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E-Z-GO 295cc Shop Rebuild Manual Download Page 46

TABLE OF CONTENTS FOR SECTION ‘D’

SECTION TITLE

PAGE NO.

Page D-i

D

ENGINE REASSEMBLY

Engine Shop Rebuild and Parts Manual

CRANKCASE ASSEMBLY.............................................................................................................. D  -  1

Hone the Crankcase Cylinder Bore ...................................................................................... D - 1
Reassemble the Pistons and Connecting Rods ................................................................... D - 1
Install the Piston Rings ......................................................................................................... D - 2
Reassemble the Crankcase End Cover ............................................................................... D - 2
Install New Crankcase Bearing ............................................................................................ D - 2
Install New Crankshaft Bearing ............................................................................................ D - 3
Install New Crankshaft Seal ................................................................................................. D - 3
Install Crankshaft into Crankcase......................................................................................... D - 3
Install the Pistons in the Crankcase ..................................................................................... D - 3
Install the Balancer Shaft...................................................................................................... D  -  3
Set the Crankshaft and Balancer Shaft Endplay .................................................................. D - 3
Install Crankshaft Endplay Spacer and Balancer Endplay Spacer....................................... D - 4
Install Alignment Dowel Pins ................................................................................................ D - 4
Install New Oil Feed O-Ring ................................................................................................. D - 4
Install Crankcase End Cover Gasket.................................................................................... D - 4
Install the Crankcase End Cover .......................................................................................... D - 4
Install the Oil Pump Gear Rotors.......................................................................................... D - 4
Install the Oil Pressure Switch.............................................................................................. D - 4
Install the Pulser Coil............................................................................................................ D - 4
Install the Fan Hub ............................................................................................................... D - 4
Set the Pulser Coil Air Gap................................................................................................... D - 5
Install the PVC Valve............................................................................................................ D - 5
Install the Oil Filter................................................................................................................ D - 5

LIST OF ILLUSTRATIONS

Fig. D-1  Crankcase Cylinder .......................................................................................................... D - 6
Fig. D-2  Piston and Connecting Rods ............................................................................................ D  -  7
Fig. D-3  Pistons and Connecting Rods con’t.................................................................................. D - 8
Fig. D-4  Crankcase End Cover, PCV Valve and Oil Filter.............................................................. D - 9
Fig. D-5  Crankshaft, Pistons and Balancer Shaft......................................................................... D - 10
Fig. D-6  Crankshaft, Pistons and Balancer Shaft con’t ................................................................ D - 11
Fig. D-7  Crankshaft and Balancer Shaft Endplay......................................................................... D - 12
Fig. D-8  Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil and Fan Hub.......................... D - 13
Fig. D-9  Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil and Fan Hub con’t ................. D - 14
Fig. D-10  Pulser Coil Air Gap ....................................................................................................... D - 15

Summary of Contents for 295cc

Page 1: ...19 17 18 13 6 5 9 15 16 7 8 10 4 3 11 1 INCLUDES ITEMS 3 16 295cc and 350cc 4 CYCLE ENGINE STARTING MODEL YEAR 1992 ENGINE SHOP REBUILD SERVICE PARTS MANUAL 27615 G01 REVISED 08 04 ...

Page 2: ... obligation to make these changes on units previously sold and the informa tion 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 E Z GO DIVISION OF TEXTRON INC 1451 MARVIN GRIFFIN RD AUGUSTA GEORGIA USA 30906 ...

Page 3: ...ABOVE FACTORY SETTINGS WILL VOID THE VEHICLE WARRANTY IF APPLICABLE REFER TO BACK COVER FOR CALIFORNIA AND OR FEDERAL EMISSIONS CONTROL WARRANTY STATEMENT Engine exhaust from this product contains chemicals known in certain quantities to cause cancer birth defects or other reproductive harm The exhaust emissions of this vehicle s engine complies with regulations set forth by the Environmental Prot...

Page 4: ... and Cam Gear A 1 Rear Timing Belt Cover A 2 Front Cylinder Baffle A 2 Rocker Cover and Gasket A 2 Rocker Assembly and Cam Shaft A 2 Cylinder Head and Gasket A 2 Valves A 3 Valve Guides A 3 ENGINE DISASSEMBLY B CRANKCASE DISASSEMBLY Oil Filter B 1 Fan Hub B 1 Pulser Coil B 1 Oil Pressure Switch B 1 Oil Pump B 1 Crankcase End Cover B 2 End Cover Gasket and Oil Feed O Ring B 2 Balancer Shaft B 2 Pis...

Page 5: ...nnecting Rod C 3 Cylinder Head Cam and Rocker Shaft Bores C 3 Valves Guides and Seats C 3 Valves and Valve Springs C 3 Camshaft C 3 Rocker Shaft and Rocker Arms C 3 Piston Ring Gap C 3 Torque Specifications C 3 ENGINE REASSEMBLY D CRANKCASE ASSEMBLY Honing the Cylinder Bores D 1 Pistons and Connecting Rods D 1 Piston Rings D 2 Crankcase End Cover D 2 Crankcase Bearings D 2 Crankshaft Bearing D 3 C...

Page 6: ...bly E 2 Rear Timing Belt Cover E 3 Drive and Cam Pulleys Idler and Timing Belt E 3 Front Timing Belt Cover E 4 Front Cylinder Baffle E 4 Rear Cylinder Baffle E 4 Exhaust Manifold and Gasket E 4 Blower Housing E 4 Coil and Mounting Bracket E 4 Valve Adjustment E 4 Spark Plugs E 4 Rocker Cover E 5 Carburetor E 5 ILLUSTRATED PARTS BREAKDOWN F ILLUSTRATED PARTS BREAKDOWN Engine Illustrations F 1 Engin...

Page 7: ...Page vi TABLE OF CONTENTS Engine Shop Rebuild and Parts Manual Notes ...

Page 8: ...eginning of each major section is a list of tools that will be required to perform the operations desired in that sec tion Do not use non specified tools vise grips hammers adjustable wrenches etc The use of these tools could cause permanent damage to the engine components WE STRONGLY RECOMMEND that no matter what your experience level you use this manual as a guide when disas sembling repairing o...

Page 9: ...viii HOW TO USE THIS MANUAL Engine Shop Rebuild and Parts Manual ...

Page 10: ...ear Cylinder Baffle A 1 Remove the Timing Belt Cover A 1 Remove the Idler Timing Belt Drive and Cam Pulleys A 1 Remove the Rear Timing Belt Cover A 2 Remove the Front Cylinder Baffle A 2 Remove the Valve Cover and Gasket A 2 Remove the Rocker Assembly and Camshaft A 2 Remove the Cylinder Head and Gasket from the Crankcase A 2 VALVE REMOVAL A 3 Remove the Valves from the Cylinder Head A 3 Valve Gui...

Page 11: ...ENGINE DISASSEMBLY Page A ii Repair and Service Manual Notes ...

Page 12: ...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...

Page 13: ...o 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...

Page 14: ...y 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 Then push the valve down and remove it from the bottom of the cylinder head C Repeat steps A and B to remove the remaining valves D Use a small flat blade screwdriver to GENTLY pry the valve stem seals ITEM 4 free Remove them from the valve guides DETAIL B Valve Guide...

Page 15: ...ENGINE DISASSEMBLY Page A 4 Engine Shop Rebuild and Parts Manual Fig A 1 Engine 1 4 9 8 10 12 11 14 13 15 16 17 18 19 20 21 22 24 26 25 28 6 7 5 27 2 11 13 12 3 A Newer Model Newer Model Newer Model ...

Page 16: ... Page A 5 Engine Shop Rebuild and Parts Manual Fig A 2 Cylinder Head Components 3 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 Crankcase 19 1 2 3 4 5 6 7 Follow numbers to remove cylinder head bolts in correct sequence A Groove ...

Page 17: ...ENGINE DISASSEMBLY Page A 6 Engine Shop Rebuild and Parts Manual Fig A 3 Valves B Pry valve stem seal loose 1 3 4 5 2 Push spring retainer down to release valve keys 6 A ...

Page 18: ...stons B 2 Remove the Crankshaft B 2 Remove the Balancer Shaft Seal and the Crankshaft Seal B 2 Inspect the Balancer Shaft Bearing and Crankshaft Bearing B 2 Remove the PCV Valve B 3 Disassemble the Crankcase End Cover B 3 Remove the Piston From Connecting Rod B 3 Removal of Crankshaft Bearing B 3 LIST OF ILLUSTRATIONS Fig B 1 Engine Components B 4 Fig B 2 Engine Components con t B 5 Fig B 3 Cranks...

Page 19: ...ENGINE DISASSEMBLY Page B ii Repair and Service Manual Notes ...

Page 20: ...t be pointed Grind off 1 8 to provide a taper If desired a nut may be used as a spacer between the puller and crankshaft Lubricate the tip and threads of the puller shaft ITEM 6 and place it in the indention in the end of the crank shaft DETAIL A 2 Install the three 3 puller bolts ITEM 7 through the puller collar ITEM 8 and into the threaded holes in the fan hub Tighten the puller bolts until each...

Page 21: ...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 the...

Page 22: ... side of the cover 1 Using a 10mm socket remove the bolt ITEM 3 and check valve cover ITEM 4 2 Remove the spring ITEM 5 and check ball ITEM 6 C Clean and inspect the crankshaft bearing ITEM 7 and the balancer shaft bearing ITEM 8 for damage If there is any doubt about a bearing remove it 1 If a bearing is to be removed tap it out with a brass drift and discard or use an oven to evenly heat the end...

Page 23: ...ENGINE DISASSEMBLY Page B 4 Engine Shop Rebuild and Parts Manual Fig B 1 Engine Components 4 5 9 10 11 12 13 14 15 16 17 18 21 22 24 23 25 26 27 Crankcase 19 1 2 3 30 Newer Model ...

Page 24: ...onents con t 90 0 Crankshaft 7 8 6 Fan hub shown without fan Grind off Crankshaft or Hold against puller screws not against the crankshaft or fan 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 A C D B ...

Page 25: ...ENGINE DISASSEMBLY Page B 6 Engine Shop Rebuild and Parts Manual Fig B 3 Crankshaft 1 2 3 4 5 6 A Seal puller ...

Page 26: ... B 7 Engine Shop Rebuild and Parts Manual Fig B 4 Balancer Shaft Bearing Crankshaft Bearing and PCV Valve 1 2 4 5 6 6 7 8 9 3 10 4 A To drive bearing out straight move drift side to side while tapping Brass drift Newer Model ...

Page 27: ...ENGINE DISASSEMBLY Page B 8 Engine Shop Rebuild and Parts Manual Fig B 5 Crankcase End Cover and Crankshaft Bearing 1 2 3 4 5 6 7 8 1 Crankshaft A B ...

Page 28: ...1 2 3 3 4 5 6 7 Insert a suitable mandrel into the pin bore of the piston Press the piston down onto the mandrel pushing the wrist pin out Remove the piston from the connecting rod Insert screwdriver into slot and push to compress ring Pry ring up and out of the retainer groove A B ...

Page 29: ...ENGINE DISASSEMBLY Page B 10 Engine Shop Rebuild and Parts Manual Notes ...

Page 30: ...r Head Cam and Rocker Shaft Bores C 3 Valve Guides and Seats C 3 Valves and Valve Springs C 3 Camshaft C 3 Rocker Shaft and Rocker Arms C 3 Piston Ring Gap C 3 Torque Specifications Wet C 3 LIST OF ILLUSTRATIONS Fig C 1 Using Telescoping and Hole Gauges C 1 Fig C 2 Flatness of Mating Surfaces C 2 Fig C 3 Crankcase Cylinder Bores C 4 Fig C 4 Crankshaft Journals and Gear and Bearing Bores C 5 Fig C ...

Page 31: ...ENGINE MEASUREMENTS Page C ii Engine Shop Rebuild and Parts Manual Notes ...

Page 32: ...ge in the hole or bore and set the tele scoping arms or ball to its true diameter Make sure that the handle of the gauge is in line with the centerline of the hole or bore Lock and remove the gauge Measure its setting with a micrometer Check flatness of Crankcase End Cover and Cylinder Head See Fig C 1 Using Telescoping and Hole Gauges on page C 1 If flatness of a surface is found to be out of tol...

Page 33: ...ne emery cloth Thoroughly clean crank shaft after polishing and reinspect journal diameters B Measure the oil seal surface diameters DIMEN SIONS H AND J in two places each 90 apart Inspect for wear roughness or pitting Replace crankshaft if below specified limit C If the bearing was removed from the crankshaft mea sure the bearing journal DIMENSION F in two places 90 apart D Inspect gear teeth and...

Page 34: ...ed with a mechanical press See NOTE above B Measure angle DIMENSION C and width DIMEN SION D of the valve seat contact surface If valve seats are worn beyond service limits they may be resurfaced with an appropriate cutter Valves and Valve Springs See Fig C 8 Valve Guides and Seats on page C 9 x A Measure the valve stem at three 3 positions DIMENSIONS A B and C in two 2 places each 90 apart B Meas...

Page 35: ... 67 000mm 67 019mm If A exceeds C or if A exceeds C by 0 004 1mm rebore the cylinder 64 000mm 64 019mm Cylinder bore dimension is determined by size of the piston to be used If over size piston is used C represents specified bore for that piston Relative dimension for A remains valid 25mm and 50mm oversize pistons are available telescoping gauge A fine cross hatched surface is the proper finish fo...

Page 36: ... 06 61 99 mm in in mm STD LIMIT mm in in mm 2 4386 2 4398 B A 2 8347 2 8359 71 938 71 968 71 985 C 2 8322 2 8334 2 4405 2 8370 2 8340 mm 0 00067 0 0024 0 00024 0 00067 in 0 017 0 060 0 006 0 017 Ball bearings onto crankshaft Ball bearings into crankcase Recommended press fits A B C D E F G Crankshaft Measure each position in 2 places 90 apart o SPECS 34 968 34 985 34 986 34 997 34 945 1 3767 1 377...

Page 37: ...on wrist pin and connecting rod 1 O S LIMIT mm mm 2 O S LIMIT mm mm in in in in in in ST ND 64 120 2 528 2 529 2 525 64 210 64 230 64 370 2 538 2 539 2 535 64 460 64 480 63 870 2 6362 2 6370 2 6327 66 960 66 980 B 350 cc 67 120 2 6461 2 6469 2 6425 67 210 67 230 67 370 2 6559 2 6567 2 6524 67 460 67 480 2 65 0 0988 1 0000 0 1043 2 510 2 540 TOP MIDDLE BOTTOM OIL 16 035 0 6296 0 6300 0 6313 15 991 ...

Page 38: ...ancer shaft bearing bores Measure each bore in 2 places 90 apart o 1 A A2 Crankcase and endcover Recommended press fit for balance shaft bearing mm in 0 0006 0 0020 0 014 0 050 Balancer shaft 1 C C2 SPECS STD LIMIT 41 950 41 975 41 990 mm mm in in 1 6516 1 6526 A B 1 6531 C D 19 975 0 7869 0 7873 0 7864 19 988 19 997 Measure each position in 2 places 90 apart o C D D A B ...

Page 39: ...A SPECS STD LIMIT 35 065 1 3780 1 3789 1 3805 35 000 35 025 mm mm in in 25 057 0 9843 0 9851 0 9865 25 000 25 021 B 34 950 34 975 26 620 26 720 26 420 34 925 24 959 24 980 24 935 1 3760 1 3770 1 048 1 052 0 9826 0 9835 1 375 1 040 0 9816 C D E E E E F F Measure cam lobes as shown Camshaft 0 00098 0 0030 0 00079 0 0024 0 025 0 075 0 020 0 062 mm in Fan side PTO Side Recommended clearance for camsha...

Page 40: ...lve guide Valve seat Measure each position in 2 places 90 apart o 1 2 A A A B SPECS STD LIMIT D 5 525 0 2165 0 2172 0 2175 5 500 5 518 mm mm in in C 90o 1 5 0 0118 0 0295 0 0591 0 30 0 75 0 10 20 30 40 50 60 70 80 90 A total difference of 1 between the finish angles of the valve and valve seat is required o ...

Page 41: ...0 075 0 056 0 092 in mm in in F 0 0276 0 0354 0 0197 0 7 0 9 0 5 SPECS Exhaust 5 40 0 2136 0 2143 0 2125 5 426 5 444 90o 3 536 0 0891 0 1281 0 1392 2 263 3 253 Intake Exhaust 0 10 20 30 40 50 60 70 80 90 0 10 20 30 40 50 60 70 80 90 o A total difference of 1 between the finish angles of the valve and valve seat is required Measure each position in 2 places 90 apart o 1 2 B B Recommended clearance ...

Page 42: ...in 12 055 0 4724 0 4731 0 4746 12 000 12 018 Rocker shaft assembly 1 A A2 A B 11 966 11 984 12 060 11 950 0 4724 0 4731 0 4748 D 0 4711 0 4718 0 016 0 052 0 016 0 052 Shaft to head 0 4704 0 100 0 105 0 0006 0 0020 12 000 12 018 0 0039 Shaft arm clearance D 1 2 B B 0 0006 0 0020 0 0041 Clearance B B Clearance Measure each position in 2 places 90 apart o Rocker shaft ...

Page 43: ...0 2 0 4 1 0 1 0 1 0 mm mm in in Top ring 2nd Ring mm mm in in in in Oil ring mm mm 0 20 0 40 0 15 0 25 0 15 0 30 0 10 0 60 0 20 0 40 0 008 0 016 0 006 0 010 0 006 0 012 0 008 0 016 0 20 0 70 0 20 0 40 0 004 0 024 0 008 0 028 0 008 0 016 EH29C 295 CC 64 MM BORE EH35C 350 CC 67 MM BORE Recommended clearances for piston ring end gap 3 Piece 1 Piece Note Engines are shipped from the factory with three...

Page 44: ...ghtening Oil drain plug Drive gear bolt Cam gear bolt Rocker arm nut Others 6mm 8mm DESCRIPTION kg cm N m ft lb 170 200 16 7 19 6 12 3 14 5 600 650 58 8 63 7 43 4 47 0 80 100 7 8 9 8 5 8 7 2 170 190 16 7 18 6 12 3 13 7 120 150 11 8 14 7 8 7 10 9 230 270 22 5 26 5 16 6 19 5 200 230 19 6 22 5 14 5 16 6 80 100 7 8 9 8 5 8 7 2 230 270 22 5 26 5 16 6 19 5 80 100 7 8 9 8 5 8 7 2 60 80 5 9 7 8 4 3 5 8 14...

Page 45: ...ENGINE MEASUREMENTS Page C 14 Engine Shop Rebuild and Parts Manual Notes ...

Page 46: ...ll New Oil Feed O Ring D 4 Install Crankcase End Cover Gasket D 4 Install the Crankcase End Cover D 4 Install the Oil Pump Gear Rotors D 4 Install the Oil Pressure Switch D 4 Install the Pulser Coil D 4 Install the Fan Hub D 4 Set the Pulser Coil Air Gap D 5 Install the PVC Valve D 5 Install the Oil Filter D 5 LIST OF ILLUSTRATIONS Fig D 1 Crankcase Cylinder D 6 Fig D 2 Piston and Connecting Rods ...

Page 47: ...ENGINE REASSEMBLY Page D ii Engine Shop Rebuild and Parts Manual Notes ...

Page 48: ...e We recommend that parts found to be acceptable but near limits be replaced if the engine will see high usage Because some mating parts with wear surfaces were machined together when the engine was manufactured or have estab lished wear patterns during operation the reassembly of engine parts in their original positions and orientations with their origi nal mating parts is critical to the perform...

Page 49: ...D C Install the wiper ring ITEM 6 with the N facing up in the middle groove with the ring gap at 120 to the top scraper of the oil ring DETAIL C 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 Reassemble the Crankcase End Cover See Fig D 4 Crankcase End Cover PCV Valve and Oil Filter on page D 9 Reassemble ...

Page 50: ... LUBRICANT OFF OF THE MATING SURFACES OF THE ROD AND ROD CAP B Make sure that the piston ring gaps are correctly positioned on the piston DETAIL C C Install a piston ring compressor on the piston leaving enough of the piston skirt protruding below the com pressor to start into the cylinder DETAIL B D With the word FAN on the connecting rod oriented toward the open side of the crankcase and the cra...

Page 51: ...sition and with the balancer shaft and crankshaft started into their bearings in the cover place the end cover on the crankcase alignment dowels and gently work it down until it rests against the crankcase Be careful not to damage oil seals B Install the end cover mounting bolts 1 Start two 2 bolts ITEM 4 M8x1 25x30L 12mm socket with lock washers ITEM 5 and six 6 bolts ITEM 6 M6x1 0x30L 10mm socke...

Page 52: ...e gaskets PCV plate valve and PCV cover ITEMS 4 9 into the PCV port in the crankcase Match the contour of the plate with the contour of the port for correct orientation B Hold the PCV cover ITEM 9 in place and start two 2 bolts ITEM 3 M6x10x18L Tighten the bolts to specified torque using a 10mm socket Install return hose ITEM 10 Install the Oil Filter See Fig D 4 Crankcase End Cover PCV Valve and ...

Page 53: ...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 ...

Page 54: ...hen installed Compression ring Wiper ring Oil ring TOP MIDDLE BOTTOM Service piston rings profile view at gap Press the piston down onto the mandrel pushing the wrist pin in 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 A B ...

Page 55: ...con t 120 o Compression ring gap Wiper ring gap Oil ring gap Top of piston Rings 45o 120o Wrist pin 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 C D OR Note Factory 3 piece oil ring is replaced by 1 piece oil ring ...

Page 56: ...ENGINE REASSEMBLY Page D 9 Engine Shop Rebuild and Parts Manual Fig D 4 Crankcase End Cover PCV Valve and Oil Filter 4 5 6 6 7 8 9 3 10 4 1 8 3 4 5 6 2 7 5 7 6 B A Newer Model ...

Page 57: ...ENGINE REASSEMBLY Page D 10 Engine Shop Rebuild and Parts Manual Fig D 5 Crankshaft Pistons and Balancer Shaft 2 8 4 7 6 14 12 13 11 3 4 1 10 9 ...

Page 58: ...shaft Pistons and Balancer Shaft con t Use mallet handle to gently tap piston through compressor and into cylinder head 4 5 Press against inner race only Fill crankshaft oil passages with engine oil Align single dot on crankshaft gear with two dots on balancer shaft gear A B B C ...

Page 59: ...nd 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 Measure to the face of the balancer and crankshaft bearing inner races then sub...

Page 60: ...ASSEMBLY Page D 13 Engine Shop Rebuild and Parts Manual Fig D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub 20 22 17 18 13 15 16 14 12 11 10 8 9 19 4 5 6 7 3 2 1 Crankcase 21 25 Newer Model ...

Page 61: ... Pressure Switch Pulser Coil and Fan Hub con t 21 Crankshaft Gently tap key into keyway 2 3 4 9 6 7 8 1 5 Follow numbers to tighten end cover bolts in correct sequence Tighten to specified torque in two stages A B Brass drift Later models do not have a keyway Some models may have 8 or 9 or 10 bolts ...

Page 62: ...p 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 NOTE Press lightly with suitable mandrel 020 039 Feeler gauge Insert phillips screwdriver through fan hub ...

Page 63: ...ENGINE REASSEMBLY Page D 16 Engine Shop Rebuild and Parts Manual Notes ...

Page 64: ...ll the Rear Cylinder Baffle E 4 Install the Exhaust Manifold and Gasket E 4 Install the Blower Housing E 4 Install the Coil Mounting Bracket and Coil Assembly E 4 Adjust the Valves E 4 Install the Spark Plugs E 4 Install the Rocker Cover E 5 Install the Carburetor E 5 LIST OF ILLUSTRATIONS Fig E 1 Valves and Valve Clearance E 6 Fig E 2 Valves con t E 7 Fig E 3 Cylinder Head Cam Shaft and Rocker As...

Page 65: ...ENGINE REASSEMBLY Page E ii Engine Shop Rebuild and Parts Manual Notes ...

Page 66: ...a clockwise direction only using firm consistent pressure B Remove no more material than is necessary to clean the valve seat C Refer to additional instructions included with cutter Lap the Valves See Fig E 1 Valves and Valve Clearance on page D 6 See Fig E 2 Valves con t on page D 7 A Turn the cylinder head upside down B Lightly lubricate the stem of one of the intake valves ITEM 4 with engine oi...

Page 67: ...ures on the bottom of the head to the features of the crankcase gasket surface Position the head on the alignment dowels and lower it gently onto the crankcase 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 25x40L tighten to specified torque in two stages in the order shown DETAIL A Install the Camshaft See...

Page 68: ...aft flange side toward the engine B Install the cam pulley ITEM 6 1 Align the notch on the rear of the cam pulley with the pin on the cam shaft and slide the pulley onto the shaft 2 Rotate the cam pulley until the smallest of the three holes on the face of the gear aligns with the notch at the top of the rear timing belt cover 3 Install the mounting bolt with lock washer ITEM 7 M8x1 25x20L and was...

Page 69: ... and route the oil pressure switch wire and pulser coil wire from behind the hous ing through the groove as shown DETAIL C B Install three 3 mounting bolts ITEMS 27 28 AND 29 M6x1 0x18L 10mm socket Do not tighten them at this time Install the Coil Mounting Bracket and Coil Assembly See Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt on page D 10 Later models have a slightly ...

Page 70: ...x 6 spacers sleeves ITEM 4 are installed in rocker cover DETAIL A C Using a 10mm socket install and tighten six 6 bolts ITEM 3 M6x1 0x23L to specified torque in two stages in the order shown Install the Carburetor See Fig E 9 Carburetor on page D 14 A Install the gasket ITEM 2 plastic insulator ITEM 3 and gasket ITEM 4 on the carburetor mounting studs B Place the carburetor on the mounting studs w...

Page 71: ...ENGINE REASSEMBLY Page E 6 Engine Shop Rebuild and Parts Manual Fig E 1 Valves and Valve Clearance 7 6 3 5 4 1 2 B 004 Feeler guage Lobe Position heel of cam lobe as shown to measure valve clearance A 8 ...

Page 72: ...ENGINE REASSEMBLY Page E 7 Engine Shop Rebuild and Parts Manual Fig E 2 Valves con t 2 3 1 B A 8 7 C Push spring retainer down to install release valve keys ...

Page 73: ...ENGINE REASSEMBLY Page E 8 Engine Shop Rebuild and Parts Manual Fig E 3 Cylinder Head Cam Shaft and Rocker Assembly 13 15 16 8 7 6 10 9 11 12 1 3 4 Crankcase 5 2 14 17 ...

Page 74: ...r Assembly con t Lobes Rotate the cam lobes so that they will not exert pressure on the rocker arms as they are installed on the rocker shaft 7 8 10 1 2 3 4 5 6 7 Follow numbers to tighten cylinder head bolts in correct sequence Tighten to specified torque in two stages Sequence Item 6 5 4 5 5 5 A B C ...

Page 75: ...op Rebuild and Parts Manual Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt 34 32 31 25 23 24 22 21 8 17 12 7 16 9 13 14 3 5 6 2 1 20 26 27 28 30 19 33 29 10 Spri ng stop 8 15 11 Crankshaft 4 Newer Model Newer Model ...

Page 76: ...d Parts Manual Fig E 6 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt con t Idler Idler clamp bolt tighten to 10 13 ft lbs torque Idler spring Spring stop Align key way with mark Align notch and mark 1 8 1 4 Deflection at 10 lbs push A ...

Page 77: ...te the oil pressure switch wire and the pulser coil wire through the groove in the blower housing 1 3 4 2 Follow numbers to tighten manifold bolts in correct sequence Tighten to specified torque in two stages Some later models may or may not have an oil pressure switch some models have location of the switch in a slightly different position C B ...

Page 78: ...ENGINE REASSEMBLY Page E 13 Engine Shop Rebuild and Parts Manual Fig E 8 Rocker Cover 1 2 3 4 Rocker cover tightening sequence A ...

Page 79: ...ENGINE REASSEMBLY Page E 14 Engine Shop Rebuild and Parts Manual Fig E 9 Carburetor 5 7 6 1 4 3 2 ...

Page 80: ...F Page F 1 ILLUSTRATED PARTS BREAKDOWN Engine Shop Rebuild and Parts Manual Illustrated Parts Breakdown ...

Page 81: ...ts Breakdown Engine Shop Rebuild and Parts Manual 19 18 9 8 10 7 6 33 14 13 16 17 42 43 48 41 40 47 46 45 37 38 36 39 35 34 31 29 28 49 97 12 11 21 22 23 23 24 25 26 215 212 27 213 214 210 209 208 21 Earlier Model Newer Model 231 235 ...

Page 82: ...own ENGINE Engine Shop Rebuild and Parts Manual 57 193 58 194 59 195 53 189 54 190 55 191 62 62 51 61 51 52 74 77 78 79 80 94 93 92 91 67 68 69 84 66 71 85 86 98 99 100 101 102 103 105 104 88 89 106 107 75 64 65 72 73 70 76 18 81 82 83 ...

Page 83: ...Page F 4 ENGINE Illustrated Parts Breakdown Engine Shop Rebuild and Parts Manual 114 116 115 126 123 124 134 111 113 110 109 112 125 121 120 118 119 122 133 Newer Model ...

Page 84: ...1 204 203 205 206 136 140 138 139 137 141 146 148 153 221 135 130 183 184 186 187 197 197 180 180 177 171 169 176 182 167 168 165 166 145 132 131 152 147 155 156 222 157 159 162 158 163 150 218 151 219 173 174 161 164 178 129 154 175 A 142 143 145 180 A 202 Newer Model Newer Model 226 227 224 225 160 ...

Page 85: ...MS 6 12 295 cc ENGINE ONLY 1 PIECE MAN EXH 1 6 26743 G01 OIL SEAL BALANCER SHAFT 1 7 26741 G01 OIL SEAL CRANKSHAFT 1 8 26737 G01 BEARING BALL 1 9 26738 G01 BEARING CRANKCASE 1 10 26708 G01 DOWEL PIN 2 11 72539 G01 ELBOW 1 12 72559 G01 GUIDE DIPSTICK 1 13 26591 G01 FILTER OIL 1 14 26710 G01 O RING OIL FILTER 1 15 16 26680 G01 BOLT AND WASHER ASSEMBLY M6 X 1 X 12MM 3 17 26678 G01 FLANGED BOLT M6 X 1...

Page 86: ... G01 WASHER 8 5MM X 28MM X 2 3MM THK 1 40 26640 G01 BOLT IDLER PIVOT 1 41 26699 G01 WASHER 8 5MM X 16MM X 1 2MM THK 1 42 26638 G01 BOLT AND WASHER ASSEMBLY M6 X 1 X 16MM 1 43 26695 G01 WASHER 6 5MM X 22MM X 2MM THK 1 44 45 72908 G01 COVER FRONT TIMING BELT 1 46 26631 G01 GROMMET TIMING BELT COVER 1 47 26678 G01 BOLT FLANGED M6 X 1 X 12MM 3 4 48 26613 G01 RETAINER PULLEY 1 49 26614 G01 PULLEY DRIVE...

Page 87: ... 601550 CRANKSHAFT INCLUDES ITEM 74 350cc ONLY 1 PIECE MAN EXH 1 71 26693 G01 WOODRUFF KEY BALANCER SHAFT 1 72 72503 G01 CRANKSHAFT INCLUDES ITEM 74 350 cc ENGINE ONLY 1 73 26605 G01 CRANKSHAFT INCLUDES ITEM 74 295 cc ENGINE ONLY 1 74 26739 G01 BEARING BALL 1 75 26692 G01 WOODRUFF KEY CRANKSHAFT 1 76 601551 CRANKSHAFT INCLUDES ITEM 74 295cc ONLY 1 PIECE MAN EXH 1 77 26684 G01 SPACER CRANKSHAFT 6MM...

Page 88: ...G01 ROTOR OUTER OIL PUMP 1 99 26594 G01 ROTOR INNER OIL PUMP 1 100 26711 G01 O RING OIL PUMP COVER 1 101 26596 G01 COVER OIL PUMP 1 102 26680 G01 BOLT AND WASHER ASSEMBLY M6 X 1 X 12MM 3 103 26678 G01 BOLT FLANGED M6 X 1 X 12MM 1 PIECE MAN EXH 3 104 601552 BOLT FLANGED M8 X 1 25 X 28MM 1 PIECE MAN EXH 2 105 72850 G01 BOLT AND WASHER ASSEMBLY M8 X 1 25 X 30MM 2 106 26671 G01 BOLT AND WASHER ASSEMBL...

Page 89: ...1 X 18MM 3 124 26641 G01 BLOWER HOUSING 1 125 26691 G01 NUT FLANGED M22 X 1 5 1 126 26676 G01 BOLT FLANGED M6 X 1 X 23MM 1 127 72391 G01 CYLINDER HEAD ASSEMBLY INCLUDES ITEMS 129 132 350 cc ENGINE ONLY 1 128 72390 G01 CYLINDER HEAD ASSEMBLY INCLUDES ITEMS 129 132 295 cc ENGINE ONLY 1 129 26715 G01 OIL SEAL CAMSHAFT 1 130 72307 G01 STUD M6 X 1 X 115MM LG 2 131 26659 G01 VALVE GUIDE OVERSIZE 4 132 7...

Page 90: ...0MM 4 151 26623 G01 NUT M6 X 75 4 152 26625 G01 SPRING ROCKER SHAFT 1 153 72394 G01 CAMSHAFT 1 154 26709 G01 PIN DOWEL 1 155 26620 G01 SHAFT ROCKER 1 156 26718 G01 GASKET CAMSHAFT COVER 1 157 26599 G01 COVER CAMSHAFT 1 158 26678 G01 BOLT FLANGED M6 X 1 X 12MM 3 159 26679 G01 BOLT M6 X 1 1 160 72866 G01 IGNITION COIL 1 PIECE MAN EXH 1 161 26657 G01 BRACKET IGNITION COIL 1 162 26706 G01 NUT FLANGED ...

Page 91: ...ANGED M8 X 1 25 X 60MM 1 185 186 26716 G01 GASKET CYLINDER HEAD 295 cc ENGINE ONLY 1 187 72512 G01 GASKET CYLINDER HEAD 350 cc ENGINE ONLY 1 188 189 72540 G01 PISTON STANDARD 350 cc ENGINE ONLY 2 190 72541 G01 PISTON 25MM OVERSIZE 350 cc ENGINE ONLY 2 191 72542 G01 PISTON 50MM OVERSIZE 350 cc ENGINE ONLY 2 192 193 72543 G01 PISTON RING SET STANDARD 350 cc ENGINE ONLY 2 194 72544 G01 PISTON RING SE...

Page 92: ... OD X 145 MM LG 1 214 72678 G01 MESH PROTECTIVE COVER 1 215 72679 G01 HOSE CLAMP 2 216 217 601556 ROCKER ARM ASSEMBLY INCLUDES ITEMS 218 219 1 PIECE MAN EXH 1 218 601557 SCREW M5 X 5 X 18 5MM 1 PIECE MAN EXH 4 219 601558 NUT M5 X 5 1 PIECE MAN EXH 4 220 221 601563 CAMSHAFT 1 PIECE MAN EXH 1 222 26599 G01 GASKET CAMSHAFT COVER 1 PIECE MAN EXH 1 223 224 72869 G01 BRACKET IGNITION COIL 350CC 1 PIECE ...

Page 93: ...icates 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 Engine Shop Rebuild and Parts Manual 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 4 ...

Page 94: ...s California Only G 5 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT 2000 G 8 YOUR WARRANTY RIGHTS AND OBLIGATIONS G 8 LIMITED WARRANTY on Emission Control Systems California Only G 8 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT 2001 G 11 YOUR WARRANTY RIGHTS AND OBLIGATIONS G 11 LIMITED WARRANTY on Emission Control Systems California Only G 11 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT 2004...

Page 95: ...LIMITED WARRANTY Page G ii Engine Shop Rebuild and Parts Manual Notes ...

Page 96: ...or assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs 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 ga...

Page 97: ...s not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep maintenance records MAINTENANCE REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DISTRIBUTOR DEALER OR SERVICE PROVIDER AUTHO RIZED BY E...

Page 98: ...cable 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 OBTAINING WARRANTY SERVICE To obtain warranty service take your engine to the nearest authorized Textron Golf Turf Specialty Products dis tributor dealer or service provider Bring your sales receipts indicating date of pu...

Page 99: ...MENT OR REPAIR OF EMISSSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DISTRIBUTOR DEALER OR SERVICE PROVIDER AUTHO RIZED BY TEXTRON GOLF TURF SPECIALTY PRODUCTS THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EF FECTIVENESS OF THE EMISSION CONTROL S...

Page 100: ... E Z GO DIVISION OF TEXTRON INC Augusta Georgia herein E Z GO to which FUJI supplies the en gine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the E Z GO War ranty Department at 1 800 241 5855 LIMITED WARRANTY on Emission Contr...

Page 101: ...distributors or warranty stations authorized by E Z GO In the event that any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855 and you will be given the appropriate warranty service facilities where the warranty repair is per formed F WHERE TO GET WARRANTY SERVICE It is recommended that warranty service be perfo...

Page 102: ... Manual The scheduled maintenance below is based on the normal engine operating schedule PROCEDURE INTERVAL a Check for sealing of fuel cap and proper operation of fuel gauge at each fueling Check that fuel cap vent is free of dirt WEEKLY b Check engine for unusual noise vibration acceleration MONTH 20 HOURS c Check engine electrical system for coil spark plug wire for cracks loose connections 3 M...

Page 103: ... GO DIVISION OF TEXTRON INC Augusta Georgia herein E Z GO to which FUJI supplies the en gine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the E Z GO War ranty Department at 1 800 241 5855 LIMITED WARRANTY on Emission Control S...

Page 104: ...stributors or warranty stations authorized by E Z GO In the event that any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855 and you will be given the appropriate warranty service facilities where the warranty repair is per formed O WHERE TO GET WARRANTY SERVICE It is recommended that warranty service be perform...

Page 105: ...of that inspection and maintenance services are performed at the times when recommended FUJI will not deny a warranty claim solely be cause you have no record of maintenance however FUJI may deny a warranty claim if your failure to per form required maintenance resulted in the failure of warranted part The proof which you maintain should be given to each subsequent owner of the engine You are resp...

Page 106: ...a herein Textron Golf Turf Specialty Prod ucts to which FUJI supplies the engine as soon as a problem exists The warranty repairs should be com pleted in a reasonable amount of time not to exceed 30 days 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 LIMITED WARRANTY on ...

Page 107: ...the event that any emission related part is found to be defective during the warranty period you should notify Textron Golf Turf Specialty Products Warranty Department at 1 800 241 5855 and you will be given the appro priate warranty service facilities where the warranty repair is performed F WHERE TO GET WARRANTY SERVICE It is recommended that warranty service be performed by the authorized deale...

Page 108: ...he times recommended in the 2001 and later Owner s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended FUJI will not deny a warranty claim solely be cause you have no record of maintenance however FUJI may deny a warranty claim if your failure to per form required maintenance resulted in the failure of warranted part The proof which you m...

Page 109: ...E Z GO Division of Textron Augusta Georgia herein E Z GO to which FUJI supplies the engine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to ex ceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the E Z GO War ranty Department at 1 800 241 5855 LIMITED WARRANTY on Emission Control Sy...

Page 110: ... Z GO In the event that any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855 and you will be given the appropriate warranty service facilities where the warranty repair is per formed O WHERE TO GET WARRANTY SERVICE It is recommended that warranty service be performed by the authorized dealer who sold you the en...

Page 111: ...ices performed at the times recom mended in the 2004 and later Owner s Manual and to retain proof that inspection and maintenance services are per formed at the times when recommended FUJI will not deny a warranty claim solely because you have no record of maintenance however FUJI may deny a warranty claim if your failure to perform required maintenance resulted in the failure of warranted part Th...

Page 112: ...anual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Rd Augusta Georgia 30906 USA ...

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