E-Z-GO 295cc, Shop Rebuild Manual, Page: 49 / 112

ENGINE REASSEMBLY
Page D-2
Engine Shop Rebuild and Parts Manual
A. Apply a coat of assembly lube to the exterior surface
of the wrist pin (ITEM 1) and to the wrist pin bores in
the connecting rod (ITEM 2) and piston (ITEM 3).
B. Insert the wrist pin through the pin bore on one side
of the piston, allowing it to protrude slightly into the
interior of the piston.
C. With the word “FAN” on the connecting rod oriented
toward the letters “DF” on the top of the piston, slide
the rod onto the end of the wrist pin protruding into
the interior of the piston. Continue pushing the wrist
pin through the piston and into the opposing bore.
D. Install the wrist pin retaining rings (ITEM 4).
1. Insert a portion of a wrist pin retaining ring into the
groove at the mouth of the wrist pin bore in the pis-
ton. Use a flat blade screwdriver to push the
remainder of the ring into the groove. (DETAIL A)
2. Use a suitable mandrel to push the wrist pin
against the retaining ring from the opposite side of
the piston. (DETAIL B)
3. Repeat step 1 to install the second wrist pin retain-
ing ring.
Install the Piston Rings
(See Fig. D-2 “Piston and Connecting Rods” on page D-7)
(See Fig. D-3 “Pistons and Connecting Rods con’t” on page D-8)
Original oil rings are three piece design. A sin-
gle oil ring is provided as a service replace-
ment.
Piston ring grooves must be clean.
Reassemble the pistons with new pis-
ton rings. Position the top ring gap at 45° to the axis of the wrist
pin.
A. Apply a light coat of engine oil to the piston rings, and
lands.
B. Install the oil ring (ITEM 5).
1. If desired, use piston ring installer or insert one
end of the oil ring into the bottom groove on the
piston, leaving the other end resting on top of the
piston. Work the rest of the ring into the groove
while rotating the piston. (DETAIL 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 the end cover with new
balancer shaft and crankshaft bearings
if the original bearings were removed. If the bearings can be
installed in the end cover by hand, without heating the end cov-
er, the end cover and crankcase must be replaced.
A. If the original crankshaft bearing (ITEM 2) and bal-
ancer shaft bearing (ITEM 3) have been removed,
install NEW ones. (DETAIL A)
1. Use an oven to evenly heat the end cover to 200
°
+
Fahrenheit.
2. Before the end cover (ITEM 1) cools, install a new
crankshaft bearing (ITEM 2) and new balancer
shaft bearing (ITEM 3) into the cover.
3. Allow the cover to cool, then lubricate the bearing
races with assembly lube.
B. Reassemble the oil pump check valve.
1. Coat the check ball (ITEM 4) with engine oil and
install it into the cover.
2. Install the spring (ITEM 5) over the check ball.
3. Set the valve cover plate (ITEM 6) in place with
the bleed hole over the spring. Hold the plate
down and install and tighten the bolt (ITEM 7,
M6x1.0x8L, 10mm socket) to specified torque.
Use 262 Loctite on the bolt; do not allow any to get
on the ball or spring.
C. Using a seal installation tool, install a NEW crank-
shaft seal (ITEM 8).
Install New Crankcase Bearing
(See Fig. D-5 “Crankshaft, Pistons and Balancer Shaft” on page D-10)
If the bearings can be installed by hand,
without a press or heating the crank-
case, the crankcase and end cover must be replaced.
A. If the original bearings were removed, use a mechan-
ical press or heat the crankcase in an oven to 200
°
Fahrenheit to install a new crankshaft bearing (ITEM
1) and new balancer shaft bearing (ITEM 2) into the
crankcase (ITEM 3).