E-Z-GO Engine, Shop Rebuild Manual

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ENGINE MEASUREMENTS
Page C-14
Kawasaki Engine Shop Rebuild Manual
Check Cylinder Inside Diameter
A. Clean and measure the cylinder inside diameter.
B. Use a dial bore gauge to measure front-to-back and
side-to-side at the points as shown in the figure.
C.
If any of the cylinder bore measurements is greater
than the service limit, replace the crankcase.
10 mm (0.39 in.) [A]
35 mm (1.38 in.) [B]
Cylinder Inside Diameter
Standard: 81.97 ~ 81.99 mm (3.227 ~ 3.228 in.)
Service Limit: 82.10 mm (3.232 in.)
Cylinder Bore Out-Round
Service Limit: 0.05 mm (0.002 in.)
CRANKSHAFT AND CONNECTING RODS
Clean/Inspect
A. After removing, clean the crankshaft and connecting
rods with a high-flash point solvent and dry them with
compressed air.
B. Inspect the teeth of the crankshaft gear for pitting,
fatigue cracks, burrs and evidence 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 the con-
necting rod big end.
C. Select an arbor of the same diameter as the piston
pin and at least 100 mm long, and insert the arbor
through the connecting rod small end.
D.
On a surface plate, set the big-end arbor on V blocks
[A].
E. With the connecting rod held vertically, use a height
gauge [B] to measure the difference in the height of
the small end arbor above the surface plate over a
100 mm length to determine the amount of connect-
ing rod bend.
F. If connecting rod bend exceeds the service limit, the
connecting rod must be replaced.
Connecting Rod Bend
Service Limit: 0.15/100 mm (0.006/3.94 in.)