E-Z-GO 4-STROKE AIR-COOLED GASOLINE ENGINE, Shop Rebuild Manual, Page: 51 / 100

D
ENGINE BOTTOM END REASSEMBLY
Page D-1
Kawasaki Engine Shop Rebuild Manual
ENGINE BOTTOM END
Tool List Qty. Required
Piston Ring Compressor Grip:
E-Z-GO Part No. N/A .................................................. 1
Piston Ring Compressor Belt, 80 ~ 91:
E-Z-GO Part No. N/A .................................................. 1
Bearing Driver Set:
E-Z-GO Part No. N/A .................................................. 1
If the engine is not going to be put back into
service immediately, completely coat all inter-
nal engine components with assembly lube. Tape intake and
exhaust openings.
Prior to engine reassembly, all parts
must be thoroughly cleaned; free of
dirt, oil, grease, carbon deposits, or residue of any kind; free of
nicks, burrs, or damage of any kind to wear surfaces; and
inspected for excessive wear. Parts that are damaged or are not
within dimensional specifications should be replaced (or
machined if applicable). We recommend that parts found to be
acceptable but near limits be replaced if the engine will have
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 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 one pass through the pattern, and then to
specified torque on the second pass.
All 4-cycle engine fasteners are plated, and
some are lubricated when installed. They are
considered “wet” and require approximately 80% of the speci-
fied torque of dry fasteners.
BREATHER
Install Breather Valve
A.
Install the reed valve [A] and back plate [B], then
tighten the breather valve screw [C].
Torque - Breather Valve Screw: 3.4 N•m ( 0.35 kgf•m,
30 in-lb)
B. Install the cylinder head (see Install Cylinder Head in
Section A).
BALANCER SHAFT
Install Balancer Shaft
A. Install the balancer shaft to the balancer shaft bear-
ing on the crankcase.
B. Install the crankcase cover (see Install Crankcase
Cover).
C.
Align the punch marks [A] on the crankshaft gear and
on the balancer shaft gear.