Club car Pioneer 900 Manual

2001 Pioneer 900 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 900 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 900 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 contin-

ually working to further improve our vehicles and other products.These improvements may affect ser-

vicing procedures. Any modiﬁcation and/or signiﬁcant change in speciﬁcations or procedures will be

forwarded to all Club Car dealers and will, when applicable, appear in future editions of this manual.

Damage to a vehicle or component thereof not resulting from a defect or that occurs due to unrea-

sonable or unintended use, overloading, abuse, or neglect (including failure to provide reasonable or

necessary maintenance as instructed in the vehicle owner’s manual), accident or alteration, 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 900 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

Stress Lines or Streaks .................................................................................................................. 4-2

Minor Impact Damage/Deformations ............................................................................................. 4-2

Minor Scratches and Surface Blemishes ....................................................................................... 4-3

Small Scratches that Cannot be Buffed out ................................................................................... 4-3

Gouges, Punctures, Tears, Large Scratches, and Abrasions ........................................................ 4-3

Brush Guard ...................................................................................................................................... 4-3

Brush Guard Removal ................................................................................................................... 4-3

Brush Guard Installation ................................................................................................................ 4-4

Front Body ......................................................................................................................................... 4-4

Front Body Removal ...................................................................................................................... 4-4

Front Body Installation ................................................................................................................... 4-4

Front Fender Extension ..................................................................................................................... 4-5

Front Fender Extension Removal .................................................................................................. 4-5

Front Fender Extension Installation ............................................................................................... 4-6

Tilt Bed .............................................................................................................................................. 4-6

Tilt Bed Removal ........................................................................................................................... 4-6

Tilt Bed Installation ........................................................................................................................ 4-8

Rear Fender ....................................................................................................................................... 4-8

Rear Fender Removal ................................................................................................................... 4-8

Rear Fender Installation ................................................................................................................ 4-8

Page iv 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual

Receiver Hitch .................................................................................................................................... 4-11

Receiver Hitch Removal ................................................................................................................. 4-11

Receiver Hitch Installation .............................................................................................................. 4-12

Tailskirt ............................................................................................................................................... 4-12

Tailskirt Removal ............................................................................................................................ 4-12

Tailskirt Installation ......................................................................................................................... 4-12

Floor Mat ............................................................................................................................................ 4-12

Floor Mat Removal ......................................................................................................................... 4-12

Floor Mat Installation ...................................................................................................................... 4-12

SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP

Brake Pedal and Park Brake .............................................................................................................. 5-2

Brake Pedal Removal .................................................................................................................... 5-2

Brake Pedal Installation ................................................................................................................. 5-2

Park Brake Removal ...................................................................................................................... 5-4

Park Brake Installation ................................................................................................................... 5-4

Accelerator Pedal ............................................................................................................................... 5-5

Accelerator Pedal Removal ............................................................................................................ 5-5

Accelerator Pedal Installation ......................................................................................................... 5-6

Pedal Group Adjustment .................................................................................................................... 5-7

SECTION 6 – WHEEL BRAKE ASSEMBLIES

General Information ........................................................................................................................... 6-1

Brake Shoe Removal ......................................................................................................................... 6-2

Brake Assembly Cleaning .................................................................................................................. 6-3

Brake Shoe Installation ...................................................................................................................... 6-5

Brake Cluster Removal and Installation ............................................................................................. 6-6

Rear Brake Cluster Removal ......................................................................................................... 6-6

Rear Brake Cluster Installation ...................................................................................................... 6-9

Front Brake Cluster Removal ......................................................................................................... 6-10

Front Brake Cluster Installation ...................................................................................................... 6-11

Front Brake Cables ............................................................................................................................ 6-11

Front Brake Cable Removal ........................................................................................................... 6-11

Front Brake Cable Installation ........................................................................................................ 6-12

Rear Brake Cables ............................................................................................................................. 6-14

Rear Brake Cable Removal ........................................................................................................... 6-14

Rear Brake Cable Installation ........................................................................................................ 6-15

2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page v

Brake Adjustment .............................................................................................................................. 6-16

Brake Cluster Adjustment .............................................................................................................. 6-16

Equalizing Brake Cables ................................................................................................................ 6-17

Final Brake Cluster Adjustment ..................................................................................................... 6-18

Test Drive Vehicle .......................................................................................................................... 6-18

SECTION 7 – STEERING AND FRONT SUSPENSION

General Information ........................................................................................................................... 7-1

Steering Wheel .................................................................................................................................. 7-1

Steering Wheel Removal ............................................................................................................... 7-1

Steering Wheel Installation ............................................................................................................ 7-2

Steering Column ................................................................................................................................ 7-3

Steering Column Removal ............................................................................................................. 7-3

Steering Column Disassembly ....................................................................................................... 7-4

Steering Column Assembly ........................................................................................................... 7-4

Steering Column Installation .......................................................................................................... 7-6

Steering Adjustment .......................................................................................................................... 7-7

Rack and Pinion ................................................................................................................................ 7-8

Rack and Pinion Removal ............................................................................................................. 7-8

Rack and Pinion Disassembly ....................................................................................................... 7-8

Rack and Pinion Assembly ............................................................................................................ 7-10

Rack and Pinion Installation .......................................................................................................... 7-13

Tie Rod and Drag Link ....................................................................................................................... 7-13

Tie Rod and Drag Link Removal .................................................................................................... 7-13

Tie Rod and Drag Link Installation ................................................................................................. 7-14

Front Suspension .............................................................................................................................. 7-14

Lubrication ..................................................................................................................................... 7-14

Wheel Alignment ............................................................................................................................ 7-15

Front Suspension Components ......................................................................................................... 7-17

Multi-Leaf Spring Removal ............................................................................................................ 7-17

Multi-Leaf Spring Installation ......................................................................................................... 7-17

Kingpin and Steering Spindle Removal ......................................................................................... 7-17

Kingpin and Steering Spindle Installation ...................................................................................... 7-18

Delta A-Plate Removal .................................................................................................................. 7-20

Delta A-Plate Installation ............................................................................................................... 7-20

Shock Absorber Removal and Inspection ...................................................................................... 7-20

Shock Absorber Installation ........................................................................................................... 7-20

Front Wheel Bearings and Hubs ....................................................................................................... 7-20

Front Wheel Free Play Inspection ................................................................................................. 7-20

Front Wheel Bearings and Hub Removal ...................................................................................... 7-22

Front Wheel Bearings and Hub Installation ................................................................................... 7-22

Page vi 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual

SECTION 8 – WHEELS AND TIRES

General Information ........................................................................................................................... 8-1

Wheels ............................................................................................................................................... 8-2

Wheel Removal .............................................................................................................................. 8-2

Wheel Installation ........................................................................................................................... 8-2

Tires ................................................................................................................................................... 8-2

Tire Removal .................................................................................................................................. 8-2

Tire Repair ..................................................................................................................................... 8-3

Tire Installation ............................................................................................................................... 8-3

SECTION 9 – REAR SUSPENSION

General Information ........................................................................................................................... 9-1

Shock Absorbers ................................................................................................................................ 9-2

Shock Absorber Removal and Inspection ...................................................................................... 9-2

Shock Absorber Installation ........................................................................................................... 9-2

Multi-Leaf Springs .............................................................................................................................. 9-3

Multi-Leaf Spring Removal ............................................................................................................. 9-3

Multi-Leaf Spring Installation .......................................................................................................... 9-5

Snubber .............................................................................................................................................. 9-5

Snubber Removal .......................................................................................................................... 9-5

Snubber Installation ....................................................................................................................... 9-5

Stabilizer Bar ...................................................................................................................................... 9-6

Stabilizer Bar Removal ................................................................................................................... 9-6

Stabilizer Bar Installation ................................................................................................................ 9-6

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

Engine Oil ........................................................................................................................................... 10-6

Oil Viscosity .................................................................................................................................... 10-6

Fueling Instructions ............................................................................................................................ 10-7

Battery ................................................................................................................................................ 10-7

SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM

General Information ........................................................................................................................... 11-2

Troubleshooting Guide ....................................................................................................................... 11-2

Wiring Diagram .................................................................................................................................. 11-6

2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page vii

Electrical System ............................................................................................................................... 11-7

Electrical Circuits ............................................................................................................................... 11-8

Starter Circuit ................................................................................................................................. 11-8

Generator Circuit ........................................................................................................................... 11-8

Engine Ignition Circuit .................................................................................................................... 11-9

Engine Kill Circuit ........................................................................................................................... 11-9

Reverse Buzzer Circuit .................................................................................................................. 11-10

Low Oil Warning Circuit ................................................................................................................. 11-11

Lockout Cam Circuit ...................................................................................................................... 11-11

Fuel Gauge and Sending Unit Circuit ............................................................................................ 11-12

Hour Gauge Circuit ........................................................................................................................ 11-13

Lighting Circuit ............................................................................................................................... 11-13

Circuit Testing .................................................................................................................................... 11-13

Testing the Starter Circuit and Generator Circuit ........................................................................... 11-14

Testing the Engine Ignition Circuit ................................................................................................. 11-15

Testing the Engine Kill Circuit ........................................................................................................ 11-15

Testing the Reverse Buzzer Circuit ............................................................................................... 11-16

Testing the Low Oil Warning Circuit .............................................................................................. 11-17

Testing the Lockout Cam Circuit .................................................................................................... 11-18

Testing the Fuel Gauge and Sending Unit Circuit ......................................................................... 11-18

Testing the Lighting Circuit ............................................................................................................ 11-19

Test Procedures ................................................................................................................................ 11-19

Index of Test Procedures ............................................................................................................... 11-19

SECTION 12 – ELECTRICAL COMPONENTS

Starter/Generator ............................................................................................................................... 12-2

Voltage Regulator .............................................................................................................................. 12-13

Diode ................................................................................................................................................. 12-14

Key Switch ......................................................................................................................................... 12-15

Solenoid ............................................................................................................................................. 12-16

Fuse ................................................................................................................................................... 12-17

Lockout Cam Limit Switch ................................................................................................................. 12-18

Lockout Cam ..................................................................................................................................... 12-19

Reverse Warning Buzzer ................................................................................................................... 12-20

Reverse Buzzer Limit Switch ............................................................................................................. 12-21

Oil Warning Light ............................................................................................................................... 12-21

Fuel/Hour Gauge ............................................................................................................................... 12-22

Fuel Level Sending Unit .................................................................................................................... 12-23

RPM Limiter ....................................................................................................................................... 12-24

Ignition Coil ........................................................................................................................................ 12-25

Oil Level Sensor ................................................................................................................................ 12-28

Page viii 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual

Headlights .......................................................................................................................................... 12-28

Headlight Diode .................................................................................................................................. 12-29

Light Switch ........................................................................................................................................ 12-30

Battery ................................................................................................................................................ 12-31

Ground Straps .................................................................................................................................... 12-35

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

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