E-Z-GO 295cc, Shop Rebuild Manual, Page: 13 / 112

ENGINE DISASSEMBLY
Page A-2
Engine Shop Rebuild and Parts Manual
D. Remove the timing belt (ITEM 20). Do not twist the
belt or turn it inside out.
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.
F. Remove the cam pulley retaining bolt (ITEM 16) and
the cam pulley (ITEM 24).
1. Remove the pulley alignment key. Using a non-fer-
rous (non-steel) punch, drive the back end of the
key down into the keyway, which will push the
front end up.
2. With the punch, gently drive the upraised key out
of the keyway.
Remove the Rear Timing Belt Cover
(See Fig. A-1 “Engine” on page A-4)
A. Using a 10mm socket, remove the two (2) bolts
(ITEM 26) that attach the rear timing belt cover (ITEM
25) to the engine.
Remove the Front Cylinder Baffle
(See Fig. A-1 “Engine” on page A-4)
A. Using a 10mm socket, remove the two (2) bolts
(ITEM 28) that attach the baffle (ITEM 27) to the
engine.
Remove the Valve Cover and Gasket
(See Fig. A-2 “Cylinder Head Components” on page A-5)
A. Using a 10mm socket, remove the six (6) bolts (ITEM
3) that attach the rocker cover (ITEM 1) to the cylin-
der head. Remove the rocker cover and gasket
(ITEM 2).
Remove the Rocker Assembly and Cam-
shaft
(See Fig. A-2 “Cylinder Head Components” on page A-5)
The rocker shafts in some early engines were
manufactured with a threaded hole in the end,
into which a blot is placed in order to pull the shaft from the cyl-
inder head.
Do not allow the camshaft lobes or
bearing surfaces to scrape against the
cylinder head. Because these parts have established wear pat-
terns during operation, mark and sort them as they are disas-
sembled so that they will be reassembled in their original
positions.
A. Remove the camshaft cover (ITEM 4).
1. Using a 10mm socket, remove the three (3) bolts
(ITEM 5) and one (1) stud (ITEM 6).
(Later models have four (4) bolts and no stud)
2. Using a rubber or wooden mallet, gently tap loose
the protruding edge of the camshaft cover and pull
it away from the engine.
B. Using a 10mm socket, loosen the four (4) rocker arm
nuts (ITEM 7).
C. With a medium flat blade screwdriver, turn the four (4)
rocker adjustment screws (ITEM 8) counterclockwise
until they no longer exert any force on the camshaft
(ITEM 9) and it can rotate freely.
D. Remove the rocker assembly.
1. Insert a small flat blade screwdriver into the
groove in the center of the rocker shaft (ITEM 10)
and push the shaft toward the fan side of the
engine. Tap lightly if required.
2. As the end of the rocker shaft slides out of the cyl-
inder head, remove the four (4) rocker arms (ITEM
11), two (2) spacers (ITEM 12), and one (1) spring
(ITEM 13) from the other end of the shaft. Mark or
sort parts as they are disassembled. Wear
parts must be reassembled in their original
positions.
E. Carefully pull the camshaft out through the fan side of
the cylinder head. Do not allow the wear surfaces of
the camshaft to scrape against the cylinder head, or
any part of the camshaft to scrape against the cylin-
der head bearing surfaces.
Remove the Cylinder Head and Gasket from
the Crankcase
(See Fig. A-2 “Cylinder Head Components” on page A-5)
Because this is an aluminum cylinder
head, it is important that the clamping
pressure of the mounting bolts be released evenly. Remove
them in the order shown in detail A (Ref Fig. A-2 on page A-5) by
loosening only 1/8 turn at a time.
A. Using a 12mm socket and extension, remove six (6)
cylinder head bolts (ITEM 16) in the sequence
shown. Remove the cylinder head (ITEM 14), gasket
(ITEM 15) and dowel pins (ITEM 19) from crankcase.