Club Car Pioneer 1200 Utility Vehicles Manuals

Manuals and User Guides for Club Car Pioneer 1200 Utility Vehicles. We have 1 Club Car Pioneer 1200 Utility Vehicles manual available for free PDF download: Maintenance Service Manual

Club Car Pioneer 1200 Maintenance Service Manual (360 pages)

Performance Utility Vehicle

Brand: Club Car | Category: Utility Vehicle | Size: 14.88 MB

Table of Contents
5
Section 1 - Safety

17
- General Warning
  17
Section 2 - Vehicle Specifications

19
- General Information
  19
  - Specifications
    19
Section 3 - General Information

21
- Serial Number Identification
  21
- Storage - Gasoline Vehicle
  21
  - Preparing the Vehicle for Extended Storage
    21
  - Returning the Stored Vehicle to Service
    22
Section 4 - Body and Trim

25
- Cleaning the Vehicle
  25
- Front Body Repair
  26
- Brush Guard
  26
  - Brush Guard Removal
    26
  - Brush Guard Installation
    26
- Front Body Components
  27
  - Dashboard Removal
    27
  - Dashboard Installation
    27
  - Front Body Removal
    27
  - Front Fender Removal
    29
  - Front Fender Installation
    29
  - Front Body Installation
    29
- Seat
  29
  - Seat Removal
    29
  - Seat Installation
    30
- Seat Support
  30
  - Seat Support Removal
    30
  - Seat Support Installation
    30
  - Armrest Removal
    31
  - Armrest Installation
    32
- Tilt Bed
  32
  - Tilt Bed Removal
    32
  - Tilt Bed Installation
    32
  - Bed Stop Bumper Adjustment
    32
- Rear Fender
  34
  - Rear Fender Removal
    34
  - Rear Fender Installation
    34
- Tailskirt
  34
  - Tailskirt Removal
    34
  - Tailskirt Installation
    34
- Receiver Hitch
  34
  - Receiver Hitch Removal
    34
  - Receiver Hitch Installation
    36
- Floor Mat
  36
  - Floor Mat Removal
    36
  - Floor Mat Installation
    36
Section 5 - Accelerator and Brake Pedal Assemblies

37
- Brake Pedal Adjustment
  37
- Accelerator Pedal Adjustment
  39
- Brake Pedal
  43
  - Brake Pedal Removal
    43
  - Brake Pedal Installation
    44
- Accelerator Pedal
  44
  - Accelerator Pedal Removal
    44
  - Accelerator Pedal Installation
    45
Section 6 - Hydraulic and Park Brake Systems

47
- General Information
  47
- Brake System Inspection
  48
- Brake System Troubleshooting
  50
- Brake Drum Removal
  53
  - Front Wheel Brake Drum Removal
    53
  - Rear Wheel Brake Drum Removal
    54
- Brake Shoe Removal
  55
- Brake Cluster Assembly Inspection and Cleaning
  56
- Brake Shoe Installation
  58
- Brake Drum Installation
  60
  - Front Wheel Brake Drum Installation
    60
  - Rear Wheel Brake Drum Installation
    62
- Brake Cluster Replacement
  63
- Wheel Cylinder Replacement
  65
  - Wheel Cylinder Removal
    66
  - Wheel Cylinder Installation
    67
- Brake Shoe Adjuster Replacement
  67
  - Brake Shoe Adjuster Removal
    67
  - Brake Shoe Adjuster Installation
    68
- Hydraulic Line and Hose Replacement
  70
- Master Cylinder and Bell Crank Replacement
  72
  - Bell Crank Removal
    72
  - Bell Crank Installation
    74
  - Master Cylinder Removal
    74
  - Master Cylinder Installation
    74
- Bleeding the Hydraulic Brake System
  75
  - Purging the Hydraulic System
    76
  - Filling the Hydraulic System
    77
- Park Brake System
  77
  - Park Brake Cable Removal
    77
  - Park Brake Cable Installation
    79
  - Park Brake Handle Removal
    79
  - Park Brake Handle Installation
    80
  - Park Brake Adjustment
    80
Section 7 - Steering and Front Suspension

81
- General Information
  81
- Steering Wheel
  81
  - Steering Wheel Removal
    81
  - Steering Wheel Installation
    83
- Steering Column
  84
  - Steering Column Removal
    84
  - Steering Column Disassembly
    84
  - Steering Column Assembly
    85
  - Steering Column Installation
    86
- Rack and Pinion
  86
  - Rack and Pinion Removal
    86
  - Rack and Pinion Disassembly
    88
  - Rack and Pinion Assembly
    90
  - Rack and Pinion Installation
    93
- Front Suspension
  93
  - Lubrication
    93
  - Wheel Alignment
    94
- Front Suspension Components
  96
- Front Wheel Bearings and Hubs
  100
Section 8 - Wheels and Tires

101
- General Information
  101
- Wheels
  102
  - Wheel Removal
    102
  - Wheel Installation
    102
- Tires
  103
  - Tire Removal
    103
  - Tire Repair
    103
  - Tire Installation
    103
Section 9 - Rear Suspension

105
- General Information
  105
- Shock Absorbers
  105
  - Shock Absorber Removal and Inspection
    105
  - Shock Absorber Installation
    107
- Multi-Leaf Springs
  107
  - Multi-Leaf Spring Removal
    107
  - Multi-Leaf Spring Installation
    108
- Snubber
  109
  - Snubber Removal
    109
  - Snubber Installation
    109
Section 10 - Periodic Maintenance

111
- General Information
  112
- Daily Pre-Operation Safety Checklist
  112
- Periodic Service Schedule
  113
- Periodic Lubrication Schedule
  114
- Master Cylinder
  116
  - Brake Fluid
    116
- Engine Oil
  116
  - Oil Viscosity
    117
- Fueling Instructions
  117
- Battery
  118
Section 11 - Troubleshooting and Electrical System

119
- General Information
  120
- Troubleshooting Guide
  120
- Wiring Diagram
  124
- Electrical System
  126
- Electrical Circuits
  127
  - Starter Circuit
    127
  - Generator Circuit
    127
  - Engine Ignition Circuit
    128
  - Engine Kill Circuit
    128
  - Reverse Buzzer Circuit
    129
  - Low Oil Warning Circuit
    130
  - Lockout Cam Circuit
    130
  - Fuel Gauge and Sending Unit Circuit
    131
  - Hour Gauge Circuit
    132
  - Lighting Circuit
    132
- Circuit Testing
  132
- Test Procedures
  138
  - Index of Test Procedures
    138
Section 12 - Electrical Components

163
- Starter/Generator
  164
- Voltage Regulator
  175
- Diode
  176
- Key Switch
  177
- Solenoid
  179
- Fuse
  180
- Lockout Cam Limit Switch
  180
- Lockout Cam
  181
- Reverse Warning Buzzer
  182
- Reverse Buzzer Limit Switch
  183
- Oil Warning Light
  184
- Fuel/Hour Gauge
  185
- Fuel Level Sending Unit
  186
- RPM Limiter
  186
- Ignition Coil
  187
- Oil Level Sensor
  190
- Headlights
  191
- Headlight Diode
  192
- Light Switch
  192
- Battery
  193
- Ground Straps
  198
Section 13 - Fe350 Engine

199
- General Information
  200
  - Special Engine Service Tools Available from Club Car
    200
  - Before Servicing
    200
  - Mechanical Systems
    200
  - Electrical System
    202
  - Lubrication System
    203
  - Hydraulic Lifters
    204
  - Spark Plug
    204
- Engine Mounting Plate
  206
- Cylinder Head
  206
  - General Information
    206
  - Cylinder Shroud Removal
    206
  - Rocker Arm and Push Rod Removal
    208
  - Cylinder Head Removal
    208
  - Valve Removal
    209
  - Breather Valve (Reed Valve)
    210
  - Cylinder Head Cleaning and Inspection
    210
  - Valve Guides
    211
  - Valve Seats
    211
  - Valves
    214
  - Rocker Arm and Rocker Shaft Inspection
    216
  - Push Rod Inspection
    217
  - Cylinder Head Installation
    217
  - Valve Clearance Check and Adjustment
    218
  - Breather Valve (Reed Valve)
    218
  - Installation of Remaining Engine Components
    219
- Crankcase
  221
  - Engine Removal
    221
  - Crankcase Cover Removal
    222
  - Oil Level Sensor
    222
  - Camshaft and Hydraulic Lifters
    223
- Piston and Connecting Rod
  225
- Cylinder Block
  228
- Ignition Coil and Flywheel
  229
- Oil Pump
  230
  - Oil Pressure Relief Valve
    232
- Crankshaft and Counterbalance
  233
  - Counterbalance Weight
    236
  - Oil Screen
    238
  - Ball Bearing
    239
  - Oil Seals
    240
- Crankshaft Axial Play Adjustment
  242
  - Crankcase Cover Installation
    245
- Engine Assembly
  246
- Service Specifications
  248
  - Specifications for Resizing Cylinder Bore
    249
  - Torque Specifications
    249
  - Adjustments and Settings
    250
Section 14 - Fuel System

251
- General Information
  251
- How the Carburetor Works
  252
  - Main System
    252
  - Slow Speed System
    252
  - Choke and Fresh Air System
    254
  - Float System
    254
- Carburetor
  254
  - Main Jet Elevation/Size Chart
    255
  - Changing the Main Jet
    255
- Engine Control Linkage
  258
  - General Information
    258
  - Accelerator Rod
    259
  - Governor Cable
    260
  - Accelerator Cable
    261
  - Closed Throttle or Idle Adjustment
    263
  - Engine RPM Adjustment
    263
- Choke and Air Intake System
  264
  - General Information
    264
  - Choke Cable Removal
    264
  - Choke Cable Installation
    264
  - Air Box Removal
    265
  - Air Box Installation
    265
  - Intake Duct Removal
    265
  - Intake Duct Installation
    266
  - Intake Duct Repair
    268
  - Air Filter
    268
- Fuel Filters
  269
  - General Information
    269
  - Fuel Filter Removal
    269
  - Fuel Filter Installation
    269
- Fuel Pump
  271
  - General Information
    271
  - Fuel Pump Removal
    271
  - Fuel Pump Disassembly
    271
  - Fuel Pump Cleaning and Inspection
    272
  - Fuel Pump Assembly
    272
  - Fuel Pump Installation
    273
- Fuel Tank
  273
  - General Information
    274
  - Preparation for Extended Storage
    274
  - Fuel Tank Removal
    274
  - Fuel Tank Disposal
    275
  - Fuel Tank Storage
    275
  - Fuel Tank Installation
    275
- Fuel Lines
  277
- Fuel Shut-Off Valve
  278
Section 15 - Exhaust System

279
- General Information
  279
- Muffler
  280
  - Muffler Removal
    280
  - Muffler Installation
    280
Section 16 - Unitized Transaxle with Differential Lock

283
- General Information
  283
  - Lubrication
    285
- Axle Shaft
  285
  - Axle Shaft and Oil Seal Removal
    286
  - Axle Bearing
    287
  - Axle Shaft Installation
    289
- Unitized Transaxle Removal
  289
- Unitized Transaxle Disassembly
  297
- Component Disassembly
  301
  - Differential Gear Lock Housing Disassembly
    301
  - Governor Gear Disassembly
    303
  - Differential Gear Case Disassembly
    304
  - Shifter Fork Disassembly
    305
  - Synchronizer Gear Disassembly
    305
  - Intermediate Gear Disassembly
    306
  - Idler Shaft Disassembly
    306
- Unitized Transaxle Component Inspection
  308
- Component Assembly
  308
  - Idler Shaft Assembly
    308
  - Intermediate Gear Assembly
    308
  - Synchronizer Gear Assembly
    308
  - Shifter Fork Assembly
    311
  - Differential Gear Case Assembly
    311
  - Governor Gear Assembly
    313
  - Differential Gear Lock Housing Assembly
    313
- Unitized Transaxle Assembly
  314
- Unitized Transaxle Installation
  321
- Forward/Reverse (F&R) Shifter Cable
  329
  - F&R Shifter Cable Removal
    329
  - F&R Shifter Cable Installation
    329
  - F&R Shifter Cable Adjustment
    330
- Differential Lock System
  331
Section 17 - Torque Converter

335
- General Information
  335
- Troubleshooting
  337
- Drive Belt
  337
  - Drive Belt Removal
    337
  - Drive Belt Installation
    338
- Drive Clutch
  338
  - Drive Clutch Removal
    338
  - Drive Clutch Cleaning and Inspection
    339
  - Drive Clutch Disassembly
    341
  - Inspection of Drive Clutch Parts
    343
  - Drive Clutch Assembly
    343
  - Drive Clutch Installation
    347
- Driven Clutch
  347
  - Driven Clutch Removal
    347
  - Driven Clutch Disassembly
    347
  - Driven Clutch Inspection
    348
  - Driven Clutch Assembly
    348
  - Driven Clutch Installation
    349

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Club Car Pioneer 1200 Utility Vehicles Manuals

Club Car Pioneer 1200 Maintenance Service Manual (360 pages)

Table of Contents

Section 1 - Safety

Section 2 - Vehicle Specifications

Section 3 - General Information

Section 4 - Body and Trim

Section 5 - Accelerator and Brake Pedal Assemblies

Section 6 - Hydraulic and Park Brake Systems

Section 7 - Steering and Front Suspension

Section 8 - Wheels and Tires

Section 9 - Rear Suspension

Section 10 - Periodic Maintenance

Section 11 - Troubleshooting and Electrical System

Section 12 - Electrical Components

Section 13 - Fe350 Engine

Section 14 - Fuel System

Section 15 - Exhaust System

Section 16 - Unitized Transaxle with Differential Lock

Section 17 - Torque Converter

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