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 (706) 863-3000, ext.3580.

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