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 [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 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