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Pioneer 1200 User Manual
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BODY AND TRIM
Seat
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Page 4-5
4
Figure 4-2 Front Bod
y 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
28
30
Table of Contents
Default Chapter
5
Table of Contents
5
Section 1 - Safety
15
General Warning
15
Section 2 - Vehicle Specifications
19
Section 3 - General Information
21
General Information
21
Serial Number Identification
21
Storage
21
Preparing the Vehicle for Extended Storage
22
To Return Vehicle to Service
22
Section 4 - Body and Trim
25
Cleaning the Vehicle
25
Front Body Repair
25
Abrasions and Haze
25
Light Scratches
26
Large Scratches and Abrasions
26
Front Body Components
26
Dashboard Removal
26
Dashboard Installation
26
Front Body Removal
27
Front Fender Removal
27
Front Fender Installation
28
Front Body Installation
28
Seat
28
Seat Adjustment
28
Front Seat Support
30
Front Seat Support Removal
30
Front Seat Support Installation
31
Rear Seat Support
31
Rear Seat Support Removal
31
Rear Seat Support Installation
31
Cargo Bed
33
Cargo Bed Removal
33
Cargo Bed Installation
33
Bed Stop Bumper Adjustment
35
Rear Fender Removal
36
Rear Fender Installation
36
Tailskirt
36
Tailskirt Removal
36
Tailskirt Installation
36
Receiver Hitch
36
Receiver Hitch Removal
36
Receiver Hitch Installation
37
Floor Mat
38
Floor Mat Removal
38
Floor Mat Installation
38
Section 5 - Accelerator and Brake Pedal Assemblies
39
Brake Pedal
39
Brake Pedal Removal
39
Brake Pedal Installation
39
Brake Pedal Adjustment
40
Accelerator Pedal
42
Accelerator Pedal Removal
42
Accelerator Pedal Installation
43
Accelerator Pedal Adjustment
43
Section 6 - Mc012C-As00 Transaxle: Hydraulic and Park Brake Systems
47
Brake System Inspection
47
Brake System Troubleshooting
49
Brake Drum Removal
52
Front Wheel Brake Drum Removal
52
Rear Wheel Brake Drum Removal
54
Brake Shoe Removal
54
Front Brake Shoe Removal
54
Rear Brake Shoe Removal
55
Brake Cluster Inspection and Cleaning
56
Brake Shoe Installation
57
Front Brake Shoe Installation
58
Rear Brake Shoe Installation
58
Brake Drum Installation
60
Front Wheel Brake Drum Installation
60
Rear Wheel Brake Drum Installation
62
Brake Cluster Assembly Replacement
63
Front Brake Cluster Assembly Removal
63
Front Brake Cluster Assembly Installation
63
Rear Brake Cluster Assembly Removal
64
Rear Brake Cluster Assembly Installation
65
Wheel Cylinder Replacement
65
Front Wheel Cylinder Removal
65
Front Wheel Cylinder Installation
66
Rear Wheel Cylinder Removal
66
Rear Wheel Cylinder Installation
66
Brake Shoe Adjuster Replacement
67
Front Brake Shoe Adjuster Removal
68
Front Brake Shoe Adjuster Installation
68
Rear Brake Shoe Adjuster Removal
68
Rear Brake Shoe Adjuster Installation
68
Hydraulic Line and Hose Replacement
69
Front Brake Line Removal
69
Front Brake Line Installation
69
Front Brake Hose Assembly Removal
70
Front Brake Hose Assembly Installation
70
Rear Brake Line Removal
70
Rear Brake Line Installation
72
Rear Brake Hose Removal
72
Rear Brake Hose Installation
73
Master Cylinder and Bell Crank Replacement
73
Bell Crank Removal
73
Bell Crank Installation
73
Master Cylinder Removal
75
Master Cylinder Installation
75
Bleeding the Hydraulic Brake System
77
Purging the Hydraulic System
78
Filling the Hydraulic System
78
Park Brake System
79
Park Brake Cable Removal
79
Park Brake Cable Installation
80
Park Brake Handle Removal
81
Park Brake Handle Installation
81
Park Brake Adjustment
81
Section 7 - Steering and Front Suspension
85
Steering Wheel
85
Steering Wheel Removal
85
Steering Wheel Installation
87
Steering Column
87
Steering Column Removal
87
Steering Column Disassembly
87
Steering Column Assembly
88
Steering Column Installation
88
Rack and Pinion
89
Rack and Pinion Removal
89
Rack and Pinion Disassembly
90
Rack and Pinion Assembly
93
Rack and Pinion Installation
94
Front Suspension
96
Lubrication
96
Wheel Alignment
96
Front Suspension Components
98
Kingpin and Steering Spindle Removal
98
Kingpin and Steering Spindle Installation
98
A-Arm Removal
99
A-Arm Installation
101
Shock Absorber Removal
101
Shock Absorber Installation
102
Front Wheel Bearings and Hubs
102
Front Wheel Free Play Inspection
102
Front Wheel Bearings and Hub Removal
103
Front Wheel Bearings and Hub Installation
103
Section 8 - Wheels and Tires
105
General Information
105
Section 9 - Rear Suspension
107
Shock Absorbers
107
Shock Absorber Removal and Inspection
107
Shock Absorber Installation
107
Multi-Leaf Springs
107
Multi-Leaf Spring Removal
107
Multi-Leaf Spring Installation
109
Snubber
110
Snubber Removal
110
Snubber Installation
110
Section 10 - Periodic Maintenance
111
Periodic Service Schedule
111
Periodic Lubrication Schedule
112
Master Cylinder
113
Brake Fluid
114
Engine Oil
114
Engine Oil Level Check
114
Engine Oil and Filter Change
115
Oil Viscosity
117
Fueling Instructions
117
Battery
118
Section 11 - Troubleshooting and Electrical System: Fe400 Engine
121
Troubleshooting Guide
121
Electrical System
125
Wiring Diagram
126
Electrical Circuits
128
Starter Circuit
128
Generator Circuit
128
Engine Ignition Circuit
129
Engine Kill Circuit
129
Reverse Buzzer Circuit
130
Low Oil Warning Circuit
130
Lockout Cam Circuit
131
Fuel Gauge and Sending Unit Circuit
132
Hour Meter Circuit
133
Lighting Circuit
133
Circuit Testing
133
Testing the Starter Circuit and Generator Circuit
134
Testing the Engine Ignition Circuit
135
Testing the Engine Kill Circuit
135
Testing the Reverse Buzzer Circuit
136
Testing the Low Oil Warning Circuit
137
Testing the Lockout Cam Circuit
138
Testing the Fuel Gauge and Sending Unit Circuit
138
Testing the Lighting Circuit
139
Test Procedures
139
Index of Test Procedures
139
Section 12 - Electrical Components: Fe400 Engine
150
Starter/Generator
150
Voltage Regulator
179
Diode
180
Key Switch
182
Solenoid
183
Fuse
183
Lockout Cam Limit Switch
185
Lockout Cam
185
Reverse Warning Buzzer
186
Reverse Buzzer Limit Switch
187
Low Oil Warning Light
188
Fuel Gauge/Hour Meter
189
Fuel Level Sending Unit
190
RPM Limiter
190
Ignition Coil
191
Oil Level Sensor
194
Headlights
194
Voltage Limiter
195
Light Switch
196
Testing the Light Switch
196
Battery
196
General Information
197
Ground Straps
201
Section 13 - Fe400 Engine
203
General Information
203
Special Engine Service Tools Available from Club Car
203
Before Servicing
203
Lubrication System
203
Spark Plug
203
Cylinder
205
Breather Valve (Reed Valve)
205
Valve Clearance Check and Adjustment
205
Crankcase
205
Engine Removal
205
Crankcase Cover Removal
206
Oil Level Sensor
206
Ignition Coil and Flywheel
207
Crankcase Cover Installation
210
Flywheel Installation
210
Engine Installation
211
Torque Specifications
212
Adjustment and Settings
212
Section 14 - Fuel System
213
General Information
213
Carburetor
213
Main Jet Elevation/Size Chart
213
Changing the Main Jet
214
Engine Control Linkage
217
General Information
217
Accelerator Rod
218
Governor Cable
219
Accelerator Cable
220
Closed Throttle or Idle Adjustment
222
Engine RPM Adjustment
222
Choke and Air Intake System
223
Choke Cable Removal
223
Choke Cable Installation
223
Air Box Removal
223
Air Box Installation
223
Intake Duct Repair
224
Intake Duct Removal
224
Intake Duct Installation
226
Air Filter
227
Fuel Filter Removal
228
Fuel Filter Installation
228
Fuel Pump
228
General Information
228
Fuel Pump Removal
231
Fuel Pump Disassembly
231
Fuel Pump Cleaning and Inspection
231
Fuel Pump Assembly
232
Fuel Pump Installation
232
Fuel Tank
233
Fuel Tank Removal
233
Fuel Tank Storage or Disposal
237
Fuel Tank Installation
237
Fuel Lines
238
Fuel Shut-Off Valve
239
Section 15 - Exhaust System
241
Muffler
241
Muffler Removal
241
Muffler Installation
241
Section 16 - Mc012C-As00 Unitized Transaxle with Differential Lock
243
General Information
243
Lubrication
244
Axle Shaft
245
Axle Shaft, Bearing, and Oil Seal Removal
245
Axle Bearing Removal
247
Axle Shaft, Bearing, and Oil Seal Installation
247
Unitized Transaxle Removal
248
Unitized Transaxle Installation
258
Forward/Reverse Shifter Cable
266
Forward/Reverse Shifter Cable Removal
266
Forward/Reverse Shifter Cable Installation
266
Forward/Reverse Shifter Cable Adjustment
267
Differential Lock System
268
Differential Lock System Inspection
268
Differential Lock Cable Removal
268
Differential Lock Cable Installation
269
Section 17 - Torque Converter
271
General Information
271
Drive Belt
273
Drive Belt Removal
273
Drive Belt Installation
274
Drive Clutch
274
Drive Clutch Removal
274
Drive Clutch Cleaning and Inspection
275
Drive Clutch Disassembly
276
Inspection of Drive Clutch Parts
277
Drive Clutch Assembly
279
Drive Clutch Installation
282
5
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Pioneer 1200 Specifications
General
Brand
Pioneer
Model
1200
Category
Utility Vehicle
Language
English
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