E-Z-GO 295cc, Shop Rebuild Manual, Page: 12 / 112

A
ENGINE DISASSEMBLY
Page A-1
Engine Shop Rebuild and Parts Manual
CYLINDER HEAD REMOVAL
Tool List 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 ....................................... 1
Screwdriver, medium flat blade ................................... 1
Socket, 8 mm, 3/8” drive ............................................. 1
Socket, 10 mm, 3/8” drive ........................................... 1
Socket, 12 mm, 3/8” drive ........................................... 1
Socket, 13/16” spark plug, 3/8” drive .......................... 1
Keep your work area clean and well organized
while performing the operations described in
this manual. This will help prevent accidents and reduce the
possibility of mistakes that could damage or impair the perfor-
mance of the engine.
Crankshaft and balancer shaft bearings should
be cleaned and inspected; and removed only if
they appear to be damaged or excessively worn. Remove bear-
ings that are pitted, nicked, burred, discolored or that rotate
roughly or noisily.
Because some mating parts with wear
surfaces were machined together when
the engine was manufactured, or have established wear patters
during operation, the reassembly of engine parts in their original
positions and orientations, with their original mating parts, is
critical to the performance and life expectancy of the engine.
Mark and sort all parts as they are disassembled so that they will
be reassembled and installed in their original positions.
Remove the Air Cleaner
A variety of air cleaner configurations exist. Refer to the
Technician’s Repair and Service Manual for removal/
installation instructions that are appropriate to the model
and year of your vehicle.
Remove the Carburetor
(See Fig. A-1 “Engine” on page A-4)
A. Remove the choke cable bracket plate (ITEM 12).
(DETAIL A)
B. Slide the carburetor (ITEM 11) off of its mounting
studs.
C. Remove the plastic carburetor insulator (ITEM 13).
Remove the Coil Mounting Bracket and Coil
(See Fig. A-1 “Engine” on page A-4)
A. Remove the spark plug wires (ITEM 1) from the
plugs.
B. Using a spark plug wrench, remove the spark plugs
(ITEM 2).
C. Using a 10mm socket, remove the nut (ITEM 3) and
the bolt (ITEM 4) attaching the coil bracket (ITEM 5)
to the engine.
Remove the Blower Housing
(See Fig. A-1 “Engine” on page A-4)
A. Using a 10mm socket, remove the three (3) remain-
ing bolts (ITEM 7) and remove the blower housing
(ITEM 6) from the engine.
Remove the Exhaust Manifold
(See Fig. A-1 “Engine” on page A-4)
(Later models have exhaust mainfold as part of the head)
A. Using a 12mm socket, remove the four (4) bolts
(ITEM 9) or nuts that attach the exhaust manifold
(ITEM 8) and gasket (ITEM 10) to the cylinder head.
Remove the Rear Cylinder Baffle
(See Fig. A-1 “Engine” on page A-4)
A. Using a 10mm socket, remove the four (4) bolts
(ITEM 12) that attach the baffle (ITEM 11) to the
engine. Lift the baffle from the engine.
Remove the Timing Belt Cover
(See Fig. A-1 “Engine” on page A-4)
A. Using a 10mm socket, remove the three (3) bolts
(ITEM 14) that attach the timing belt cover (ITEM 13)
to the engine.
Remove the Idler, Timing Belt, Drive and
Cam Pulleys
(See Fig. A-1 “Engine” on page A-4)
Do not twist, crimp or turn the belt
inside out. This will cause the belt to
fail.
A. Using a 12mm socket, loosen the idler and cam pul-
ley retaining bolts (ITEMS 15 AND 16).
B. Using a 10mm socket, loosen the drive pulley retain-
ing bolt (ITEM 17).
C. Remove the idler retaining bolt (ITEM 15), idler (ITEM
18), and idler spring (ITEM 19).