E-Z-GO 295cc, Shop Rebuild Manual, Page: 21 / 112

ENGINE DISASSEMBLY
Page B-2
Engine Shop Rebuild and Parts Manual
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).
(DETAIL C) (Later models do not have a hub key))
1. Using a non-ferrous (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.
B. Using a 12mm socket, remove two (2) bolts (ITEM
21).
C. Using a 10mm socket, remove the six (6) remaining
bolts (ITEM 22) attaching the cover to the crankcase.
D. Using a wooden or rubber mallet, lightly tap the cover
to break it loose from the crankcase. TAP ONLY THE
PLACE SHOWN. (DETAIL D)
E. Remove the cover from the crankcase. Do not lose
the crankshaft and balancer shaft spacers (ITEMS 23
and 24) that could fall from the engine when the
cover is removed.
F. Drain any remaining oil from the crankcase. Note any
unusual debris that might identify a problem.
G. Remove dowel pins (ITEM 30).
H. Remove the end cover gasket (ITEM 25) and the oil
feed O-ring (ITEM 26).
Remove the Balancer Shaft
(See Fig. B-1 “Engine Components” on page B-4)
A. While pushing the shaft from the PTO (clutch) side of
the engine, gently work the balancer shaft gear free
from the crankshaft balancer gear and remove the
shaft (ITEM 27) from the crankcase.
Remove the Pistons
(See Fig. B-3 “Crankshaft” on page B-6)
Remove any carbon deposits from the top of
the cylinder wall. These might damage the pis-
ton or prevent it from being removed.
Because the pistons, rods, and caps
were machined and have established
wear patterns as assemblies, it is critical to the life expectancy
and performance of the engine that they are reassembled with
their original mates and in their original positions. Mark and sort
mating parts as they are disassembled.
A. Rotate the crankshaft until the pistons (ITEM 1) are at
bottom dead center, or are positioned to allow best
access to the connecting rod bolts (ITEM 2).
B. Using a 10mm socket, remove the connecting rod
bolts and cap (ITEM 3) from the fan side piston
assembly.
C. Reposition the crankshaft at top dead center and
push the piston and rod out through the top of the
block. Reattach the connecting rod cap to the rod to
insure correct match of mating parts.
D. Repeat steps A., B., and C. to remove the PTO
(clutch) side piston assembly.
Remove the Crankshaft
(See Fig. B-3 “Crankshaft” on page B-6)
On engines with many hours of operation, it
may be necessary to gently tap the crankshaft
on the PTO (clutch) end to dislodge it. Use a light wooden or
rubber mallet handle only.
Remove the Balancer Shaft Seal and the
Crankshaft Seal
(See Fig. B-3 “Crankshaft” on page B-6)
Do not scratch or score the seal bore.
A. Using a seal puller, pry the shaft seal (ITEM 5) and
crankshaft seal (ITEM 6) from the block. (DETAIL A)
Inspect the Balancer Shaft Bearing and
Crankshaft Bearing
(See Fig. B-4 “Balancer Shaft Bearing, Crankshaft Bearing and PCV
Valve” on page B-7)
A. Remove the balancer shaft bearing (ITEM 1) and
crankshaft bearing (ITEM 2) only if they appear to be
worn or damaged.
Do not use direct heat, flame, or hot liq-
uid to expand parts. Parts must be heat-
ed evenly in an oven.
B. Clean the bearings and inspect for damage: blue dis-
coloration, pitting, rough or noisy rotation, etc. If there
is any doubt about a bearing, remove it and discard.