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Pioneer 900
Club Car Pioneer 900 Maintenance Service Manual
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Table of Contents
Table of Contents
5
Section 1 - Safety
15
General Warning
15
Section 2 - Vehicle Specifications
17
General Information
17
Specifications
17
Section 3 - General Information
19
Serial Number Identification
19
Storage - Gasoline Vehicle
19
Preparing the Vehicle for Extended Storage
19
Returning the Stored Vehicle to Service
20
Section 4 - Body and Trim
23
Cleaning the Vehicle
23
Front Body Repair
24
Stress Lines or Streaks
24
Minor Impact Damage/Deformations
24
Minor Scratches and Surface Blemishes
25
Small Scratches that Cannot be Buffed out
25
Gouges, Punctures, Tears, Large Scratches, and Abrasions
25
Brush Guard
25
Brush Guard Removal
25
Brush Guard Installation
26
Front Body
26
Front Body Removal
26
Front Body Installation
26
Front Fender Extension
27
Front Fender Extension Removal
27
Front Fender Extension Installation
28
Tilt Bed
28
Tilt Bed Removal
28
Tilt Bed Installation
30
Rear Fender
30
Rear Fender Removal
30
Rear Fender Installation
30
Receiver Hitch
33
Receiver Hitch Removal
33
Receiver Hitch Installation
34
Tailskirt
34
Tailskirt Removal
34
Tailskirt Installation
34
Floor Mat
34
Floor Mat Removal
34
Floor Mat Installation
34
Section 5 - Accelerator and Brake Pedal Group
35
Brake Pedal and Park Brake
36
Brake Pedal Removal
36
Brake Pedal Installation
36
Park Brake Removal
38
Park Brake Installation
38
Accelerator Pedal
39
Accelerator Pedal Removal
39
Accelerator Pedal Installation
40
Pedal Group Adjustment
41
Section 6 - Wheel Brake Assemblies
47
General Information
47
Brake Shoe Removal
48
Brake Assembly Cleaning
49
Brake Shoe Installation
51
Brake Cluster Removal and Installation
52
Rear Brake Cluster Removal
52
Rear Brake Cluster Installation
55
Front Brake Cluster Removal
56
Front Brake Cluster Installation
57
Front Brake Cables
57
Front Brake Cable Removal
57
Front Brake Cable Installation
58
Rear Brake Cables
60
Rear Brake Cable Removal
60
Rear Brake Cable Installation
61
Brake Adjustment
62
Brake Cluster Adjustment
62
Equalizing Brake Cables
63
Final Brake Cluster Adjustment
64
Test Drive Vehicle
64
Section 7 - Steering and Front Suspension
65
General Information
65
Steering Wheel
65
Steering Wheel Removal
65
Steering Wheel Installation
66
Steering Column
67
Steering Column Removal
67
Steering Column Disassembly
68
Steering Column Assembly
68
Steering Column Installation
70
Steering Adjustment
71
Rack and Pinion
72
Rack and Pinion Removal
72
Rack and Pinion Disassembly
72
Rack and Pinion Assembly
74
Rack and Pinion Installation
77
Tie Rod and Drag Link
77
Tie Rod and Drag Link Removal
77
Tie Rod and Drag Link Installation
78
Front Suspension
78
Lubrication
78
Wheel Alignment
79
Front Suspension Components
81
Multi-Leaf Spring Removal
81
Multi-Leaf Spring Installation
81
Kingpin and Steering Spindle Removal
81
Kingpin and Steering Spindle Installation
82
Delta A-Plate Removal
84
Delta A-Plate Installation
84
Shock Absorber Removal and Inspection
84
Shock Absorber Installation
84
Front Wheel Bearings and Hubs
84
Front Wheel Free Play Inspection
84
Front Wheel Bearings and Hub Removal
86
Front Wheel Bearings and Hub Installation
86
Section 8 - Wheels and Tires
89
General Information
89
Wheels
90
Wheel Removal
90
Wheel Installation
90
Tires
90
Tire Removal
90
Tire Repair
91
Tire Installation
91
Section 9 - Rear Suspension
93
General Information
93
Shock Absorbers
94
Shock Absorber Removal and Inspection
94
Shock Absorber Installation
94
Multi-Leaf Springs
95
Multi-Leaf Spring Removal
95
Multi-Leaf Spring Installation
97
Snubber
97
Snubber Removal
97
Snubber Installation
97
Stabilizer Bar
98
Stabilizer Bar Removal
98
Stabilizer Bar Installation
98
Section 10 - Periodic Maintenance
101
General Information
102
Daily Pre-Operation Safety Checklist
102
Periodic Service Schedule
103
Periodic Lubrication Schedule
104
Engine Oil
106
Oil Viscosity
106
Fueling Instructions
107
Battery
107
Section 11 - Troubleshooting and Electrical System
109
Electrical Circuits
116
Starter Circuit
116
Generator Circuit
116
Engine Ignition Circuit
117
Engine Kill Circuit
117
Reverse Buzzer Circuit
118
Low Oil Warning Circuit
119
Lockout Cam Circuit
119
Fuel Gauge and Sending Unit Circuit
120
Hour Gauge Circuit
121
Lighting Circuit
121
Circuit Testing
121
Testing the Starter Circuit and Generator Circuit
122
Testing the Engine Ignition Circuit
123
Testing the Engine Kill Circuit
123
Testing the Reverse Buzzer Circuit
124
Testing the Low Oil Warning Circuit
125
Testing the Lockout Cam Circuit
126
Testing the Fuel Gauge and Sending Unit Circuit
126
Testing the Lighting Circuit
127
Test Procedures
127
Index of Test Procedures
127
Section 12 - Electrical Components
153
Starter/Generator
154
Voltage Regulator
165
Diode
166
Key Switch
167
Solenoid
168
Fuse
169
Lockout Cam Limit Switch
170
Lockout Cam
171
Reverse Warning Buzzer
172
Reverse Buzzer Limit Switch
173
Oil Warning Light
173
Fuel/Hour Gauge
174
Fuel Level Sending Unit
175
RPM Limiter
176
Ignition Coil
177
Oil Level Sensor
180
Headlights
180
Headlight Diode
181
Light Switch
182
Battery
183
Ground Straps
187
Section 13 - Fe350 Engine
189
General Information
190
Special Engine Service Tools Available from Club Car
190
Before Servicing
190
Mechanical Systems
190
Electrical System
192
Lubrication System
193
Hydraulic Lifters
194
Spark Plug
194
Engine Mounting Plate
196
Cylinder Head
196
General Information
196
Cylinder Shroud Removal
196
Rocker Arm and Push Rod Removal
198
Cylinder Head Removal
198
Valve Removal
199
Breather Valve (Reed Valve)
200
Cylinder Head Cleaning and Inspection
200
Valve Guides
201
Valve Seats
201
Valves
204
Rocker Arm and Rocker Shaft Inspection
206
Push Rod Inspection
207
Cylinder Head Installation
207
Valve Clearance Check and Adjustment
208
Breather Valve (Reed Valve)
208
Installation of Remaining Engine Components
209
Crankcase
211
Engine Removal
211
Crankcase Cover Removal
212
Oil Level Sensor
212
Camshaft and Hydraulic Lifters
213
Piston and Connecting Rod
215
Cylinder Block
218
Ignition Coil and Flywheel
219
Oil Pump
220
Oil Pressure Relief Valve
222
Crankshaft and Counterbalance
223
Counterbalance Weight
226
Oil Screen
228
Ball Bearing
229
Oil Seals
230
Crankshaft Axial Play Adjustment
232
Crankcase Cover Installation
235
Engine Assembly
236
Service Specifications
238
Specifications for Resizing Cylinder Bore
239
Torque Specifications
239
Adjustments and Settings
240
Section 14 - Fuel System
241
General Information
241
How the Carburetor Works
242
Main System
242
Slow Speed System
242
Choke and Fresh Air System
244
Float System
244
Carburetor
244
Main Jet Elevation/Size Chart
245
Changing the Main Jet
245
Engine Control Linkage
248
General Information
248
Accelerator Rod
249
Governor Cable
250
Accelerator Cable
251
Closed Throttle or Idle Adjustment
253
Engine RPM Adjustment
253
Choke and Air Intake System
254
General Information
254
Choke Cable Removal
254
Choke Cable Installation
254
Air Box Removal
255
Air Box Installation
255
Intake Duct Removal
255
Intake Duct Installation
255
Intake Duct Repair
256
Air Filter
258
Fuel Filters
258
General Information
258
Fuel Filter Removal
259
Fuel Filter Installation
259
Fuel Pump
259
General Information
259
Fuel Pump Removal
260
Fuel Pump Disassembly
261
Fuel Pump Cleaning and Inspection
261
Fuel Pump Assembly
261
Fuel Pump Installation
262
Fuel Tank
263
General Information
263
Preparation for Extended Storage
263
Fuel Tank Removal
263
Fuel Tank Disposal
264
Fuel Tank Storage
264
Fuel Tank Installation
265
Fuel Lines
266
Fuel Shut-Off Valve
267
Section 15 - Exhaust System
269
General Information
269
Muffler
270
Muffler Removal
270
Muffler Installation
270
Section 16 - Unitized Transaxle
273
General Information
273
Lubrication
275
Axle Shaft
275
Axle Shaft and Oil Seal Removal
277
Axle Bearing
277
Axle Shaft Installation
279
Unitized Transaxle Removal
279
Unitized Transaxle Disassembly
286
Component Disassembly
291
Governor Gear Disassembly
291
Differential Gear Case Disassembly
291
Shifter Fork Disassembly
292
Synchronizer Gear Disassembly
292
Intermediate Gear Disassembly
293
Idler Shaft Disassembly
294
Unitized Transaxle Component Inspection
294
Component Assembly
295
Idler Shaft Assembly
295
Intermediate Gear Assembly
296
Synchronizer Gear Assembly
296
Shifter Fork Assembly
298
Differential Gear Case Assembly
299
Governor Gear Assembly
301
Unitized Transaxle Assembly
301
Unitized Transaxle Installation
307
Forward/Reverse (F&R) Shifter Cable
313
F&R Shifter Cable Removal
313
F&R Shifter Cable Installation
313
F&R Shifter Cable Adjustment
314
Section 17 - Torque Converter
317
General Information
317
Troubleshooting
319
Drive Belt
319
Drive Belt Removal
319
Drive Belt Installation
320
Drive Clutch
320
Drive Clutch Removal
320
Drive Clutch Cleaning and Inspection
321
Drive Clutch Disassembly
323
Inspection of Drive Clutch Parts
325
Drive Clutch Assembly
325
Drive Clutch Installation
329
Driven Clutch
329
Driven Clutch Removal
329
Driven Clutch Disassembly
329
Driven Clutch Inspection
330
Driven Clutch Assembly
330
Driven Clutch Installation
331
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Club Car Pioneer 900 Specifications
General
Fuel Type
Gasoline
Transmission
Automatic
Ground Clearance
4.5 in (11.4 cm)
Cargo Bed Capacity
300 lbs
Overall Width
48 inches
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