Choke And Air Intake System; Choke Cable Removal; Choke Cable Installation; Air Box Removal - Pioneer 1200 Maintenance Service Manual

FUEL SYSTEM

CHOKE AND AIR INTAKE SYSTEM

See General Warning, Section 1, Page 1-1.

CHOKE CABLE REMOVAL

1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Remove the screw (17) securing cable to air box and detach cable end from choke lever (6)
(Figure 14-10, Page 14-17 or Figure 14-11, Page 14-18).
3. Remove three screws (19), nuts (21) and washers (20) from body and remove choke cable assembly.
4. Pioneer 1200 SE:
4.1. Cut wire tie (23) around cable and air duct (Figure 14-11, Page 14-18).

CHOKE CABLE INSTALLATION

1. Insert choke cable through hole in body until choke lever assembly seats against body.
2. Install three screws (19), washers (20), and locknuts (21) (Figure 14-10, Page 14-17 or Figure 14-11,
Page 14-18).Tghten to 18 in-lb (2.0 N·m).
3. Check the hex nut on the cable at the back of the choke lever assembly and tighten it until the lock washer
beside it collapses completely.
4. Attach choke cable to choke lever (6) on air box top (4) and install screw (17) to secure cable to air box.
Tighten screw to 18 in-lb (2.0 N·m).
5. Pioneer 1200SE:
5.1. Attach a new wire tie (23) around the cable and air duct (Figure 14-11, Page 14-18).

AIR BOX REMOVAL

1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Remove choke cable bracket screw (17) and cable (18) from air box top (4) (Figure 14-10, Page 14-17
or Figure 14-11, Page 14-18).
3. Pioneer 1200:
3.1. Remove air intake box (12) from the vehicle by removing hose clamp (15), intake hose (16), three
screws (23) and washers (22) (Figure 14-10, Page 14-17).
4. Pioneer 1200SE:
4.1. Remove air intake box (12) from the vehicle by removing hose clamp (15), intake hose (16), three
screws (25) and washers (24) (Figure 14-11, Page 14-18).

AIR BOX INSTALLATION

NOTE: The intake duct must be in place before the air box can be installed.
1. Check to be sure the intake seal (13) is tightly seated (Figure 14-10, Page 14-17 or Figure 14-11,
Page 14-18).
2. Pioneer 1200:
2.1. Place air box assembly into vehicle and install three flat washers (22) and screws (23) from under-
side of air box mounting plate into air box (12) (Figure 14-10, Page 14-17). Tighten to 33 in-lb (3.7
N·m).
2.2. Place hose (16) onto air box top (4) and secure with wire clamp (15).
2.3. Attach choke cable (18) to the air box top (4). See Choke Cable Installation on page 14-11.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Choke and Air Intake System
Page 14-11
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