page 16 13 9 Lower the hydraulic jack allowing the vehicle I beam frame to rest on the jack stands but allow the jack to remain under and in contact with the transaxle case guard Figure 16 26 Page 16 13 10 Remove the bolts securing the leaf springs to their front mounts Fig...

Page 254: ... the vehicle and resting on the floor 14 Grasp the ends of the leaf springs at the rear of the powertrain and roll the powertrain out from under the vehicle Figure 16 30 Page 16 14 15 Place blocks under the engine pan so they will completely support the engine and keep it level to the floor Figure 16 31 Page 16 14 See following NOTE NOTE Place the blocks so they will support the engine when the tr...

Page 255: ...icle Maintenance and Service Manual Page 16 13 16 Figure 16 25 Raise Vehicle Figure 16 26 Position Jack Stands Figure 16 27 Spring Retainer Bolts Figure 16 28 Rear Shackles PROPER POSITIONING OF FLOOR JACK PROPER POSITIONING OF JACK STANDS APPROX 17 1 2 44 5 cm REMOVE BOLTS THEN ROTATE SHACKLES UP AND AWAY FROM SPRINGS ...

Page 256: ...15 See following NOTE NOTE The governor cable and the accelerator cable should remain attached to the governor arm 21 Remove the two bolts that secure the differential lock cable bracket to the transaxle housing and unhook the cable spring from the differential lock arm Figure 16 37 Page 16 15 22 Remove the six bolts mounting the unitized transaxle to the engine 22 1 Remove four transaxle mounting...

Page 257: ...6 34 Accelerator Cable Bracket Figure 16 35 Governor Arm and Cable Bracket Figure 16 36 Forward Reverse Shifter Bracket Figure 16 37 Differential Lock Arm and Bracket Figure 16 38 Transaxle Mounting RETAINING BOLT BRACKET GOVERNOR ARM RETAINING BOLT ClubCar ClubCar 3 6 7 9 1 2 ClubCar ClubCar ClubCar TYPICAL 4 PLACES TRANSAXLE MOUNTING NUTS TYPICAL 2 PLACES WOODEN BLOCKS TRANSAXLE MOUNTING BOLT AN...

Page 258: ...6 Install the differential lock cable and bracket 6 1 Connect the differential lock cable spring 1 to the differential lock arm on the housing Figure 16 40 Page 16 16 6 2 Install two bolts 2 to secure cable bracket to the transaxle case and tighten to 134 in lb 15 1 N m 7 Install the accelerator cable bracket to transaxle case and tighten screws to 134 in lb 15 1 N m Figure 16 41 Page 16 17 8 Inst...

Page 259: ...ll the key onto the input shaft Figure 16 44 Page 16 18 12 Position the driven clutch on the transaxle input shaft and install the washer yellow side facing out and mounting bolt and tighten to 14 ft lb 19 0 N m 13 Install the drive belt See Drive Belt Installation Section 17 Page 17 4 Figure 16 41 Accelerator Cable Bracket Figure 16 42 Governor Cable Bracket Figure 16 43 Governor Arm BRACKET 1 In...

Page 260: ... 17 Raise the vehicle with the floor jack and remove the jack stands Gently lower the vehicle and finish tight ening the lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 18 Position shocks in the shock mounts and install cushions mounting washers and nuts and tighten until cushions expand to be the same diameter as the mounting washers Figure 16 49 Page 16 20 19 Connect the park brake cabl...

Page 261: ...8 gauge white black stripe to the bullet connector at the lower right front of the engine Figure 16 48 Page 16 19 23 Install three wire ties to secure the engine kill wire and accelerator cable 24 Connect the oil level sensor wire 18 gauge yellow to the jumper wire Figure 16 50 Page 16 21 Figure 16 46 Leaf Springs Figure 16 47 Leaf Springs and Shackles Figure 16 48 Ignition Kill Wire WHITE BLACK W...

Page 262: ...with the woodruff key onto the Forward Reverse shaft 15 26 4 Install the nut 3 washer 4 and bolt 7 on the Forward Reverse shifter lever and tighten to 23 in lb 4 1 N m 26 5 Position the shifter cable in the shifter cable mounting bracket on the transaxle and tighten the mounting nuts to 22 ft lb 29 8 N m Connect shifter cable rod end to the shifter arm Figure 16 52 Page 16 21 27 Attach the ground ...

Page 263: ...6 21 16 Figure 16 50 Oil Level Sensor Jumper Wire Figure 16 51 Starter Generator Figure 16 52 Connect Shifter Cable Figure 16 53 Engine Ground Figure 16 54 Connect Cable to Cam Figure 16 55 Connect Fuel Line STARTER GENERATOR YELLOW OIL SENDING UNIT JUMPER WIRE DF F2 WHITE YELLOW GROUND SPRING RELEASE NUTS TOP VIEW ClubCar TOP VIEW ACCELERATOR CABLE Club Car CLAMP ...

Page 264: ...able sheath toward the front of the vehicle to secure the cable to the bracket Figure 16 63 Page 16 28 33 5 Secure the cable to the vertical support with a wire tie 6 34 Install transaxle drain plug and tighten to 21 ft lb 28 5 N m 35 Fill transaxle with 29 oz 85 liters 80 90 WT API class GL 3 or 80 90 WT AGMA class 5 EP gear lubri cant Install and tighten the level indicator hole plug to 21 ft lb...

Page 265: ...gure 16 59 Differential Cable End Installation Figure 16 60 Differential Cable Installation Club Car CLAMP CCI102046601 REDUCED STEERING CONTROL MAY CAUSE SERIOUS INJURY OR DEATH Disengage differential lock on paved surfaces WARNING Step 2 Step 1 Step 3 CCI102046601 REDUCED STEERING CONTROL MAY CAUSE SERIOUS INJURY OR DEATH Disengage differential lock on paved surfaces WARNING 1 2 Push cable into ...

Page 266: ...le 3 Loosen the retaining nuts 5 on both ends of the cable and remove the wire tie and cable FORWARD REVERSE SHIFTER CABLE INSTALLATION 1 Route the cable to the transaxle shifter lever beginning at the Forward Reverse shifter 2 Secure the cable with retaining nut 5 on each side of the shifter cable support bracket at the transaxle Figure 16 62 Page 16 25 and tighten nuts to 22 ft lb 29 8 N m 3 Sec...

Page 267: ...re wiring could result in vehicle malfunction property damage or personal injury FORWARD REVERSE SHIFTER CABLE ADJUSTMENT Place the shift lever in the NEUTRAL position straight up Figure 16 62 Page 16 25 For minor adjust ments the nut 1 may be loosened and the ball joint socket 2 rotated to get the proper adjustment Figure 16 62 Page 16 25 See following CAUTION Figure 16 62 Forward Reverse Shifter...

Page 268: ...ift the rear of the vehicle with a floor jack and place jack stands under the axle tubes to support the vehicle See WARNING Lift only one end of the vehicle in General Warning Section 1 Page 1 1 2 With the differential lock handle in the forward position unlocked rotate one of the rear wheels by hand The wheel should be fairly easy to rotate and the other rear wheel should rotate in the opposite d...

Page 269: ...vehicle to remove the cable from the bracket 2 and vehicle DIFFERENTIAL LOCK CABLE INSTALLATION 1 Route the cable through the engine mounting plate as illustrated Figure 16 63 Page 16 28 2 Route the cable spring 1 through the cable bracket 2 3 Connect the differential lock cable spring end 1 to the differential lock arm 3 on the differential lock housing 4 Push the cable 5 toward the rear of the v...

Page 270: ...erential Lock Cable Routing CCI 102046601 REDUCED STEERING CONTROL MAY CAUSE SERIOUS INJURY OR DEATH Disengage differential lock on paved surfaces WARNING 1 Rotate the cable connector toward the passenger side of the vehicle to connect the cable to the differential lock lever 2 Push plastic cable retainer toward the front of the vehicle to secure the cable to the bracket 4 3 1 2 6 5 ...

Page 271: ...o provides excellent starting and low speed torque As engine speed increases centrifugal force on internal weights closes the drive clutch pushing the belt up to a higher position on the drive clutch increasing the diameter of the belt loop As the diameter of the belt loop increases at the drive clutch the driven clutch is forced open as the diameter of its belt loop decreases At governed top spee...

Page 272: ...ter Tool Kit TORQUE CONVERTER TOOL KIT CCI P N 1014510 DRIVE CLUTCH PULLER CCI P N 1014496 DRIVEN CLUTCH PULLER PLUG CCI P N 1014507 DRIVEN CLUTCH CAM PRESS TOOL CCI P N 101809101 DRIVE CLUTCH HUB PULLER CCI P N 1014497 DRIVE CLUTCH HOLDER TOOL CCI P N 1015524 CAM INSTALLATION TOOL CCI P N 101808401 DRIVEN CLUTCH CAM PULLER CCI P N 1014508 WARNING ...

Page 273: ... both clutches with water to remove any dust or dirt then drive the vehicle and check for proper operation 3 If cleaning both clutches does not solve the problem disassemble and thoroughly clean all parts in the drive clutch Be sure to clean the plastic drive buttons 10 Figure 17 7 Page 17 8 DRIVE BELT See General Warning Section 1 Page 1 1 The drive belt should be inspected semiannually for wear ...

Page 274: ... be properly balanced If either clutch is dropped assume that it is damaged and replace it DRIVE CLUTCH REMOVAL 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 Disconnect the spark plug SeeWARNING To avoid unin...

Page 275: ...damage the surface of the shaft Do not use solvents Solvents will damage 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 the clutch should be replaced Figure 17 3 Loosen Retaining Bolt Figure 17 4 Drive Clutch Removal WAR NING Use Club Car clutch holder ...

Page 276: ... nut has been mechanically crimped and locked into position acting as an integrated assembly with the bolt 2 3 Thread the three small bolts of the puller into the puller attachment holes in the clutch Tighten bolts evenly making sure the face of the puller plate is parallel to the clutch face Figure 17 6 Page 17 7 NOTE The nuts on each of the three small puller bolts are mechanically crimped and l...

Page 277: ...moved replace it with a new bearing 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 7 Page 17 8 See also Figure 17 11 Page 17 10 Discard the rings INSPECTION OF DRIVE CLUTCH PARTS 1 Inspect the idler bearing 6 for smooth rotation or seal damage Figure 17 7 Page 17 8 NOTE It is normal for a small amount of grease to be...

Page 278: ...Page 17 8 2003 Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual 17 Inspection of Drive Clutch Parts Continued Figure 17 7 Drive Clutch Assembly 2 1 3 5 4 13 6 23 7 11 12 16 15 14 22 20 21 17 19 10 TYPICAL 3 PLACES ...

Page 279: ... or damage If the sheaves are excessively worn or damaged replace the entire fixed face drive assembly DRIVE CLUTCH ASSEMBLY 1 Press idler bearing 6 onto the shaft of the fixed face assembly 7 Press on the inner race of the bearing only Make sure that the cup side of bearing is facing away from the fixed face Figure 17 7 Page 17 8 2 Use a needle nose pliers to install the spring retainer 5 onto th...

Page 280: ... the shaft 6 2 Install the retaining ring 3 Figure 17 7 Page 17 8 7 Install the primary weights on the mounting pins Figure 17 12 Page 17 10 Figure 17 10 Remove Idler Bearing Figure 17 11 Spiral Back up Rings Figure 17 12 Install Pin and Washer Figure 17 13 Install Secondary Weight PRESS RAM IDLER BEARING BEARING PULLER FIXED FACE ASSEMBLY Use a scribe to remove spiral back up rings from both side...

Page 281: ...nstall the 1 4 20 screws and washers 2 and tighten them to 10 ft lb 13 N m Figure 17 7 Page 17 8 See following NOTE NOTE Make sure there is at least a minimum gap of 0 020 inch 0 51 mm between each end of the mounting pin and the mounting screw 13 Install all drive button take up springs 13 1 Install springs on right side of the three button mounting posts when looking into the interior of the clu...

Page 282: ...erator belt and adjust belt tension as instructed See Starter Generator Installa tion Section 12 Page 12 9 Tighten the starter generator mounting hardware to 23 ft lb 31 2 N m and the adjusting hardware to 13 ft lb 17 6 N m 4 Install the drive belt as instructed See Drive Belt Installation on page 17 4 5 Connect the spark plug 6 Connect the battery cables positive cable first and tighten terminals...

Page 283: ...e cam when removing the cam The moveable face may spin when the cam buttons release from the cam ramps resulting in severe personal injury 2 Insert a puller plug CCI P N 1014507 Figure 17 18 Page 17 15 into the shaft bore and use a driven clutch cam puller CCI P N 1014508 to remove the cam 4 from the fixed face shaft 8 Retain the key 3 Figure 17 16 Page 17 14 3 Remove the spring 5 Figure 17 16 Pag...

Page 284: ...TORQUE CONVERTER Driven Clutch Page 17 14 2003 Pioneer 1200 1200SE 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 285: ...6 3 to 9 5 mm 5 1 Press Assembly Process 5 1 1 Place the clutch assembly in a press and position the cam press tool CCI P N 101809101 on the cam as shown Figure 17 19 Page 17 16 5 1 2 Hold the fixed face assembly 3 and rotate the moveable face assembly 1 one third turn clockwise then press the cam 2 onto the fixed face assembly Figure 17 19 Page 17 16 5 1 3 Install the retaining ring 2 Figure 17 1...

Page 286: ...y be assembled in the order described and shown 5 2 3 Slide the bolt 1 through the clutch body 5 until the threaded bolt washers bearing and hub guide are against the fixed face hub Figure 17 20 Page 17 16 5 2 4 Hold the clutch assembly and cam installation tool together and place the fixed face down on spaced blocks Figure 17 19 Page 17 16 5 2 5 Place the cam press hub 6 onto the cam installation...

Page 287: ...d face hub A metal hammer will damage the shaft DRIVEN CLUTCH INSTALLATION 1 To install the driven clutch reverse the removal procedure Make sure that the washer 12 is mounted with the flat portion of the washer against the driven clutch as shown Figure 17 16 Page 17 14 Secure with a new bolt 11 See following NOTE NOTE The bolt 11 must be replaced with a new bolt CCI P N 102242101 containing a loc...

Page 288: ...17 ...

Page 289: ...11 22 water level 12 29 bed cargo see cargo bed belt drive see drive belt body front components 4 2 installation 4 4 removal 4 2 repair 4 1 brakes adjuster front installation 6 22 removal 6 22 adjuster rear installation 6 22 removal 6 22 bell crank installation 6 27 removal 6 27 brake fluid 10 4 cluster cleaning 6 10 inspection 6 3 6 10 drum and shoe inspection 6 3 drum hub front installation 6 14...

Page 290: ...llation 4 2 removal 4 2 differential lock cable installation 16 27 removal 16 26 differential lock lever 16 2 system inspection 16 26 diode testing 11 29 diode headlight installation 12 28 removal 12 27 testing 11 46 drive belt inspection 17 3 installation 17 4 removal 17 3 drive clutch assembly 17 9 cleaning and inspection 17 5 17 7 disassembly 17 6 general information 17 1 installation 17 12 rem...

Page 291: ...fuel level sending unit 12 22 testing 11 42 fuel lines 14 1 fuel pump 14 1 14 16 assembly 14 20 cleaning and inspection 14 19 disassembly 14 19 installation 14 20 removal 14 19 fuel shut off valve 14 27 fuel tank disposal 14 25 installation 14 25 removal 14 21 fueling instructions 10 7 fuse installation 12 16 removal 12 15 testing 11 23 G generator circuit see starter generator circuit governor ca...

Page 292: ...t switch 11 27 installation 12 17 removal 12 17 removal 12 18 testing 11 42 troubleshooting 11 18 lockout cam circuit function 11 11 low oil warning circuit function 11 10 troubleshooting 11 17 low oil warning light installation 12 20 12 21 removal 12 20 testing 11 41 12 20 lubrication front suspension 7 12 lubrication system 13 1 periodic lubrication schedule 10 2 unitized transaxle 16 2 M mainte...

Page 293: ...edule see periodic service schedule see also periodic lubrication schedule shock absorber see suspension front and suspension rear snubber installation 9 4 removal 9 4 solenoid installation 12 15 removal 12 15 testing 11 26 spark plug 13 1 14 1 gap adjustment 13 2 14 1 installation 13 3 removal 13 2 testing 13 2 specifications torque 13 10 vehicle 2 1 starter generator armature 12 4 ground test 12...

Page 294: ...cuit 11 25 kill circuit engine 11 40 kill wire engine 11 40 lockout cam cam 11 42 limit switch 11 27 low oil warning light 11 41 oil level sensor 11 41 reverse buzzer 11 41 reverse buzzer limit switch 11 40 RPM limiter 11 33 solenoid 11 26 starter generator 11 28 11 31 voltage regulator 11 31 wire continuity 11 29 test procedures index of 11 19 testing circuit testing 11 13 engine ignition circuit...

Page 295: ... Pioneer 1200 1200SE Gasoline Vehicle Maintenance and Service Manual Page i 7 W WARNING definition of 1 1 wheel see tire wheel cylinder see brakes wheel cylinder wire continuity testing 11 29 wiring diagram 11 5 ...

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Page 300: ...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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