Pioneer 1200 Manuals

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

Pioneer 1200 Maintenance Service Manual (300 pages)

2003

Brand: Pioneer | Category: Utility Vehicle | Size: 13.32 MB

Table of Contents
5
Section 1 - Safety

15
- General Warning
  15
Section 2 - Vehicle Specifications

19
Section 3 - General Information

21
- General Information
  21
- Serial Number Identification
  21
- Storage
  21
  - Preparing the Vehicle for Extended Storage
    22
  - To Return Vehicle to Service
    22
Section 4 - Body and Trim

25
- Cleaning the Vehicle
  25
- Front Body Repair
  25
  - Abrasions and Haze
    25
  - Light Scratches
    26
  - Large Scratches and Abrasions
    26
- Front Body Components
  26
  - Dashboard Removal
    26
  - Dashboard Installation
    26
  - Front Body Removal
    27
  - Front Fender Removal
    27
  - Front Fender Installation
    28
  - Front Body Installation
    28
- Seat
  28
  - Seat Adjustment
    28
- Front Seat Support
  30
  - Front Seat Support Removal
    30
  - Front Seat Support Installation
    31
- Rear Seat Support
  31
  - Rear Seat Support Removal
    31
  - Rear Seat Support Installation
    31
- Cargo Bed
  33
  - Cargo Bed Removal
    33
  - Cargo Bed Installation
    33
  - Bed Stop Bumper Adjustment
    35
  - Rear Fender Removal
    36
  - Rear Fender Installation
    36
- Tailskirt
  36
  - Tailskirt Removal
    36
  - Tailskirt Installation
    36
- Receiver Hitch
  36
  - Receiver Hitch Removal
    36
  - Receiver Hitch Installation
    37
- Floor Mat
  38
  - Floor Mat Removal
    38
  - Floor Mat Installation
    38
Section 5 - Accelerator and Brake Pedal Assemblies

39
- Brake Pedal
  39
  - Brake Pedal Removal
    39
  - Brake Pedal Installation
    39
- Brake Pedal Adjustment
  40
- Accelerator Pedal
  42
  - Accelerator Pedal Removal
    42
  - Accelerator Pedal Installation
    43
- Accelerator Pedal Adjustment
  43
Section 6 - Mc012C-As00 Transaxle: Hydraulic and Park Brake Systems

47
Section 7 - Steering and Front Suspension

85
- Steering Wheel
  85
  - Steering Wheel Removal
    85
  - Steering Wheel Installation
    87
- Steering Column
  87
  - Steering Column Removal
    87
  - Steering Column Disassembly
    87
  - Steering Column Assembly
    88
  - Steering Column Installation
    88
- Rack and Pinion
  89
  - Rack and Pinion Removal
    89
  - Rack and Pinion Disassembly
    90
  - Rack and Pinion Assembly
    93
  - Rack and Pinion Installation
    94
- Front Suspension
  96
  - Lubrication
    96
  - Wheel Alignment
    96
- Front Suspension Components
  98
  - Kingpin and Steering Spindle Removal
    98
  - Kingpin and Steering Spindle Installation
    98
  - A-Arm Removal
    99
  - A-Arm Installation
    101
  - Shock Absorber Removal
    101
  - Shock Absorber Installation
    102
- Front Wheel Bearings and Hubs
  102
Section 8 - Wheels and Tires

105
- General Information
  105
Section 9 - Rear Suspension

107
- Shock Absorbers
  107
  - Shock Absorber Removal and Inspection
    107
  - Shock Absorber Installation
    107
- Multi-Leaf Springs
  107
  - Multi-Leaf Spring Removal
    107
  - Multi-Leaf Spring Installation
    109
- Snubber
  110
  - Snubber Removal
    110
  - Snubber Installation
    110
Section 10 - Periodic Maintenance

111
- Periodic Service Schedule
  111
- Periodic Lubrication Schedule
  112
- Master Cylinder
  113
  - Brake Fluid
    114
- Engine Oil
  114
  - Engine Oil Level Check
    114
  - Engine Oil and Filter Change
    115
  - Oil Viscosity
    117
- Fueling Instructions
  117
- Battery
  118
Section 11 - Troubleshooting and Electrical System: Fe400 Engine

121
- Troubleshooting Guide
  121
- Electrical System
  125
- Wiring Diagram
  126
- Electrical Circuits
  128
  - Starter Circuit
    128
  - Generator Circuit
    128
  - Engine Ignition Circuit
    129
  - Engine Kill Circuit
    129
  - Reverse Buzzer Circuit
    130
  - Low Oil Warning Circuit
    130
  - Lockout Cam Circuit
    131
  - Fuel Gauge and Sending Unit Circuit
    132
  - Hour Meter Circuit
    133
  - Lighting Circuit
    133
- Circuit Testing
  133
- Test Procedures
  139
  - Index of Test Procedures
    139
Section 12 - Electrical Components: Fe400 Engine

150
- Starter/Generator
  150
- Voltage Regulator
  179
- Diode
  180
- Key Switch
  182
- Solenoid
  183
- Fuse
  183
- Lockout Cam Limit Switch
  185
- Lockout Cam
  185
- Reverse Warning Buzzer
  186
- Reverse Buzzer Limit Switch
  187
- Low Oil Warning Light
  188
- Fuel Gauge/Hour Meter
  189
- Fuel Level Sending Unit
  190
- RPM Limiter
  190
- Ignition Coil
  191
- Oil Level Sensor
  194
- Headlights
  194
- Voltage Limiter
  195
- Light Switch
  196
  - Testing the Light Switch
    196
- Battery
  196
  - General Information
    197
- Ground Straps
  201
Section 13 - Fe400 Engine

203
- General Information
  203
  - Special Engine Service Tools Available from Club Car
    203
  - Before Servicing
    203
  - Lubrication System
    203
  - Spark Plug
    203
- Cylinder
  205
  - Breather Valve (Reed Valve)
    205
  - Valve Clearance Check and Adjustment
    205
- Crankcase
  205
  - Engine Removal
    205
  - Crankcase Cover Removal
    206
  - Oil Level Sensor
    206
- Ignition Coil and Flywheel
  207
  - Crankcase Cover Installation
    210
- Flywheel Installation
  210
- Engine Installation
  211
  - Torque Specifications
    212
  - Adjustment and Settings
    212
Section 14 - Fuel System

213
- General Information
  213
- Carburetor
  213
  - Main Jet Elevation/Size Chart
    213
  - Changing the Main Jet
    214
- Engine Control Linkage
  217
  - General Information
    217
  - Accelerator Rod
    218
  - Governor Cable
    219
  - Accelerator Cable
    220
  - Closed Throttle or Idle Adjustment
    222
  - Engine RPM Adjustment
    222
- Choke and Air Intake System
  223
  - Choke Cable Removal
    223
  - Choke Cable Installation
    223
  - Air Box Removal
    223
  - Air Box Installation
    223
  - Intake Duct Repair
    224
  - Intake Duct Removal
    224
  - Intake Duct Installation
    226
  - Air Filter
    227
  - Fuel Filter Removal
    228
  - Fuel Filter Installation
    228
- Fuel Pump
  228
  - General Information
    228
  - Fuel Pump Removal
    231
  - Fuel Pump Disassembly
    231
  - Fuel Pump Cleaning and Inspection
    231
  - Fuel Pump Assembly
    232
  - Fuel Pump Installation
    232
- Fuel Tank
  233
  - Fuel Tank Removal
    233
  - Fuel Tank Storage or Disposal
    237
  - Fuel Tank Installation
    237
- Fuel Lines
  238
- Fuel Shut-Off Valve
  239
Section 15 - Exhaust System

241
- Muffler
  241
  - Muffler Removal
    241
  - Muffler Installation
    241
Section 16 - Mc012C-As00 Unitized Transaxle with Differential Lock

243
- General Information
  243
  - Lubrication
    244
- Axle Shaft
  245
- Unitized Transaxle Removal
  248
- Unitized Transaxle Installation
  258
- Forward/Reverse Shifter Cable
  266
- Differential Lock System
  268
Section 17 - Torque Converter

271
- General Information
  271
- Drive Belt
  273
  - Drive Belt Removal
    273
  - Drive Belt Installation
    274
- Drive Clutch
  274
  - Drive Clutch Removal
    274
  - Drive Clutch Cleaning and Inspection
    275
  - Drive Clutch Disassembly
    276
  - Inspection of Drive Clutch Parts
    277
  - Drive Clutch Assembly
    279
  - Drive Clutch Installation
    282

Pioneer Categories

Car Receiver Receiver Stereo Receiver Amplifier

CD Player

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Pioneer 1200 Manuals

Pioneer 1200 Maintenance Service Manual (300 pages)

Table of Contents

Section 1 - Safety

Section 2 - Vehicle Specifications

Section 3 - General Information

Section 4 - Body and Trim

Section 5 - Accelerator and Brake Pedal Assemblies

Section 6 - Mc012C-As00 Transaxle: Hydraulic and Park Brake Systems

Section 7 - Steering and Front Suspension

Section 8 - Wheels and Tires

Section 9 - Rear Suspension

Section 10 - Periodic Maintenance

Section 11 - Troubleshooting and Electrical System: Fe400 Engine

Section 12 - Electrical Components: Fe400 Engine

Section 13 - Fe400 Engine

Section 14 - Fuel System

Section 15 - Exhaust System

Section 16 - Mc012C-As00 Unitized Transaxle with Differential Lock

Section 17 - Torque Converter

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