Ezgo 1600xd Repair Manual page 40

TABLE OF CONTENTS
5.4 Engine oil pressure .............................. 3-36
5.5 Injection nozzle inspection ................... 3-37
5.6 Bubble test for radiator ......................... 3-37
5.7 Intake and exhaust valves .................... 3-38
5.7.1 Clearance adjustment ................. 3-38
5.7.2 Valve spring inspection
(length, tension and squareness) ..... 3-39
5.7.3 Valve spring squareness (tilt) ..... 3-39
5.8 Rocker arm assembly check ................ 3-40
5.9 Cylinder head check ............................. 3-40
5.9.1 Cylinder head surface fl atness ...... 3-40
5.9.2 Cylinder head valve recess ........ 3-41
5.9.3 Cylinder bore check .................... 3-41
5.10 Piston check ......................................... 3-42
5.10.1 Piston pin bore ............................ 3-42
5.10.2 Clearance between piston pin and
bushing ....................................... 3-42
5.10.3 Piston ring end gap .................... 3-43
5.10.4 Piston ring clearance .................. 3-43
5.11 Crankshaft check ................................. 3-44
5.11.1 Crankshaft defl ection .................. 3-44
5.11.2 Oil clearance between crankshaft
journal and bearing 1 .................. 3-44
5.11.3 Oil clearance between crankshaft
journal and bearing 2 .........................3-45
5.11.4 Oil clearance between crank pin and
connecting rod big end bearing ........ 3-45
5.12 Timing gear .......................................... 3-46
5.12.1 Timing gear setting ..................... 3-46
5.12.2 Timing gear backlash ................. 3-46
5.12.3 Idle gear side clearance ............. 3-47
5.12.4 Valve camshaft gear side
clearance .................................... 3-47
5.12.5 Idle gear oil clearance
measurement .............................. 3-48
5.12.6 Valve camshaft oil clearance
measurement .............................. 3-48
5.12.7 Valve camshaft defl ection check .....3-49
5.12.8 Valve cam height measurement . 3-49
5.13 Flywheel defl ection and crankshaft end
play check ............................................ 3-50
5.14 Oil pump check .................................... 3-50
6. DISASSEMBLY, SERVICE AND
ASSEMBLY ........................................... 3-52
6.1 Engine removal .................................... 3-52
6.2 Engine component disassembly and
assembly .............................................. 3-58
6.2.1 Cylinder head ............................. 3-58
6.2.2 Fuel injection pump .................... 3-60
6.2.3 Speed control lever plate and
governor spring ........................... 3-61
6.2.4 Fuel camshaft (gear case) .......... 3-62
6.2.5 Valve camshaft ........................... 3-64
6.2.6 Idle gear shaft, oil pump and
oil pan ......................................... 3-65
6.2.7 Piston, fl ywheel and crankshaft .. 3-66
6.3 Engine component disassembly and
assembly .............................................. 3-70
6.3.1 Rocker arm ................................. 3-70
6.3.2 Intake and exhaust valves .......... 3-70
6.3.3 Injection nozzle ........................... 3-71
6.3.4 Piston assembly ......................... 3-72
6.3.5 Thermostat ................................. 3-73
6.3.6 Water pump ................................ 3-74
6.3.7 Main bearing case assembly ...... 3-75
6.3.8 njection pump gear assembly
(fuel camshaft gear) .................... 3-76
6.3.9 Engine oil relief valve .................. 3-76
6.4 Cylinder head gasket replacement ....... 3-77
6.5 Gear case disassembly and reassembly
(gear case gasket, crankshaft oil seal
and oil pump replacement) .................. 3-79
7. ENGINE EXPLODED VIEW .................. 3-82
7.1 E010 Cylinder block ............................. 3-82
7.2 E020 Oil pan ........................................ 3-83
7.3 E030 Cylinder head .............................. 3-84
7.4 E040 Gear case ................................... 3-85
7.5 E050 main bearing case ...................... 3-86
7.6 E080 Valve rocker arm ......................... 3-87
7.7 E090 Cylinder head cover .................... 3-88
7.8 E100 Camshaft .................................... 3-89
7.9 E110 Piston & crank shaft .................... 3-90
7.10 E120 Flywheel ...................................... 3-91
7.11 E130 Nozzle, holder ............................. 3-92
7.12 E140 Fuel camshaft ............................. 3-93
7.13 E150 Speed control plate ..................... 3-94
7.14 E160 Engine stop lever ........................ 3-95
7.15 E170 Governor ..................................... 3-96
7.16 E190 Water hose .................................. 3-97
7.17 E200 Dynamo ...................................... 3-98
7.18 E220 Mainfold ...................................... 3-99