E-Z-GO 295cc, Shop Rebuild Manual, Page: 51 / 112

ENGINE REASSEMBLY
Page D-4
Engine Shop Rebuild and Parts Manual
C. Using a depth gauge and straight edge, measure the
distance from the gasket surface of the crankcase to
the faces of both the crankshaft and balancer shaft
gears close to the shafts, then subtract the width of
the straight edge from each measurement.
D. Using a depth gauge and straight edge, measure the
distance from the gasket surface of the end cover to
the inner races of both end cover bearings, then sub-
tract the width of the straight edge from each mea-
surement.
E. Add the figures from steps C. and D., plus .005 (gas-
ket thickness) for each shaft. Subtract from each fig-
ure the thickness of its spacer to find the clearance
for each shaft. If either clearance is not between .003
and .015, replace the spacer to achieve correct end-
play.
Install Crankshaft Endplay Spacer and Bal-
ancer Endplay Spacer
(See Fig. D-5 “Crankshaft, Pistons and Balancer Shaft” on page D-10)
A. Place the Crankshaft endplay spacer (ITEM 13) on
the crankshaft, and the balancer endplay spacer
(ITEM 14) on the balancer shaft.
Install Alignment Dowel Pins
(See Fig. D-8 “Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil
and Fan Hub” on page D-13)
Install alignment dowel pins (ITEM 25).
Install New Oil Feed O-Ring
(See Fig. D-8 “Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil
and Fan Hub” on page D-13)
A. Install a new oil feed O-ring (ITEM 1).
Install Crankcase End Cover Gasket
(See Fig. D-8 “Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil
and Fan Hub” on page D-13)
A. Place a new crankcase end cover gasket (ITEM 2)
on the end cover alignment dowel pins (ITEM 25).
Install the Crankcase End Cover
(See Fig. D-8 “Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil
and Fan Hub” on page D-13)
(See Fig. D-9 “Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil
and Fan Hub con’t” on page D-14)
A. Lift the crankcase end cover into position, 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 socket) with
lock washers (ITEM 7), and snug them in the order
shown. (DETAIL A)
2. In the same order, tighten the bolts to 1/2 of speci-
fied torque. Repeat the sequence, tightening the
bolts to specified torque.
Install the Oil Pump Gear Rotors
(See Fig. D-8 “Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil
and Fan Hub” on page D-13)
A. Coat the internal gear rotor (ITEM 8) with engine oil
and place it on the rotor shaft in the pump bore.
B. Lubricate the external gear rotor (ITEM 9) with engine
oil and place it in the pump bore.
C. Install a new O-ring (ITEM 10) in the ring groove.
D. Hold the oil pump cover (ITEM 11) in place. Install
and tighten three (3) mounting bolts with lock wash-
ers (ITEM 12, M6x1.0x12L, 10mm socket) to speci-
fied torque.
Install the Oil Pressure Switch
(See Fig. D-8 “Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil
and Fan Hub” on page D-13)
A. Apply a small amount of pipe sealer or teflon tape to
the switch threads.
B. Use an oil pressure switch socket to install and snug
the switch.
C. Use a 7mm socket to attach the switch wire (ITEM
14) and mounting screw (ITEM 15, M4x.4x6L) with
lock washer (ITEM 16).
Install the Pulser Coil
(See Fig. D-8 “Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil
and Fan Hub” on page D-13)
A. Hold the pulser coil (ITEM 17) in place and start the
two (2) mounting screws (ITEM 18, M5x0.8x10L,
8mm socket) with lock washers (ITEM 19).
B. Snug the mounting screws using an 8mm socket.
Install the Fan Hub
(See Fig. D-8 “Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil
and Fan Hub” on page D-13)
(See Fig. D-9 “Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil
and Fan Hub con’t” on page D-14)
A. Install the fan hub alignment key (ITEM 21).