Service manual

ManualsBrandsEzgo ManualsOffroad VehicleTE5 PDS

1 - INCLUDES ITEMS 3 - 16

295cc and 350cc 4 CYCLE ENGINE

STARTING MODEL YEAR: 1992

ENGINE SHOP REBUILD

SERVICE PARTS MANUAL

27615-G01-rev.B

REVISED: 08/04

Summary of content (114 pages)

PAGE 1
27615-G01-rev.
PAGE 2
PAGE 3
ENGINE SHOP REBUILD & SERVICE PARTS MANUAL 295cc and 350cc ENGINE E-Z-GO Division of Textron, Inc. reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice. E-Z-GO Division of Textron, Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
PAGE 4
NOTES TO OBTAIN A COPY OF THE LIMITED WARRANTY THAT IS APPLICABLE TO THE VEHICLE, CALL OR WRITE THE LOCAL DISTRUBUTOR, E-Z-G0 BRANCH OR E-Z-G0 WARRANTY DEPARTMENT WITH VEHICLE SERIAL NUMBER AND MANUFACTURER’S CODE. THE USE OF NON E-Z-GO PARTS AND HARDWARE MAY VOID THE WARRANTY. TAMPERING WITH OR ADJUSTING GOVERNOR TO PERMIT VECLE TO OPERATE AT ABOVE FACTORY SETTINGS WILL VOID THE VEHICLE WARRANTY. IF APPLICABLE, REFER TO BACK COVER FOR CALIFORNIA AND/OR FEDERAL EMISSIONS CONTROL WARRANTY STATEMENT.
PAGE 5
TABLE OF CONTENTS Section Page No. How to use the E-Z-GO Service Manual.............. ............................................. .......................................... vii Federal and California Emissions Warranty Statements .................................... .................................... Section G ENGINE DISASSEMBLY A CYLINDER HEAD REMOVAL • Air Cleaner ........................................... ............................................. .........................................
PAGE 6
TABLE OF CONTENTS Section ENGINE MEASUREMENTS AND SPECIFICATIONS Page No. C ENGINE MEASUREMENTS AND SPECIFICATIONS • Check Flatness of Crankcase, End Cover and Cylinder Head .......... ......................................... C-1 • Crankcase Cylinder Bores ................... ............................................. ......................................... C-2 • Crankcase and End Cover Crankshaft Bearing Bores ...................... .........................................
PAGE 7
TABLE OF CONTENTS Section Page No. • Oil Pressure Switch ............................. ............................................. .........................................D-4 • Pulser Coil ........................................... ............................................. .........................................D-4 • Fan Hub ............................................... ............................................. .........................................D-4 • Pulser Coil and Air Gap ........
PAGE 8
TABLE OF CONTENTS Notes: Page vi Engine Shop Rebuild and Parts Manual
PAGE 9
HOW TO USE THIS MANUAL This manual is designed to suit the needs of mechanics at all levels of experience with the E-Z-GO 4-cycle engine. The outline format will allow the mechanic to choose the level of instructional detail needed to completely disassemble, diagnose, repair/overhaul and reassemble the engine. The manual is divided into four major operational sections, which are each divided into smaller operational sections.
PAGE 10
HOW TO USE THIS MANUAL viii Engine Shop Rebuild and Parts Manual
PAGE 11
ENGINE DISASSEMBLY TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE A PAGE NO. CYLINDER HEAD REMOVAL..........................................................................................................A - 1 Remove the Air Cleaner ........................................................................................................A - 1 Remove the Carburetor .........................................................................................................
PAGE 12
ENGINE DISASSEMBLY Notes: Page A-ii Repair and Service Manual
PAGE 13
A ENGINE DISASSEMBLY CYLINDER HEAD REMOVAL Tool List Remove the Coil Mounting Bracket and Coil Qty. Required Extension, 3/8” drive, 4" .............................................. 1 Mallet, medium wood or rubber .................................. 1 Puller, seal .................................................................. 1 Ratchet, 3/8” drive....................................................... 1 Screwdriver, small flat blade .......................................
PAGE 14
ENGINE DISASSEMBLY D. Remove the timing belt (ITEM 20). Do not twist the belt or turn it inside out. 1. Using a 10mm socket, remove the three (3) bolts (ITEM 5) and one (1) stud (ITEM 6). E. Remove the drive pulley retaining bolt (ITEM 17), front belt retainer (ITEM 21), drive pulley (ITEM 22). Rear belt retainer (ITEM 23) was present on early production engines. (Later models have four (4) bolts and no stud) F. Remove the cam pulley retaining bolt (ITEM 16) and the cam pulley (ITEM 24). B.
PAGE 15
ENGINE DISASSEMBLY VALVE REMOVAL Remove the Valves from the Cylinder Head (See Fig. A-3 “Valves” on page A-6) A. While supporting the valve (ITEM 1) from the bottom to prevent its downward motion, push the valve spring retainer (ITEM 2) down so that the valve stem keys (ITEM 6) are released from the retainer. It may be necessary to remove valve stem keys using a pair of needle nose pliers. (DETAIL A) B. Remove the spring retainer and spring (ITEM 3).
PAGE 16
Page A-4 14 13 Newer Model 12 A 15 18 16 17 20 11 21 22 19 13 24 26 Newer Model 25 27 28 5 2 3 1 Newer Model 10 8 6 9 4 12 11 7 ENGINE DISASSEMBLY Fig.
PAGE 17
14 13 Crankcase 7 11 15 12 2 1 3 8 16 19 9 10 Groove 6 6 2 A 4 Engine Shop Rebuild and Parts Manual 5 1 3 Follow numbers to remove cylinder head bolts in correct sequence 5 4 7 ENGINE DISASSEMBLY Fig.
PAGE 18
ENGINE DISASSEMBLY A 2 6 3 4 5 Push spring retainer down to release valve keys B Pry valve stem seal loose 1 Fig.
PAGE 19
ENGINE DISASSEMBLY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE B PAGE NO. CRANKCASE DISASSEMBLY.........................................................................................................B - 1 Remove the Oil Filter.............................................................................................................B - 1 Remove the Fan Hub ............................................................................................................B - 1 Remove the Pulser Coil.........
PAGE 20
ENGINE DISASSEMBLY Notes: Page B-ii Repair and Service Manual
PAGE 21
B ENGINE DISASSEMBLY CRANKCASE DISASSEMBLY Tool List Qty. Required Extension, 3/8” drive, 4" .............................................. 1 Extension, 3/8” drive, 6" .............................................. 1 Mallet, medium wood or rubber .................................. 1 Puller, (E-Z-GO P/N 27111-G01)................................. 1 Puller, seal .................................................................. 1 Punch, non-ferrous .....................................................
PAGE 22
ENGINE DISASSEMBLY Remove the Crankcase End Cover (See Fig. B-1 “Engine Components” on page B-4) (See Fig. B-2 “Engine Components con’t” on page B-5) Do not lose the crankshaft and balancer shaft end-play spacers. These are individually fitted to each engine, and are likely to fall from the engine when the cover is removed. If the end cover must be tapped loose, use a wooden or rubber mallet. Gently tap only the place shown in Detail D. A. Remove the fan hub alignment key (ITEM 20).
PAGE 23
ENGINE DISASSEMBLY C. To remove a bearing, turn the crankcase on its side, PTO (clutch) side up, and gently tap the bearing out with a brass drift (DETAIL A). Discard the bearing. The bearings can also be removed by heating the crankcase to 200°+ Fahrenheit. This will expand the aluminum crankcase and release the bearings. Crankcase must be heated evenly in an oven. DO NOT USE DIRECT HEAT, FLAME OR HOT LIQUID. Remove the PCV Valve (See Fig.
PAGE 24
30 23 1 3 2 Crankcase 26 27 13 11 24 25 12 15 16 18 17 14 9 10 19 4 21 22 5 Newer Model ENGINE DISASSEMBLY Fig.
PAGE 25
ENGINE DISASSEMBLY A B or Crankshaft Grind off 6 8 7 90 Crankshaft 0 Hold against puller screws, not against the crankshaft or fan Fan hub (shown without fan) D C 20 Crankshaft Drive end of key down and gently drive key up and out Lightly tap flanged edge of cover with a wooden or rubber mallet Fig.
PAGE 26
ENGINE DISASSEMBLY 1 4 5 3 6 2 A Seal puller Fig.
PAGE 27
ENGINE DISASSEMBLY Brass drift To drive bearing out straight, move drift side to side while tapping Newer Model A 4 6 4 9 8 6 5 7 1 3 10 2 Fig.
PAGE 28
ENGINE DISASSEMBLY A 1 2 8 6 5 4 3 7 B Crankshaft 1 Fig.
PAGE 29
ENGINE DISASSEMBLY B 5 6 7 3 4 Insert a suitable mandrel into the pin bore of the piston 3 1 2 Press the piston down onto the mandrel, pushing the wrist pin out A Insert screwdriver into slot and push to compress ring. Pry ring up and out of the retainer groove Remove the piston from the connecting rod Fig.
PAGE 30
ENGINE DISASSEMBLY Notes: Page B-10 Engine Shop Rebuild and Parts Manual
PAGE 31
ENGINE MEASUREMENTS TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE C PAGE NO. ENGINE MEASUREMENTS AND SPECIFICATIONS.................................................................... C - 1 Using Telescoping Gauges and Hole Gauges ..................................................................... C - 1 Check flatness of Crankcase, End Cover and Cylinder Head .............................................. C - 1 Crankcase Cylinder Bores...................................................................
PAGE 32
ENGINE MEASUREMENTS Notes: Page C-ii Engine Shop Rebuild and Parts Manual
PAGE 33
C ENGINE MEASUREMENTS ENGINE MEASUREMENTS AND SPECIFICATIONS Tool List Qty. Required Calipers, dial ............................................................... 1 Gauge, depth .............................................................. 1 Gauge Set, feeler ........................................................ 1 Gauge Set, telescoping............................................... 1 Micrometer, 1" ............................................................. 1 Micrometer, 2" ......................
PAGE 34
ENGINE MEASUREMENTS F. Turn the cylinder head so that the valve cover gasket surface rests on the surface plate. Check for flatness. A. Measure the rod and bearing journal diameters (DIMENSIONS A, B, C, D, E, AND G), in two (2) places each, 90° apart. If rod journals are excessively rough, scored or out of round, replace the crankshaft. Minor scratches on journals can be carefully polished using extra fine emery cloth. Thoroughly clean crankshaft after polishing and reinspect journal diameters. B.
PAGE 35
ENGINE MEASUREMENTS Wrist Pin (See Fig. C-5 “Piston, Wrist Pin and Connecting Rod” on page C-6) A. Measure wrist pin outside diameter at three (3) positions (DIMENSIONS E, F AND G), in two (2) places each, 90° apart. A. Measure the valve stem at three (3) positions (DIMENSIONS A, B, and C), in two (2) places each, 90° apart. B. Measure angle (D) and widths (DIMENSION E AND F) of the valve face. C. Measure valve spring free length (DIMENSION G). Connecting Rod (See Fig.
PAGE 36
ENGINE MEASUREMENTS Measure each position in the cylinder bore at 2 places A1 A2 B1 2 B A fine cross-hatched surface is the proper finish for a cylinder bore. Crankcase Detail A C2 C1 90 o A If "A1 " exceeds "C1 ", or if "A2 " exceeds "C2" by 0.004" (.1mm), rebore the cylinder. B C telescoping gauge 295cc 2.519"~2.520" STD. (64.000mm~64.019mm) 350cc 2.6378"~2.6385" STD. (67.000mm~67.019mm) Cylinder bore dimension is determined by size of the piston to be used.
PAGE 37
ENGINE MEASUREMENTS B1 B2 B A C Measure each bore in 2 places 90 o apart Crankcase and Endcover Cutaway view of crankcase and endcover through crankshaft bearing bores Recommended press Ball bearings onto fits: crankshaft Ball bearings into crankcase (0.00024~0.00067) (0.006~0.017) (in) (mm) E1 (0.00067~0.0024) (0.017~0.060) Measure each position o in 2 places 90 apart SPECS A B C (in) 2.4386~2.4398 (61.940~61.970) 2.8347~2.8359 (72.002~72.032) 2.8322~2.8334 (71.938~71.968) (in) 2.
PAGE 38
ENGINE MEASUREMENTS J 50 60 40 30 70 20 80 1 90 0 C 10 J D Measure the width and depth of each ring groove 2 K1 A1 120 Piston, wrist pin and connecting rod o B A2 K E1 Measure each position o in 2 places 90 apart 2 F E G E2 Recommended clearance for piston to cylinder wall (in) New engine Maximum wear limit (0.0008 ~ 0.0023) (0.0039) (mm) (0.020 ~ 0.059) (0.100) Recommended clearance for connecting rod to crankshaft (in) (.0006 ~ .0019) (0.0039) (mm) (0.015 ~ 0.
PAGE 39
ENGINE MEASUREMENTS Balancer shaft Crankcase and endcover A B SPECS C D STD. (in) (mm) 1.6516~1.6526 0.7869~0.7873 (41.950~41.975) (19.988~19.997) LIMIT (in) (mm) 1.6531 0.7864 (41.990) (19.975) Recommended press fit for balance shaft bearing (in) (mm) (0.0006~0.0020) (0.014~0.050) Cutaway view of crankcase and endcover through balancer shaft bearing bores Measure each bore o in 2 places 90 apart A1 A B A2 Measure each position o in 2 places 90 apart C2 D C1 D C Fig.
PAGE 40
ENGINE MEASUREMENTS Camshaft Cylinder head Recommended clearance for camshaft to cylinder head: (in) (mm) STD. (in) (mm) LIMIT (in) (mm) PTO Side (0.00079~0.0024) (0.020~0.062) B A SPECS Fan side (0.00098~0.0030) (0.025~0.075) C D E 1.3780~1.3789 0.9843~0.9851 1.3760~1.3770 (35.000~35.025) (25.000~25.021) F 1.048~1.052 0.9826~0.9835 (34.950~34.975) (26.620~26.720) (24.959~24.980) 1.3805 0.9865 1.375 1.040 0.9816 (35.065) (25.057) (34.925) (26.420) (24.
PAGE 41
ENGINE MEASUREMENTS A B SPECS STD. (in) 0.2165~0.2172 (mm) LIMIT (in) (mm) C D o 0.0118~0.0295 90 (5.500~5.518) 0.2175 (5.525) (0.30~0.75) 0.0591 * (1.5) * A total difference of 1o between the finish angles of the valve and valve seat is required. A1 A Measure each position o in 2 places 90 apart A2 Valve guide B Valve seat C* D 50 60 40 30 70 20 80 90 0 10 Fig.
PAGE 42
ENGINE MEASUREMENTS Valve Recommended clearance for valve to valve guide (in) (mm) Intake Exhaust (0.0018~0.0030) (0.045~0.075) (0.0022~0.0036) (0.056~0.092) A B C SPECS STD. (in) (mm) LIMIT (in) (mm) D Exhaust Intake 0.2143~0.2148 0.2136~0.2143 (5.443~5.455) (5.426~5.444) 0.2125 0.2125 (5.40) 90 * (5.40) * A total difference of 1 o F E 0.0891~0.1281 0.0276~0.0354 o (2.263~3.253) (0.7~0.9) 0.1392 0.0197 (3.536) (0.
PAGE 43
ENGINE MEASUREMENTS Rocker shaft assembly Cylinder head D Clearance Shaft to head Clearance A B C STD. (in) (mm) 0.4724~0.4731 (12.000~12.018) 0.4711~0.4718 (11.966~11.984) 0.4724~0.4731 (12.000~12.018) 0.0006~0.0020 (0.016~0.052) 0.0006~0.0020 (0.016~0.052) LIMIT (in) (mm) 0.4748 (12.060) 0.4704 (11.950) 0.4746 (12.055) 0.0039 (0.100) 0.0041 (0.105) SPECS C C Fan side Measure each position in 2 places 90o apart B1 Rocker shaft B2 B B 1 A A2 (Shaft/arm clearance) D Fig.
PAGE 44
ENGINE MEASUREMENTS 1" EH29C Recommended clearances 295 CC (64 MM BORE) for piston ring end gap EH35C 350 CC (67 MM BORE) Top ring (in) (mm) (0.008~0.016) (0.20~0.40) (0.006~0.010) (0.15~0.25) 2nd Ring (in) (mm) (0.008~0.016) (0.20~0.40) (0.006~0.012) (0.15~0.30) Oil ring (in) 3 Piece (mm) (0.008~0.028) (0.20~0.70) (0.004~0.024) (0.10~0.60) (in) (mm) (0.008~0.016) (0.20~0.40) 1 Piece Ring end gap Compression (Top) Wiper (Middle) * Oil (Bottom) 3 Piece 1 Piece STD. (in) (mm) 0.008~0.
PAGE 45
ENGINE MEASUREMENTS TIGHTENING TORQUE DESCRIPTION ft / lb kg / cm N/m Cylinder head bolts 16.6~19.5 230~270 22.5~26.5 Connecting rod cap bolts 12.3~14.5 170~200 16.7~19.6 Fan hub nut 43.4~47.0 600~650 58.8~63.7 6mm 5.8~7.2 80~100 7.8~9.8 8mm 12.3~13.7 170~190 16.7~18.6 New plug 8.7~10.9 120~150 11.8~14.7 Retightening 16.6~19.5 230~270 22.5~26.5 14.5~16.6 200~230 19.6~22.5 Drive gear bolt 5.8~7.2 80~100 7.8~9.8 Cam gear bolt 16.6~19.5 230~270 22.5~26.
PAGE 46
ENGINE MEASUREMENTS Notes: Page C-14 Engine Shop Rebuild and Parts Manual
PAGE 47
ENGINE REASSEMBLY TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE D PAGE NO. CRANKCASE ASSEMBLY.............................................................................................................. D - 1 Hone the Crankcase Cylinder Bore ...................................................................................... D - 1 Reassemble the Pistons and Connecting Rods ................................................................... D - 1 Install the Piston Rings ..............................
PAGE 48
ENGINE REASSEMBLY Notes: Page D-ii Engine Shop Rebuild and Parts Manual
PAGE 49
D ENGINE REASSEMBLY ‘CRANKCASE ASSEMBLY Tool List Qty. Required Compressor, piston ring .............................................. 1 Drill, electric ................................................................ 1 Gauge, feeler (E-Z-GO P/N 72525-G01) ........................................... 1 Gauge, wire spark plug ............................................... 1 Flex Hone, ball, 240 grit, 2 1/2 “cylinder (E-Z-GO P/N 72517-G01) ...........................................
PAGE 50
ENGINE REASSEMBLY A. Apply a coat of assembly lube to the exterior surface of the wrist pin (ITEM 1) and to the wrist pin bores in the connecting rod (ITEM 2) and piston (ITEM 3). D. Install the compression ring (ITEM 7), with the “N” facing up, in the top groove with the ring gap at 120° Fahrenheit to the wiper ring. (DETAIL C) B. Insert the wrist pin through the pin bore on one side of the piston, allowing it to protrude slightly into the interior of the piston. Reassemble the Crankcase End Cover C.
PAGE 51
ENGINE REASSEMBLY Install New Crankshaft Bearing (See Fig. D-6 “Crankshaft, Pistons and Balancer Shaft con’t” on page D-11) Press only against the inner race of the bearing when installing it on the shaft. A. If the bearing (ITEM 4) was removed from the crankshaft (ITEM 5), use a mechanical press to install a new bearing. (DETAIL A) Install New Crankshaft Seal (See Fig. D-5 “Crankshaft, Pistons and Balancer Shaft” on page D-10) A.
PAGE 52
ENGINE REASSEMBLY C. Using a depth gauge and straight edge, measure the distance from the gasket surface of the crankcase to the faces of both the crankshaft and balancer shaft gears close to the shafts, then subtract the width of the straight edge from each measurement. D. Using a depth gauge and straight edge, measure the distance from the gasket surface of the end cover to the inner races of both end cover bearings, then subtract the width of the straight edge from each measurement. E.
PAGE 53
ENGINE REASSEMBLY 1. Place key in the keyway on the crankshaft spindle. Use a brass drift to tap it into position. (DETAIL B) B. Align the slot in the fan hub with the key and slide the fan hub onto the crankshaft. Install the Oil Filter (See Fig. D-4 “Crankcase End Cover, PCV Valve and Oil Filter” on page D-9) C. Install the fan hub nut (ITEM 22, M22x1.5). Tighten the nut to specified torque using a 30mm socket.
PAGE 54
ENGINE REASSEMBLY An electric drill is used to rotate the honing tool while steadily moving it up and down inside the cylinder. Generally, the faster the rpm of tool, the faster the up and down motion in the cylinder. Beads should not be permitted to extend out of the cylinder, as uneven wearing of the beads may occur. The desired result is a finely cross-hatched surface pattern as shown above. Fig.
PAGE 55
ENGINE REASSEMBLY Service piston rings profile view at gap 7 6 5 4 Compression ring (TOP) 1 4 3 Wiper ring (MIDDLE) 2 Oil ring (BOTTOM) "N" Faces up when installed B A Pin Mandrel Insert a portion of the retaining ring into the ring groove. Use a flat blade screwdriver to push the remainder of the ring into the groove. Press the piston down onto the mandrel, pushing the wrist pin in Fig.
PAGE 56
ENGINE REASSEMBLY C Compression ring gap o 120 45 o Top of piston Wiper ring gap Wrist pin Rings 120 o Oil ring gap D Note: Factory 3 piece oil ring is replaced by 1 piece oil ring. OR Start one end of ring into the groove, leaving the other end on top of the piston. Rotate piston while working rest of ring into groove. Fig.
PAGE 57
ENGINE REASSEMBLY A 1 3 4 5 6 8 7 2 B 9 4 4 8 7 6 6 5 3 10 Newer Model 6 5 7 Fig.
PAGE 58
ENGINE REASSEMBLY 14 12 8 2 13 4 7 10 9 1 11 3 4 6 Fig.
PAGE 59
ENGINE REASSEMBLY A Fill crankshaft oil passages with engine oil Press against inner race only 5 4 B Use mallet handle to gently tap piston through compressor and into cylinder head C Align single dot on crankshaft gear with two dots on balancer shaft gear Fig.
PAGE 60
ENGINE REASSEMBLY Make sure the gears are completely seated and that their faces are perfectly flush . Rest the straight edge on the gasket surface of the crankcase and measure to the face of the balancer gear and crankshaft gear with a depth gauge. Subtract the width of the straight edge from the measurements. Rest the straight edge on the gasket surface of the end cover, and across the centers of the bearings. The straight edge should sit solidly on the gasket surface without rocking.
PAGE 61
ENGINE REASSEMBLY 15 20 16 22 14 11 12 10 9 8 13 17 19 18 5 4 1 Crankcase Newer Model 7 6 21 3 25 2 Fig.
PAGE 62
ENGINE REASSEMBLY A Follow numbers to tighten end cover bolts in correct sequence. Tighten to specified torque in two stages 7 9 4 1 2 5 3 8 6 (Some models may have 8 or 9 or 10 bolts) B Gently tap key into keyway Brass drift (Later models do not have a keyway) 21 Crankshaft Fig.
PAGE 63
ENGINE REASSEMBLY NOTE: Press lightly with suitable mandrel For clarity, the fan is shown pulled away from the hub, and the fan hub is partially cut-a-way. It is not necessary to remove the fan or hub to set the air gap. Use the access holes provided. .020 - .039 Feeler gauge Insert phillips screwdriver through fan hub Fig.
PAGE 64
ENGINE REASSEMBLY Notes: Page D-16 Engine Shop Rebuild and Parts Manual
PAGE 65
ENGINE REASSEMBLY TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE E PAGE NO. CYLINDER HEAD ASSEMBLY........................................................................................................E - 1 Install Valve Guides...............................................................................................................E - 1 Cutting Valve Seats ...............................................................................................................E - 1 Lap the Valves.............
PAGE 66
ENGINE REASSEMBLY Notes: Page E-ii Engine Shop Rebuild and Parts Manual
PAGE 67
E ENGINE REASSEMBLY CYLINDER HEAD ASSEMBLY Install Valve Guides (See Fig. E-1 “Valves and Valve Clearance” on page D-6) Tool List Qty. Required Compressor, piston ring .............................................. 1 Drill, electric ................................................................ 1 Gauge, feeler (E-Z-GO P/N 72525-G01) ........................................... 1 Gauge, wire spark plug ............................................... 1 Valve seat cutter (E-Z-GO P/N 72516-G01) ..........
PAGE 68
ENGINE REASSEMBLY Install New Valve Stem Seals (See Fig. E-2 “Valves con’t” on page D-7) A. Place a new seal on a valve guide, large diameter down, and push until it snaps into place. Repeat to install the remaining guides. (DETAIL B) Install the Valves (See Fig. E-1 “Valves and Valve Clearance” on page D-6) D. Install and hand tighten seven (7) cylinder head mounting bolts (ITEM 4, 1 each, M8x1.25x60L; ITEM 5, 4 each, M8x1.25x50L; and ITEM 6, 2 each, M8x1.
PAGE 69
ENGINE REASSEMBLY F. Install the camshaft cover (ITEM 14) and new gasket (ITEM 15). 1. With the flanged side of the cover oriented away from the engine, hold the cover and gasket in place and install three (3) bolts (ITEM 16, M6x1.0x12L) and one (1) stud (ITEM 17, M6x1.0). The stud is mounted in the top right corner of the cover. 2. Tighten the mounting bolts and stud to specified torque. Install the Rear Timing Belt Cover (See Fig.
PAGE 70
ENGINE REASSEMBLY Install the Front Timing Belt Cover (See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and Timing Belt” on page D-10) A. Hold the cover (ITEM 17) in place and install three (3) bolts (ITEM 18, M6x1.0x12L, 10mm socket). Tighten the bolts to specified torque. Install the Front Cylinder Baffle (See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and Timing Belt” on page D-10) A. Hold the baffle (ITEM 19) in place and install and tighten two (2) bolts (ITEM 20, M6x1.
PAGE 71
ENGINE REASSEMBLY Install the Rocker Cover Install the Carburetor (See Fig. E-8 “Rocker Cover” on page D-13) (See Fig. E-9 “Carburetor” on page D-14) A. Install a new rocker cover gasket (ITEM 2) in the cover. Match the shape of the gasket to the shape of the cover for proper orientation. A. Install the gasket (ITEM 2), plastic insulator (ITEM 3), and gasket (ITEM 4) on the carburetor mounting studs. B.
PAGE 72
ENGINE REASSEMBLY A 8 7 6 3 1 2 5 B 4 .004" Feeler guage Lobe Position heel of cam lobe as shown to measure valve clearance Fig.
PAGE 73
ENGINE REASSEMBLY A B 3 1 2 C 7 8 Push spring retainer down to install/release valve keys Fig.
PAGE 74
ENGINE REASSEMBLY 7 17 9 10 12 13 16 8 4 11 6 1 5 3 2 Crankcase Fig.
PAGE 75
ENGINE REASSEMBLY A 6 3 5 Item 5 5 Sequence 7 6 4 1 5 5 4 2 Follow numbers to tighten cylinder head bolts in correct sequence Tighten to specified torque in two stages C B 8 10 7 Lobes Rotate the cam lobes so that they will not exert pressure on the rocker arms as they are installed on the rocker shaft Fig.
PAGE 76
Crankshaft 14 16 12 11 8 17 7 9 8 15 10 Spring stop 1 3 13 19 5 2 6 20 4 30 Newer Model 21 33 Newer Model 32 34 26 22 24 23 29 31 27 28 25 ENGINE REASSEMBLY Fig.
PAGE 77
ENGINE REASSEMBLY A Align notch and mark Spring stop Idler spring 1/8" - 1/4" Deflection at 10 lbs "push" Idler clamp bolt tighten to 10 - 13 ft lbs torque Idler Align key way with mark Fig.
PAGE 78
ENGINE REASSEMBLY B 3 2 4 1 Follow numbers to tighten manifold bolts in correct sequence Tighten to specified torque in two stages C Some later models may or may not have an oil pressure switch, some models have location of the switch in a slightly different position. Route the oil pressure switch wire and the pulser coil wire through the groove in the blower housing Fig.
PAGE 79
ENGINE REASSEMBLY 3 4 1 2 A Rocker cover tightening sequence Fig.
PAGE 80
ENGINE REASSEMBLY 7 6 1 4 3 2 5 Fig.
PAGE 81
Illustrated Parts Breakdown F ILLUSTRATED PARTS BREAKDOWN Engine Shop Rebuild and Parts Manual Page F-1
PAGE 82
ENGINE Illustrated Parts Breakdown Newer Model Earlier Model 21 23 231 - 235 22 24 26 21 23 25 97 27 212 215 213 214 210 209 19 11 18 9 208 12 29 28 34 35 37 45 38 36 39 8 10 41 31 40 33 47 46 49 42 43 13 48 16 17 Page F-2 6 14 Engine Shop Rebuild and Parts Manual 7
PAGE 83
62 53 189 54 190 55 191 57 193 58 194 59 195 51 64 65 61 18 71 62 74 66 67 68 69 52 51 70 76 91 72 73 93 94 92 75 84 77 78 79 80 98 101 100 99 85 102 103 81 82 83 105 104 88 106 107 89 86 Illustrated Parts Breakdown ENGINE Engine Shop Rebuild and Parts Manual Page F-3
PAGE 84
ENGINE Illustrated Parts Breakdown Newer Model 122 133 114 116 126 125 124 134 109 121 115 123 110 112 111 113 Page F-4 120 119 Engine Shop Rebuild and Parts Manual 118
PAGE 85
Engine Shop Rebuild and Parts Manual 175 Newer Model 198 229 199 200 201 202 203 205 204 129 135 186 187 182 183 130 206 136 140 184 197 A 180 180 197 131 132 145 154 139 138 167 168 177 146 148 137 141 178 152 224 225 176 174 171 155 159 158 173 169 150 218 151 219 156 222 157 160 227 Newer Model 165 166 147 153 221 226 A 162 180 145 142 143 164 161 163 Illustrated Parts Breakdown ENGINE Page F-5
PAGE 86
ENGINE Illustrated Parts Breakdown When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. 1 2 1 2 3 4 5 DESCRIPTION QTY. 72845-G01 SERVICE ENGINE, 295CC (INCLUDES ITEMS 5 - 197, 208 - 215).................. 1 72846-G02 SERVICE ENGINE, 350CC (INCLUDES ITEMS 4,6 - 197, 208 - 215)...............
PAGE 87
Illustrated Parts Breakdown ENGINE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY. 30 31 72536-G01 IDLER SPRING ............................................................................................ 1 33 26681-G01 BOLT, FLANGED, M6 X 1 X 8MM............................
PAGE 88
ENGINE Illustrated Parts Breakdown When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY. 59 26663-G01 PISTON RING SET (.50MM OVERSIZE), 295 cc ENGINE ONLY............... 2 61 26609-G01 PIN, PISTON.....................................................................................
PAGE 89
Illustrated Parts Breakdown ENGINE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY. 87 88 26713-G01 GASKET, PLUG ........................................................................................... 1 89 26666-G01 PLUG, CRANKCASE ........................................
PAGE 90
ENGINE Illustrated Parts Breakdown When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. 116 72865-G01 PULSER COIL (1 PIECE MAN/EXH) ........................................................... 1 117 72556-G01 BLOWER ASSEMBLY (INCLUDES ITEMS 118 - 121).................................
PAGE 91
Illustrated Parts Breakdown ENGINE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY. 145 72511-G01 SPRING, VALVE .......................................................................................... 4 146 26719-G01 GASKET, ROCKER COVER ....................................
PAGE 92
ENGINE Illustrated Parts Breakdown When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY. 175 601560 CYLINDER BAFFLE, EXHAUST (1 PIECE MAN/EXH) ............................... 1 176 26642-G01 CYLINDER BAFFLE, EXHAUST .................................................................
PAGE 93
Illustrated Parts Breakdown ENGINE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY. 205 72883-G01 INSULATOR, 295 cc ENGINE ONLY ................................................................. 1 206 26726-G01 GASKET, ENGINE....................................................
PAGE 94
ENGINE Illustrated Parts Breakdown When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. 234 72877-G01 COVER, BREATHER COMPLETE (1 PIECE MAN/EXH) ............................ 1 235 72879-G01 BOLT, FLANGED, M6 X 1 X 40MM (1 PIECE MAN/EXH)............................
PAGE 95
LIMITED WARRANTY TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE G PAGE NO. FEDERAL EMISSION CONTROL WARRANTY STATEMENT ........................................................ G-1 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT(1995-1999)............................... G-5 YOUR WARRANTY RIGHTS AND OBLIGATIONS .............................................................. G-5 LIMITED WARRANTY on Emission Control Systems - California Only -...............................
PAGE 96
LIMITED WARRANTY Notes: Page G-ii Engine Shop Rebuild and Parts Manual
PAGE 97
LIMITED WARRANTY - FEDERAL FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California Fuji Heavy Industries Ltd.
PAGE 98
LIMITED WARRANTY - FEDERAL deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the engine owner, you should however be aware that E-Z-GO may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. You are responsible for presenting your engine to the nearest distributor, dealer, or service provider authorized by E-Z-GO when a problem exists.
PAGE 99
LIMITED WARRANTY - FEDERAL (2001) EMISSION COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all states, except the State of California. Fuji Heavy Industries Ltd.
PAGE 100
LIMITED WARRANTY - FEDERAL (2001) You are responsible for presenting your engine to the nearest distributor, dealer, or service provider authorized by Textron Golf, Turf & Specialty Products when a problem exists. If you have any questions regarding your warranty rights and responsibilities, you should contact the Textron Golf, Turf & Specialty Products Warranty Department at 1-800-241-5855 for the information.
PAGE 101
LIMITED WARRANTY - CALIFORNIA (1995-1999) CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd. (herein “FUJI”) are pleased to explain the emission control system warranty on your 1995 and later specialty vehicle engine (herein “engine”). In California, the engine must be designed, built and equipped to meet the State’s stringent anti-smog standards.
PAGE 102
LIMITED WARRANTY - CALIFORNIA (1995-1999) part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement point for that part. 3. DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized dealer, distributor or warranty station. 4.
PAGE 103
LIMITED WARRANTY - CALIFORNIA (1995-1999) (4) Exhaust Manifold (5) Miscellaneous Items Used in Above Systems (i) Fuel hoses, clamps and sealing gaskets I. MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 1995 and later Owner’s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended.
PAGE 104
LIMITED WARRANTY - CALIFORNIA (2000) CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd. (herein “FUJI”) are pleased to explain the emission control system warranty on your 2000 and later small off-road engine (herein “engine”). In California, the engine must be designed, built and equipped to meet the State’s stringent anti-smog standards.
PAGE 105
LIMITED WARRANTY - CALIFORNIA (2000) part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement point for that part. 3. DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized dealer, distributor or warranty station. 4.
PAGE 106
LIMITED WARRANTY - CALIFORNIA (2000) (4) Exhaust Manifold (5) Miscellaneous Items Used in Above Systems (i) Fuel hoses, clamps and sealing gaskets R. MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2000 and later Owner’s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended.
PAGE 107
LIMITED WARRANTY - CALIFORNIA (2001) CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd. (herein “FUJI”) are pleased to explain the emission control system warranty on your 2001 and later small off-road engine (herein “engine”). In California, the engine must be designed, built and equipped to meet the State’s stringent anti-smog standards.
PAGE 108
LIMITED WARRANTY - CALIFORNIA (2001) part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement point for that part. 3. DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized dealer, distributor or service provider. 4.
PAGE 109
LIMITED WARRANTY - CALIFORNIA (2001) (iii) Spark advance/retard system, if applicable (4) Exhaust Manifold, if applicable (5) Miscellaneous Items Used in Above Systems (i) Electronic controls, if applicable (ii) Hoses, belts, connectors, and assemblies (iii) Filter lock assembly (gaseous fuel, if applicable) I.
PAGE 110
LIMITED WARRANTY - CALIFORNIA (2004) CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd. (herein "FUJI") are pleased to explain the emission control system warranty on your 2004 and later small off-road engine (herein "engine"). In California, new engine must be designed, built and equipped to meet the State's stringent anti-smog standards.
PAGE 111
LIMITED WARRANTY - CALIFORNIA (2004) part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement point for that part. 3. DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized dealer, distributor or service provider. 4.
PAGE 112
LIMITED WARRANTY - CALIFORNIA (2004) (ii) Magneto or electronic ignition system. (iii) Spark advance/retard system, if applicable (4) Exhaust manifold, if applicable (5) Miscellaneous Items Used in Above Systems (i) Electronic controls, if applicable (ii) Hoses, belts, connectors, and assemblies (iii) Filter lock assy (gaseous fuel, if applicable) R.
PAGE 113
PAGE 114
E-Z-GO Division of Textron Inc. 1451 Marvin Griffin Rd. Augusta, Georgia 30906 USA Inside USA Phone: 1-800-241-5855, FAX: 1-800-448-8124 Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc.