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Club Car Pioneer 900 Owner's Manual

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2004 OWNER'S MANUAL
Pioneer 900

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Summary of Contents for Club Car Pioneer 900

  • Page 1 2004 OWNER'S MANUAL Pioneer 900...
  • Page 3 • Magneto or electronic ignition system system is used to eliminate blow-by gases. The System Warranty requires that you return your engine to an authorized Club Car Dealer for blow-by gases are led to the breather chamber • Fuel filter element through the crankcase.
  • Page 4 Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
  • Page 5 We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehi- cle, please include the manual so that the next owner will have the important operating, safety, and mainte- nance information it contains.
  • Page 6 Page 4 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 7: Table Of Contents

    Limited Two Year Warranty for 2004 Pioneer Vehicles ....... 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 8: Vehicle Feature Identification

    When driving on uneven terrain or down steep hills, • and warnings on dash. Maximum trailer hitch tongue weight - 150 lbs. reduce speed and load. • CCI 102006701 Page 6 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...
  • Page 9 Do not contact positive (+) battery post or cable to frame. Can cause severe injury or death. Disconnect negative battery lead first. Do not tamper with engine governor adjustment. CCI 101915201 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 7...
  • Page 10 Safety signs like you see above may at first seem shocking, but their impact is mild compared with the reality of severe personal injury. Your safety and satisfaction are of the utmost importance to Club Car. That is why before operating the vehicle, we urge you to review the information in this manual.

  • Page 11: Safety Details

    • A CAUTION without the safety alert symbol indicates a situation that potentially could result in property damage. AS SEEN FROM PASSENGER SIDE OF VEHICLE Remove negative cable first. DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE Figure 1 Battery Cable Removal 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 9...

  • Page 12: General Warnings

    • A Club Car vehicle will not provide protection from lightning, flying objects, or other storm- related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.

  • Page 13: General Information

    • Do not tamper with the governor. Doing so will void the warranty, as well as damage the engine and other components, and could result in property damage, personal injury, or death due to unsafe speeds. WARNING CONTINUED ON NEXT PAGE... 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 11...
  • Page 14 Failure to heed this caution could result in damage to the unitized transaxle. NOTE: The key can be removed only when the key switch is in the OFF position. Figure 3 Key Switch Page 12 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...
  • Page 15 When the accelerator pedal is released, it will return to the original position and the engine will idle. See WARNING and CAUTION on page 12. Figure 6 Brake Pedal Figure 7 Park Brake Pedal 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 13...
  • Page 16 See follow- ing CAUTION. CAUTION • Failure to add oil immediately when the low oil warning light stays on may result in permanent engine damage. Page 14 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 17: Pre-Operation And Daily Safety Checklist

    FUEL GAUGE/HOUR METER The Pioneer 900 is equipped with a fuel gauge/hour meter, located on the dash panel (Figure 9) . The fuel gauge allows the operator to monitor the fuel level in the vehicle. The hour gauge should be used by the trained technician in order to track vehicle usage and determine when periodic service procedures are required.
  • Page 18 • General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle’s ride and perfor- mance. Have a Pioneer distributor/dealer or a trained technician investigate anything unusual. Page 16 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 19: Driving Instructions

    To ensure safe operation of the vehicle, follow exactly and in order, all of the following procedures. Read and understand all instructions prior to driving the vehicle. 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 17...
  • Page 20 • When stopped on a hill, use the brake pedal to hold your position. Do not use the accelerator pedal. To stop the vehicle, release the accelerator pedal and press the brake pedal until the vehicle comes to a com- plete stop. Page 18 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 21: Bed Latch

    (Figure 11). When pulling the bed latch handle and lifting the bed, the prop rod will come to rest in one of the notches in the prop rod track. See following DANGER and WARNING. 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 19...

  • Page 22: Loading And Unloading

    • Avoid stopping on a hill when loaded. If you must stop on a hill, avoid sudden starts, or rolling backwards and stopping suddenly. Failure to heed this warning may cause vehicle to overturn, possibly resulting in severe personal injury. Page 20 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 23: Towing With The Vehicle

    • Reduce normal driving speed when transporting a vehicle or trailer. • For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. WARNING CONTINUED ON NEXT PAGE... 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 21...

  • Page 24: Storage

    • Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery. Frozen batteries can explode. ∆ CAUTION • Batteries in a low state of charge will freeze at low temperatures. Page 22 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...
  • Page 25 6. To protect the engine, remove the spark plug and pour 1/2 ounce (14.2 mL) of SAE 10 weight oil into engine through the spark plug hole. Rotate engine crankshaft by hand several times and then install spark plug. 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 23...
  • Page 26 PARTIALLY CLOSED POSITION POSITION VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE Figure 13 Fuel Shut-off Valve – Open Position Figure 14 Incorrect Fuel Shut-off Valve Setting Page 24 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 27: Maintenance

    See General Warnings on page 10. ∆ WARNING • Service, repairs, and adjustments must be made per instructions in the Pioneer 900 Maintenance and Service Manual. NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, the preventive maintenance procedures should be performed more often than recommended in the periodic ser- vice and lubrication schedules.
  • Page 28 • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death. Page 26 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 29: Periodic Lubrication Schedule

    200 hours of Change engine oil and oil filter (1.12 liters) with filter. See Oil Viscosity operation or annually, on page 28. whichever comes first. FLOORBOARD Figure 15 Lubrication Points 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 27...

  • Page 30: Engine Oil

    Choose the viscosity according to the temperature as indicated by the oil viscosity chart (Figure 17). See fol- lowing NOTE. NOTE: Using multi-grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. Check oil level more frequently when using them. Page 28 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 31: Fueling Instructions

    See preceding DANGER, CAUTION, and NOTE. 3. Replace fuel cap on tank. Make sure cap is tightened securely. 4. Replace seat bottom. VENT FUEL SHUT-OFF VALVE FUEL TANK TO CARBURETOR VENT TUBES Figure 18 Fuel Tank 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 29...

  • Page 32: Battery

    WARNING • Do not jump-start a dead battery using another battery and jumper cables. The battery in a Club Car vehicle is a 12-volt, low-maintenance battery that requires infrequent checks (Figure 19). Electrolyte level should be checked semiannually. 1. Turn the key switch to the OFF position and remove the key. Place the Forward/Reverse handle in the NEUTRAL position.

  • Page 33: Cleaning The Vehicle

    fine grade (No. 00) steel wool. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.

  • Page 34: Accessories

    In the event a vehicle is bought as a used vehicle from another individual or from a dealer, we strongly urge the new owner to register the vehicle with Club Car. This will enable us to contact you if the need arises.

  • Page 35: Vehicle Specifications

    48.0 x 49.8 x 10.9 in. Load bed size (box bed inside dimensions) (121.9 x 126 x 28 cm) (15.3 cubic feet) Floorboard height 16.0 in. (40 cm) Specifications continued on next page... 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 33...
  • Page 36 Engine crankcase with filter 38 oz. (1.12 liters) Unitized transaxle 27 oz. (.8 liters) Fuel tank 7 gallons (26.5 liters) TIRE PRESSURE Off-road tread 14-18 psi (.97-1.24 Bars) Turf tread 18-20 psi (1.24-1.38 Bars) Page 34 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 37: Rear Fender Installation

    3. Position a fender in the vehicle, align the hole in the fender with the slot in the frame as shown and install bolt (1), large flat washers (2), and locknut (3) (Figure 21). Finger-tighten only at this time. DRIVER SIDE SHOWN HOLES TO BE DRILLED Figure 21 Install Hardware in Fender Hole 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual Page 35...
  • Page 38 FRONT MOUNTING BRACKET Before drilling holes, move fender as far forward as possible. Do not allow any gap DRIVER SIDE SHOWN between fender and side panel. Figure 22 Drill Additional Mounting Holes Page 36 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...

  • Page 39: Wheel And Tire Installation

    Pioneer 900 wheel and tire assemblies. Unlike some other vehicles, the Pioneer 900’s front and rear wheels are NOT interchangeable. The rear wheels have a different offset than do the front wheels; the rear wheels must be installed with the deeper off- set facing out.

  • Page 40: Club Car ® Limited Two Year Warranty For 2004 Pioneer Vehicles

    Also excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including unreasonable or unintended strain or use, improper installation of accessories, installation of parts or accessories that are not original equipment, overloading, accident, alteration, abuse or neglect.
  • Page 41 6. DISCLAIMER: THIS LIMITED WARRANTY IS EXCLUSIVE. CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY.
  • Page 42 2. Ease of Finding Information 3. Clarity of Illustrations 4. Periodic Service and Periodic Lubrication Schedules Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2004 Pioneer 900 Gasoline Vehicle Owner’s Manual...
  • Page 44 Manual No. 102397408 Edition Code 0803A00000 Club Car, Inc. www.clubcar.com Phone 1.706.863.3000 P.O. Box 204658 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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