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.
Copyright © 2003 Club Car, Inc.
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
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page ix
Ignition Coil and Flywheel ................................................................................................................. 13-5
Crankcase Cover Installation ........................................................................................................ 13-8
Flywheel Installation ......................................................................................................................... 13-8
Engine Installation ............................................................................................................................ 13-9
Torque Specifications ................................................................................................................... 13-10
Adjustment and Settings ............................................................................................................... 13-10
SECTION 14 – FUEL SYSTEM
General Information .......................................................................................................................... 14-1
Carburetor ......................................................................................................................................... 14-1
Main Jet Elevation/Size Chart ....................................................................................................... 14-1
Changing the Main Jet .................................................................................................................. 14-2
Engine Control Linkage .................................................................................................................... 14-5
General Information ...................................................................................................................... 14-5
Accelerator Rod ............................................................................................................................ 14-6
Governor Cable ............................................................................................................................ 14-7
Accelerator Cable ......................................................................................................................... 14-8
Closed Throttle or Idle Adjustment ............................................................................................... 14-10
Engine RPM Adjustment ............................................................................................................... 14-10
Choke and Air Intake System ........................................................................................................... 14-11
Choke Cable Removal .................................................................................................................. 14-11
Choke Cable Installation ............................................................................................................... 14-11
Air Box Removal ........................................................................................................................... 14-11
Air Box Installation ........................................................................................................................ 14-11
Intake Duct Repair ........................................................................................................................ 14-12
Intake Duct Removal .................................................................................................................... 14-12
Intake Duct Installation ................................................................................................................. 14-14
Air Filter ........................................................................................................................................ 14-15
Fuel Filter Removal ....................................................................................................................... 14-16
Fuel Filter Installation .................................................................................................................... 14-16
Fuel Pump ........................................................................................................................................ 14-16
General Information ...................................................................................................................... 14-16
Fuel Pump Removal ..................................................................................................................... 14-19
Fuel Pump Disassembly ............................................................................................................... 14-19
Fuel Pump Cleaning and Inspection ............................................................................................. 14-19
Fuel Pump Assembly .................................................................................................................... 14-20
Fuel Pump Installation .................................................................................................................. 14-20
Fuel Tank .......................................................................................................................................... 14-21
Fuel Tank Removal ....................................................................................................................... 14-21
Fuel Tank Storage or Disposal ..................................................................................................... 14-25
Fuel Tank Installation .................................................................................................................... 14-25
Page x 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Fuel Lines ......................................................................................................................................... 14-26
Fuel Shut-Off Valve .......................................................................................................................... 14-27
SECTION 15 – EXHAUST SYSTEM
Muffler .............................................................................................................................................. 15-1
Muffler Removal ........................................................................................................................... 15-1
Muffler Installation ........................................................................................................................ 15-1
SECTION 16 – MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
General Information ......................................................................................................................... 16-1
Lubrication .................................................................................................................................... 16-2
Axle Shaft ......................................................................................................................................... 16-3
Axle Shaft, Bearing, and Oil Seal Removal .................................................................................. 16-3
Axle Bearing Removal .................................................................................................................. 16-5
Axle Shaft, Bearing, and Oil Seal Installation ............................................................................... 16-5
Unitized Transaxle Removal ............................................................................................................ 16-6
Unitized Transaxle Installation ......................................................................................................... 16-16
Forward/Reverse Shifter Cable ........................................................................................................ 16-24
Forward/Reverse Shifter Cable Removal ..................................................................................... 16-24
Forward/Reverse Shifter Cable Installation .................................................................................. 16-24
Forward/Reverse Shifter Cable Adjustment ................................................................................. 16-25
Differential Lock System .................................................................................................................. 16-26
Differential Lock System Inspection ............................................................................................. 16-26
Differential Lock Cable Removal .................................................................................................. 16-26
Differential Lock Cable Installation ............................................................................................... 16-27
SECTION 17 – TORQUE CONVERTER
General Information ......................................................................................................................... 17-1
Drive Belt .......................................................................................................................................... 17-3
Drive Belt Removal ...................................................................................................................... 17-3
Drive Belt Installation ................................................................................................................... 17-4
Drive Clutch ...................................................................................................................................... 17-4
Drive Clutch Removal .................................................................................................................. 17-4
Drive Clutch Cleaning and Inspection .......................................................................................... 17-5
Drive Clutch Disassembly ............................................................................................................ 17-6
Inspection of Drive Clutch Parts ................................................................................................... 17-7
Drive Clutch Assembly ................................................................................................................. 17-9
Drive Clutch Installation ............................................................................................................... 17-12
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page xi
Driven Clutch .................................................................................................................................... 17-13
Driven Clutch Removal ................................................................................................................. 17-13
Driven Clutch Disassembly ........................................................................................................... 17-13
Driven Clutch Inspection ............................................................................................................... 17-13
Driven Clutch Assembly ................................................................................................................ 17-15
Driven Clutch Installation .............................................................................................................. 17-17
SECTION i – INDEX
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 1-1
1
SECTION 1 – SAFETY
To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from damage resulting
from improper service or maintenance, the procedures in this manual must be followed. It is important to note
that throughout this manual there are statements contained within headings labeled DANGER, WARNING,
CAUTION, or NOTE.These special statements relate to specific safety issues, and must be read, understood,
and heeded before proceeding.
∆
DANGER
•ADANGER indicates an immediate hazard that will result in severe personal injury or death.
∆
WARNING
•AWARNING indicates an immediate hazard that could result in severe personal injury or
death.
∆
CAUTION
•ACAUTION indicates a hazard or unsafe practice that could result in product or property
damage or minor personal injury.
CAUTION
•ACAUTION without the safety alert symbol indicates a potentially hazardous situation that
could result in property damage.
GENERAL WARNING
The following safety procedures must be followed whenever the vehicle is being operated, repaired, or ser-
viced. Service technicians should become familiar with these general statements, which can be found
throughout this manual. Also, other specific warnings appear throughout this manual and on the vehicle.
∆
DANGER
•Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area.Ventilate when charging or operating vehicle in an enclosed area.Wear a full face
shield and rubber gloves when working on or near batteries.
•Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or
clothing. Antidotes:
- External: Flush with water. Call a physician immediately.
-Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
-Eyes: Flush with water for 15 minutes. Call a physician immediately.
•Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the
vehicle and service area. Service only in a well-ventilated area.
•Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine
produces carbon monoxide, which is an odorless, deadly poison.
SAFETY General Warning
Page 1-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
1
∆
WARNING
•Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and
CAUTION statements in this manual as well as those on the vehicle.
•Only trained technicians should service or repair the vehicle. Anyone doing even simple
repairs or service should have knowledge and experience in electrical and mechanical repair.
The appropriate instructions must be used when performing maintenance, service, or
accessory installation.
•Prior to servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF,
remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Chock the
wheels when servicing the vehicle.
•To avoid unintentionally starting the vehicle:
- Disconnect battery cables, negative (–) cable first (Figure 1-1, Page 1-3).
- Disconnect the spark plug wire from the spark plug.
•Frame ground – Do not allow tools or other metal objects to contact frame when
disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch
the vehicle frame, engine, or any other metal component.
•Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face
shield and rubber gloves when working on or near batteries.
•Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the
vehicle.
•Moving parts! Do not attempt to service the vehicle while it is running.
•Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning
could result in severe burns.
•Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
•Check the vehicle owner’s manual for proper location of all vehicle safety and operation
decals and make sure they are in place and are easy to read.
•Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
•Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic
floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold
vehicle in raised position. Use approved jack stands of proper weight capacity to support the
vehicle and chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
•If wires are removed or replaced, make sure wiring and wire harness are properly routed and
secured. Failure to properly route and secure wiring could result in vehicle malfunction,
property damage, personal injury, or death.
•For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle.
If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is
raised. Do not close bed until all persons are clear of cargo bed area. Keep hands clear of all
crush areas. Do not drop cargo bed; lower gently and keep entire body clear. Failure to heed
this warning could result in severe personal injury or death.
•Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance, severe personal injury, or death.
• Do not leave children unattended on vehicle.
SAFETY General Warning
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 1-3
1
Figure 1-1 Battery
FRONT
OF VEHICLE
AS SEEN FROM
PASSENGER SIDE
OF VEHICLE
REMOVE
NEGATIVE
CABLE FIRST
DISCONNECT BATTERY CABLES
BEFORE WORKING ON VEHICLE
1
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 2-1
2
SECTION 2 – VEHICLE SPECIFICATIONS
SPECIFICATIONS
PIONEER 1200 PIONEER 1200 SE
POWER SOURCE
Engine:
4-cycle OHV, 400 cc, 13 hp rated, single-cylinder, air-cooled, with pressure lubrica-
tion system ••
Fuel system:
Side-draft carburetor with float bowl, fixed jets, fuel filters, and impulse fuel
pump ••
Governor:
Automatic ground-speed sensing, internally-geared in unitized transaxle • •
Ignition:
Transistor electronic ignition with electronic RPM limiter • •
Unitized transaxle, MC012C-AS00:
Fully synchronized forward and reverse with neutral
(14.9:1 forward, 20.5:1 reverse) and differential lock feature ••
Electrical system:
12 volt, 500 cca at 0 °F (-17.8 °C), 650 at 32 °F (0 °C). 105-minute
reserve capacity and 35-amp charging capacity ••
Torque converter:
Automatic, variable-speed, dry type • •
STEERING/SUSPENSION/BRAKES
Steering:
Self-adjusting rack and pinion, Ackerman • •
Suspension:
Front:
Independent A-arms with coil-over shocks
Rear:
Semi-independent suspension with multi-leaf springs and dual hydraulic shocks ••
Brakes:
Hydraulic brake system – self-adjusting drum brakes on each wheel with separate
hand-operated park brake ••
BODY/CHASSIS
Frame/Chassis:
Twin I-Beam welded aluminum • •
Side and rear body:
All aluminum with a powder-coated steel cargo bed •
Side and rear body:
All aluminum with an aluminum cargo bed •
Front body:
ABS/DR acrylic cap ••
Tires:
23 x 10.50 - 12 tubeless, 4-ply rated load range, front and rear • •
DIMENSIONS/WEIGHT
Overall length
(with box bed) 123.4 in. (313.4 cm) 144.4 in. (366.8 cm)
Overall width
54 in. (137 cm)
Overall height
(at steering wheel) 51 in. (130 cm)
Overall height
(at light bar) 75.3 in. (191 cm)
Wheelbase
80 in. (203 cm) 101 in. (256 cm)
Ground clearance
:
under differential
under foot platform 6.6 in (17 cm)
11.4 in (29 cm)
Front wheel tread
43 in. (109 cm)
Rear wheel tread, MC012C-AS00 transaxle
44.5 in. (113 cm)
Weight
(dry):
with all-terrain tread
with turf tread 1106 lb. (501.7 kg)
1066 lb. (477.2 kg) 1200 lb. (544.2 kg)
1160 lb. (526.0 kg)
Forward speed
17-19 mph (27-31 km/h)
Governed RPM
3850 (±30) RPM
Curb clearance circle
(diameter) 24 ft. 1 in. (734 cm) 31 ft. 8 in. (965 cm)
Turning radius
(per SAE J 695) 139.6 in. (355 cm) 15 ft. 6 in. (472.4 cm)
Intersecting aisle clearance
112.2 in. (285 cm) 120 in. (304 cm)
Specifications continued on next page...
VEHICLE SPECIFICATIONS
Page 2-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
2
Floorboard height
17 in. (43 cm)
Seat height
(at seat bottom) 35 in. (89 cm)
Load bed height
31.1 in. (79 cm)
Load bed size
(box bed inside dimensions) 48.0 x 49.8 x 10.9 in.
(121.9 x 126.4 x 27.6 cm)
(15.3 cubic feet)
37.6 x 45.1 x 9.3 in.
(96 x 115 x 23 cm)
(9.13 cubic feet)
Load bed size
(flat bed dimensions) 46.9 x 48.3 in.
(119 x 123 cm) 35.8 x 44.3 in.
(91 x 112 cm)
Vehicle rated capacity
(level surface only) 1200 lb. (544 kg) 1300 lb. (590 kg)
Bed load capacity
(level surface only) 800 lb. (363 kg) 500 lb. (227 kg)
Standard seating capacity
24
LIQUID CAPACITIES
Engine crankcase without filter
32 oz. (.95 liters)
Engine crankcase with filter
38 oz. (1.12 liters)
Unitized transaxle, MC012C-AS00
29 oz. (.85 liters)
Master cylinder
8 oz. (240 ml)
Fuel tank
(unleaded gasoline only) 7 gallons (26.5 liters) 6.5 gallons (24.6 liters)
TIRE PRESSURE
All terrain tread (standard)
Front: 7-11 psi
(.48-.76 Bars)
Rear: 14-18 psi
(.97-1.24 Bars)
Front: 7-11 psi
(.48-.76 Bars)
Rear: 14-18 psi
(.97-1.24 Bars)
Turf tread (optional)
Front: 12-16 psi
(.83-1.10 Bars)
Rear: 16-20 psi
(1.10-1.38 Bars)
Front: 12-16 psi
(.83-1.10 Bars)
Rear: 16-20 psi
(1.10-1.38 Bars)
Traks Max II tread (optional)
Front: 14-16 psi
(.97-1.10 Bars)
Rear: 18-20 psi
(1.24-1.38 Bars)
Front: 14-16 psi
(.97-1.10 Bars)
Rear: 18-20 psi
(1.24-1.38 Bars)
SPECIFICATIONS
PIONEER 1200 PIONEER 1200 SE
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