Fuel Pump Removal; Fuel Pump Disassembly; Fuel Pump Cleaning And Inspection - Pioneer 1200 Maintenance Service Manual

FUEL SYSTEM

FUEL PUMP REMOVAL

1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 1, Page 1-1.
3. Turn fuel shut-off valve on top of the fuel tank to the closed (OFF) position (Figure 14-20, Page 14-27).
4. Remove hardware (25) attaching the fuel pump (18) and lift fuel pump from the engine compartment
(Figure 14-15, Page 14-23 or Figure 14-16, Page 14-24).
5. Remove the clamp (20) and impulse line (7) from fuel pump.
6. Remove clamps (16) and fuel lines (2 and 3) from the fuel pump. Plug lines to prevent gasoline leakage.
See following WARNING.
∆
WARNING
• Carefully drain any fuel remaining in the pump into a clean container. Add drained fuel back
into fuel tank or dispose of properly.

FUEL PUMP DISASSEMBLY

NOTE: A fuel pump rebuild kit is available from Club Car (CCI P/N 1014524).
1. Remove four screws (24) and lock washers (25) from front of the fuel pump (Figure 14-12, Page 14-20).
2. Remove the front cover of the fuel pump while holding the rest of the pump intact.
3. Note the orientations of the impulse gasket (27), the diaphragm (28), and the gasket (29), then remove
them from the pump. See following CAUTION.
CAUTION
• Fuel pump gaskets and diaphragms must be reinstalled in exactly the same positions and
orientations they were in before disassembly, or the pump could leak. If leaking occurs, all
new gaskets and diaphragms must be installed.
4. Remove the pumping chamber (30).
5. Remove the back cover (36), the fuel diaphragm (34), and gasket (35).

FUEL PUMP CLEANING AND INSPECTION

1. Use a nonflammable solvent to clean the front cover, pumping chamber, and back cover. Be sure the vent
on the front cover is clean both inside and out.
2. Inspect the valve assemblies (31, 32, and 33), gaskets and diaphragms for damage (Figure 14-12,
Page 14-20).
3. If a valve assembly is damaged, the rubber retaining plug (33) and valve assembly must be replaced.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
14
Fuel Pump
Page 14-19