Club Car Pioneer 1200 Manual

2001 MAINTENANCE & SERVICE MANUAL
1200
Manual No. 102190012 Edition Code 1000A00000

2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page i
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.
This manual provides detailed information for the maintenance and repair of the Pioneer 1200 vehicle, and
should be thoroughly reviewed prior to servicing the vehicle.The procedures provided herein must be prop-
erly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.
This manual was written for the trained technician who already possesses knowledge and skills in electrical
and mechanical repair. If the technician does not have such knowledge and skills, attempted service or
repairs to the vehicle may render the vehicle unsafe. For this 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
knowledge and facilities so they can provide prompt and efficient service for vehicle owners.Regional techni-
cal representatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals,
and other service publications also represent Club Car’s continuing commitment to customer support.
This manual covers all aspects of typical vehicle service; unique situations, however, do sometimes occur
when servicing a vehicle. If it appears that a service question is not answered in this manual, you may write
to us at: Club Car, Inc.; P.O. Box 204658; Augusta, Georgia 30917; Attention:Technical Services, or contact
a Club Car Technical Service Representative at [phone], ext.3580.
©2000 Club Car, Inc.
Club Car is a registered trademark of Club Car, Inc.
This manual effective October 2, 2000

Page ii 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
∆ WARNING
• Read Section 1 – Safety before attempting any service on this vehicle.
• Before servicing vehicle, read complete section(s) and any referenced information that may
be relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car, Inc.is con-
tinually working to further improve our vehicles and other products.These improvements may affect
servicing procedures. Any modification and/or significant change in specifications or procedures will
beforwardedto allClubCar dealersand will, whenapplicable,appearinfuture editionsof 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, includ-
ing increasing vehicle speed beyond factory specifications or modifications that affect the stability of
the vehicle or the operation thereof, will void the warranty.
Club Car, Inc.reserves the right to change specifications and designs at any time without notice and
without incurring any obligation or liability whatsoever.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle owner’s manual or write to Club Car, Inc., P.O. BOX 204658, Augusta, Georgia 30917-4658
USA, Attention:Warranty Department.

2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ................................................................................................................................ 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
General Information ........................................................................................................................... 2-1
Specifications ................................................................................................................................. 2-1
SECTION 3 – GENERAL INFORMATION
Serial Number Identification ............................................................................................................... 3-1
Storage – Gasoline Vehicle ............................................................................................................... 3-1
Preparing the Vehicle for Extended Storage ................................................................................. 3-1
Returning the Stored Vehicle to Service ........................................................................................ 3-2
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle .......................................................................................................................... 4-1
Front Body Repair .............................................................................................................................. 4-2
Light Scratches, Abrasions and Haze ............................................................................................ 4-2
Deeper Scratches .......................................................................................................................... 4-2
Gouges, Punctures, Tears, Large Scratches, and Abrasions ........................................................ 4-2
Brush Guard ...................................................................................................................................... 4-2
Brush Guard Removal ................................................................................................................... 4-2
Brush Guard Installation ................................................................................................................ 4-2
Front Body Components .................................................................................................................... 4-3
Dashboard Removal ...................................................................................................................... 4-3
Dashboard Installation ................................................................................................................... 4-3
Front Body Removal ...................................................................................................................... 4-3
Front Fender Removal ................................................................................................................... 4-5
Front Fender Installation ................................................................................................................ 4-5
Front Body Installation ................................................................................................................... 4-5
Seat ................................................................................................................................................... 4-5
Seat Removal ................................................................................................................................ 4-5
Seat Installation ............................................................................................................................. 4-6

Page iv 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
Seat Support ...................................................................................................................................... 4-6
Seat Support Removal ................................................................................................................... 4-6
Seat Support Installation ................................................................................................................ 4-6
Armrest Removal ........................................................................................................................... 4-7
Armrest Installation ........................................................................................................................ 4-8
Tilt Bed ............................................................................................................................................... 4-8
Tilt Bed Removal ............................................................................................................................ 4-8
Tilt Bed Installation ......................................................................................................................... 4-8
Bed Stop Bumper Adjustment ........................................................................................................ 4-8
Rear Fender ....................................................................................................................................... 4-10
Rear Fender Removal .................................................................................................................... 4-10
Rear Fender Installation ................................................................................................................. 4-10
Tailskirt ............................................................................................................................................... 4-10
Tailskirt Removal ............................................................................................................................ 4-10
Tailskirt Installation ......................................................................................................................... 4-10
Receiver Hitch .................................................................................................................................... 4-10
Receiver Hitch Removal ................................................................................................................. 4-10
Receiver Hitch Installation .............................................................................................................. 4-12
Floor Mat ............................................................................................................................................ 4-12
Floor Mat Removal ......................................................................................................................... 4-12
Floor Mat Installation ...................................................................................................................... 4-12
SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES
Brake Pedal Adjustment ..................................................................................................................... 5-1
Accelerator Pedal Adjustment ............................................................................................................ 5-3
Brake Pedal ........................................................................................................................................ 5-7
Brake Pedal Removal .................................................................................................................... 5-7
Brake Pedal Installation ................................................................................................................. 5-8
Accelerator Pedal ............................................................................................................................... 5-8
Accelerator Pedal Removal ............................................................................................................ 5-8
Accelerator Pedal Installation ......................................................................................................... 5-9
SECTION 6 – HYDRAULIC AND PARK BRAKE SYSTEMS
General Information ........................................................................................................................... 6-1
Brake System Inspection ................................................................................................................... 6-2
Brake System Troubleshooting .......................................................................................................... 6-4
Brake Drum Removal ......................................................................................................................... 6-7
Front Wheel Brake Drum Removal ................................................................................................ 6-7
Rear Wheel Brake Drum Removal ................................................................................................. 6-8
Brake Shoe Removal ......................................................................................................................... 6-9

2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page v
Brake Cluster Assembly Inspection and Cleaning ............................................................................. 6-10
Brake Shoe Installation ...................................................................................................................... 6-12
Brake Drum Installation ..................................................................................................................... 6-14
Front Wheel Brake Drum Installation ............................................................................................. 6-14
Rear Wheel Brake Drum Installation ............................................................................................. 6-16
Brake Cluster Replacement ............................................................................................................... 6-17
Front Brake Cluster Removal ........................................................................................................ 6-17
Front Brake Cluster Installation ..................................................................................................... 6-17
Rear Brake Cluster Removal ......................................................................................................... 6-18
Rear Brake Cluster Installation ...................................................................................................... 6-19
Wheel Cylinder Replacement ............................................................................................................ 6-19
Wheel Cylinder Removal ............................................................................................................... 6-20
Wheel Cylinder Installation ............................................................................................................ 6-21
Brake Shoe Adjuster Replacement ................................................................................................... 6-21
Brake Shoe Adjuster Removal ....................................................................................................... 6-21
Brake Shoe Adjuster Installation .................................................................................................... 6-22
Hydraulic Line and Hose Replacement ............................................................................................. 6-24
Front Brake Line Removal ............................................................................................................. 6-24
Front Brake Line Installation .......................................................................................................... 6-24
Front Brake Cluster Hose Removal ............................................................................................... 6-24
Front Cluster Hose Installation ...................................................................................................... 6-25
Rear Brake Line Removal .............................................................................................................. 6-25
Rear Brake Line Installation ........................................................................................................... 6-25
Rear Brake Cluster Hose Removal ................................................................................................ 6-26
Rear Cluster Hose Installation ....................................................................................................... 6-26
Master Cylinder and Bell Crank Replacement ................................................................................... 6-26
Bell Crank Removal ....................................................................................................................... 6-26
Bell Crank Installation .................................................................................................................... 6-28
Master Cylinder Removal .............................................................................................................. 6-28
Master Cylinder Installation ........................................................................................................... 6-28
Bleeding the Hydraulic Brake System ............................................................................................... 6-29
Purging the Hydraulic System ....................................................................................................... 6-30
Filling the Hydraulic System .......................................................................................................... 6-31
Park Brake System ............................................................................................................................ 6-31
Park Brake Cable Removal ........................................................................................................... 6-31
Park Brake Cable Installation ........................................................................................................ 6-33
Park Brake Handle Removal ......................................................................................................... 6-33
Park Brake Handle Installation ...................................................................................................... 6-34
Park Brake Adjustment .................................................................................................................. 6-34

Page vi 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information ........................................................................................................................... 7-1
Steering Wheel ................................................................................................................................... 7-1
Steering Wheel Removal ............................................................................................................... 7-1
Steering Wheel Installation ............................................................................................................ 7-3
Steering Column ................................................................................................................................ 7-4
Steering Column Removal ............................................................................................................. 7-4
Steering Column Disassembly ....................................................................................................... 7-4
Steering Column Assembly ............................................................................................................ 7-5
Steering Column Installation .......................................................................................................... 7-6
Rack and Pinion ................................................................................................................................. 7-6
Rack and Pinion Removal .............................................................................................................. 7-6
Rack and Pinion Disassembly ........................................................................................................ 7-8
Rack and Pinion Assembly ............................................................................................................ 7-10
Rack and Pinion Installation ........................................................................................................... 7-13
Front Suspension ............................................................................................................................... 7-13
Lubrication ...................................................................................................................................... 7-13
Wheel Alignment ............................................................................................................................ 7-14
Front Suspension Components .......................................................................................................... 7-16
Kingpin and Steering Spindle Removal .......................................................................................... 7-16
Kingpin and Steering Spindle Installation ....................................................................................... 7-17
A-Arm Removal .............................................................................................................................. 7-17
A-Arm Installation ........................................................................................................................... 7-18
Shock Absorber Removal and Inspection ...................................................................................... 7-18
Shock Absorber Installation ........................................................................................................... 7-19
Front Wheel Bearings and Hubs ........................................................................................................ 7-20
Front Wheel Free Play Inspection .................................................................................................. 7-20
Front Wheel Bearings and Hub Removal ....................................................................................... 7-20
Front Wheel Bearings and Hub Installation .................................................................................... 7-20
SECTION 8 – WHEELS AND TIRES
General Information ........................................................................................................................... 8-1
Wheels ............................................................................................................................................... 8-2
Wheel Removal .............................................................................................................................. 8-2
Wheel Installation ........................................................................................................................... 8-2
Tires ................................................................................................................................................... 8-3
Tire Removal .................................................................................................................................. 8-3
Tire Repair ..................................................................................................................................... 8-3
Tire Installation ............................................................................................................................... 8-3

2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page vii
SECTION 9 – REAR SUSPENSION
General Information ........................................................................................................................... 9-1
Shock Absorbers ............................................................................................................................... 9-1
Shock Absorber Removal and Inspection ...................................................................................... 9-1
Shock Absorber Installation ........................................................................................................... 9-3
Multi-Leaf Springs .............................................................................................................................. 9-3
Multi-Leaf Spring Removal ............................................................................................................ 9-3
Multi-Leaf Spring Installation ......................................................................................................... 9-4
Snubber ............................................................................................................................................. 9-5
Snubber Removal .......................................................................................................................... 9-5
Snubber Installation ....................................................................................................................... 9-5
SECTION 10 – PERIODIC MAINTENANCE
General Information ........................................................................................................................... 10-2
Daily Pre-Operation Safety Checklist ................................................................................................ 10-2
Periodic Service Schedule ................................................................................................................. 10-3
Periodic Lubrication Schedule ........................................................................................................... 10-4
Master Cylinder .................................................................................................................................. 10-6
Brake Fluid ..................................................................................................................................... 10-6
Engine Oil .......................................................................................................................................... 10-6
Oil Viscosity ................................................................................................................................... 10-7
Fueling Instructions ........................................................................................................................... 10-7
Battery ............................................................................................................................................... 10-8
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM
General Information ........................................................................................................................... 11-2
Troubleshooting Guide ...................................................................................................................... 11-2
Wiring Diagram .................................................................................................................................. 11-6
Electrical System ............................................................................................................................... 11-8
Electrical Circuits ............................................................................................................................... 11-9
Starter Circuit ................................................................................................................................. 11-9
Generator Circuit ........................................................................................................................... 11-9
Engine Ignition Circuit .................................................................................................................... 11-10
Engine Kill Circuit ........................................................................................................................... 11-10
Reverse Buzzer Circuit .................................................................................................................. 11-11
Low Oil Warning Circuit ................................................................................................................. 11-12
Lockout Cam Circuit ...................................................................................................................... 11-12
Fuel Gauge and Sending Unit Circuit ............................................................................................ 11-13
Hour Gauge Circuit ........................................................................................................................ 11-14
Lighting Circuit ............................................................................................................................... 11-14

Page viii 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
Circuit Testing .................................................................................................................................... 11-14
Testing the Starter Circuit and Generator Circuit ........................................................................... 11-15
Testing the Engine Ignition Circuit ................................................................................................. 11-16
Testing the Engine Kill Circuit ........................................................................................................ 11-16
Testing the Reverse Buzzer Circuit ................................................................................................ 11-17
Testing the Low Oil Warning Circuit ............................................................................................... 11-18
Testing the Lockout Cam Circuit .................................................................................................... 11-19
Testing the Fuel Gauge and Sending Unit Circuit .......................................................................... 11-19
Testing the Lighting Circuit ............................................................................................................. 11-20
Test Procedures ................................................................................................................................. 11-20
Index of Test Procedures ............................................................................................................... 11-20
SECTION 12 – ELECTRICAL COMPONENTS
Starter/Generator ............................................................................................................................... 12-2
Voltage Regulator .............................................................................................................................. 12-13
Diode .................................................................................................................................................. 12-14
Key Switch ......................................................................................................................................... 12-15
Solenoid ............................................................................................................................................. 12-17
Fuse ................................................................................................................................................... 12-18
Lockout Cam Limit Switch .................................................................................................................. 12-18
Lockout Cam ...................................................................................................................................... 12-19
Reverse Warning Buzzer ................................................................................................................... 12-20
Reverse Buzzer Limit Switch ............................................................................................................. 12-21
Oil Warning Light ................................................................................................................................ 12-22
Fuel/Hour Gauge ................................................................................................................................ 12-23
Fuel Level Sending Unit ..................................................................................................................... 12-24
RPM Limiter ....................................................................................................................................... 12-24
Ignition Coil ........................................................................................................................................ 12-25
Oil Level Sensor ................................................................................................................................. 12-28
Headlights .......................................................................................................................................... 12-29
Headlight Diode .................................................................................................................................. 12-30
Light Switch ........................................................................................................................................ 12-30
Battery ................................................................................................................................................ 12-31
Ground Straps .................................................................................................................................... 12-36

2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page ix
SECTION 13 – FE350 ENGINE
General Information ........................................................................................................................... 13-2
Special Engine Service Tools Available from Club Car ................................................................. 13-2
Before Servicing ............................................................................................................................ 13-2
Mechanical Systems ...................................................................................................................... 13-2
Electrical System ........................................................................................................................... 13-4
Lubrication System ........................................................................................................................ 13-5
Hydraulic Lifters ............................................................................................................................. 13-6
Spark Plug ..................................................................................................................................... 13-6
Engine Mounting Plate ...................................................................................................................... 13-8
Cylinder Head .................................................................................................................................... 13-8
General Information ....................................................................................................................... 13-8
Cylinder Shroud Removal .............................................................................................................. 13-8
Rocker Arm and Push Rod Removal ............................................................................................. 13-10
Cylinder Head Removal ................................................................................................................. 13-10
Valve Removal ............................................................................................................................... 13-11
Breather Valve (Reed Valve) ......................................................................................................... 13-12
Cylinder Head Cleaning and Inspection ........................................................................................ 13-12
Valve Guides ................................................................................................................................. 13-13
Valve Seats .................................................................................................................................... 13-13
Valves ............................................................................................................................................ 13-16
Rocker Arm and Rocker Shaft inspection ...................................................................................... 13-18
Push Rod Inspection ...................................................................................................................... 13-19
Cylinder Head Installation .............................................................................................................. 13-19
Valve Clearance Check and Adjustment ....................................................................................... 13-20
Breather Valve (Reed Valve) ......................................................................................................... 13-20
Installation of Remaining Engine Components .............................................................................. 13-21
Crankcase ......................................................................................................................................... 13-23
Engine Removal ............................................................................................................................ 13-23
Crankcase Cover Removal ............................................................................................................ 13-24
Oil Level Sensor ............................................................................................................................ 13-24
Camshaft and Hydraulic Lifters ...................................................................................................... 13-25
Piston and Connecting Rod ............................................................................................................... 13-27
Cylinder Block .................................................................................................................................... 13-30
Ignition Coil and Flywheel .................................................................................................................. 13-31
Oil Pump ............................................................................................................................................ 13-32
Oil Pressure Relief Valve ............................................................................................................... 13-34

Page x 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
Crankshaft and Counterbalance ........................................................................................................ 13-35
Counterbalance Weight .................................................................................................................. 13-38
Oil Screen ...................................................................................................................................... 13-40
Ball Bearing .................................................................................................................................... 13-41
Oil Seals ......................................................................................................................................... 13-42
Crankshaft Axial Play Adjustment ...................................................................................................... 13-44
Crankcase Cover Installation ......................................................................................................... 13-47
Engine Assembly ............................................................................................................................... 13-48
Service Specifications ........................................................................................................................ 13-50
Specifications for Resizing Cylinder Bore ...................................................................................... 13-51
Torque Specifications ..................................................................................................................... 13-51
Adjustments and Settings .............................................................................................................. 13-52
SECTION 14 – FUEL SYSTEM
General Information ........................................................................................................................... 14-1
How the Carburetor Works ................................................................................................................. 14-2
Main System .................................................................................................................................. 14-2
Slow Speed System ....................................................................................................................... 14-2
Choke and Fresh Air System ......................................................................................................... 14-4
Float System .................................................................................................................................. 14-4
Carburetor .......................................................................................................................................... 14-4
Main Jet Elevation/Size Chart ........................................................................................................ 14-5
Changing the Main Jet ................................................................................................................... 14-5
Engine Control Linkage ...................................................................................................................... 14-8
General Information ....................................................................................................................... 14-8
Accelerator Rod ............................................................................................................................. 14-9
Governor Cable .............................................................................................................................. 14-10
Accelerator Cable ........................................................................................................................... 14-11
Closed Throttle or Idle Adjustment ................................................................................................. 14-13
Engine RPM Adjustment ................................................................................................................ 14-13
Choke and Air Intake System ............................................................................................................. 14-14
General Information ....................................................................................................................... 14-14
Choke Cable Removal ................................................................................................................... 14-14
Choke Cable Installation ................................................................................................................ 14-14
Air Box Removal ............................................................................................................................ 14-15
Air Box Installation ......................................................................................................................... 14-15
Intake Duct Removal ...................................................................................................................... 14-15
Intake Duct Installation ................................................................................................................... 14-16
Intake Duct Repair ......................................................................................................................... 14-18
Air Filter .......................................................................................................................................... 14-18

2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page xi
Fuel Filters ......................................................................................................................................... 14-19
General Information ....................................................................................................................... 14-19
Fuel Filter Removal ........................................................................................................................ 14-19
Fuel Filter Installation ..................................................................................................................... 14-19
Fuel Pump ......................................................................................................................................... 14-21
General Information ....................................................................................................................... 14-21
Fuel Pump Removal ...................................................................................................................... 14-21
Fuel Pump Disassembly ................................................................................................................ 14-21
Fuel Pump Cleaning and Inspection .............................................................................................. 14-22
Fuel Pump Assembly ..................................................................................................................... 14-22
Fuel Pump Installation ................................................................................................................... 14-23
Fuel Tank ........................................................................................................................................... 14-23
General Information ....................................................................................................................... 14-24
Preparation for Extended Storage ................................................................................................. 14-24
Fuel Tank Removal ........................................................................................................................ 14-24
Fuel Tank Disposal ........................................................................................................................ 14-25
Fuel Tank Storage ......................................................................................................................... 14-25
Fuel Tank Installation ..................................................................................................................... 14-25
Fuel Lines .......................................................................................................................................... 14-27
Fuel Shut-Off Valve ........................................................................................................................... 14-28
SECTION 15 – EXHAUST SYSTEM
General Information ........................................................................................................................... 15-1
Muffler ................................................................................................................................................ 15-2
Muffler Removal ............................................................................................................................. 15-2
Muffler Installation .......................................................................................................................... 15-2
SECTION 16 – UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
General Information ........................................................................................................................... 16-1
Lubrication ..................................................................................................................................... 16-3
Axle Shaft .......................................................................................................................................... 16-3
Axle Shaft and Oil Seal Removal ................................................................................................... 16-4
Axle Bearing .................................................................................................................................. 16-5
Axle Shaft Installation .................................................................................................................... 16-7
Unitized Transaxle Removal .............................................................................................................. 16-7
Unitized Transaxle Disassembly ........................................................................................................ 16-15

Page xii 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
Component Disassembly ................................................................................................................... 16-19
Differential Gear Lock Housing Disassembly ................................................................................. 16-19
Governor Gear Disassembly .......................................................................................................... 16-21
Differential Gear Case Disassembly .............................................................................................. 16-22
Shifter Fork Disassembly ............................................................................................................... 16-23
Synchronizer Gear Disassembly .................................................................................................... 16-23
Intermediate Gear Disassembly ..................................................................................................... 16-24
Idler Shaft Disassembly ................................................................................................................. 16-24
Unitized Transaxle Component Inspection ........................................................................................ 16-26
Component Assembly ........................................................................................................................ 16-26
Idler Shaft Assembly ...................................................................................................................... 16-26
Intermediate Gear Assembly .......................................................................................................... 16-26
Synchronizer Gear Assembly ......................................................................................................... 16-26
Shifter Fork Assembly .................................................................................................................... 16-29
Differential Gear Case Assembly ................................................................................................... 16-29
Governor Gear Assembly ............................................................................................................... 16-31
Differential Gear Lock Housing Assembly ...................................................................................... 16-31
Unitized Transaxle Assembly ............................................................................................................. 16-32
Unitized Transaxle Installation ........................................................................................................... 16-39
Forward/Reverse (F&R) Shifter Cable ............................................................................................... 16-47
F&R Shifter Cable Removal ........................................................................................................... 16-47
F&R Shifter Cable Installation ........................................................................................................ 16-47
F&R Shifter Cable Adjustment ....................................................................................................... 16-48
Differential Lock System .................................................................................................................... 16-49
Differential Lock System Inspection ............................................................................................... 16-49
Differential Lock Cable Removal .................................................................................................... 16-49
Differential Lock Cable Installation ................................................................................................. 16-51
SECTION 17 – TORQUE CONVERTER
General Information ........................................................................................................................... 17-1
Troubleshooting ................................................................................................................................. 17-3
Drive Belt ............................................................................................................................................ 17-3
Drive Belt Removal ........................................................................................................................ 17-3
Drive Belt Installation ..................................................................................................................... 17-4
Drive Clutch ........................................................................................................................................ 17-4
Drive Clutch Removal .................................................................................................................... 17-4
Drive Clutch Cleaning and Inspection ............................................................................................ 17-5
Drive Clutch Disassembly .............................................................................................................. 17-7
Inspection of Drive Clutch Parts ..................................................................................................... 17-9
Drive Clutch Assembly ................................................................................................................... 17-9
Drive Clutch Installation ................................................................................................................. 17-13

2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page xiii
Driven Clutch ..................................................................................................................................... 17-13
Driven Clutch Removal .................................................................................................................. 17-13
Driven Clutch Disassembly ............................................................................................................ 17-13
Driven Clutch Inspection ................................................................................................................ 17-14
Driven Clutch Assembly ................................................................................................................. 17-14
Driven Clutch Installation ............................................................................................................... 17-15

2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 1-1
1
SECTION 1 – SAFETY
To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage
resulting from improper service or maintenance, the procedures in this manual must be followed. It is impor-
tant to note that throughout this manual there are statements labeled DANGER , WARNING , or CAUTION .
These special statements relate to specific safety issues, and must be read, understood, and heeded before
proceeding with procedures. There are statements labeled NOTE , which provide other essential service or
maintenance information.
∆ DANGER
• A DANGER indicates an immediate hazard that will result in severe personal injury or death.
∆ WARNING
• A WARNING indicates an immediate hazard that could result in severe personal injury or
death.
∆ CAUTION
• A CAUTION indicates hazards or unsafe practices that could result in product or property damage or
minor personal injury.
GENERALWARNING
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 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.
• Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or
clothing. Antidotes:
- External: Flush with water. Call a physician immediately.
- Internal: Drink large quantities of water. Follow with milk of magnesia or vegetable oil. Call a
physician immediately.
- Eyes: Flush with water for 15 minutes. Call a physician immediately.
• Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from vehicle
and service area. Service only in a well-ventilated area.
• Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine
produces carbon monoxide, which is an odorless, deadly poison.
• A Club Car vehicle will not provide protection from lightning, flying objects, or other storm
related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek
shelter in accordance with applicable safety guidelines for your location.

SAFETY General Warning
Page 1-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
1
∆ WARNING
• Only trained technicians should repair or service the vehicle. Anyone doing even simple
repairs or service should have knowledge and experience in electrical and mechanical repair.
• Follow the procedures exactly as stated in this manual, and heed all DANGER,WARNING, and
CAUTION statements in this manual as well as those affixed to the vehicle.
• Improper use of the vehicle or failure to properly maintain it, could result in decreased vehicle
performance or severe personal injury.
• Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
• Check the vehicle owner’s manual for proper location of all vehicle warning decals and make
sure they are in place and are easy to read.
• Wear safety glasses or approved eye protection when servicing the vehicle.
• Do not wear loose clothing. Remove jewelry such as rings, watches, chains, etc. before
servicing vehicle.
• Moving parts! Do not attempt to service the vehicle while it is running.
• Hot! Do not attempt to service hot engine or exhaust systems. Failure to heed this warning
could result in severe burns.
• Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
• Turn the key switch to OFF and remove key. Chock the wheels, place the Forward/Reverse
handle in NEUTRAL, and disconnect battery prior to servicing the vehicle.
• To avoid unintentionally starting the vehicle:
- Disconnect battery cables, negative cable (–) first (Figure 1-1, Page 1-2).
- Disconnect the spark plug wire from the spark plug.
• Frame ground – Do not allow tools or other metal objects to contact frame when
disconnecting battery cables or other electric wiring. Never allow a positive wire to touch the
vehicle frame, engine, or any other metal component.
• Lift only one end of the vehicle at a time. Before lifting, set the park brake when lifting the front
of the vehicle, unload the cargo bed and chock the wheels that remain on the floor. Use a
suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum
lifting capacity. Do not use lifting device to hold vehicle in raised position. Use approved jack
stands of proper weight capacity to support the vehicle.
Figure 1-1 Battery
FRONT
OF VEHICLE
AS SEEN FROM
PASSENGER'S SIDE
OF VEHICLE
REMOVE
NEGATIVE
CABLE FIRST
DISCONNECT BATTERY CABLES
BEFORE WORKING ON VEHICLE

2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 2-1
2
SECTION 2 – VEHICLE SPECIFICATIONS
GENERAL INFORMATION
Club Car, Inc.reserves the right to change specifications and design of the vehicle at any time without notice
and without obligation to make these changes on units previously sold.
SPECIFICATIONS
POWER SOURCE
Engine: 4 cycle, OHV, 351 cc, 11 hp rated, single cylinder, air cooled, with pressure lubrication system
•
Fuel System: Side draft carburetor with float bowl, fixed jets, fuel filters, and impulse fuel pump
•
Governor: Automatic ground speed sensing, internally geared in unitized transaxle
•
Ignition: Transistor electronic ignition with electronic RPM limiter
•
Transaxle: Fully synchronized forward and reverse with neutral (15:1 forward, 20.6:1 reverse) with dif-
ferential lock feature
•
Torque Converter: Automatic, variable speed, dry type
•
Electrical System: 12 volt, 500 cca at 0 °F (-17.8 °C), 650 at 32 °F (0 °C), 105-minute reserve capac-
ity and 35-amp charging capacity
•
STEERING/SUSPENSION/BRAKES
Steering: Self-adjusting rack and pinion
•
Suspension:
Front : Independent A-arms with coil-over shocks
Rear : Semi-independent rear suspension with multi-leaf springs and dual hydraulic shocks
•
Brakes: Hydraulic 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 box bed
•
Front Body: ABS/DR acrylic molded-in color
•
Tires: 23 x 10.50 - 12 tubeless, 4 ply rated load range, front and rear
•
DIMENSIONS/WEIGHT
Overall Length (box bed configuration)
123.4 in. (313.4 cm)
OverallWidth
54 in. (137 cm)
Overall Height (at steering wheel)
51 in. (130 cm)
Wheelbase
80 in. (203 cm)
Ground Clearance:
(under differential):
(under foot platform):
6.6 in. (17 cm)
11.4 in. (29 cm)
Front Wheel Tread
43 in. (109 cm)
Rear Wheel Tread
43.5 in. (111 cm)
Weight: (dry):
(with all-terrain tread):
(With turf tread):
1101 lb. (499.9 kg)
1047 lb. (475.4 kg)
Forward Speed:
17-19 mph (27-31 km/h)
Curb Clearance Circle (diameter)
24 ft. 1 in. (734 cm)
Turning Radius (per SAE J 695)
139.6 in. (355 cm)
Intersecting Aisle Clearance
112.2 in. (285 cm)
Floorboard Height
17 in. (43 cm)
Load Bed Height
31.1 in. (79 cm)
Vehicle Specifications continued on next page...

VEHICLE SPECIFICATIONS General Information
Page 2-2 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
2
DIMENSIONS/WEIGHT (Continued)
Seat Height
35 in. (89 cm)
Load Bed Size (box bed inside dimensions)
48.0 x 49.8 x 10.9 in. (121.9 x
126.4 x 27.6 cm)
Load Bed Size (flat bed dimensions)
46.9 x 48.3 in.
(119 x 123 cm)
Vehicle Rated Capacity (level surface only)
1200 lb. (544 kg)
Bed Load Capacity (level surface only)
800 lb. (363 kg)
Standard Seating Capacity
2
LIQUID CAPACITIES
Engine Crankcase without filter 32 oz. (.95 liters)
Engine Crankcase with filter 38 oz. (1.12 liters)
UnitizedTransaxle 31 oz. (.92 liters)
FuelTank 7 gal. (26.5 liters)
Master Cylinder 8 oz. (240 ml)
TIRE PRESSURE
AllTerrainTread
Front: 7-11 psi (48-76 kPa)
Rear: 14-18 psi (97-124 kPa)
TurfTread
Front: 12-16 psi (83-110 kPa)
Rear: 16-20 psi (110-138 kPa)
Traks Max IITread
Front: 14-16 psi (97-110 kPa)
Rear: 18-20 psi (124-138 kPa)
SPECIFICATIONS