E-Z-GO Engine, Shop Rebuild Manual

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TABLE OF CONTENTS FOR SECTION ‘C’
SECTION TITLE PAGE NO.
Page C-i
C
ENGINE MEASUREMENTS
Kawasaki Engine Shop Rebuild Manual
ENGINE MEASUREMENTS AND SPECIFICATIONS...................................................................... C-1
Tool List .................................................................................................................................. C-1
Using Telescoping Gauges and Hole Gauges ....................................................................... C-1
CYLINDER HEAD ............................................................................................................................. C-1
Measure Cylinder Compression ............................................................................................. C-1
Inspect Push Rod ................................................................................................................... C-3
Inspect Rocker Arm ................................................................................................................ C-3
Measure Cylinder Head Warp ................................................................................................ C-3
VALVES ............................................................................................................................................ C-4
Inspect Valve Clearance......................................................................................................... C-4
Adjust Valve Clearance .......................................................................................................... C-4
Inspect Valve Seat.................................................................................................................. C-4
Repair Vavle Seat................................................................................................................... C-4
Operating Procedures ............................................................................................................ C-5
Measure Valve Spring Free Length ....................................................................................... C-8
Measure Vavle Head Thickness............................................................................................. C-8
Measure Valve Stem Bend .................................................................................................... C-8
Measure Valve Stem Diameter .............................................................................................. C-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 Diameter ........................................................................................... C-14
CRANKSHAFT AND CONNECTING RODS................................................................................... C-14
Clean/Inspect........................................................................................................................ C-14
Measure Connecting Rod Bend/Twist .................................................................................. C-14
Measure Connecting Rod Big End/Crankpin Width Wear .................................................... C-15
Measure Connecting Rod Big End Bearing/Crankpin Wear ................................................ C-15
Measure Crankshaft Runout................................................................................................. C-16
Measure Crankshaft Main Bearing/Journal Wear ................................................................ C-16
BALANCER SHAFT ........................................................................................................................ C-17
Measure Balancer Shaft Bearing/Journal Wear .................................................................. C-17
BREATHER VALVE ........................................................................................................................ C-17
Inspect Breather Valve ......................................................................................................... C-17