Ezgo 1600xd Repair Manual page 39

TABLE OF CONTENTS
1. GENERAL INFORMATION ..................... 3-3
1.1 Engine views .......................................... 3-3
1.2 Engine identifi cation .............................. 3-3
2. SPECIFICATIONS ................................... 3-4
2.1 Engine dimensions ................................. 3-4
2.2 General specifi cations ............................ 3-5
2.3 Service specifi cations ............................. 3-6
2.3.1 Cylinder head ............................... 3-6
2.3.2 Valves ........................................... 3-6
2.3.3 Valve springs ................................ 3-6
2.3.4 Valve rocker arms ......................... 3-7
2.3.5 Camshaft ...................................... 3-7
2.3.6 Piston rings ................................... 3-7
2.3.7 Pistons .......................................... 3-8
2.3.8 Crankshaft .................................... 3-8
2.3.10 Injection pump .............................. 3-9
2.3.11 Oil pump ....................................... 3-9
2.3.12 Radiator ........................................ 3-9
2.3.13 Thermostat ................................... 3-9
2.3.14 Fanbelt .......................................... 3-9
2.3.15 Tightening torque ........................ 3-10
3. STRUCTURE AND FUNCTION .............3-11
3.1 Body and power train ........................... 3-11
3.1.1 Cylinder head ............................. 3-11
3.1.2 Cylinder block ............................ 3-11
3.1.3 Crankshaft ................................. 3-12
3.1.5 Connecting rods ......................... 3-12
3.1.6 Camshaft and fuel camshaft ...... 3-13
3.1.7 Rocker arm assembly ................ 3-13
3.1.8 Inlet and exhaust valves ............ 3-13
3.1.9 Timing gears ............................... 3-14
3.1.10 Flywheel ..................................... 3-14
ENGINE
3.2 Lubrication system ............................... 3-16
3.3 Cooling system ..................................... 3-19
3.4 Fuel system .......................................... 3-22
3.5 Governor system .................................. 3-27
3.6 Intake and exhaust system .................. 3-30
4. TROUBLESHOOTING .......................... 3-32
5. INSPECTION AND ADJUSTMENT ....... 3-34
5.1 Fan belt tension adjustment ................. 3-34
5.2 Measuring the piston compression
5.3 Checking and adjusting the injection
CHAPTER 3
3.1.11 MLS cylinder head gasket .......... 3-15
3.2.1 Engine oil fl ow ............................ 3-17
3.2.2 Relief valve ................................ 3-18
3.2.4 Oil pressure switch .................... 3-18
3.2.5 Oil pump .................................... 3-19
3.3.1 Water pump ............................... 3-20
3.3.2 Thermostat ................................. 3-20
3.3.3 Radiator ...................................... 3-21
3.3.4 Radiator cap ............................... 3-21
3.4.1 Flow of fuel ................................. 3-22
3.4.2 Fuel fi lter and bleeding ............... 3-22
3.4.3 Bleeding the fuel system ............ 3-22
3.4.4 Fuel feed pump ........................... 3-23
3.4.5 Fuel injection pump .................... 3-23
3.5.1 Disassembled view ..................... 3-27
3.5.2 Basic principle of governor system ... 3-28
3.5.3 Operation of governor ................. 3-29
3.6.1 Flow of intake air and exhaust gas .......3-30
3.6.2 Air cleaner .................................. 3-30
3.6.3 Muffl er ......................................... 3-30
3.6.4 Pcv valve .................................... 3-31
pressure ....................................................... 3-34
timing .................................................... 3-35