2003 Club Car Pioneer 1200 1200SE Service Maintenance Manual

Description

This Official 2003 Club Car Pioneer 1200 1200SE Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2003 Club Car Pioneer 1200 1200SE Gas Powered Performance Vehicles.  Covers the FE350 engine.

This manual includes the following repair information:

SECTION 1 – SAFETY
General Warning

SECTION 2 – VEHICLE SPECIFICATIONS

SECTION 3 – GENERAL INFORMATION
General Information
Serial Number Identification
Storage
Preparing the Vehicle for Extended Storage
To Return Vehicle to Service

SECTION 4 – BODY AND TRIM
Cleaning the Vehicle
Front Body Repair
Abrasions and Haze
Light Scratches
Large Scratches and Abrasions
Front Body Components
Dashboard Removal
Dashboard Installation
Front Body Removal
Front Fender Removal
Front Fender Installation
Front Body Installation
Seat
Seat Adjustment
Front Seat Support
Front Seat Support Removal
Front Seat Support Installation
Rear Seat Support
Rear Seat Support Removal
Rear Seat Support Installation
Cargo Bed
Cargo Bed Removal
Cargo Bed Installation
Bed Stop Bumper Adjustment
Rear Fender Removal
Rear Fender Installation
Tailskirt
Tailskirt Removal
Tailskirt Installation
Receiver Flitch
Receiver Flitch Removal
Receiver Hitch Installation
Floor Mat
Floor Mat Removal
Floor Mat Installation

SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES
Brake Pedal
Brake Pedal Removal
Brake Pedal Installation
Brake Pedal Adjustment
Accelerator Pedal
Accelerator Pedal Removal
Accelerator Pedal Installation
Accelerator Pedal Adjustment

SECTION 6 – MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS
Brake System Inspection
Brake System Troubleshooting
Brake Drum Removal
Front Wheel Brake Drum Removal
Rear Wheel Brake Drum Removal
Brake Shoe Removal
Front Brake Shoe Removal
Rear Brake Shoe Removal
Brake Cluster Inspection and Cleaning
Brake Shoe Installation
Front Brake Shoe Installation
Rear Brake Shoe Installation
Brake Drum Installation
Front Wheel Brake Drum Installation
Rear Wheel Brake Drum Installation
Brake Cluster Assembly Replacement
Front Brake Cluster Assembly Removal
Front Brake Cluster Assembly Installation
Rear Brake Cluster Assembly Removal
Rear Brake Cluster Assembly Installation
Wheel Cylinder Replacement
Front Wheel Cylinder Removal
Front Wheel Cylinder Installation
Rear Wheel Cylinder Removal
Rear Wheel Cylinder Installation
Brake Shoe Adjuster Replacement
Front Brake Shoe Adjuster Removal
Front Brake Shoe Adjuster Installation
Rear Brake Shoe Adjuster Removal
Rear Brake Shoe Adjuster Installation
Hydraulic Line and Flose Replacement
Front Brake Line Removal
Front Brake Line Installation
Front Brake Flose Assembly Removal
Front Brake Flose Assembly Installation
Rear Brake Line Removal
Rear Brake Line Installation
Rear Brake Hose Removal
Rear Brake Hose Installation
Master Cylinder And Bell Crank Replacement
Bell Crank Removal
Bell Crank Installation
Master Cylinder Removal
Master Cylinder Installation
Bleeding the Hydraulic Brake System
Purging the Hydraulic System
Filling the Hydraulic System
Park Brake System
Park Brake Cable Removal
Park Brake Cable Installation
Park Brake Handle Removal
Park Brake Handle Installation
Park Brake Adjustment

SECTION 7 – STEERING AND FRONT SUSPENSION
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Disassembly
Steering Column Assembly
Steering Column Installation
Rack and Pinion
Rack and Pinion Removal
Rack and Pinion Disassembly
Rack and Pinion Assembly
Rack and Pinion Installation
Front Suspension
Lubrication
Wheel Alignment
Front Suspension Components
Kingpin and Steering Spindle Removal
Kingpin and Steering Spindle Installation
A-Arm Removal
A-Arm Installation
Shock Absorber Removal
Shock Absorber Installation
Front Wheel Bearings and Hubs
Front Wheel Free Play Inspection
Front Wheel Bearings and Hub Removal
Front Wheel Bearings and Hub Installation

SECTION 8 – WHEELS AND TIRES
General Information

SECTION 9 – REAR SUSPENSION
Shock Absorbers
Shock Absorber Removal and Inspection
Shock Absorber Installation
Multi-Leaf Springs
Multi-Leaf Spring Removal
Multi-Leaf Spring Installation
Snubber
Snubber Removal
Snubber Installation

SECTION 10-PERIODIC MAINTENANCE
Periodic Service Schedule
Periodic Lubrication Schedule
Master Cylinder
Brake Fluid
Engine Oil
Engine Oil Level Check
Engine Oil and Filter Change
Oil Viscosity
Fueling Instructions
Battery

SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400 ENGINE
Troubleshooting Guide
Electrical System
Wiring Diagram
Electrical Circuits
Starter Circuit
Generator Circuit
Engine Ignition Circuit
Engine Kill Circuit
Reverse Buzzer Circuit
Low Oil Warning Circuit
Lockout Cam Circuit
Fuel Gauge and Sending Unit Circuit
Hour Meter Circuit
Lighting Circuit
Circuit Testing
Testing the Starter Circuit and Generator Circuit
Testing the Engine Ignition Circuit
Testing the Engine Kill Circuit
Testing the Reverse Buzzer Circuit
Testing the Low Oil Warning Circuit
Testing the Lockout Cam Circuit
Testing the Fuel Gauge and Sending Unit Circuit
Testing the Lighting Circuit
Test Procedures
Index of Test Procedures

SECTION 12- ELECTRICAL COMPONENTS: FE400 ENGINE
Starter/Generator
Voltage Regulator
Diode
Key Switch
Solenoid
Fuse
Lockout Cam Limit Switch
Lockout Cam
Reverse Warning Buzzer
Reverse Buzzer Limit Switch
Low Oil Warning Light
Fuel Gauge/Hour Meter
Fuel Level Sending Unit
RPM Limiter
Ignition Coil
Oil Level Sensor
Headlights
Voltage Limiter
Light Switch
Testing the Light Switch
Battery
General information
Ground Straps

SECTION 13-FE400 ENGINE
General Information
Special Engine Service Tools Available From Club Car
Before Servicing
Lubrication System
Spark Plug
Cylinder
Breather Valve (Reed Valve)
Valve Clearance Check and Adjustment
Crankcase
Engine Removal
Crankcase Cover Removal
Oil Level Sensor
Test Procedures
Index of Test Procedures
ignition Coil and Flywheel
Crankcase Cover Installation
Flywheel Installation
Engine Installation
Torque Specifications
Adjustment and Settings

SECTION 14-FUEL SYSTEM
General Information
Carburetor
Main Jet Elevation/Size Chart
Changing the Main Jet
Engine Control Linkage
General Information
Accelerator Rod
Governor Cable
Accelerator Cable
Closed Throttle or Idle Adjustment
Engine RPM Adjustment
Choke and Air Intake System
Choke Cable Removal
Choke Cable Installation
Air Box Removal
Air Box Installation
Intake Duct Repair
Intake Duct Removal
Intake Duct Installation
Air Filter
Fuel Filter Removal
Fuel Filter Installation
Fuel Pump
General Information
Fuel Pump Removal
Fuel Pump Disassembly
Fuel Pump Cleaning and Inspection
Fuel Pump Assembly
Fuel Pump Installation
Fuel Tank
Fuel Tank Removal
Fuel Tank Storage or Disposal
Fuel Tank Installation
Fuel Lines
Fuel Shut-Off Valve

SECTION 15-EXHAUST SYSTEM
Muffler
Muffler Removal
Muffler Installation

SECTION 16-MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
General Information
Lubrication
Axle Shaft
Axle Shaft, Bearing, and Oil Seal Removal
Axle Bearing Removal
Axle Shaft, Bearing, and Oil Seal Installation
Unitized Transaxle Removal
Unitized Transaxle Installation
Forward/Reverse Shifter Cable
Forward/Reverse Shifter Cable Removal
Forward/Reverse Shifter Cable Installation
Forward/Reverse Shifter Cable Adjustment
Differential Lock System
Differential Lock System Inspection
Differential Lock Cable Removal
Differential Lock Cable Installation

SECTION 17-TORQUE CONVERTER
Genera! Information
Drive Belt
Drive Belt Removal
Drive Belt Installation
Drive Clutch
Drive Clutch Removal
Drive Clutch Cleaning and Inspection
Drive Clutch Disassembly
Inspection of Drive Clutch Parts
Drive Clutch Assembly
Drive Clutch Installation
Driven Clutch
Driven Clutch Removal
Driven Clutch Disassembly
Driven Clutch Inspection
Driven Clutch Assembly
Driven Clutch Installation