Page 3 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.
Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is contin- ually working to further improve our vehicles and other products. These improvements may affect ser- vicing procedures.
Page 5: Table Of Contents
Front Fender Extension Removal ....................Front Fender Extension Installation ....................Tilt Bed .............................. Tilt Bed Removal ........................... Tilt Bed Installation ........................Rear Fender ............................Rear Fender Removal ........................Rear Fender Installation ........................ 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page iii...
Page 6 Front Brake Cable Removal ......................6-11 Front Brake Cable Installation ......................6-12 Rear Brake Cables ..........................6-14 Rear Brake Cable Removal ......................6-14 Rear Brake Cable Installation ......................6-15 Page iv 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 7 Front Wheel Bearings and Hubs ....................... 7-20 Front Wheel Free Play Inspection ....................7-20 Front Wheel Bearings and Hub Removal ..................7-22 Front Wheel Bearings and Hub Installation ................... 7-22 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page v...
Page 8 Oil Viscosity ............................ 10-6 Fueling Instructions ..........................10-7 Battery ..............................10-7 SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM General Information ........................... 11-2 Troubleshooting Guide ........................11-2 Wiring Diagram ..........................11-6 Page vi 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 9 Reverse Buzzer Limit Switch ......................12-21 Oil Warning Light ..........................12-21 Fuel/Hour Gauge ..........................12-22 Fuel Level Sending Unit ........................12-23 RPM Limiter ............................12-24 Ignition Coil ............................12-25 Oil Level Sensor ..........................12-28 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page vii...
Page 10 Crankcase Cover Removal ......................13-24 Oil Level Sensor ..........................13-24 Camshaft and Hydraulic Lifters ...................... 13-25 Piston and Connecting Rod ....................... 13-27 Cylinder Block ............................ 13-30 Ignition Coil and Flywheel ........................13-31 Page viii 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 11 14-8 General Information ........................14-8 Accelerator Rod ..........................14-9 Governor Cable ..........................14-10 Accelerator Cable .......................... 14-11 Closed Throttle or Idle Adjustment ....................14-13 Engine RPM Adjustment ........................ 14-13 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page ix...
Page 12 SECTION 15 – EXHAUST SYSTEM General Information ........................... 15-1 Muffler ..............................15-2 Muffler Removal ..........................15-2 Muffler Installation .......................... 15-2 SECTION 16 – UNITIZED TRANSAXLE General Information ........................... 16-1 Lubrication ............................16-3 Page x 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 13 Drive Clutch Cleaning and Inspection .................... 17-5 Drive Clutch Disassembly ......................17-7 Inspection of Drive Clutch Parts ....................17-9 Drive Clutch Assembly ........................17-9 Drive Clutch Installation ......................... 17-13 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page xi...
Page 14 Driven Clutch Removal ........................17-13 Driven Clutch Disassembly ......................17-13 Driven Clutch Inspection ........................ 17-14 Driven Clutch Assembly ......................... 17-14 Driven Clutch Installation ....................... 17-15 SECTION I – INDEX Page xii 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 15: Section 1 - Safety
SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is impor- tant to note that throughout this manual there are statements labeled DANGER , WARNING , or CAUTION .
Page 16 Use approved jack stands of proper weight capacity to support vehicle. AS SEEN FROM PASSENGER'S SIDE OF VEHICLE REMOVE NEGATIVE DISCONNECT BATTERY CABLES CABLE FIRST BEFORE WORKING ON VEHICLE GASOLINE VEHICLE BATTERY DISCONNECT Figure 1-1 Gasoline Vehicle Page 1-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 17: Section 2 - Vehicle Specifications
SECTION 2 – VEHICLE SPECIFICATIONS GENERAL INFORMATION Club Car, Inc. reserves the right to change speciﬁcations and design of the vehicle at any time without notice and without obligation to make these changes on units previously sold. SPECIFICATIONS POWER SOURCE...
Page 18 27 oz. (.8 liters) Fuel Tank (unleaded gasoline only) 7 gallons (26.5 liters) TIRE PRESSURE Off-road tread tire 14-18 psi (97-124 kPa) Turf tread tire 18-20 psi (124-138 kPa) Page 2-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 19: Section 3 - General Information
• Warranties SERIAL NUMBER IDENTIFICATION The serial number of each Club Car vehicle is printed on a bar code decal mounted on the frame directly above the accelerator pedal (Example: AE0101-123456) (Figure 3-1, Page 3-1). There is also a second serial number decal mounted on the front body frame behind the center dash panel.
Page 20: Returning The Stored Vehicle To Service
9. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling. RETURNING THE STORED VEHICLE TO SERVICE 1. Connect the battery cables, positive cable (+) ﬁrst. 2. Restore fuel system to operation. Page 3-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 21 SIDE OF VALVE Figure 3-2 Closed Fuel Shut-off Valve Figure 3-3 Open Fuel Shut-off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 3-4 Incorrect Fuel Shut-off Valve 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 3-3...
Page 23: Section 4 - Body And Trim
To remove oxidation or discoloration from aluminum, use a commercially available aluminum cleaner paste and ﬁne grade (No. 00) steel wool. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 4-1...
Page 24: Front Body Repair
3. Continue heating and bending the body until the original shape returns. Under no circumstance should the gun be held closer than 6 inches (15 cm) to the body. See preceding CAUTION. Page 4-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 25: Minor Scratches And Surface Blemishes
Tears, Large Scratches, and Abrasions on page 4-3. 3. Using the brush provided with the touch-up paint (touch-up paint – Red, Club Car Part No. 101997206), apply paint to the scratch. Multiple layers of paint may be required to ﬁll the scratch.
Page 26: Brush Guard Installation
3. Tighten screws (19) holding front body trim against front body to 17 in-lb (1.9 N·m) (Figure 4-1, Page 4-5). 4. Reconnect the light wiring harness to the headlight assemblies. 5. Install the brush guard. See Brush Guard Installation on page 4-4. Page 4-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 27: Front Fender Extension
Read WARNING and CAUTION on page 4-1. FRONT FENDER EXTENSION REMOVAL 1. Remove the brush guard. See Brush Guard Removal on page 4-3. 2. Remove the front body. See Front Body Removal on page 4-4. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 4-5...
Page 28: Front Fender Extension Installation
Remove prop rod (17) from bed and place prop rod between prop rod track (18) and rear body panel. Lower bed onto vehicle frame (Figure 4-3, Page 4-7). Page 4-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 29 Tilt Bed TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 4-3 Tilt Bed 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 4-7...
Page 30: Tilt Bed Installation
ﬂat washers (1) from the top of fender (6) (Figure 4-6, Page 4-11). 3. Remove fender (6) from vehicle (Figure 4-6, Page 4-11). REAR FENDER INSTALLATION 1. Unload the cargo bed. 2. Open the cargo bed and engage the prop rod. Page 4-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 31 4. Make sure fender is correctly aligned in the vehicle. 4.1. Make sure outer fender rib is ﬂush with the inside surface of the upper side panel (Figure 4-5, Page 4-10). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 4-9...
Page 32 SIDE PANEL FENDER RIB Before drilling holes, move fender as far forward as possible. Do not allow any gap between fender and side panel. Figure 4-5 Drill Additional Mounting Holes Page 4-10 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 33: Receiver Hitch
2. Where the hitch (7) is mounted to frame, remove two nuts (12), lock washers (11) washers (10) and bolts (9) (Figure 4-6, Page 4-11). TYPICAL 2 PLACES Figure 4-6 Rear Fender, Tailskirt, and Receiver Hitch 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 4-11...
Page 34: Receiver Hitch Installation
FLOOR MAT INSTALLATION 1. Install the ﬂoor mat in the reverse order of removal. 2. Install the brake and accelerator pedals. See Section 5 – Accelerator and Brake Pedal Group. Page 4-12 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 35: Section 5 - Accelerator And Brake Pedal Group
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. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 5-1...
Page 36: Brake Pedal And Park Brake
4. Adjust brake pedal height to 6 inches (15.2 cm) (Figure 5-1, Page 5-2). CORRECT PEDAL POSITION IS 6 INCHES (15.2 CM ) FROM FLOORMAT TO BACK OF BRAKE PEDAL Figure 5-1 Pedal Position Page 5-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 37 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake TYPICAL 2 PLACES Figure 5-2 Brake and Park Brake Pedal Assembly and Mounting – Pioneer 900 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 5-3...
Page 38: Park Brake Removal
(10) (Figure 5-4, Page 5-4). 2. Install the spacer (23) and torsion spring (22) on the park brake pedal shaft on the brake pedal weld- ment (Figure 5-4, Page 5-4). Page 5-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 39: Accelerator Pedal
5. Remove the nut (10), ball stud (8), and pivot support bearing (9) from the accelerator pivot rod assem- bly (6) (Figure 5-18, Page 5-12). 6. Slide the spring retainer (11) off of the accelerator pivot rod. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 5-5...
Page 40: Accelerator Pedal Installation
(it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines accessible). The ratchet may have to be rotated counterclockwise slightly to align the splines. Page 5-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 41: Pedal Group Adjustment
ﬂoorboard. Proper brake pedal height is 6 inches (15.2 cm) (Figure 5-10, Page 5-8). 1.4. Tighten the jam nut (31) to 8 ft-lb (9.5 N·m) (Figure 5-9, Page 5-8) 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 5-7...
Page 42 NOTE: The accelerator rod must also be checked if the ratchet/pawl gap is adjusted. See step 4 of Pedal Group Adjustment on page 5-10. The accelerator rod must be disconnected before proceeding to step 2.3. Page 5-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 43 Reconnect ball joint (Figure 5-14, Page 5-10). 2.7. If the accelerator push rod was disconnected from the accelerator pedal, reconnect it. 2.8. Check for proper brake operation prior to driving the vehicle. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 5-9...
Page 44 • To prevent accidentally starting the vehicle, disconnect the battery as instructed in WARNING on page 5-1. This will prevent the possibility of the vehicle running over you when you are adjusting the accelerator rod. Page 5-10 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 45 3100 (±30) RPM. See Engine RPM Adjustment, Section 14, Page 14-13. 4.7. Install the electrical box cover and screw. 5. Adjust the brakes. See Brake Adjustment, Section 6, Page 6-16. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 5-11...
Page 46 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Figure 5-18 Accelerator Pedal – Pioneer 900 Page 5-12 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 47: Section 6 - Wheel Brake Assemblies
Use approved jack stands of proper weight capacity to support the vehicle. GENERAL INFORMATION The Pioneer 900 vehicle is equipped with four-wheel, manually adjusted brakes. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 6-1...
Page 48: Brake Shoe Removal
4. Loosen the front brake equalizer (Figure 6-2, Page 6-2). Figure 6-1 Loosen Rear Brake Equalizer Nuts Figure 6-2 Loosen Front Brake Equalizer Nuts Figure 6-3 Remove Axle Retaining Ring Page 6-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 49: Brake Assembly Cleaning
After lubricating, work slide back and forth to ensure it slides smoothly and easily (Figure 6- 6, Page 6-4). Reinstall rubber boot onto backing plate. See following WARNING. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 6-3...
Page 50 6. Use a small brush to carefully apply a liberal amount of white lithium NLGI #2 grease (Dow Corning BR2-Plus or equivalent) to the brake actuator assembly as shown (Figure 6-9, Page 6-4). See preced- ing WARNING. Figure 6-8 Grease Shoes Figure 6-9 Grease Actuator Page 6-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 51: Brake Shoe Installation
4. While maintaining spring attachment on both shoes, position the tips of the second shoe into mounting slots and then push shoe into place. Hold shoe in position and install the retaining clip and pin (Figure 6-12, Page 6-6). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 6-5...
Page 52: Brake Cluster Removal And Installation
4.1. Using 90° snap ring pliers, remove the axle retaining ring (1) (Figure 6-3, Page 6-2). 4.2. Pull the axle shaft (2) from the axle tube (Figure 6-3, Page 6-2). Page 6-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 53 WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 6-14 Rear Manually Adjusted Brake Assembly 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 6-7...
Page 54 WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation Figure 6-15 Front Manually Adjusted Brake Assembly Page 6-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 55: Rear Brake Cluster Installation
Loss of vehicle control could result in severe personal injury or death. 4. Adjust brakes. See Brake Adjustment on page 6-16. DETAIL B DETAIL A Figure 6-16 Front Brake Cable Routing 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 6-9...
Page 56: Front Brake Cluster Removal
(20) and hex nuts (19) that mount the brake assembly to the spindle (Figure 6-15, Page 6-8). 9. Remove brake cluster assembly from spindle. TYPICAL 4 PLACES Figure 6-17 Front Spindle Assembly Page 6-10 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 57: Front Brake Cluster Installation
2. Remove cotter pin (2) and clevis pin (3) from brake lever arm on front brake cluster (Figure 6-18, Page 6-11) TYPICAL BOTH SIDES OF VEHICLE Figure 6-18 Front Brake Cables 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 6-11...
Page 58: Front Brake Cable Installation
4. Route cable along I-beam towards front of the vehicle and secure with wire ties as shown (Figure 6-16, Page 6-9). 5. Route brake cables between the shock support (8) and brake cable guide bracket (7) as shown (Figure 6-18, Page 6-11). Page 6-12 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 59 (8), and around the brake cables (10) as shown (Figure 6-20, Page 6-13). See also, Figure 6- 18, Page 6-11. Figure 6-20 Secure Front Brake Cables Use back of shock tower as a reference point Figure 6-21 Align Cables With Tower 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 6-13...
Page 60: Rear Brake Cables
2. Loosen equalizer retaining nuts (1) on equalizer rod (2) to slightly loosen brake cables (3) (Figure 6-23, Page 6-15). 3. Rotate brake cables upward and pull ends through holes in top of equalizer. Page 6-14 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 61: Rear Brake Cable Installation
2. Place the cables in the cable support brackets (5) and secure with new E-clips (3). Connect the cables to the brake actuator arms using new clevis pins (2) and cotter pins (1) (Figure 6-24, Page 6-15). 3. Adjust brakes. See Brake Adjustment on page 6-16. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 6-15...
Page 62: Brake Adjustment
Figure 6-26 Rear Brake Adjustment Bolt 4. Using a torque wrench and a 7 mm 8 point socket or Club Car brake adjustment tool (CCI 1013582), turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft-lb (20.3 N·m) and continue clockwise rotation to the point at which torque is released.
Page 63: Equalizing Brake Cables
• If the brake pedal return spring (6) was disconnected while equalizing the brake cables, be sure to reconnect it before proceeding (Figure 6-29, Page 6-17). Figure 6-28 Adjust Front Equalizer Figure 6-29 Adjust Rear Equalizer 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 6-17...
Page 64: Final Brake Cluster Adjustment
See Equalizing Brake Cables on page 6-17. See also Final Brake Cluster Adjustment on page 6-18. Brake adjustment must be maintained so the brake pedal cannot be depressed to the ﬂoor under any circumstance. Page 6-18 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 65: Section 7 - Steering And Front Suspension
3. Match mark the steering wheel (25) and steering column shaft (19) so when the steering wheel is removed it can be placed back in exactly the same position on steering column shaft (Figure 7-4, Page 7-5). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-1...
Page 66: Steering Wheel Installation
2. Install the steering wheel nut (27) and tighten to 13 ft-lb (17.6 N·m). 3. Install the steering wheel plate (28) and plate mounting screws (30) (Figure 7-4, Page 7-5). Tighten screws to 16 in-lb (1.8 N·m). Page 7-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 67: Steering Column
4.5. Disconnect the wires from the electrical components mounted on the dash panel. Do not allow wires to touch. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-3...
Page 68: Steering Column Disassembly
1-3/16 inches (3.3 cm) and a minimum inside diameter of 7/8 inch (2.2 cm). Be sure the bearing is installed in the bearing seat as shown (Figure 7-5, Page 7-6) so the wedge (16) will ride against the inner race of the bearing. Page 7-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 69 3. Install the wedge (16), spring (15), washer (14), and snap ring (13) onto the bottom end of the steering shaft (19) (Figure 7-5, Page 7-6). 4. Insert the shaft (19) from the bottom of the steering tube (20) (Figure 7-4, Page 7-5). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-5...
Page 70: Steering Column Installation
(8) washers (7) and nuts (9) (Figure 7-4, Page 7-5). Thread the nuts onto the bolts but do not tighten them. 4. Reinstall washer (11) and screw (10). Tighten to 20 ft-lb (27 N·m) (Figure 7-4, Page 7-5). Page 7-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 71: Steering Adjustment
(20) (Figure 7-22, Page 7-21), and rack assembly (17) (Figure 7-12, Page 7-11). Also inspect front suspension assemblies; e.g., A-plates (1), urethane bushings (2) (Figure 7-21, Page 7- 19) and leaf springs (6) (Figure 7-22, Page 7-21). Replace components as necessary. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-7...
Page 72: Rack And Pinion
1. Remove ball joint and inspect it for excessive wear (Figure 7-8, Page 7-8). 2. Remove the drag link (28) (Figure 7-12, Page 7-11). 3. Remove both bellows clamps (2) (plastic wire ties) (Figure 7-12, Page 7-11). Page 7-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 73 Figure 7-9 Remove Pinion from Housing Figure 7-10 Remove Bearing from Pinion INNER BALL TAB WASHER JOINT Secure rack using wood blocks and a vise. Figure 7-11 Secure Rack in Vise 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-9...
Page 74: Rack And Pinion Assembly
See following CAUTION. ∆ CAUTION • Do not force the pinion-bearing assembly into the housing. The gear teeth or the small bearing could be damaged. Page 7-10 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 75 8. Using a socket to apply pressure evenly, press in a new dust seal (Figure 7-13, Page 7-12). 9. Apply a small amount of grease to the rack guide (13) where it comes into contact with the rack (17) (Figure 7-12, Page 7-11). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-11...
Page 76 11.4. If measured resistance does not equal 7 to 15 in-lb, loosen the lock nut (15) and tighten the screw (16) until it bottoms out, then back the screw off one quarter turn. Tighten the lock nut to 28 ft-lb (38 N·m) (Figure 7-14, Page 7-12). Page 7-12 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 77: Rack And Pinion Installation
7-21, Page 7-19) and loosen jam nuts (27 and 29) on the drag link (Figure 7-12, Page 7-11). 2. Remove the cotter pins (22) and ball joint retaining nuts (25 or 20) (Figure 7-12, Page 7-11 or Figure 7-21, Page 7-19). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-13...
Page 78: Tie Rod And Drag Link Installation
Five grease ﬁttings are provided (one in each spindle housing, one in the ball joint on each end of the tie rod, and one in the ball joint of the steering drag link). Lubricate these ﬁttings semi-annually with the proper lubri- cant. See Periodic Lubrication Schedule, Section 10, Page 10-4. Page 7-14 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 79: Wheel Alignment
5. Subtract the measurement on the front of the tires from the measurement on the rear of the tires. The difference is the toe-in. Proper toe-in is 1/8 to 3/8 of an inch (3.2 to 9.5 mm). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-15...
Page 80 There should be equal travel to the left and right. See following NOTE. NOTE: If the minimum turning radius is not the same for both left and right turns, adjust the steering (see Page 7-7). Page 7-16 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 81: Front Suspension Components
4. Remove the nut (17) and lock washer (18) from the top of the kingpin (26) (Figure 7-22, Page 7-21). 5. Raise the upper clevis (16) from the kingpin (Figure 7-22, Page 7-21). 6. Remove the thrust washer (19) (Figure 7-22, Page 7-21). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-17...
Page 82: Kingpin And Steering Spindle Installation
7. Connect the front brake cables in reverse order of disassembly (Figure 7-20, Page 7-18). 8. Install front hub and wheel. See Front Wheel Bearings and Hub Installation on page 7-22. Page 7-18 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 83 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 7-21 Four-Wheel Brake Vehicle – Upper Portion 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-19...
Page 84: Delta A-Plate Removal
(1) and cotter pin (2) and then tighten the spindle nut (3) until the bearing (5) fully seats in the bearing race (7) (Figure 7-23, Page 7-22). Page 7-20 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 85 STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs TYPICAL 4 PLACES DRIVER SIDE ONLY PASSENGER SIDE ONLY TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-22 Four-Wheel Brake – Lower Portion 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-21...
Page 86: Front Wheel Bearings And Hub Removal
Make sure the grease is forced between the rollers (Figure 7-23, Page 7-22). 2. If bearing cups (7) were removed, press new ones in squarely against stops in the hub (Figure 7-23, Page 7-22). Page 7-22 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 87 9. Install the wheels and then ﬁnger tighten the lug nuts. 10. Lower the vehicle and ﬁnish tightening lug nuts (using a crisscross pattern) to 55 ft-lb (74.6 N·m). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 7-23...
Page 89: Section 8 - Wheels And Tires
Off-road tread tire 14-18 psi (97-124 kPa) Turf tread tire 18-20 psi (124-138 kPa) • Keep lug nuts properly tightened. • Keep the front end properly aligned and adjusted. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 8-1...
Page 90: Wheels
3. Remove the lug nuts and remove the wheel. WHEEL INSTALLATION 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 91: Tire Repair
2. Adjust air pressure in the tire to the recommended pressure and immerse the wheel and tire assembly in water to make sure there are no leaks. 3. Install the wheel. See Wheel Installation on page 8-2. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 8-3...
Page 93: Section 9 - Rear Suspension
GENERAL INFORMATION The rear suspension and powertrain of the Pioneer 900 vehicle move independently from the vehicle frame. The suspension includes two multi-leaf springs controlled by two hydraulic shock absorbers mounted between the spring mounting plate and the frame. The engine is mounted on an engine mounting plate that moves with the suspension.
Page 94: Shock Absorbers
3. On the lower shock absorber mount, install mounting hardware. Tighten the nut (5) until the rubber bushing (10) expands to the same diameter as the cup washer (Figure 9-1, Page 9-2). Page 9-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 95: Multi-Leaf Springs
(Figure 9-4, Page 9-4). Remove spring from vehicle. 11. Inspect the rubber bushings (4) and steel sleeves (3) in the spring eyes and replace them if they are worn or damaged (Figure 9-4, Page 9-4). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 9-3...
Page 96 REAR SUSPENSION Multi-Leaf Springs TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE TYPICAL 2 PLACES Figure 9-4 Rear Suspension Page 9-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 97: Multi-Leaf Spring Installation
3. Slide snubber and bracket assembly toward battery to remove it from vehicle. SNUBBER INSTALLATION 1. Install in the reverse order of removal. 2. Tighten snubber bracket mounting nuts (1) to 13 ft-lb (17.6 N·m) (Figure 9-5, Page 9-6). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 9-5...
Page 98: Stabilizer Bar
5. Place lock washer (7), ﬂat washer (4), spacer (2), and compression mount (3) onto bolt (6). Install bolt through mounting hole in stabilizer bar and place another compression mount (3) and ﬂat washer (4) onto bolt (Figure 9-6, Page 9-7). Page 9-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 99 8. Tighten bolts (6) in the stabilizer bar links (5) to 17 ft-lb (23 N·m). 9. Place jack under transaxle and raise vehicle enough to remove jack stands. Lower the vehicle to the ground. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 9-7...
Page 101: Section 10 - Periodic Maintenance
- Disconnect battery cables, negative cable (–) ﬁrst (Figure 10-1, Page 10-2). - Disconnect the spark plug wire from the spark plug. - Turn fuel shut-off valve to closed (OFF) (Figure 10-5, Page 10-7). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 10-1...
Page 102: General Information
Inspect and drive the vehicle, using the Pre-Operation Checklist and Performance Inspection in the Pioneer Owner’s Manual as a guide to check the following items. • Vehicle warning decals • Brake system • Park brake Page 10-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 103: Periodic Service Schedule
Front wheel alignment and toe-in See Section 7 – Steering and Front Suspension. Electrical wiring and connections Check for tightness and damage. Periodic Service Schedule continued on next page... 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 10-3...
Page 104: Periodic Lubrication Schedule
RECOMMENDED LUBRICANT PLACE Semiannually by owner or trained technician Brake pedal shaft bearings Dry Moly Lube (CCI 1012151) (every 50 hours of operation) Periodic Lubrication Schedule continued on next page... Page 10-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 105 Change engine oil and oil ﬁlter liters) with ﬁlter operation or annually, See Oil Viscosity on page 10-6. whichever comes ﬁrst) *(Figure 10-2, Page 10-5). FLOORBOARD Figure 10-2 Lubrication Points 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 10-5...
Page 106: Engine Oil
-4°F 14°F 68°F Figure 10-4 Oil Viscosity Chart NOTE: Using multi-grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. Check oil level more frequently when using multi-grade oils. Page 10-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 107: Fueling Instructions
4. Replace seat bottom. FUEL VENT SHUT-OFF VALVE GAS TANK TO CARBURETOR VENT TUBES Figure 10-5 Fuel Tank BATTERY For periodic battery maintenance, see Battery, Section 12, Page 12-31. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 10-7...
Page 109: Section 11 - Troubleshooting And Electrical System
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. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-1...
Page 110 Section 14 – Fuel System Fouled spark plug Section 13 – FE350 Engine Spark plug wire damaged or loose Section 13 – FE350 Engine Troubleshooting Guide continued on next page... Page 11-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 111 Unsuitable fuel, or incorrect (rich) fuel Section 14 – Fuel System mixture Section 11 – Troubleshooting and Electrical Ignition coil failed System Test Procedures 14, 15, and 16 Troubleshooting Guide continued on next page... 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-3...
Page 112 Generator ﬁeld coil is shorted System Test Procedure 11 Section 12 – Electrical Components Brushes are worn or commutator is dirty Starter/Generator on page 12-2 Troubleshooting Guide continued on next page... Page 11-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 113 Test Procedures 4 and 17 Carburetor is too lean; check main and Section 14 – Fuel System pilot jet sizes Carburetor throttle stop screw out of Section 14 – Fuel System adjustment 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-5...
Page 114 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagram WIRING DIAGRAM PASSENGER SIDE HEADLIGHT DRIVER SIDE HEADLIGHT LIGHT SWITCH Figure 11-1 Wiring Diagram for Pioneer 900 Page 11-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 115 For a complete wiring diagram, see page 11-6. AS SEEN FROM PASSENGER SIDE OF VEHICLE REMOVE NEGATIVE CABLE FIRST DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE Figure 11-2 Battery Disconnect 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-7...
Page 116: Electrical Circuits
To prevent battery overcharging, the voltage regulator senses bat- tery voltage, and by opening and closing an electronic switch, controls the amount of charge going to the battery. Page 11-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 117: Engine Ignition Circuit
The engine kill circuit consists of the key switch and connecting wires. The engine can be stopped by turning the key switch to the OFF position. See Lockout Cam Circuit on page 11-11. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-9...
Page 118: Reverse Buzzer Circuit
Forward/Reverse shifter. When the Forward/Reverse handle is placed in REVERSE, a cam depresses the reverse limit switch, closing the circuit. The reverse buzzer sounds. Figure 11-7 Reverse Buzzer Circuit for Pioneer 900 Page 11-10 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 119: Low Oil Warning Circuit
LOCKOUT CAM CIRCUIT The Pioneer 900 is equipped with a lockout cam that allows the engine to be started only when the Forward/ Reverse handle is in the NEUTRAL position. The lockout cam (yellow) is located on the back of the Forward/ Reverse handle, inside the engine compartment.
Page 120: Fuel Gauge And Sending Unit Circuit
ON position. The power goes through the gauge to the sending unit at the fuel tank. The send- ing unit tells the gauge how much fuel is in the tank (Figure 11-11, Page 11-12). Figure 11-11 Fuel Gauge and Sending Unit Circuit Page 11-12 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 121: Hour Gauge Circuit
A hydrometer, multimeter, and 160 ampere load tester will be required. See Test Procedure 1 – Battery on page 11-20. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-13...
Page 122: Testing The Starter Circuit And Generator Circuit
CHECK DIODE (TEST PROCEDURE 10) CHECK STARTER/GENERATOR (GENERATOR FUNCTION) (TEST PROCEDURE 11) CHECK VOLTAGE REGULATOR (TEST PROCEDURE 12) CHECK WIRE CONTINUITY (TEST PROCEDURE 9) Figure 11-15 Testing the Generator Circuit Page 11-14 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 123: Testing The Engine Ignition Circuit
OF CIRCUIT WIRING WIRES CORRECTLY WIRES INCORRECTLY CONNECTED CONNECTED CONNECT WIRES CORRECTLY CHECK CONTINUITY OF CIRCUIT WIRES (TEST PROCEDURE 9) NO CONTINUITY REPLACE WIRE Figure 11-17 Testing the Engine Kill Circuit 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-15...
Page 124: Testing The Reverse Buzzer Circuit
WIRES INCORRECTLY CONNECTED CONNECTED CHECK CONTINUITY RECONNECT WIRES OF CIRCUIT WIRES TO REVERSE BUZZER CONTINUITY NO CONTINUITY REPLACE REVERSE BUZZER REPLACE WIRE Figure 11-18 Testing the Reverse Buzzer Circuit Page 11-16 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 125: Testing The Low Oil Warning Circuit
LOW OIL WARNING LIGHT LOW OIL WARNING LIGHT ILLUMINATES DOES NOT ILLUMINATE REPLACE CONTINUITY OIL LEVEL SENSOR REPLACE LOW OIL WARNING LIGHT Figure 11-19 Testing the Low Oil Warning Circuit 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-17...
Page 126: Testing The Lockout Cam Circuit
GAUGE (TEST PROCEDURE 26) (TEST PROCEDURE 26) VOLTAGE READINGS VOLTAGE READINGS INCORRECT INCORRECT REPLACE FUEL GAUGE REPLACE FUEL GAUGE Figure 11-20 Testing the Fuel Gauge and Sending Unit Circuit Page 11-18 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 127: Testing The Lighting Circuit
INDEX OF TEST PROCEDURES 1. Battery 2. Fuse 3. Ground Straps 4. Key Switch (Starter Circuit) 5. Key Switch (Accessory Terminal) 6. Solenoid 7. Lockout Cam Limit Switch 8. Starter/Generator (Starter Function) 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-19...
Page 128 - 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. Page 11-20 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 129 For each 10 °F (5.6 °C) above 80 °F (27 °C), add 0.004 to the reading. For each 10 °F (5.6 °C) below 80 °F (27 °C), subtract 0.004 from the reading. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-21...
Page 130 NOTE: A fully charged battery that is in good condition should have a speciﬁc gravity of at least 1.225 in all cells, and the difference in the speciﬁc gravity of any two cells should be less than 50 points. Open circuit voltage should be at least 12.4 volts. Page 11-22 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 131 TEST PROCEDURE 3 – GROUND STRAPS Read DANGER and WARNING on page 11-1. 1. Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels and disconnect the bat- tery, negative cable ﬁrst. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-23...
Page 132 Figure 11-26 Battery Ground Cable Test 4. Check voltage regulator ground connection (at battery frame ground). Make sure it is clean and tight. 5. Check the battery ground cable. Page 11-24 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 133 Ω Ω 200nA Ω 200nA 1000 --- FUSED 1000 --- FUSED 750V 750V Figure 11-27 Key Switch Test – Accessory Terminal Figure 11-28 Key Switch Test – Starter Circuit 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-25...
Page 134 ﬁrst. 2. Remove the electrical component box cover. 3. Check that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Page 11-26 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 135 Ω Ω COMPONENT Ω Ω 200nA 200nA ELECTRICAL 1000 --- FUSED 1000 --- FUSED 750V 750V COMPONENT BOX FRAME Figure 11-30 Test Solenoid Continuity Figure 11-31 Test Solenoid Ground 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-27...
Page 136 1. Turn the key switch OFF, place the Forward/Reverse handle in the NEUTRAL position, chock the wheels and disconnect the battery, negative cable ﬁrst. 2. Check that wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Page 11-28 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 137 The starter/generator will need to be removed from the vehicle and disas- sembled by a qualiﬁed technician. See Starter/Generator Removal, Section 12, Page 12-2. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-29...
Page 138 1. Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and disconnect the battery, negative (–) cable ﬁrst. 2. Disconnect the two wires from the diode assembly, which is located on the I-beam close to the battery. Page 11-30 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 139 NOTE: Perform Test Procedures 10 and 11 before proceeding with this test procedure. Keep the battery connected while performing this test procedure. 1. Place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-31...
Page 140 2. Disconnect the engine-kill white/black wire at the bullet connector located next to the RPM limiter (Fig- ure 11-39, Page 11-33). WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11-37 Test Voltage Regulator Page 11-32 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 141 (Figure 11-38, Page 11-33). IGNITION GAP TEST TOOL SPARK PLUG WIRE SPARK PLUG Disconnect FRAME white/black LIMITER engine kill wire Figure 11-38 Ignition Spark Test Figure 11-39 Disconnect White/Black Engine Kill Wire 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-33...
Page 142 If the engine runs properly, keep the new RPM Limiter in the circuit. RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK KILL CIRCUIT WIRE FEMALE BULLET TERMINAL BLACK WIRE Figure 11-40 RPM Limiter Page 11-34 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 143 200k 2000 Ω 200k Ω Ω 200nA 1000 --- Ω FUSED 200nA 750V 1000 --- FUSED 750V Figure 11-41 Test Ignition Primary Coil Figure 11-42 Test Ignition Secondary Coil 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-35...
Page 144 There should be NO continuity when the key switch is in the ON or START position. If there is continuity, check for worn insulation on the white/black wire that is allowing the wire to ground to the frame. Page 11-36 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 145 13, Page 13-24. 5. Fill the engine with new oil and install a new oil ﬁlter before returning the vehicle to service. See Engine Oil, Section 10, Page 10-6. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-37...
Page 146 3.2. If the reading is below 9.6 volts at 70 °F (21 °C) (electrolyte temperature), check the battery. See Test Procedure 1 – Battery on page 11-20. Page 11-38 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 147 Also check the continuity of the yellow wire from the fuel/hour gauge to the key switch, and the black ground wires at the fuel level sending unit and at the fuel/hour gauge. See Fuel/Hour Gauge Removal, Section 12, Page 12-22. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-39...
Page 148 The voltage reading should be the same as the full battery voltage reading obtained in step 5. If the reading is incorrect, replace fuel/hour gauge (Figure 11-46, Page 11-41). Page 11-40 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 149 • Before connecting battery cables, make sure none of the electrical components touch the front body trim or other parts of the vehicle frame. Place a dry towel between the body trim and the center dash to prevent an electrical short. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-41...
Page 150 Place a dry towel between the body trim and the center dash to prevent an electrical short circuit. 5. Connect the battery, positive cable ﬁrst. Page 11-42 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 151 Place the red (+) probe into the blue wire terminal. 5. Pull the light switch to the ON position. If the multimeter reads approximately 12 volts, replace the headlight bulb. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 11-43...
Page 152 12 volts, the black wire has continuity. BLACK WIRE WAVETEK BLUE WIRE 1000 WIRE HARNESS 2000 200k Ω Ω 200nA 1000 --- FUSED 750V LEFT HEADLIGHT Figure 11-49 Check Voltage to Headlight Socket Page 11-44 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 153: Section 12 - Electrical Components
• If wires are removed or replaced, make sure wiring is properly routed and secured to vehicle frame. Failure to properly route and secure wiring could result in vehicle malfunction, property damage or personal injury. WARNING CONTINUED ON NEXT PAGE... 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-1...
Page 154: Starter/Generator
2. Disconnect the battery cables, negative cable (–) ﬁrst (Figure 12-1, Page 12-2). 3. Disconnect the wires from the starter/generator (1). Mark wires before disconnecting. Loosen the pivot nuts (7) and bolts (5) (Figure 12-2, Page 12-3). Page 12-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 155 2. Check the wear line on the side of the brush. If the end of the brush is within 1/16 of an inch (1.6 mm) of the wear line, replace all four brushes (Figure 12-5, Page 12-4). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-3...
Page 156 1. Connect the brush wires to the holders using four lockwashers (26) and four screws (25), making sure the crossover leads are connected also. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12-4, Page 12-4). Page 12-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 157 (29) in the openings in the commutator end cover (23) (Figure 12-4, Page 12-4). BRUSH BEING HELD BY BRUSH SPRING Figure 12-7 Pull Brushes Away From Center of the Commutator End Cover 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-5...
Page 158 Bearings should be replaced if there is extensive wear or pitting on the balls or on the rolling surfaces. Do not remove the bearings unless they are to be replaced. Page 12-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 159 Remove the four pole piece screws from the housing. Remove the four pole pieces from inside the housing. Remove the ﬁeld coils from the inside of the housing (Figure 12-11, Page 12-8). See following NOTE. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-7...
Page 160 Check for loose or raised commutator bars. Slight roughness of the commuta- tor can be polished away with 400 grit (or ﬁner) sandpaper. See following CAUTION. Page 12-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 161 If the insulation on the ﬁeld coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings. Be sure the insulators are tight in the housing. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-9...
Page 162 Install a ﬂat washer, lockwasher and nut onto each threaded terminal on the outside of the housing. Tighten nuts to 47.5 in-lb (5.4 N·m) (Figure 12-11, Page 12-8). Page 12-10 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 163 Position the starter/generator in the mounting bracket so that the bolts will go through the starter/generator before going through the bracket. Install a locknut (7) onto each bolt. Tighten to ﬁnger tight (Figure 12-14, Page 12-12). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-11...
Page 164 4. Push the starter/generator down so it is at the lowest point of its adjustment travel. With the starter/gen- erator belt fully in place around the drive clutch pulley, install the starter/generator belt (3) around the pulley (10) on the end of the starter/generator. Page 12-12 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 165: Voltage Regulator
4. Remove the voltage regulator mounting screw (8) and remove the voltage regulator (9). TO KILL LIMIT SWITCH TO BATTERY FRAME GROUND TO BULLET ELECTRICAL TO SOLENOID CONNECTOR COMPONENT BOX Figure 12-16 Voltage Regulator 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-13...
Page 166: Diode
2. Disconnect wires from the diode (1) (Figure 12-17, Page 12-14). 3. Remove the mounting hardware (2) from the diode and remove it from the vehicle. Figure 12-17 Diode Page 12-14 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 167: Key Switch
Diagram, Section 11, Page 11-6. Coat the connectors with Battery Protector Spray (CCI 1014305) to prevent corrosion. Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-15...
Page 168: Solenoid
1. Install the solenoid in the electrical component box. Use two screws to secure the solenoid to the box and tighten to 14 in-lb (1.6 N·m). See following WARNING. Page 12-16 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 169: Fuse
• If a fuse is blown, determine the cause of the failure and make necessary repairs before installing a new fuse. Use the appropriately rated fuse; if a fuse with a higher amp rating is used, damage to the vehicle electrical system may occur. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-17...
Page 170: Lockout Cam Limit Switch
1. Install the lockout cam limit switch (5) with two washers (6) and two nuts (2) (Figure 12-19, Page 12- 18). Tighten to 5 in-lb (0.6 N·m). Place the Forward/Reverse handle in REVERSE to make sure that both switches actuate. See following CAUTION. Page 12-18 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 171: Lockout Cam
Forward/Reverse handle is in the NEUTRAL position. 4. Connect battery cables, positive cable ﬁrst and tighten the terminals to 20 ft-lb (27.1 N·m). Coat termi- nals with Battery Protector Spray (CCI 1014305). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-19...
Page 172: Reverse Warning Buzzer
5. Connect battery cables, positive cable ﬁrst and tighten the terminals to 20 ft-lb (27.1 N·m). Coat termi- nals with Battery Protector Spray (CCI 1014305). AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED Figure 12-21 Front Reverse Warning Buzzer Page 12-20 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 173: Reverse Buzzer Limit Switch
6. Turn the key switch to the ON position. Shift the Forward/Reverse handle to the REVERSE position. The buzzer should sound. OIL WARNING LIGHT Read DANGER and WARNING on page 12-1. Testing the Oil Warning Light See Test Procedure 22, Section 11, Page 11-38. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-21...
Page 174: Fuel/Hour Gauge
1. Disconnect the battery cables, negative cable (–) ﬁrst (Figure 12-1, Page 12-2). 2. Remove the center dash panel. See Key Switch Removal on page 12-15. 3. Disconnect the wires from the fuel/hour gauge (Figure 12-23, Page 12-23). Page 12-22 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 175: Fuel Level Sending Unit
The fuel level sending unit is an integral part of the fuel tank and should never be removed. Thoroughly test the fuel level sending unit before replacing the fuel tank. Testing the Fuel Level Sending Unit See Test Procedure 25, Section 11, Page 11-39. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-23...
Page 176: Rpm Limiter
ﬂange head bolt and secure the left side of the band. Use another ﬂange head bolt to secure the other side of the band. Make sure the band holds the RPM limiter securely in place. Tighten fasteners to 7 ft- lb (9.5 N·m). Page 12-24 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 177: Ignition Coil
9. Disconnect the 18 gauge black wire (12) from the spade terminal on the ignition coil (11) and remove the coil by removing two bolts (10) (Figure 12-27, Page 12-26). Figure 12-25 Remove Stiffener 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-25...
Page 178 If the existing ignition coil will be remounted, proceed to step 9. 1. Remove the rubber gasket (1) on the plug cap (2) by rolling back the gasket onto the spark plug wire. Page 12-26 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 179 19. Connect the spark plug wire to the spark plug. 20. Connect battery cables, positive cable ﬁrst and tighten the terminals to 20 ft-lb (27.1 N·m). Coat termi- nals with Battery Protector Spray (CCI 1014305). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-27...
Page 180: Oil Level Sensor
3. Remove the wire harness/halogen bulb assembly (4 and 6) from the headlight lens (7). 4. Lift the retaining tabs on the connector (4) and remove halogen bulb assembly (6). Page 12-28 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 181: Headlight Diode
4. Remove the mounting hardware (2) from the headlight diode and remove it from the vehicle. Headlight Diode Installation 1. Mount the headlight diode to the frame using the mounting hardware. Tighten to 25 in-lb (2.8 N·m) (Fig- ure 12-31, Page 12-29). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-29...
Page 182: Light Switch
5. Connect battery cables, positive cable ﬁrst and tighten the terminals to 20 ft-lb (27.1 N·m). Coat termi- nals with Battery Protector Spray (CCI 1014305). Page 12-30 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 183: Battery
Club Car recommends a group 70, side-post battery (CCI 1012328), with a 650 cranking amp rating at 32 °F (0 °C) (500 CCA at 0 °F (-17.8 °C)) and a reserve capacity of at least 105 minutes. The group 70 classiﬁca- tion indicates battery size: 8-1/4 inches W x 6-1/2 inches D x 7-1/4 inches H (21.0 cm W x 16.5cm D x 18.4...
Page 184 ALLOWABLE CONTENT IN IMPURITY PARTS PER MILLION Suspended matter TRACE Total solids 100.0 Calcium and magnesium oxides 40.0 Iron Ammonia Organic matter 50.0 Nitrates 10.0 Nitrites Chloride Page 12-32 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 185 • If the charger must be stopped, disconnect the AC supply cord from the wall outlet before disconnecting the DC leads from the battery. Allow the battery to cool to room temperature and resume charging battery at a lower amp rate. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-33...
Page 186 60 °F (16 °C) prior to charging. The battery will not charge effectively in cold temperatures for the same reasons that it does not discharge as rapidly in cold temperatures. Page 12-34 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 187: Ground Straps
∆ WARNING • Do not jump-start a dead battery using another battery and jumper cables. GROUND STRAPS Testing the Ground Straps See Test Procedure 3, Section 11, Page 11-23. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-35...
Page 189: Section 13 - Fe350 Engine
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. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-1...
Page 190: General Information
GENERAL INFORMATION Read DANGER and WARNING on page 13-1. All Club Car gasoline vehicles are powered by 4-cycle, overhead valve, single cylinder, air-cooled engines. The 4-cycle engine has an oil reservoir (crankcase) similar to automobiles, trucks, aircraft, heavy equipment, machinery and other applications designed for reliable heavy-duty service. The engine has two major com- ponent assemblies: the cylinder assembly and the crankcase assembly.
Page 191 A part installed using a press or driver, such as a seal, should ﬁrst be coated with oil on its outer or inner cir- cumference (contact surface) so that it will go into place smoothly. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-3...
Page 192: Electrical System
See also Section 11 – Troubleshooting and Electrical System and Section 12 – Electrical Components. 1. Always minimize shock hazards when working on electrical equipment. Work in a clean, dry environ- ment with dry hands. Page 13-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 193: Lubrication System
(Figure 13-1, Page 13-5 and Figure 13-3, Page 13-6): • Inlet ﬁlter screen (2) • Trochoid pump (3) • Cartridge ﬁlter (5) • Pressure relief valve (8) 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-5...
Page 194: Hydraulic Lifters
Spark plugs are selected to suit speciﬁc engine design and vehicle operating conditions. The spark plug (CCI 101881101) is designed to give maximum life and efﬁcient combustion of fuel. The spark gap is 0.027 to 0.031 in. (0.69 to 0.79 mm). Page 13-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 195 Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible. Spark should be blue and strong and able to jump a 5/16 inch (8 mm) gap. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-7...
Page 196: Engine Mounting Plate
3. Loosen air intake hose clamp (7) from intake pipe (5) and remove hose (6) (Figure 13-6, Page 13-9). 4. Disconnect the fuel line (9) and vent tube (10) from the carburetor (4) (Figure 13-7, Page 13-9). Page 13-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 197 11. Remove the nine bolts (14) and two-ended bolt (11) (Figures 13-8 and 13-9, Page 13-10). 12. Take off the head shroud (13), the upper shroud (23) and the bracket (22). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-9...
Page 198: Rocker Arm And Push Rod Removal
1. Remove the six bolts (1) and take off the cylinder head assembly (2) (Figure 13-12, Page 13-11). 2. Remove head gasket (3). Note the position of the two dowels (4) as shown (Figure 13-13, Page 13-11). Page 13-10 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 199: Valve Removal
• The valve stem seal cannot be reused. Replace valve stem seal with a new one. 5. Remove spring seat (9) (Figure 13-15, Page 13-11). PADDING Figure 13-14 Valve Removal Figure 13-15 Spring Seat Removal 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-11...
Page 200: Breather Valve (Reed Valve)
Do not remove any more material than is necessary or change the shape of the combustion chamber (Figure 13-18, Page 13-13). • Do not grind the valve seats or the gasket surface. Page 13-12 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 201: Valve Guides
2. Using Prussian Blue, coat the valve seat. 3. Push the valve into the guide. 4. Rotate the valve against the seat with a lapping tool (1) (Figure 13-23, Page 13-14). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-13...
Page 202 Valve Seat Repair ∆ CAUTION • If you are unfamiliar with the following procedures, Club Car suggests that the cylinder head be taken to a professional engine machine shop for reconditioning. Page 13-14 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 203 2.6. Turn the seat cutter (1) clockwise one turn at a time while pressing down very lightly. Recheck the width after each cutter revolution. See following CAUTION and NOTE. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-15...
Page 204: Valves
Figure 13-28 Valve Head Seating Area VALVES Visual Inspection of Valves 1. Inspect the valve head seating area (1) for erosion, nicks and warping, etc. (Figure 13-28, Page 13- 16). See following NOTE. Page 13-16 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 205 1. Using a micrometer, measure the diameter of the stem at several points along its length (Figure 13-31, Page 13-18). 2. If the outside diameter is less than the service limit of 0.2728 inch (6.930 mm) intake, 0.2722 inch (6.915 mm) exhaust, replace the valve. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-17...
Page 206: Rocker Arm And Rocker Shaft Inspection
4. If the outside diameter is less than the service limit of 0.4704 inch (11.949 mm), replace the shaft. Measure each position in two places 90 ° apart. Figure 13-32 Measure Valve Spring Length Figure 13-33 Measure Rocker Arm Bearing I.D. Page 13-18 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 207: Push Rod Inspection
(25 N·m). See following CAUTION. ∆ CAUTION • Do not turn any one bolt down completely before tightening the others. Doing so may cause the cylinder head to warp. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-19...
Page 208: Valve Clearance Check And Adjustment
NOTE: Place the reed valve on the seat so there is a slight gap (2) 0.008 inch maximum (0.203 mm) between the valve and the seat (Figure 13-38, Page 13-21). Page 13-20 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 209: Installation Of Remaining Engine Components
2/3 turn after gasket contact. Fill crankcase with the correct level of oil (Figure 13-41, Page 13-22). See Section 2 – Vehicle Speciﬁcations. 10. Run the engine for three minutes to check for leaking oil. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-21...
Page 210 Reinsert dip stick until fully seated. Level Oil must be in the safe level. Figure 13-41 Check Engine Oil Level Figure 13-42 Oil Level Sensor Wire Figure 13-43 Crankcase Cover Page 13-22 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 211: Crankcase
• Before removal and disassembly, clean the engine. 1. Remove the powertrain by performing steps 1 through 15, pages 16-7 through 16-12 in Section 16 – Unitized Transaxle. See following NOTE. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-23...
Page 212: Crankcase Cover Removal
3. Connect sensor wire (2) to cord connector (1) (Figure 13-45, Page 13-25). 4. Install screw (3) through wire clamp and into crankcase cover. Tighten to 30 in-lb (3.4 N·m). Page 13-24 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 213: Camshaft And Hydraulic Lifters
Page 13-26 and Figure 13-49, Page 13-26). 6. If the camshaft journal diameter is less than 0.9026 inch (22.927 mm) at either end of the shaft, replace the camshaft. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-25...
Page 214 The engine cranks at 550 to 650 RPM and the ACR closes at approximately 700 RPM. After the engine starts, it will idle at 1050 to 1150 RPM. Page 13-26 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 215: Piston And Connecting Rod
1. Remove two retaining rings holding the piston pin in place. 2. Remove the piston pin. Piston Inspection and Repair 1. Remove all deposits from the piston. 2. Clean the carbon from the piston ring grooves. See following CAUTION. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-27...
Page 216 NOTE: It is difﬁcult to measure exactly the oil ring thickness. Replace the oil ring whenever the compression rings (top and second) are replaced. Figure 13-53 Measure Ring End-Gap Figure 13-54 Measure Piston Ring Thickness Page 13-28 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 217 4. Remount the connecting rod cap to the connecting rod at the large bore end, aligning the pilot groove on the rod. Screw in the connecting rod bolts and tighten them to 16.5 ft-lb (23 N·m). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-29...
Page 218: Cylinder Block
Always resize the bore to exactly 0.020 inches (0.50 mm) over standard size. 1. The bore size 0.020 inches over standard size is 3.2858 - 3.2866 inches (83.460 - 83.480 mm). See Speciﬁcations for Resizing Cylinder Bore on page 13-51. Page 13-30 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 219: Ignition Coil And Flywheel
3. Hold the ﬂywheel (4), not the fan (7), with a strap wrench (5) and, using a 25 mm socket, remove the ﬂywheel nut (and ﬂat washer) by turning it counterclockwise (Figure 13-63, Page 13-32). See follow- ing CAUTION. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-31...
Page 220: Oil Pump
1. Remove the six screws (1 - 6) and remove the oil pump cover (7) (Figure 13-65, Page 13-33). 2. Peel off the oil pump cover gasket (8). 3. Remove the pump gear cover plate (9) and ﬁlter screen (10). Page 13-32 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 221 4.5. If the rotor thickness is less than 0.3905 inch (9.920 mm), replace both rotors. Measure two Measure two places 90° apart. places 90° apart. Figure 13-67 Measure Pump Shaft Bearing Surface Figure 13-68 Measure Outer Rotor O.D. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-33...
Page 222: Oil Pressure Relief Valve
Oil Pressure Relief Valve Installation 1. Installation is the reverse of removal. If necessary, put the ball in position and lightly tap with a plastic hammer to form a perfect seat. Page 13-34 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 223: Crankshaft And Counterbalance
2. Pull out the crankshaft and the counterbalance together as an assembly (Figure 13-74, Page 13-35). Figure 13-73 Counterbalance Guide Shaft Figure 13-74 Crankshaft and Counterbalance and O-Ring Removal 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-35...
Page 224 • Use a press when removing the spur gear and helical gear from, or installing them on the crankshaft. 5. Remove the woodruff key. 6. Slide the remaining link rod off the crankshaft. Page 13-36 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 225 Figure 13-77 Inspect Link Rod Figure 13-78 Measure Link Rod Small Bore I.D. Measure each position in 2 places 90° apart. Figure 13-79 Measure Link Rod Large Bore I.D 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-37...
Page 226: Counterbalance Weight
3. If the outside diameter is smaller than 1.0199 inches (25.907 mm), or the shaft shows signs of wear or damage, replace the guide shaft. 4. Check the O-ring seal to make sure the O-ring is not damaged. Replace if necessary. Page 13-38 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 227 Figure 13-83 Measure Crankshaft Journals Measure each position Measure each position in 2 places 90° apart. in 2 places 90° apart. Figure 13-84 Measure Connecting Rod Journal Figure 13-85 Measure Link Rod Journals 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-39...
Page 228: Oil Screen
2. Clean the oil screen thoroughly with a high ﬂash-point solvent, then dry the screen. Oil Screen Installation 1. To install the oil screen, reverse the removal procedure. 2. Tighten bolts (1) to 30 in-lb (3.4 N·m). Page 13-40 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 229: Ball Bearing
2. Place the crankcase cover (1) on a bench with its outside up (gasket surface against bench) (Figure 13-89, Page 13-41). 3. Using a bearing driver (2) (Part of Club Car Bearing Driver Kit, Part No. 1016416), drive out the ball bearing (3) as shown.
Page 230: Oil Seals
1.1841 inch (30.075 mm), replace the crankcase (Figure 13-91, Page 13-41). CHAMFERED INSIDE DIAMETER CHAMFERED INSIDE DIAMETER Figure 13-92 Inspect Camshaft Bearing Surface Figure 13-93 Crankshaft Assembly in Crankcase Cover Page 13-42 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 231 PRESS RAM SPUR GEAR (CHAMFERED INSIDE (NOTE DIAMETER FACING DOWN) TIMING MARK) PRESS TABLE LINK ROD Figure 13-94 Crankshaft Installation Figure 13-95 Press on Spur Gear and Helical Gear 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-43...
Page 232: Crankshaft Axial Play Adjustment
The correct crankshaft shim is 1.53 mm (Figure 13-100, Page 13-45). See following NOTE. 5. Install the shim (5) on the crankshaft (6) (Figure 13-99, Page 13-45). NOTE: Crankshaft shim sizes for FE350 engines range from 1.11 to 1.81 mm. Page 13-44 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 233 1. Installation is the reverse of removal. See page 13-25. 2. Apply a light ﬁlm of engine oil to the camshaft journals and cam lobes. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-45...
Page 234 5. Install the shim (1) on the camshaft (2) (Figure 13-104, Page 13-46). Figure 13-103 Measurements to be Recorded Figure 13-104 Shim Installation on Camshaft for Camshaft Shim Table Page 13-46 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 235: Crankcase Cover Installation
130 in-lb (14 N·m). Then, repeating the sequence, tighten them to 250 in-lb (28.2 N·m). 5. Connect the yellow jumper wire (11) to the cord connector (12) (Figure 13-42, Page 13-22). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-47...
Page 236: Engine Assembly
7. Place engine onto engine mounting plate and tighten the mounting hardware (1, 2 and 5) to 21 ft-lb (28.4 N·m). Tighten nuts (6) to 17 ft-lb (23.1 N·m) (Figure 13-44, Page 13-23). Page 13-48 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 237 17. Connect the battery cables, positive ﬁrst and tighten to 20 ft-lb (27.1 N·m). 18. Adjust the engine RPM setting. See Engine RPM Adjustment, Section 14, Page 14-13. 19. Test-drive vehicle to ensure all systems are functional and correctly adjusted. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-49...
Page 238: Service Specifications
(0.50 to 1.10mm) Valve seat width (max.) 0.075 in. (1.9 mm) Valve face angle (exhaust, intake) Standard 45° (Ex.), 30° (In.) Valve margin (exhaust, intake) (max.) 0.024 in. (0.6 mm) Page 13-50 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 239: Specifications For Resizing Cylinder Bore
90 in-lb (10 N·m) Fan shroud screws 25 in-lb (2.8 N·m) 130 in-lb (15 N·m) Bolts marked with “4” (when used with nuts) 50 in-lb (5.9 N·m) 30 in-lb (3.4 N·m) 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 13-51...
Page 240: Adjustments And Settings
1.18 in. (30 mmHg) Cylinder head-gasket surface ﬂatness (max.) 0.002 in. (0.05 mm) ACR lift (standard) 0.059 in. (1.5 mm) ACR lift (min.) 0.0354 in. (0.9 mm) Engine RPM 3100 (±30) RPM Page 13-52 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 241: Section 14 - Fuel System
The engine is equipped with a ﬂoat bowl type carburetor with ﬁxed jets that require no adjustment. The car- buretor atomizes the fuel, mixes it with air, and feeds the combustible mixture into the cylinder. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-1...
Page 242: How The Carburetor Works
The throttle valve (Figure 14-3, Page 14-3) is almost closed when this is the case, and as high negative pressure is created on the back side of the throttle valve, intake air is drawn in and Page 14-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 243 CARBURETOR BORE TO ENGINE MAIN AIR JET MIXTURE MIXTURE INTAKE CYLINDER CYLINDER THROTTLE VALVE MAIN NOZZLE BLEED PIPE FLOAT MAIN JET FUEL INLET FUEL INLET FLOAT CHAMBER Figure 14-3 Carburetor 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-3...
Page 244: Choke And Fresh Air System
• Choke and air intake system (for restriction of air ﬂow). See Choke and Air Intake System on page 14-14. • Fuel pump. See Fuel Pump on page 14-19. Page 14-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 245: Main Jet Elevation/Size Chart
The carburetor must be kept upright during removal. 2. Position the carburetor with the drain screw (11) over a catch basin (Figure 14-7, Page 14-7). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-5...
Page 246 4. Mark the body of the carburetor and the carburetor fuel bowl with an indelible ink marker so that, after removal, the bowl can be installed again in the same position (Figure 14-7, Page 14-7). Page 14-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 247 7. Select the proper size main jet. See chart on page 14-5. Check the size designation on the jet to make sure it is the correct part. 8. Install the new main jet and tighten it to 12 in-lb (1.4 N·m). See following CAUTION and NOTE. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-7...
Page 248: Engine Control Linkage
Read DANGER and WARNING on page 14-1. GENERAL INFORMATION For proper vehicle operation, it is important the accelerator pedal, governor linkage, and throttle adjustments are done correctly and in the proper sequence. See following CAUTION. Page 14-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 249: Accelerator Rod
2. Install the ball joint on the ball stud at the accelerator pedal (Figure 14-8, Page 14-9). 3. Access the engine compartment. See DANGER on page 14-1. 3.1. Tilt the bed and ensure that the prop rod is engaged. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-9...
Page 250: Governor Cable
4. Remove the cotter pin (9) and clevis pin (8) from the governor lever arm (15) (Figure 14-11, Page 14-12). 5. Remove the cable (2) (Figure 14-11, Page 14-12). Page 14-10 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 251: Accelerator Cable
Page 14-12). Pull the cable housing out of the bracket. 5. Disconnect the spring (16) from the engine governor arm by rotating the arm counterclockwise one-half turn. Remove the cable assembly from the vehicle (Figure 14-11, Page 14-12). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-11...
Page 252 FUEL SYSTEM Engine Control Linkage TYPICAL 2 PLACES REFERENCE EXHAUST SECTION Figure 14-11 Governor and Accelerator Cables Page 14-12 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 253: Closed Throttle Or Idle Adjustment
1. If the governor is adjusted, proceed to step 2; otherwise, adjust the governor. See Governor Cable Installation and Adjustment on page 14-11. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-13...
Page 254: Choke And Air Intake System
1. Insert choke cable through hole in body until choke lever assembly seats against body. 2. Install three screws (18), washers (19), and locknuts (20) as shown and tighten to 18 in-lb (2.0 N·m) (Figure 14-14, Page 14-17). Page 14-14 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 255: Air Box Removal
1. Slide the intake duct between the round crossmember and the ﬂoorboard, moving it to the rear along the underside of the ﬂoorboard. Insert the end of the intake duct through the slot in the front of the air box mounting plate. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-15...
Page 256: Intake Duct Repair
In the event of puncture damage to the intake duct, a repair kit is available (CCI 101971001). This kit is designed to repair small cracks or holes. If the intake duct is badly torn, it will need to be replaced. Page 14-16 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 257 Choke and Air Intake System REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 14-14 Air Intake and Choke Assemblies 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-17...
Page 258: Air Filter
• If air box is extremely dirty, remove air box from vehicle and clean thoroughly. • Use only Club Car replacement air ﬁlters (CCI 1015426). The use of other air ﬁlters could result in engine damage. If the air ﬁlter is too thin, the cover will seat before the ﬁlter can seal, leaving space for dirt to pass into the engine on all sides of the element.
Page 259: Fuel Filter Removal
• Inspect the impulse line and fuel lines for damage or clogging. • Make sure the air vent on the fuel pump is not clogged with dirt. • Make sure the fuel ﬁlters are not clogged. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-19...
Page 260: Fuel Pump Removal
1. Turn fuel shut-off valve on top of the gas tank to the closed (OFF) position (Figure 14-20, Page 14-27). 2. Remove hardware attaching the fuel pump (24) and lift the fuel pump out of the engine compartment (Figure 14-15, Page 14-20). Page 14-20 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 261: Fuel Pump Disassembly
FUEL PUMP DISASSEMBLY NOTE: A fuel pump rebuild kit is available from Club Car (CCI 1014524). This kit includes all gaskets, dia- phragms, and valves. 1. Remove four screws (24) and lock washers (25) from front of the fuel pump (Figure 14-16, Page 14-22).
Page 262: Fuel Pump Installation
15, Page 14-20). 4. Install the fuel pump onto the mounting bracket with two thread-rolling screws (25) and tighten to 40 in- lb (4.5 N·m) (Figure 14-15, Page 14-20). Page 14-22 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 263: Fuel Tank
7. Using a siphon with a suction device, siphon all fuel out of the tank and into an approved container. See following DANGER and WARNING. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-23...
Page 264: Fuel Tank Disposal
3. In a well-ventilated area, set the tank upside down so that the water can drain out of it. To make sure that the tank dries completely, allow the tank to sit for 24 hours. 4. Store the tank upside down, with the cap installed, in a well-ventilated area. Page 14-24 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 265: Fuel Tank Installation
2.2. Install the screws (12) into the speed nuts (11). Tighten screws and nuts to 25 in-lb (2.8 N·m) (Figure 14-15, Page 14-20). 3. Install seat back support. See Section 4 – Body and Trim. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-25...
Page 266: Fuel Lines
Small spring steel band clamps are used on all hose connections except at the carburetor. A screw band clamp should be used at the carburetor (Figure 14-15, Page 14-20). Page 14-26 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 267: Fuel Shut-Off Valve
SIDE OF VALVE Figure 14-20 Closed Fuel Shut-off Valve Figure 14-21 Open Fuel Shut-off Valve PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 14-22 Incorrect Fuel Shut-off Valve 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 14-27...
Page 269: Section 15 - Exhaust System
GENERAL INFORMATION The exhaust system is designed to provide quiet vehicle operation. If the mufﬂer should ever need to be removed for repairs or replacement, follow the instructions below. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 15-1...
Page 270: Muffler
4. Install the hex nuts (10) and lock washers (11). Tighten the nuts ﬁngertight. 5. Install the hex head cap screw (7), lock washer (8), and ﬂat washer (9). Tighten the cap screw ﬁngertight. Page 15-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 271 y y yy z z || ~~ P QQ TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 15-2 Exhaust System 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 15-3...
Page 273: Section 16 - Unitized Transaxle
GENERAL INFORMATION All gasoline-powered Club Car vehicles manufactured since the beginning of the 1997 model year are equipped with heavy-duty, fully-synchronized unitized transaxle. The unitized transaxle utilizes fully-synchro- nized internal gearing to change vehicle direction. Because the unitized transaxle is used to reverse vehicle direction, the engine, drive clutch, belt, and driven clutch rotate in the same direction;...
Page 274 FORWARD or REVERSE direction. Lockout Cam The Pioneer 900 vehicle has a lockout circuit that prevents a driver from starting the vehicle when it is in gear. The engine can be started only when the Forward/Reverse handle is in the NEUTRAL position. See Lockout Cam Circuit, Section 11, Page 11-11.
Page 275: Lubrication
If the unitized transaxle is to be removed from the vehicle, then do not remove the wheels, axle shafts, or axle tubes ﬁrst. Instructions for removing the unitized transaxle from the vehicle begin on page 16-7. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-3...
Page 276 UNITIZED TRANSAXLE Axle Shaft REFERENCE PASSENGER SIDE CASE REFERENCE DRIVER SIDE CASE Figure 16-5 Differential Gear Case/Axle Tubes Page 16-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 277: Axle Shaft And Oil Seal Removal
ﬂange and the bearing. See following CAUTION. ∆ CAUTION • Do not tighten the bearing puller wedge attachment against the axle shaft. This could damage the axle shaft when pressing the bearing and collar off. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-5...
Page 278 6. Place the bearing puller wedge attachment against collar and press both bearing and collar onto shaft. Install the retaining ring (74) (Figure 16-5, Page 16-4). See following CAUTION. Page 16-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 279: Axle Shaft Installation
3.5. Remove the cover from the electrical component box. Then loosen the hardware securing the accelerator cable to the box. Disconnect the cable from the actuator cam and remove it from the box (Figure 16-13, Page 16-8). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-7...
Page 280 Figure 16-10 Air Intake Hose Figure 16-11 Impulse Line TOP VIEW Loosen retaining nuts to remove throttle Remove fuel line. cable from electric box. Figure 16-12 Fuel Line Figure 16-13 Throttle Cable Page 16-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 281 YELLOW Remove OIL SENDING 6 gauge UNIT JUMPER white wire. WIRE Remove ground wire at A2 terminal. Figure 16-16 Generator Wires Figure 16-17 Oil Level Sensor Jumper Wire 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-9...
Page 282 SIDE OF VEHICLE WHITE/BLACK WIRE REAR OF VEHICLE BLACK WIRE Figure 16-18 Ignition Kill Wire Figure 16-19 Brake Cable Club Car Disconnect shock absorbers at lower mounts. Figure 16-20 Shock Absorbers Page 16-10 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 283 12. Carefully lift the snubber out of the snubber bracket in the vehicle frame and lower it to the ﬂoor (Figure 16-25, Page 16-12). The powertrain should be completely disconnected from the vehicle and resting on the ﬂoor. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-11...
Page 284 15.1. Grasp belt midway between drive and driven clutch and pull up on belt to force the driven clutch sheaves apart. Roll the belt counterclockwise while pulling it off driven clutch (Figure 16-28, Page 16-12). Page 16-12 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 285 Figure 16-30 Governor Arm Remove two screws holding accelerator cable retaining bracket. BRACKET Remove two screws holding governor cable bracket. Figure 16-31 Governor Cable Bracket Figure 16-32 Accelerator Cable Bracket 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-13...
Page 286: Unitized Transaxle Disassembly
7. Turn the case section containing the gearing on edge as shown (Figure 16-35, Page 16-16). While holding it in this position, gently rock all the gear assemblies to slightly loosen them in their seating. Page 16-14 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 287 8. When all the gear assemblies are slightly loosened, remove the differential gear case assembly by gently rocking it while pulling it from the case (Figure 16-36, Page 16-16). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-15...
Page 288 15.1. Remove the cotter pin (20) and ﬂat washer (21) from the pivot arm (24) (Figure 16-34, Page 16-15). 15.2. Remove the pivot arm (24) by pulling it through the wall to the interior of the case. Page 16-16 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 289 Use a small chisel or similar tool to pry out the pivot arm oil seal. OIL FLOW GUIDE Figure 16-39 Oil Flow Guide Figure 16-40 Pivot Arm Oil Seal 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-17...
Page 290 UNITIZED TRANSAXLE Unitized Transaxle Disassembly DRIVER SIDE CASE REFERENCE PASSENGER SIDE CASE Figure 16-41 Unitized Transaxle Page 16-18 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 291: Component Disassembly
Using a hammer and drift punch, lightly tap governor gear and washer from case. Figure 16-42 Remove Governor Gear Figure 16-43 Pry Gear from Shaft 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-19...
Page 292: Shifter Fork Disassembly
1. Place a bearing puller wedge attachment (CCI 1012812) between the bearing (38) and spur (governor drive) gear (40) (Figure 16-41, Page 16-18), then press the bearing off the input shaft as shown (Fig- ure 16-47, Page 16-22). See preceding CAUTION. Page 16-20 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 293: Intermediate Gear Disassembly
(CCI 1012812) ARBOR to press bearing from gear case. WEDGE ATTACHMENT Push differential pin through differential gear case. Figure 16-45 Differential Pin Figure 16-46 Remove Bearing 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-21...
Page 294: Idler Shaft Disassembly
5. Using a feeler gauge, measure the distance X at several points around the assembly. The synchro ring should be replaced when X is 0.02 inch (0.5 mm) or less (Figure 16-53, Page 16-24). Page 16-22 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 295: Component Assembly
Read DANGER and WARNING on page 16-1. IDLER SHAFT ASSEMBLY 1. Press a new bearing (66) (Figure 16-41, Page 16-18) onto each end of the idler shaft (Figure 16-54, Page 16-24). See following CAUTION. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-23...
Page 296: Intermediate Gear Assembly
(x) distance is less than .02 inch (0.5 mm). Turn idler shaft over and press bearing on other end. Figure 16-53 Synchro. Ring Figure 16-54 Idler Shaft Page 16-24 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 297 (Figure 16-41, Page 16-18). 14. Install the spring washer (39) onto shaft with the raised center toward the end of the shaft (Figure 16- 41, Page 16-18). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-25...
Page 298: Shifter Fork Assembly
(34). Remove screwdriver when the shift rod is inserted far enough for it to depress the ball and spring, then continue to insert rod until the ball is positioned in the middle groove on the rod (Fig- ure 16-41, Page 16-18). Page 16-26 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 299: Differential Gear Case Assembly
...then tap differential pin into carrier case, through thrust plate and idler gear, then continue to tap differential pin about another inch past idler gear. Figure 16-60 Differential Gear Figure 16-61 Idler Gear 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-27...
Page 300 DOWEL PIN to 18 ft-lb (24.4 N·m)..then tap ring gear onto the differential gear case. DOWEL HOLE Figure 16-64 Ring Gear Figure 16-65 Retaining Bolts Page 16-28 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 301: Governor Gear Assembly
(40) is meshed with the governor gear (63) (Figure 16-41, Page 16-18), and the shifter lever (14) (Figure 16-34, Page 16-15) is positioned in the bracket on the shifter fork. See also Figure 16-76, Page 16-33. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-29...
Page 302 Press oil seal in left side of case into right side until end of shaft case. is even with end of tool. Figure 16-66 Install Seals Figure 16-67 Governor Gear Shaft Page 16-30 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 303 16-5, Page 16-4). 11.1. Make sure the mating surfaces of the axle tubes and the transaxle case are clean and free of oil, grease, or residue of any kind. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-31...
Page 304 Position shifter fork on synchronizer sleeve. Cutaway view of shifter SLOT fork and synchronizer gear assembly being inserted as a unit into casing. Figure 16-74 Oil Guide Figure 16-75 Synchronizer Ring Gear Page 16-32 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 305 GEAR Shifter arm and the (These three gears mesh.) shifter fork slotted DIFFERENTIAL arm also mesh. RING GEAR SMALL IDLER GEAR Figure 16-76 Gear Alignment Figure 16-77 Gear Alignment 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-33...
Page 306 Three Bond No. 1215 to mating surface. Figure 16-80 Casing Torque Sequence Figure 16-81 Axle Tube Surface Page 16-34 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 307: Unitized Transaxle Installation
12. Position the driven clutch on the transaxle input shaft and install the washer (yellow side facing out) and mounting bolt. Tighten the mounting bolt to 14 ft-lb (19.0 N·m) (Figure 16-88, Page 16-37). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-35...
Page 308 2. Turn shaft counterclockwise. Install two governor cable bracket mounting screws. 3. Pull governor arm rearward. Figure 16-86 Governor Cable Bracket Figure 16-87 Governor Arm Page 16-36 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 309 22. Install three wire ties to secure the engine kill wire to the accelerator cable where they both route together on the passenger side of the engine. 23. Connect the oil level sensor wire (18 gauge yellow) to the jumper wire (Figure 16-94, Page 16-39). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-37...
Page 310 Install and tighten the level indicator hole plug to 21 ft-lb (28.5 N·m). WHITE/BLACK WIRE Connect shock absorbers at BLACK lower mounts. WIRE Figure 16-92 Shock Absorber Figure 16-93 Ignition Kill Wire Page 16-38 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 311 Connect engine ground and tighten retaining nut. Pull spring release back to Tighten nuts. connect shifter cable to lever. TOP VIEW Figure 16-96 Connect Shifter Cable Figure 16-97 Engine Ground 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-39...
Page 312 IMPULSE LINE Figure 16-100 Impulse Line Figure 16-101 Air Intake Hose Connect tube to carburetor. Squeeze clamp to position it. Figure 16-102 Carburetor Tube Page 16-40 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 313: Forward/Reverse (F&R) Shifter Cable
5. Install the ball joint socket (2) on the F&R shifter assembly ball stud (3) (Figure 16-104, Page 16-42). 6. Install wire tie (8) to secure wire harness to cable at the support bracket near the F&R shifter assembly (Figure 16-104, Page 16-42). See following WARNING. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-41...
Page 314: F&R Shifter Cable Adjustment
Forward/Reverse handle (9) (Figure 16-104, Page 16-42) should be straight up. For minor adjustments, the nut (1) may be loosened and the ball joint socket (2) rotated to get the proper adjustment (Figure 16-104, Page 16-42). See following CAUTION. Page 16-42 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 315 NEUTRAL position (Figure 16-103, Page 16-41). Retighten nuts to 22 ft-lb (29.8 N·m); retighten nuts (5) at the F&R assembly to 43 in-lb (4.9 N·m). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-43...
Page 317: Section 17 - Torque Converter
(smaller diameter) on the drive clutch. The driven clutch is mounted on the transaxle. It is in the closed position, and the drive belt is riding at a high position (large diameter) on it when the engine is at idle. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 17-1...
Page 318 DRIVEN CLUTCH DRIVEN CLUTCH CAM PULLER PULLER PLUG (CCI 1014508) (CCI 1014507) DRIVE CLUTCH HOLDER TOOL DRIVE (CCI 1015524) CLUTCH PULLER (CCI 1014496) Figure 17-1 Torque Converter Tool Kit Page 17-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 319: Troubleshooting
Maintaining proper adjustment of the engine and governor, as well as the torque converter, is essential to the troubleshooting process. If these adjustments are within Club Car speciﬁcations and, when climbing a steep hill, the engine begins to lose RPM before the drive belt reaches the top of the driven clutch, there is a torque converter problem.
Page 320: Drive Belt Installation
6. Support the drive clutch assembly in your hand and back the clutch puller tool out of the crankshaft. ∆ CAUTION • Do not hit or tap the clutch with a hammer. Do not pry the clutch. These actions will damage the clutch. Page 17-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 321: Drive Clutch Cleaning And Inspection
2. Inspect the belt contact surfaces of the clutch sheaves for wear. If any area of a sheave contact surface has wear of 0.060 inch (1.52 mm) or more, the clutch should be replaced. 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 17-5...
Page 322 TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES (ONE SPRING PER CLUTCH) Figure 17-5 Drive Clutch Assembly Page 17-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 323: Drive Clutch Disassembly
DRIVE CLUTCH HUB PULLER TOOL (CCI 1014497) Mark the clutch cover and its corresponding position on the moveable casting. Figure 17-6 Mark Clutch Cover Figure 17-7 Remove Clutch Cover 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 17-7...
Page 324 9. Use a scribe or small pick to remove the spiral backup rings (12) from each end of the bore in the ﬁxed face assembly (Figure 17-5, Page 17-6 and Figure 17-11, Page 17-9). Discard the rings. Page 17-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 325: Inspection Of Drive Clutch Parts
4. Install the spacer (13) onto the shaft of the ﬁxed face (Figure 17-5, Page 17-6). 5. Install a new spiral backup ring (12) in each end of the bore of the moveable face assembly (14) (Fig- ure 17-5, Page 17-6). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 17-9...
Page 326 NOTE: Make sure there is at least a (minimum) gap of 0.020 inch (0.51 mm) between each end of the mounting pin and the mounting screw. 13. Install one drive button take-up spring. Page 17-10 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 327 16. Install a number 10-24 button retaining screw with ﬂat washer through each button and into the rib. Tighten the screws to 34 in-lb (3.8 N·m) (Figure 17-9, Page 17-8). DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED Figure 17-15 Correct Orientation of Drive Button Take-up Spring 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 17-11...
Page 328 18. Install the hub assembly (1) on the moveable face assembly and align the match marks made before disassembling the clutch. Press the hub assembly on by hand (Figure 17-5, Page 17-6). TYPICAL 3 PLACES Figure 17-16 Driven Clutch Assembly Page 17-12 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 329: Drive Clutch Installation
3. Remove the spring (5) (Figure 17-16, Page 17-12). 4. Retain the key (3). 5. Slide the moveable face (7) off the ﬁxed face shaft (8) (Figure 17-16, Page 17-12). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 17-13...
Page 330: Driven Clutch Inspection
Rotate the cam until the keyway is aligned with the key (3) on the ﬁxed face assembly, and then start the cam onto the shaft approximately 1/4 to 3/8 inch (6.3 to 9.5 mm). Page 17-14 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 331: Driven Clutch Installation
1. To install the driven clutch, reverse the removal procedure. Before tightening the center bolt (11) to 14 ft-lb (19.0 N·m), make sure the mounting washer (12) is installed between the center bolt and the clutch (yellow side facing out) (Figure 17-16, Page 17-12). 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 17-15...
Page 333 ............13-25 vibration damage .......... 12-32 carburetor voltage test ............ 11-22 choke and fresh air system ......14-4 water level ............. 12-32 closed throttle or idle adjustment ....14-13 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page i-1...
Page 334 ............17-14 installation ..........13-42 disassembly ...........17-13 removal ............. 13-42 inspection ............17-14 removal ............13-24 installation ............17-15 crankshaft axial play adjustment ........13-44 operation ............17-1 disassembly ........... 13-36 removal ............17-13 Page i-2 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 335 ............12-17 floor mat testing ............11-23 removal and installation ........4-12 flywheel installation generator circuit see engine assembly operation ............11-8 removal ............13-31 troubleshooting ..........11-14 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page i-3...
Page 336 ......13-41 rear crankshaft ............13-39 installation .............9-5 cylinder head ..........13-12 removal ............9-3 drive clutch ............17-5 lighting circuit drive clutch parts ......... 17-9 operation ............11-13 Page i-4 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 337 ............11-37 removal ............. 12-21 oil light testing ..........11-28, 11-37 see low oil warning light removal ............12-20 oil pressure relief valve inspection ............13-34 testing ............11-37 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page i-5...
Page 338 ............12-16 testing ............11-26 rack and pinion spark plug assembly ............. 7-10 cleaning, inspection and repair ......13-7 disassembly ..........7-8 installation ........... 7-13 adjustment ..........13-8 removal ............7-8 Page i-6 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 339 ............. 4-6 tire tailskirt installation ............8-3 removal and installation ........4-12 test procedure pressure ............8-1 battery ..........11-20, 11-38 removal ............. 8-2 diode ............. 11-30 repair ..............8-3 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page i-7...
Page 340 ............7-20 valve guides installation ............7-22 inspection ............13-13 removal ............7-22 replacement ........... 13-13 wire valve seat continuity testing ..........11-30 inspection ............13-13 wiring diagram ............11-6 Page i-8 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual...
Page 344 Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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