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HOW TO USE THIS MANUAL
Kawasaki Engine Shop Rebuild Manual
This manual is designed to suit the needs of mechanics at all levels of experience with the E-Z-GO 4-cycle engine. The
outline format allows the mechanic to choose the level of instructional detail needed to completely disassemble, diag-
nose, repair/overhaul and reassemble the engine.
The manual is divided into four major operational sections, which are each divided into smaller operational sections. At
the beginning 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/overhauling and reassembling the engine. Before working on the engine,
read and understand the
text and in particular each NOTE, CAUTION and WARNING.
Some illustrations may show components that differ from your engine. This is the result of ongoing improvements to the
engine design.
Summary of Contents for Engine
Page 2: ......
Page 10: ...Page viii Kawasaki Engine Shop Rebuild Manual Notes...
Page 12: ...ENGINE TOP END DISASSEMBLY Kawasaki Engine Shop Rebuild Manual Page A ii Notes...
Page 18: ...Page A 6 Kawasaki Engine Shop Rebuild Manual Notes...
Page 20: ...ENGINE BOTTOM END DISASSEMBLY Page B ii Kawasaki Engine Shop Rebuild Manual Notes...
Page 28: ...Page B 8 Kawasaki Engine Shop Rebuild Manual Notes...
Page 30: ...ENGINE MEASUREMENTS Page C ii Kawasaki Engine Shop Rebuild Manual Notes...
Page 37: ...ENGINE MEASUREMENTS Page C 7 Kawasaki Engine Shop Rebuild Manual...
Page 48: ...Page C 18 Kawasaki Engine Shop Rebuild Manual Notes...
Page 50: ...ENGINE BOTTOM END REASSEMBLY Page D ii Kawasaki Engine Shop Rebuild Manual Notes...
Page 56: ...Page D 6 Kawasaki Engine Shop Rebuild Manual Notes...
Page 58: ...ENGINE TOP END REASSEMBLY Page E ii Kawasaki Engine Shop Rebuild Manual Notes...
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 66: ...ILLUSTRATED PARTS BREAKDOWN Page F 4 Kawasaki Engine Shop Rebuild Manual PISTON CRANKSHAFT...
Page 68: ...ILLUSTRATED PARTS BREAKDOWN Page F 6 Kawasaki Engine Shop Rebuild Manual VALVE CAMSHAFT...
Page 70: ...ILLUSTRATED PARTS BREAKDOWN Page F 8 Kawasaki Engine Shop Rebuild Manual LUBRICATION...
Page 72: ...ILLUSTRATED PARTS BREAKDOWN Page F 10 Kawasaki Engine Shop Rebuild Manual COOLING...
Page 74: ...ILLUSTRATED PARTS BREAKDOWN Page F 12 Kawasaki Engine Shop Rebuild Manual ELECTRICAL...
Page 80: ...ILLUSTRATED PARTS BREAKDOWN Page F 18 Kawasaki Engine Shop Rebuild Manual Notes...
Page 82: ...LIMITED WARRANTY Page G ii Kawasaki Engine Shop Rebuild Manual Notes...
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