Pioneer 1200 Manual

2003 MAINTENANCE & SERVICE MANUAL

1200/1200SE

Manual No. 102318813 Edition Code 0503A00000

2003 Pioneer 1200/1200SE 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 and Pioneer

1200SE vehicles, and should be thoroughly reviewed prior to servicing the vehicles. The procedures provided

must be properly 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 knowl-

edge and facilities so they can provide prompt and efﬁcient service for vehicle owners. Regional technical rep-

resentatives, 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, GA 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 July 22, 2002.

Page ii 2003 Pioneer 1200/1200SE 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

continually working to further improve our vehicles and other products. These improvements may

affect servicing procedures. Any modiﬁcation and/or signiﬁcant change in speciﬁcations or proce-

dures 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,

including 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, GA 30917-4658 USA,

Attention: Warranty Department.

2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page iii

CONTENTS

SECTION 1 – SAFETY

General Warning ............................................................................................................................... 1-1

SECTION 2 – VEHICLE SPECIFICATIONS

SECTION 3 – GENERAL INFORMATION

General Information .......................................................................................................................... 3-1

Serial Number Identification .............................................................................................................. 3-1

Storage ............................................................................................................................................. 3-1

Preparing the Vehicle for Extended Storage ................................................................................ 3-2

To Return Vehicle to Service ........................................................................................................ 3-2

SECTION 4 – BODY AND TRIM

Cleaning the Vehicle ......................................................................................................................... 4-1

Front Body Repair ............................................................................................................................. 4-1

Abrasions and Haze ..................................................................................................................... 4-1

Light Scratches ............................................................................................................................. 4-2

Large Scratches and Abrasions .................................................................................................... 4-2

Front Body Components ................................................................................................................... 4-2

Dashboard Removal ..................................................................................................................... 4-2

Dashboard Installation .................................................................................................................. 4-2

Front Body Removal ..................................................................................................................... 4-3

Front Fender Removal .................................................................................................................. 4-3

Front Fender Installation ............................................................................................................... 4-4

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

Seat .................................................................................................................................................. 4-4

Seat Adjustment ........................................................................................................................... 4-4

Front Seat Support ........................................................................................................................... 4-6

Front Seat Support Removal ........................................................................................................ 4-6

Front Seat Support Installation ..................................................................................................... 4-7

Rear Seat Support ............................................................................................................................ 4-7

Rear Seat Support Removal ......................................................................................................... 4-7

Rear Seat Support Installation ...................................................................................................... 4-7

Page iv 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual

Cargo Bed ........................................................................................................................................ 4-9

Cargo Bed Removal ..................................................................................................................... 4-9

Cargo Bed Installation .................................................................................................................. 4-9

Bed Stop Bumper Adjustment ...................................................................................................... 4-11

Rear Fender Removal .................................................................................................................. 4-12

Rear Fender Installation ............................................................................................................... 4-12

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

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

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

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

Receiver Hitch Removal ............................................................................................................... 4-12

Receiver Hitch Installation ............................................................................................................ 4-13

Floor Mat .......................................................................................................................................... 4-14

Floor Mat Removal ....................................................................................................................... 4-14

Floor Mat Installation .................................................................................................................... 4-14

SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES

Brake Pedal ...................................................................................................................................... 5-1

Brake Pedal Removal .................................................................................................................. 5-1

Brake Pedal Installation ............................................................................................................... 5-1

Brake Pedal Adjustment ................................................................................................................... 5-2

Accelerator Pedal ............................................................................................................................. 5-4

Accelerator Pedal Removal .......................................................................................................... 5-4

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

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

SECTION 6 – MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE

SYSTEMS

Brake System Inspection ................................................................................................................. 6-1

Brake System Troubleshooting ........................................................................................................ 6-3

Brake Drum Removal ....................................................................................................................... 6-6

Front Wheel Brake Drum Removal .............................................................................................. 6-6

Rear Wheel Brake Drum Removal ............................................................................................... 6-8

Brake Shoe Removal ....................................................................................................................... 6-8

Front Brake Shoe Removal .......................................................................................................... 6-8

Rear Brake Shoe Removal .......................................................................................................... 6-9

Brake Cluster Inspection and Cleaning ............................................................................................ 6-10

Brake Shoe Installation .................................................................................................................... 6-11

Front Brake Shoe Installation ....................................................................................................... 6-12

Rear Brake Shoe Installation ....................................................................................................... 6-12

2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page v

Brake Drum Installation .................................................................................................................... 6-14

Front Wheel Brake Drum Installation ............................................................................................ 6-14

Rear Wheel Brake Drum Installation ............................................................................................ 6-16

Brake Cluster Assembly Replacement ............................................................................................. 6-17

Front Brake Cluster Assembly Removal ....................................................................................... 6-17

Front Brake Cluster Assembly Installation .................................................................................... 6-17

Rear Brake Cluster Assembly Removal ....................................................................................... 6-18

Rear Brake Cluster Assembly Installation .................................................................................... 6-19

Wheel Cylinder Replacement ........................................................................................................... 6-19

Front Wheel Cylinder Removal ..................................................................................................... 6-19

Front Wheel Cylinder Installation .................................................................................................. 6-20

Rear Wheel Cylinder Removal ..................................................................................................... 6-20

Rear Wheel Cylinder Installation .................................................................................................. 6-20

Brake Shoe Adjuster Replacement .................................................................................................. 6-21

Front Brake Shoe Adjuster Removal ............................................................................................ 6-22

Front Brake Shoe Adjuster Installation ......................................................................................... 6-22

Rear Brake Shoe Adjuster Removal ............................................................................................. 6-22

Rear Brake Shoe Adjuster Installation .......................................................................................... 6-22

Hydraulic Line and Hose Replacement ............................................................................................ 6-23

Front Brake Line Removal ............................................................................................................ 6-23

Front Brake Line Installation ......................................................................................................... 6-23

Front Brake Hose Assembly Removal .......................................................................................... 6-24

Front Brake Hose Assembly Installation ....................................................................................... 6-24

Rear Brake Line Removal ............................................................................................................. 6-24

Rear Brake Line Installation .......................................................................................................... 6-26

Rear Brake Hose Removal ........................................................................................................... 6-26

Rear Brake Hose Installation ........................................................................................................ 6-27

Master Cylinder And Bell Crank Replacement ................................................................................. 6-27

Bell Crank Removal ...................................................................................................................... 6-27

Bell Crank Installation ................................................................................................................... 6-27

Master Cylinder Removal ............................................................................................................. 6-29

Master Cylinder Installation .......................................................................................................... 6-29

Bleeding the Hydraulic Brake System .............................................................................................. 6-31

Purging the Hydraulic System ...................................................................................................... 6-32

Filling the Hydraulic System ......................................................................................................... 6-32

Park Brake System ........................................................................................................................... 6-33

Park Brake Cable Removal .......................................................................................................... 6-33

Park Brake Cable Installation ....................................................................................................... 6-34

Park Brake Handle Removal ........................................................................................................ 6-35

Park Brake Handle Installation ..................................................................................................... 6-35

Park Brake Adjustment ................................................................................................................. 6-35

Page vi 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual

SECTION 7 – STEERING AND FRONT SUSPENSION

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

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

Steering Wheel Installation .......................................................................................................... 7-3

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

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

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

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

Steering Column Installation ........................................................................................................ 7-4

Rack and Pinion ............................................................................................................................... 7-5

Rack and Pinion Removal ............................................................................................................ 7-5

Rack and Pinion Disassembly ...................................................................................................... 7-6

Rack and Pinion Assembly .......................................................................................................... 7-9

Rack and Pinion Installation ......................................................................................................... 7-10

Front Suspension ............................................................................................................................. 7-12

Lubrication .................................................................................................................................... 7-12

Wheel Alignment .......................................................................................................................... 7-12

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

Kingpin and Steering Spindle Removal ........................................................................................ 7-14

Kingpin and Steering Spindle Installation ..................................................................................... 7-14

A-Arm Removal ............................................................................................................................ 7-15

A-Arm Installation ......................................................................................................................... 7-17

Shock Absorber Removal ............................................................................................................ 7-17

Shock Absorber Installation ......................................................................................................... 7-18

Front Wheel Bearings and Hubs ...................................................................................................... 7-18

Front Wheel Free Play Inspection ................................................................................................ 7-18

Front Wheel Bearings and Hub Removal ..................................................................................... 7-19

Front Wheel Bearings and Hub Installation .................................................................................. 7-19

SECTION 8 – WHEELS AND TIRES

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

SECTION 9 – REAR SUSPENSION

Shock Absorbers .............................................................................................................................. 9-1

Shock Absorber Removal and Inspection .................................................................................... 9-1

Shock Absorber Installation ......................................................................................................... 9-1

Multi-Leaf Springs ............................................................................................................................ 9-1

Multi-Leaf Spring Removal ........................................................................................................... 9-1

Multi-Leaf Spring Installation ........................................................................................................ 9-3

2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page vii

Snubber ............................................................................................................................................ 9-4

Snubber Removal ......................................................................................................................... 9-4

Snubber Installation ...................................................................................................................... 9-4

SECTION 10 – PERIODIC MAINTENANCE

Periodic Service Schedule ................................................................................................................ 10-1

Periodic Lubrication Schedule

........................................................................................................ 10-2

Master Cylinder ................................................................................................................................. 10-3

Brake Fluid .................................................................................................................................... 10-4

Engine Oil ......................................................................................................................................... 10-4

Engine Oil Level Check ................................................................................................................ 10-4

Engine Oil and Filter Change ........................................................................................................ 10-5

Oil Viscosity .................................................................................................................................. 10-7

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

Battery .............................................................................................................................................. 10-8

SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400 ENGINE

Troubleshooting Guide ..................................................................................................................... 11-1

Electrical System .............................................................................................................................. 11-5

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

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 ................................................................................................................ 11-10

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

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

Hour Meter 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

Page viii 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual

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

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

SECTION 12 – ELECTRICAL COMPONENTS: FE400 ENGINE

Starter/Generator ............................................................................................................................. 12-1

Voltage Regulator ............................................................................................................................ 12-11

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

Key Switch ....................................................................................................................................... 12-14

Solenoid ........................................................................................................................................... 12-15

Fuse ................................................................................................................................................. 12-15

Lockout Cam Limit Switch ................................................................................................................ 12-17

Lockout Cam .................................................................................................................................... 12-17

Reverse Warning Buzzer ................................................................................................................. 12-18

Reverse Buzzer Limit Switch ........................................................................................................... 12-19

Low Oil Warning Light ...................................................................................................................... 12-20

Fuel Gauge/Hour Meter ................................................................................................................... 12-21

Fuel Level Sending Unit ................................................................................................................... 12-22

RPM Limiter ..................................................................................................................................... 12-22

Ignition Coil ...................................................................................................................................... 12-23

Oil Level Sensor ............................................................................................................................... 12-26

Headlights ........................................................................................................................................ 12-26

Voltage Limiter ................................................................................................................................. 12-27

Light Switch ...................................................................................................................................... 12-28

Testing the Light Switch ............................................................................................................... 12-28

Battery .............................................................................................................................................. 12-28

General Information ..................................................................................................................... 12-29

Ground Straps .................................................................................................................................. 12-33

SECTION 13 – FE400 ENGINE

General Information ......................................................................................................................... 13-1

Special Engine Service Tools Available From Club Car .............................................................. 13-1

Before Servicing ........................................................................................................................... 13-1

Lubrication System ....................................................................................................................... 13-1

Spark Plug .................................................................................................................................... 13-1

Cylinder ............................................................................................................................................ 13-3

Breather Valve (Reed Valve) ....................................................................................................... 13-3

Valve Clearance Check and Adjustment ...................................................................................... 13-3

Crankcase ........................................................................................................................................ 13-3

Engine Removal ........................................................................................................................... 13-3

Crankcase Cover Removal .......................................................................................................... 13-4

Oil Level Sensor ........................................................................................................................... 13-4