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E-Z-GO 4-STROKE AIR-COOLED GASOLINE ENGINE Shop Rebuild Manual Download Page 100

Copyrighted Material

This manual 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

Inside USA  Phone: 1-800-241-5855, FAX:  1-800-448-8124

Outside USA  Phone: 010-1-706-798-4311, FAX:  010-1-706-771-4609

  

Summary of Contents for 4-STROKE AIR-COOLED GASOLINE ENGINE

Page 1: ...19 17 18 13 6 5 9 15 16 7 8 10 4 3 11 1 INCLUDES ITEMS 3 16 4 STROKE AIR COOLED GASOLINE ENGINE STARTING MODEL YEAR 2008 KAWASAKI ENGINE SHOP REBUILD MANUAL 608172 ...

Page 2: ......

Page 3: ...d 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 CUSTOMER SERVICE DEPARTMENT IN USA PHONE 1 800 241 5855 FAX 1 800 448 8124 OUTSIDE USA PHONE 010 1 706 798 4311 FAX 010 1 706 771 4609 E Z GO DIVISION...

Page 4: ...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 comply with regulations set forth by the Environmental Protec...

Page 5: ...ism A 2 SPECIFICATIONS A 3 EXPLODED VIEW A 4 ENGINE BOTTOM END DISASSEMBLY B ENGINE BOTTOM END Tool List B 1 CRANKCASE Remove Crankcase Cover B 1 CAMSHAFT AND TAPPETS Remove Camshaft Tappet B 1 CYLINDERS AND PISTONS Remove Piston B 2 CRANKSHAFT AND CONNECTING RODS Remove Connecting Rod B 3 Remove Crankshaft B 3 BALANCER SHAFT Remove Balancer Shaft B 3 BREATHER VALVE Remove Breather Valve B 3 SPECI...

Page 6: ...ter C 9 Measure Valve Guide Inside Diameter C 9 Measure Valve Guide Clearance Wobble Method C 9 CAMSHAFT AND TAPPETS Measure Camshaft Bearing Journal Wear C 10 CYLINDER AND PISTONS Clean Piston C 11 Check Piston Ring and Ring Groove Wear C 11 Measure Piston Ring End Gap C 12 Measure Piston Pin Piston Pin Hole and Connecting Rod Wear C 13 Measure Piston Diameter C 13 Check Cylinder Inside Diameter ...

Page 7: ... Install Balancer Shaft D 1 CRANKSHAFT AND CONNECTING RODS Install Crankshaft D 2 Install Connecting Rod D 2 CYLINDERS AND PISTONS Install Piston D 2 CAMSHAFT AND PISTONS Install Camshaft Tappet D 4 CRANKCASE Assemble Crankcase Cover D 4 Install Crankcase Cover D 4 ENGINE TOP END REASSEMBLY E ENGINE TOP END Tool List E 1 VALVES Install Valve Mechanism E 1 CYLINDER HEAD Install Cylinder Head E 1 ...

Page 8: ...COOLING F 10 ELECTRICAL F 12 CARBURETOR CABLE BRACKETS F 14 AIR INTAKE BREATHER EXHAUST F 16 LIMITED WARRANTY G Federal Emissions Component Defect Warranty G 1 California Emission Control Warranty Statement 1995 1999 G 5 California Emission Control Warranty Statement 2000 G 8 California Emission Control Warranty Statement 2001 G 11 California Emission Control Warranty Statement 2004 G 14 ...

Page 9: ...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 10: ...Page viii Kawasaki Engine Shop Rebuild Manual Notes ...

Page 11: ...i Kawasaki Engine Shop Rebuild Manual A ENGINE TOP END DISASSEMBLY ENGINE TOP END A 1 Tool List A 1 CYLINDER HEAD A 1 Remove Cylinder Head A 1 VALVES A 2 Remove Valve Mechanism A 2 SPECIFICATIONS A 3 EXPLODED VIEW A 4 LIST OF ILLUSTRATIONS Fig 1 Cylinder Head A 4 ...

Page 12: ...ENGINE TOP END DISASSEMBLY Kawasaki Engine Shop Rebuild Manual Page A ii Notes ...

Page 13: ...emoved only if they appear to be damaged or excessively worn Remove bearings that are pitted nicked burred discolored or that rotate roughly or noisily 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 na...

Page 14: ... occur if they are used as pry points Remove cylinder head bolts A push rod guides B and cylinder head C VALVES Remove Valve Mechanism A Remove cylinder head see Remove Cylinder Head B Support the valve head in the combustion chamber with a folded shop towel C Wear eye protection while removing collets Valve springs are under tension and may propel collets during removal causing injury to eyes To ...

Page 15: ...1 09 in __ __ __ Width Inlet 1 1 1 7 mm 0 043 0 067 in __ __ __ Exhaust 1 0 1 5 mm 0 039 0 059 in __ __ __ Valve Seat Cutting Angle 45 __ __ __ Valve Spring Free Length 35 mm 1 38 in 32 6 mm 1 28 in Valve Head Thickness 0 4 mm 0 016 in 0 4 mm 0 016 in Valve Stem Bend Less than 0 01 mm 0 0004 in TIR TIR 0 05 mm 0 0020 in Valve Stem Diameter Inlet 6 960 6 975 mm 0 2740 0 2746 in 6 95 mm 0 274 in Exh...

Page 16: ...ENGINE TOP END DISASSEMBLY Page A 4 Kawasaki Engine Shop Rebuild Manual Exploded View Fig 1 Cylinder Head ...

Page 17: ...Follow the specific tightening sequence No E Z GO Part No Fastener Torque Remarks N m kgf m ft lb in lb 1 603523 Cylinder Head Cover Bolts 6 9 0 70 61 in lb 2 603525 Cylinder Head Bolts 37 3 8 27 ft lb S 3 603570 Engine Shroud Bolts 5 9 0 60 52 in lb 4 603545 Valve Adjusting Nut Lock Screws 6 9 0 70 61 in lb 5 603549 Rocker Arm Bolts 28 2 9 21 ft lb ...

Page 18: ...Page A 6 Kawasaki Engine Shop Rebuild Manual Notes ...

Page 19: ...B 1 Remove Crankcase Cover B 1 CAMSHAFT AND TAPPETS B 1 Remove Camshaft Tappet B 1 CYLINDERS AND PISTONS B 2 Remove Piston B 2 CRANKSHAFT AND CONNECTING RODS B 3 Remove Connecting Rod B 3 Remove Crankshaft B 3 BALANCER SHAFT B 3 Remove Balancer Shaft B 3 BREATHER VALVE B 3 Remove Breather Valve B 3 SPECIFICATIONS B 4 EXPLODED VIEW B 6 LIST OF ILLUSTRATIONS Fig 1 Crankcase B 6 ...

Page 20: ...ENGINE BOTTOM END DISASSEMBLY Page B ii Kawasaki Engine Shop Rebuild Manual Notes ...

Page 21: ...l If the crankcase cover sticks tap lightly with a wooden or plastic mallet near the dowel pins C B C Remove crankcase cover bolts A and crankcase cover B CAMSHAFT AND TAPPETS Remove Camshaft Tappet A Drain the engine oil B Remove crankcase cover see Remove Crankcase Cover C Remove valve cover A D Position the piston TDC at the end of the compres sion stroke E Remove the lock screws A and the valv...

Page 22: ...ting rod cap bolts A C Remove the bolts and take off the connecting rod cap B Note the position of the connecting rod cap for reinstalling the cap D Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder E Remove one of the piston pin snap rings A with needle nose pliers F Remove the piston by pushing the piston pin A out the side from which the sn...

Page 23: ...on of the breather is to create a negative pres sure in the crankcase which prevents oil from being forced out of the engine through the piston rings oil seals or gaskets A sealed type crankcase emission control system is used to prevent blow by gases from emitting in the air The blow by gases are drawn into the clean side of the air cleaner through the crankcase and the cylinder head and mixed wi...

Page 24: ... Side 50 000 50 025 mm 50 09 mm 1 9685 1 9695 in 1 972 in Crankshaft and Connecting Rods Connecting Rod Bend 0 15 100 mm 0 006 3 94 in Connecting Rod Twist 0 15 100 mm 0 006 3 94 in Connecting Rod Big End Width 27 4 27 7 mm 27 0 mm 1 08 1 09 in 1 06 in Crankpin Width 28 0 28 2 mm 28 4 mm 1 10 1 11 in 1 12 in Connecting Rod Big End Inside Diameter 43 004 43 015 mm 43 04 mm 1 6931 1 6935 in 1 694 in...

Page 25: ... 74803 in 0 7465 in Piston Pin Hole Inside Diameter 19 004 19 015 mm 19 08 mm 0 74819 0 74862 in 0 7512 in Connecting Rod Small End Inside Diameter 19 010 19 021 mm 19 06 mm 0 74842 0 74886 in 0 7504 in Piston Diameter 81 935 81 955 mm 81 79 mm 3 2258 3 2266 in 3 220 in Cylinder Inside Diameter 81 97 81 99 mm 82 10 mm 3 227 3 228 in 3 232 in Cylinder Bore Out Round 0 05 mm 0 002 in Piston Cylinder...

Page 26: ...ENGINE BOTTOM END DISASSEMBLY Page B 6 Kawasaki Engine Shop Rebuild Manual Exploded View Fig 1 Crankcase ...

Page 27: ...ulfide grease R Replacement Parts S Follow the specific tightening sequence No E Z GO Part No Fastener Torque Remarks N m kgf m ft lb in lb 1 603535 Connecting Rod Big End Cap Bolts 5 9 0 60 52 in lb EO 2 603526 Breather Valve Screw 37 0 35 30 in lb 3 603518 Oil Filter Joint 6 9 0 70 61 in lb 4 603522 Oil Line Plugs 3 9 0 40 34 in lb L 5 603524 Crankcase Cover Bolts 22 2 2 16 ft lb S ...

Page 28: ...Page B 8 Kawasaki Engine Shop Rebuild Manual Notes ...

Page 29: ...9 Measure Valve Guide Inside Diameter C 9 Measure Valve Guide Clearance Wobble Method C 9 CAMSHAFT AND TAPPETS C 10 Measure Camshaft Bearing Journal Wear C 10 CYLINDER AND PISTONS C 11 Clean Piston C 11 Check Piston Ring and Ring Groove Wear C 11 Measure Piston Ring End Gap C 12 Measure Piston Pin Piston Pin Hole and Connecting Rod Wear C 13 Measure Piston Diameter C 13 Check Cylinder Inside Diame...

Page 30: ...ENGINE MEASUREMENTS Page C ii Kawasaki Engine Shop Rebuild Manual Notes ...

Page 31: ...d if the engine will see high usage Check micrometers for proper calibration before beginning the operations described in this section Using Telescoping Gauges and Hole Gauges Telescoping gauges and hole gauges are transfer type measuring instruments They are not calibrated and are used to record a distance which is then transferred to a micrometer for measurement Position the gauge in the hole or...

Page 32: ...oil seal and or damaged piston oil rings Remove the carbon deposits and replace damaged parts if necessary Incorrect cylinder head gasket thickness Replace with a gasket of the proper thick ness Cylinder compression lower than usable range Gas leakage around cylinder head Replace damaged gas ket and check cylin der head warp Bad condition of valve seating Repair if possible Incorrect valve piston ...

Page 33: ... Rocker Arm Push Rod Runout Service Limit TIR 0 5 mm 0 02 in Inspect Rocker Arm A Clean and inspect the rocker arm where it touches the push rod and valve stem B If the contact points A are worn or damaged replace the rocker arm Measure Cylinder Head Warp A Lay a straightedge A across the lower surface of the head at several different points and measure warp by inserting a thickness gauge B betwee...

Page 34: ...side diameter D of the seating pat tern on the valve seat I If the outside diameter of the valve seating pattern is too large or too small repair the seat Valve Seating Surface Outside Diameter Inlet 32 8 mm 1 29 in Exhaust 27 6 mm 1 09 in J Measure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F Too Wide G Too Narrow ...

Page 35: ...sh off any ground particles sticking to the cutter 5 After use wash the cutter with washing oil and apply a thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A repre sent the following 60 Cutter angle B 37 5 Outer diameter of cutter C Operating Procedures A Clean the seat area carefully B Coat the seat with machinist s dye C Fit a 45 cu...

Page 36: ...once the seat width and O D are within the ranges specified above K Put a little coarse grinding compound on the face of the valve in a number of places around the valve head L Spin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve M Repeat the process with a fine grinding compound A Lapping Tool B Valve Seat C Valve N The seat...

Page 37: ...ENGINE MEASUREMENTS Page C 7 Kawasaki Engine Shop Rebuild Manual ...

Page 38: ...ickness is less than the service limit replace the valve with a new one Valve Head Thickness Standard 0 4 mm 0 016 in Service Limit 0 4 mm 0 016 in Measure Valve Stem Bend A Place the valve in V blocks at each end of the stem and set a dial gauge A on the stem at a point half way between the blocks Turn the valve to measure the bend The difference between the highest and the lowest dial readings i...

Page 39: ... mm 0 2756 0 2762 in Service Limit 7 08 mm 0 279 in Measure Valve Guide Clearance Wobble Method A If a small bore gauge is not available inspect the valve guide wear by measuring the valve guide clear ance with the wobble method as indicated below B Insert a new valve A into the guide B from the top of the head C Set a dial gauge against the stem perpendicular to it as close as possible to the cyl...

Page 40: ...nal Diameter Standard 19 967 19 980 mm 0 78610 0 78661 in Service Limit 19 94 mm 0 7850 in Crankcase Cover Side Camshaft Journal Diameter Standard 49 959 49 975 mm 1 9669 1 9675 in Service Limit 49 93 mm 1 966 in E Measure the inside diameter A of the camshaft bearing on the crankcase at several points F Replace the crankcase if the inside diameter is more than the service limit Camshaft Bearing I...

Page 41: ...at will not cause damage Scrape the carbon off the piston head with a scraper A C Be careful not to widen the ring grooves Damaged ring grooves will require piston replacement D Clean the piston ring grooves A with a broken piston ring or other suitable tools Check Piston Ring and Ring Groove Wear A Clean the piston see Clean Piston Visually inspect the piston rings and ring grooves B If the pisto...

Page 42: ...tandard Top Second 1 47 1 49 mm 0 0579 0 0587 in Service Limit Top Second 1 40 mm 0 0551 in When using new rings in a used piston check for uneven groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Measure Piston Ring End Gap A Remove the piston rings B Push each ring one at a time into the cylinder bore to a point close to the bottom of the cylinder ...

Page 43: ... replace the piston Piston Pin Hole Inside Diameter Standard 19 004 19 015 mm 0 74819 0 74862 in Service Limit 19 08 mm 0 7512 in F Measure the inside diameter A of the small end of the connecting rod at several points Use a dial bore gauge G If the inside diameter is more than the service limit replace the connecting rod Connecting Rod Small End Inside Diameter Standard 19 010 19 021 mm 0 74842 0...

Page 44: ...e of improper tooth contact C Replace the gear if necessary D Inspect the crankshaft and connecting rods espe cially at the bearing surfaces for wear scratches evi dence of improper contact or other damages E Replace them if necessary Measure Connecting Rod Bend Twist A Measure connecting rod bend B Select an arbor of the same diameter as the connect ing rod big end and insert the arbor through th...

Page 45: ...ess than the service limit replace the connecting rod Connecting Rod Big End Width Standard 27 4 27 7 mm 1 08 1 09 in Service Limit 27 0 mm 1 06 in C Measure the crankpin width A with a dial caliper D If the crankpin width is more than the service limit replace the crankshaft Crankpin Width Standard 28 0 28 2 mm 1 10 1 11 in Service Limit 28 4 mm 1 12 in Measure Connecting Rod Big End Bearing Cran...

Page 46: ... and lowest dial gauge readings TIR is the amount of runout E If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 002 in Measure Crankshaft Main Bearing Journal Wear A Measure the diameter A of the crankshaft main jour nal B If the journal has worn enough to exceed the service limit replace the cra...

Page 47: ...e Standard 32 000 32 016 mm 1 2598 1 2605 in Service Limit 32 06 mm 1 262 in E Measure the inside diameter A of the balancer shaft bearing on the crankcase cover at several points F If inside diameter is more than the service limit replace the crankcase cover with a new one Balancer Shaft Bearing Inside Diameter Crankcase cover Standard 32 000 32 016 mm 1 2598 1 2605 in Service Limit 32 06 mm 1 26...

Page 48: ...Page C 18 Kawasaki Engine Shop Rebuild Manual Notes ...

Page 49: ...l List D 1 BREATHER VALVE D 1 Install Breather Valve D 1 BALANCER SHAFT D 1 Install Balancer Shaft D 1 CRANKSHAFT AND CONNECTING RODS D 2 Install Crankshaft D 2 Install Connecting Rod D 2 CYLINDERS AND PISTONS D 2 Install Piston D 2 CAMSHAFT AND PISTONS D 4 Install Camshaft Tappet D 4 CRANKCASE D 4 Assemble Crankcase Cover D 4 Install Crankcase Cover D 4 ...

Page 50: ...ENGINE BOTTOM END REASSEMBLY Page D ii Kawasaki Engine Shop Rebuild Manual Notes ...

Page 51: ...n 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 performance and life expectan cy of the engine When tightening torquing a number of screws or bolts in a giv en pattern tighten them in two stages Tighten them to 1 2 of specified torque in...

Page 52: ...l Connecting Rod A Refer to Install Piston CYLINDERS AND PISTONS Install Piston A Install the expander A in the piston oil ring groove so that the expander ends B touch never overlap B There is no up or down to the rails They can be installed either way Install the upper and lower steel rails C Do not mix up the top and second rings Install the second ring so that the notched edge A faces down The...

Page 53: ... Apply engine oil to the piston skirt and the cylinder bore J Using the piston ring compressor grip A and the belt B lightly tap the top of the piston with a plastic mal let C to insert the piston and connecting rod into the cylinder Special Tools Piston Ring Compressor Grip E Z GO Part No N A Piston Ring Compressor Belt 80 91 E Z GO Part No N A K Position the arrow mark D on the top of the piston...

Page 54: ...aft gear and on the camshaft gear E Install the crankcase cover see Install Crankcase Cover F Install the push rods see Install Cylinder Head in Section A G Mount the rocker arms on the push rods and install the valve clearance adjusting nuts and the lock screws Torque Valve Adjusting Nut Lock Screws 6 9 N m 0 70 kgf m 61 in b H Adjust the valve clearance see Adjust Valve Clear ance in Section C I...

Page 55: ...EASSEMBLY Page D 5 Kawasaki Engine Shop Rebuild Manual C Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown Torque Crankcase Cover Bolts 22 N m 2 2 kgf m 16 ft lb ...

Page 56: ...Page D 6 Kawasaki Engine Shop Rebuild Manual Notes ...

Page 57: ...R SECTION E SECTION TITLE PAGE NO Page E i E ENGINE TOP END REASSEMBLY Kawasaki Engine Shop Rebuild Manual ENGINE TOP END E 1 Tool List E 1 VALVES E 1 Install Valve Mechanism E 1 CYLINDER HEAD E 1 Install Cylinder Head E 1 ...

Page 58: ...ENGINE TOP END REASSEMBLY Page E ii Kawasaki Engine Shop Rebuild Manual Notes ...

Page 59: ...Part No N A 1 VALVES Install Valve Mechanism A Apply engine oil to the valve stems and install them B Check to see that the valve moves smoothly up and down in the guide C Install the spring and the valve retainer D Install the valve retainer while pushing down the valve retainer with the thumbs E Install cylinder head See Install Cylinder Head in Section A CYLINDER HEAD Install Cylinder Head A Cl...

Page 60: ... push rods on each cylinder are at the lowest position on the cam lobes D If not turn the alternator rotor clockwise one turn and position the crankshaft at TDC of the compres sion stroke I Be sure the ends of the push rods are correctly seated on the tappets J Apply engine oil to the rocker arms K Install rocker arms and valve clearance adjusting nuts L Check and adjust the valve clearance see In...

Page 61: ...E NO Page Fi F ILLUSTRATED PARTS BREAKDOWN Kawasaki Engine Shop Rebuild Manual CYLINDER CRANKCASE F 2 PISTON CRANKSHAFT F 4 VALVE CAMSHAFT F 6 LUBRICATION F 8 COOLING F 10 ELECTRICAL F 12 CARBURETOR CABLE BRACKETS F 14 AIR INTAKE BREATHER EXHAUST F 16 ...

Page 62: ...ILLUSTRATED PARTS BREAKDOWN Page Fii Kawasaki Engine Shop Rebuild Manual ...

Page 63: ...F ILLUSTRATED PARTS BREAKDOWN Page F 1 Kawasaki Engine Shop Rebuild Manual Notes ...

Page 64: ...ILLUSTRATED PARTS BREAKDOWN Page F 2 Kawasaki Engine Shop Rebuild Manual CYLINDER CRANKCASE ...

Page 65: ...T COVER CRANKCASE 603512 1 1 5 GASKET CAS COVER 603513 1 1 6 PLATE BREATHER 603514 1 1 7 VALVE BREATHER 603515 1 1 8 PIPE BREATHER 603516 1 1 9 COVER CRANKCASE 603517 1 1 10 CRANKCASE COMPLETE 603518 1 1 11 PIN DOWEL 603519 4 4 12 SEAL OIL SD35X48X8 603520 1 1 13 SEAL OIL 603521 1 1 14 PLUG 603522 2 2 15 BOLT FLANGED 603523 4 4 16 BOLT FLANGED 603524 8 8 17 BOLT FLANGED 603525 4 4 18 SCREW PAS CRO...

Page 66: ...ILLUSTRATED PARTS BREAKDOWN Page F 4 Kawasaki Engine Shop Rebuild Manual PISTON CRANKSHAFT ...

Page 67: ...tem Description E Z GO Part Number Quantity GOLF UTILITY 20 PISTON ENGINE 603528 1 1 21 PIN PISTON 603529 1 1 22 RING SET PISTON 603530 1 1 23 CRANKSHAFT COMPLETE 603531 1 1 24 BALANCER COMPLETE 603532 1 1 25 ASSY CONNECT ROD 603533 1 1 26 RING SNAP 603534 2 2 27 BOLT M6X1 0X35 0 LG 603535 2 2 ...

Page 68: ...ILLUSTRATED PARTS BREAKDOWN Page F 6 Kawasaki Engine Shop Rebuild Manual VALVE CAMSHAFT ...

Page 69: ...36 1 1 29 VALVE EXHAUST 603537 1 1 30 RETAINER VALVE SPRING 603538 2 2 31 COLLECT 603539 4 4 32 ARM ROCKER 603540 2 2 33 TAPPET 603541 2 2 34 GUIDE PUSH ROD 603542 2 2 35 ROD PUSH 603543 2 2 36 SPRING ENGINE VALVE 603544 2 2 37 CAMSHAFT COMPLETE 607461 1 1 38 SCREW 603545 2 2 39 NUT 603546 2 2 40 SEAL OIL 603547 2 2 41 SPRING NOT SHOWN 603548 1 1 42 BOLT 603549 2 2 ...

Page 70: ...ILLUSTRATED PARTS BREAKDOWN Page F 8 Kawasaki Engine Shop Rebuild Manual LUBRICATION ...

Page 71: ...E 603555 1 1 48 FILTER OIL FJ400D 607454 1 1 49 DIPSTICK OIL LOW SUSP 606390 1 1 50 DIPSTICK OIL HIGH SUSP NOT SHOWN 606391 1 51 RING SNAP 603556 1 1 52 PLUG 603557 3 3 53 BALL 603558 1 1 54 SPRING OIL RELIEF 603559 1 1 55 BOLT 603560 2 2 56 BOLT FLANGED 603561 1 1 57 O RING 16MM 603562 3 3 58 SWITCH OIL PRESSURE NOT SHOWN 608398 1 Utility vehicles may be equipped with either high or low suspensio...

Page 72: ...ILLUSTRATED PARTS BREAKDOWN Page F 10 Kawasaki Engine Shop Rebuild Manual COOLING ...

Page 73: ...1 Kawasaki Engine Shop Rebuild Manual COOLING Item Description E Z GO Part Number Quantity GOLF UTILITY 59 SHROUD ENGINE 603563 1 60 GUARD 603564 1 1 61 FAN 603566 1 1 62 HOUSING FAN 603567 1 1 63 RIVET GUARD 603569 1 1 64 BOLT 603560 5 5 ...

Page 74: ...ILLUSTRATED PARTS BREAKDOWN Page F 12 Kawasaki Engine Shop Rebuild Manual ELECTRICAL ...

Page 75: ...ity GOLF UTILITY 65 PLATE FAN 603571 1 1 66 ASSY IGNITION COIL 603572 1 1 67 FLYWHEEL ASSEMBLY 607463 1 1 68 WIRE LEAD 603573 1 1 69 PLUG 603522 1 1 70 PLUG SPARK BPR2ES 607462 1 1 71 BOLT M12X39MM LG 603575 1 1 72 WASHER 603576 1 1 73 BOLT FLANGED 603577 2 2 74 SCREW PAN WP CROS NOT SHOWN 603578 4 4 75 KEY WOODRUFF 603579 1 1 ...

Page 76: ...ILLUSTRATED PARTS BREAKDOWN Page F 14 Kawasaki Engine Shop Rebuild Manual CARBURETOR CABLE BRACKETS ...

Page 77: ...BURETOR AS03 607954 1 81 CARBURETOR AS07 SPEC NOT SHOWN 607955 1 82 PLUG PILOT JET 603585 1 1 83 JET PILOT 44 608021 1 84 JET PILOT 52 NOT SHOWN 607957 1 85 JET MAIN 106 607956 1 86 JET MAIN 104 607683 1 87 JET MAIN 102 607684 88 JET MAIN 100 NOT SHOWN 607685 89 VALVE FLOAT 607686 1 1 90 FLOAT 607687 1 1 91 PIN FLOAT 607688 1 1 92 GASKET BOWEL 607689 1 1 93 ASSY FLOAT CHAMBER 607690 1 1 94 GASKET ...

Page 78: ...ILLUSTRATED PARTS BREAKDOWN Page F 16 Kawasaki Engine Shop Rebuild Manual AIR INTAKE BREATHER EXHAUST ...

Page 79: ...AKE BREATHER Item Description E Z GO Part Number Quantity GOLF UTILITY 97 GASKET CHOKE 603593 1 1 98 PIPE INTAKE 603594 1 1 99 NUT M6X1 0 V 603595 2 2 100 CLAMP INTAKE PIPE 603596 1 1 101 CLAMP CYLINDR HEAD 603597 1 1 102 TUBE BREATHER 603598 1 1 EXHAUST 103 SCREW EXHAUST 608022 2 2 ...

Page 80: ...ILLUSTRATED PARTS BREAKDOWN Page F 18 Kawasaki Engine Shop Rebuild Manual Notes ...

Page 81: ...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 82: ...LIMITED WARRANTY Page G ii Kawasaki Engine Shop Rebuild Manual Notes ...

Page 83: ...r 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 gas...

Page 84: ...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 85: ...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 86: ...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 87: ... 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 88: ...r 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 per...

Page 89: ... 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 MONTH 50 HOU...

Page 90: ...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 Sy...

Page 91: ...istributors 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 perfor...

Page 92: ...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 93: ...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 94: ...n 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 dea...

Page 95: ...e 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 ma...

Page 96: ... 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 Sys...

Page 97: ... 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 performed by the authorized dealer who sold you the ...

Page 98: ...ces 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 The...

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Page 100: ... 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 Inside USA Phone 1 800 241 5855 FAX 1 800 448 8124 Outside USA Phone 010 1 706 798 4311 FAX 010 1 706 771 4609 ...

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