Club Car IntelliTach XRT 1550, Maintenance And Service Manual

Page: 355 / 564

KAWASAKI GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Gasoline Engine
2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 13a-3
13A
11. Remove the choke cable. See Choke Cable Removal on page 13a-20.
12. Remove the engine air inlet hose (4). See Air Filter Outlet Hose Removal on page 13a-26.
13. Remove the accelerator cable. See Accelerator Cable Removal on page 13a-18.
14. Remove the muffler. See Muffler Removal on page 13a-6.
15. Remove the intermediate exhaust pipe. See Intermediate Pipe Removal on page 13a-7.
16. Remove the clutch outer cover. See Clutch Outer Cover Removal on page 13a-37.
17. Remove the clutches (5). See Drive Clutch Removal on page 13a-29. Also See Driven Clutch
Removal on page 13a-34.
18. Remove the clutch inner cover (6). See Clutch Inner Cover Removal on page 13a-37.
19. Remove the exhaust manifold (7).
20. Remove the electrical connectors:
20.1. Disconnect the engine harness from the chassis harness.
20.2. Disconnect all wires attached to the starter solenoid. See following NOTE.
NOTE: Mark or tape together, for identification, the connectors on the starter solenoid posts.
21. Drain the engine oil. See Engine Oil and Filter Change, Section 10b, Page 10b-8.
22. Remove engine oil inlet and outlet hoses from the engine. See Oil Filter Hose Removal on page 13a-5.
See also following NOTE.
NOTE: Plug each line as it is removed from the engine. Without plugs, oil will leak from the lines.
23. Remove the engine mounting hardware (8) (Figure 13a-1, Page 13a-2) .
24. Lift the engine out by its lift tabs (9).
25. If a new engine will be installed, remove and retain the following:
• Oil Filter Adapter (1) (Figure 13a-2, Page 13a-4)
• Engine Lift Tabs
• Choke Cable Return Spring
ENGINE INSTALLATION
See General Warning, Section 1, Page 1-1.
1. Before a new engine is installed, the following components must be installed:
• Oil Filter Adapter (1) (new o-rings (2) required) (Figure 13a-2, Page 13a-4) – Tighten the hardware to
33 ft-lb (44 N·m)
• Engine Lift Tabs – Tighten the hardware to 21 ft-lb (28 N·m)
• Choke Cable Return Spring
2. Lower the engine into the engine compartment and closely align the engine block mounting holes with
the holes in the engine plate (10) (Figure 13a-1, Page 13a-2) .