E-Z-GO 295cc Shop Rebuild Manual
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E-Z-GO 295cc Shop Rebuild Manual

E-Z-GO 295cc Shop Rebuild Manual

295cc and 350cc 4 cycle engine
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ENGINE SHOP REBUILD
SERVICE PARTS MANUAL
295cc and 350cc 4 CYCLE ENGINE
STARTING MODEL YEAR: 1992
&
REVISED: 08/04
27615-G01
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1 - I N C L U D E S I T E M S 3 - 1 6
1 9
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January 30, 2025

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Summary of Contents for E-Z-GO 295cc

  • Page 1 27615-G01 1 - I N C L U D E S I T E M S 3 - 1 6 ENGINE SHOP REBUILD & SERVICE PARTS MANUAL 295cc and 350cc 4 CYCLE ENGINE STARTING MODEL YEAR: 1992 REVISED: 08/04...
  • Page 2 E-Z-GO Division of Textron, Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
  • Page 3 CALL OR WRITE THE LOCAL DISTRUBUTOR, E-Z-G0 BRANCH OR E-Z-G0 WARRANTY DEPARTMENT WITH VEHICLE SERIAL NUMBER AND MANUFACTURER’S CODE. THE USE OF NON E-Z-GO PARTS AND HARDWARE MAY VOID THE WARRANTY. TAMPERING WITH OR ADJUSTING GOVERNOR TO PERMIT VECLE TO OPERATE AT ABOVE FACTORY SETTINGS WILL VOID THE VEHICLE WARRANTY.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Section Page No. How to use the E-Z-GO Service Manual..................... vii Federal and California Emissions Warranty Statements ................ Section G ENGINE DISASSEMBLY CYLINDER HEAD REMOVAL • Air Cleaner ..........................A-1 • Carburetor..........................A-1 •...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section Page No. ENGINE MEASUREMENTS AND SPECIFICATIONS ENGINE MEASUREMENTS AND SPECIFICATIONS • Check Flatness of Crankcase, End Cover and Cylinder Head ........... C-1 • Crankcase Cylinder Bores ......................C-2 • Crankcase and End Cover Crankshaft Bearing Bores ............... C-2 •...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Section Page No. • Oil Pressure Switch ........................D-4 • Pulser Coil ..........................D-4 • Fan Hub .............................D-4 • Pulser Coil and Air Gap ......................D-5 • PCV Valve..........................D-5 • Oil Filter .............................D-5 ENGINE REASSEMBLY CYLINDER HEAD ASSEMBLY •...
  • Page 7 TABLE OF CONTENTS Notes: Engine Shop Rebuild and Parts Manual Page vi...

  • Page 8: How To Use This Manual

    HOW TO USE THIS 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 will allow the mechanic to choose the level of instructional detail needed to completely disassemble, diag- nose, repair/overhaul and reassemble the engine.
  • Page 9 HOW TO USE THIS MANUAL Engine Shop Rebuild and Parts Manual viii...
  • Page 10 ENGINE DISASSEMBLY TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. CYLINDER HEAD REMOVAL......................A - 1 Remove the Air Cleaner ......................A - 1 Remove the Carburetor ......................A - 1 Remove the Coil Mounting Bracket and Coil.................A - 1 Remove the Blower Housing ....................A - 1 Remove the Exhaust Manifold....................A - 1 Remove the Rear Cylinder Baffle ..................A - 1 Remove the Timing Belt Cover....................A - 1...
  • Page 11 ENGINE DISASSEMBLY Notes: Repair and Service Manual Page A-ii...

  • Page 12: Air Cleaner

    ENGINE DISASSEMBLY CYLINDER HEAD REMOVAL Remove the Coil Mounting Bracket and Coil (See Fig. A-1 “Engine” on page A-4) Tool List Qty. Required A. Remove the spark plug wires (ITEM 1) from the Extension, 3/8” drive, 4" ..........1 plugs. Mallet, medium wood or rubber ........

  • Page 13: Rear Timing Belt Cover

    ENGINE DISASSEMBLY D. Remove the timing belt (ITEM 20). Do not twist the 1. Using a 10mm socket, remove the three (3) bolts belt or turn it inside out. (ITEM 5) and one (1) stud (ITEM 6). E. Remove the drive pulley retaining bolt (ITEM 17), (Later models have four (4) bolts and no stud) front belt retainer (ITEM 21), drive pulley (ITEM 22).

  • Page 14: Valves

    ENGINE DISASSEMBLY VALVE REMOVAL Remove the Valves from the Cylinder Head (See Fig. A-3 “Valves” on page A-6) A. While supporting the valve (ITEM 1) from the bottom to prevent its downward motion, push the valve spring retainer (ITEM 2) down so that the valve stem keys (ITEM 6) are released from the retainer.
  • Page 15 ENGINE DISASSEMBLY Fig. A-1 Engine Engine Shop Rebuild and Parts Manual Page A-4...
  • Page 16 ENGINE DISASSEMBLY Fig. A-2 Cylinder Head Components Engine Shop Rebuild and Parts Manual Page A-5...
  • Page 17 ENGINE DISASSEMBLY Push spring retainer down to release valve keys Pry valve stem seal loose Fig. A-3 Valves Engine Shop Rebuild and Parts Manual Page A-6...
  • Page 18 ENGINE DISASSEMBLY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. CRANKCASE DISASSEMBLY......................B - 1 Remove the Oil Filter......................B - 1 Remove the Fan Hub ......................B - 1 Remove the Pulser Coil......................B - 1 Remove the Oil Pressure Switch...................B - 1 Remove the Oil Pump ......................B - 1 Remove the Crankcase End Cover ..................B - 2 Remove the Balancer Shaft....................B - 2...
  • Page 19 ENGINE DISASSEMBLY Notes: Repair and Service Manual Page B-ii...

  • Page 20: Oil Filter

    26MM) impact socket, remove the fan hub nut (ITEM Remove the Oil Pump (See Fig. B-1 “Engine Components” on page B-4) B. Using and E-Z-GO Fan Hub Puller, remove the fan A. Using a 10mm socket, remove three (3) bolts (ITEM hub (ITEM 4).

  • Page 21: Crankcase End Cover

    ENGINE DISASSEMBLY Remove the Crankcase End Cover Because the pistons, rods, and caps were machined and have established (See Fig. B-1 “Engine Components” on page B-4) wear patterns as assemblies, it is critical to the life expectancy (See Fig. B-2 “Engine Components con’t” on page B-5) and performance of the engine that they are reassembled with their original mates and in their original positions.

  • Page 22: Pcv Valve

    ENGINE DISASSEMBLY C. To remove a bearing, turn the crankcase on its side, C. Clean and inspect the crankshaft bearing (ITEM 7) PTO (clutch) side up, and gently tap the bearing out and the balancer shaft bearing (ITEM 8) for damage. with a brass drift (DETAIL A).
  • Page 23 ENGINE DISASSEMBLY Fig. B-1 Engine Components Engine Shop Rebuild and Parts Manual Page B-4...
  • Page 24 ENGINE DISASSEMBLY Crankshaft Grind off Crankshaft Hold against puller screws, not against the crankshaft or fan Fan hub (shown without fan) Crankshaft Drive end of key down and gently drive Lightly tap flanged edge of cover with a key up and out wooden or rubber mallet Fig.
  • Page 25 ENGINE DISASSEMBLY Seal puller Fig. B-3 Crankshaft Engine Shop Rebuild and Parts Manual Page B-6...
  • Page 26 ENGINE DISASSEMBLY To drive bearing out straight, move drift side to side Brass drift while tapping Newer Model Fig. B-4 Balancer Shaft Bearing, Crankshaft Bearing and PCV Valve Engine Shop Rebuild and Parts Manual Page B-7...
  • Page 27 ENGINE DISASSEMBLY Crankshaft Fig. B-5 Crankcase End Cover and Crankshaft Bearing Engine Shop Rebuild and Parts Manual Page B-8...
  • Page 28 ENGINE DISASSEMBLY Insert a suitable mandrel into the pin bore of the piston Press the piston down onto the mandrel, pushing the wrist pin out Insert screwdriver into slot and push to compress ring. Pry ring up and out of the retainer groove Remove the piston from the connecting rod Fig.
  • Page 29 ENGINE DISASSEMBLY Notes: Engine Shop Rebuild and Parts Manual Page B-10...
  • Page 30 ENGINE MEASUREMENTS TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. ENGINE MEASUREMENTS AND SPECIFICATIONS..............C - 1 Using Telescoping Gauges and Hole Gauges ..............C - 1 Check flatness of Crankcase, End Cover and Cylinder Head ..........C - 1 Crankcase Cylinder Bores....................
  • Page 31 ENGINE MEASUREMENTS Notes: Engine Shop Rebuild and Parts Manual Page C-ii...

  • Page 32: Check Flatness Of Crankcase, End Cover And Cylinder Head

    ENGINE MEASUREMENTS ENGINE MEASUREMENTS AND SPECIFICATIONS Tool List Qty. Required Calipers, dial ............... 1 Gauge, depth .............. 1 Gauge Set, feeler ............1 Gauge Set, telescoping..........1 Micrometer, 1" ............. 1 Micrometer, 2" ............. 1 Micrometer, 3" ............. 1 Surface plate ............... 1 All engine parts must be thoroughly cleaned, and free of all dirt, oil, grease, carbon deposits or residue of any kind before beginning this...

  • Page 33: Crankcase Cylinder Bores

    ENGINE MEASUREMENTS F. Turn the cylinder head so that the valve cover gasket A. Measure the rod and bearing journal diameters surface rests on the surface plate. Check for flatness. (DIMENSIONS A, B, C, D, E, AND G), in two (2) places each, 90°...

  • Page 34: Wrist Pin

    ENGINE MEASUREMENTS Wrist Pin A. Measure the valve stem at three (3) positions (DIMENSIONS A, B, and C), in two (2) places each, (See Fig. C-5 “Piston, Wrist Pin and Connecting Rod” on page C-6) 90° apart. A. Measure wrist pin outside diameter at three (3) posi- B.
  • Page 35 A fine cross-hatched surface is the proper finish for a cylinder bore. Crankcase Detail A If "A " exceeds "C ", or if "A " exceeds "C " by 0.004" (.1mm), rebore the cylinder. 295cc 350cc 2.519"~2.520" STD. 2.6378"~2.6385" STD. (64.000mm~64.019mm) (67.000mm~67.019mm) telescoping...
  • Page 36 ENGINE MEASUREMENTS Measure each bore in 2 places 90 apart Crankcase and Endcover Cutaway view of crankcase and endcover through crankshaft bearing bores Recommended press Ball bearings onto Ball bearings into fits: crankshaft crankcase (0.00024~0.00067) (in) (0.00067~0.0024) Measure each position (mm) (0.006~0.017) (0.017~0.060)
  • Page 37 ENGINE MEASUREMENTS Measure the width and depth of each ring groove Piston, wrist pin and connecting rod Measure each position in 2 places 90 apart Recommended clearance Maximum wear limit New engine for piston to cylinder wall (in) (0.0008 ~ 0.0023) (0.0039) (mm) (0.020 ~ 0.059)
  • Page 38 ENGINE MEASUREMENTS Balancer shaft Crankcase and endcover SPECS Recommended press fit for balance shaft bearing (in) 1.6516~1.6526 0.7869~0.7873 STD. (mm) (41.950~41.975) (19.988~19.997) (in) (0.0006~0.0020) (in) 1.6531 0.7864 LIMIT (mm) (0.014~0.050) (mm) (41.990) (19.975) Cutaway view of crankcase and endcover through balancer shaft bearing bores Measure each bore in 2 places 90 apart Measure each position...
  • Page 39 ENGINE MEASUREMENTS Camshaft Cylinder head Recommended clearance for camshaft to cylinder head: Fan side PTO Side (in) (0.00098~0.0030) (0.00079~0.0024) (mm) (0.025~0.075) (0.020~0.062) SPECS 1.3780~1.3789 0.9843~0.9851 1.3760~1.3770 1.048~1.052 0.9826~0.9835 (in) STD. (mm) (35.000~35.025) (25.000~25.021) (34.950~34.975) (26.620~26.720) (24.959~24.980) 1.3805 0.9865 1.375 1.040 0.9816 (in) LIMIT...
  • Page 40 ENGINE MEASUREMENTS SPECS (in) 0.2165~0.2172 0.0118~0.0295 STD. (mm) (5.500~5.518) (0.30~0.75) 0.2175 0.0591 (in) LIMIT (mm) (5.525) (1.5) A total difference of 1 between the finish angles of the valve and valve seat is required. Measure each position in 2 places 90 apart Valve guide Valve seat Fig.
  • Page 41 ENGINE MEASUREMENTS Valve Recommended clearance for valve to valve guide Intake Exhaust (in) (0.0018~0.0030) (0.0022~0.0036) (mm) (0.045~0.075) (0.056~0.092) A B C SPECS Intake Exhaust (in) 0.2143~0.2148 0.2136~0.2143 0.0891~0.1281 0.0276~0.0354 STD. (mm) (5.443~5.455) (5.426~5.444) (2.263~3.253) (0.7~0.9) 0.2125 0.2125 0.1392 0.0197 (in) LIMIT (5.40) (5.40)
  • Page 42 ENGINE MEASUREMENTS Rocker shaft assembly Cylinder head SPECS Clearance Shaft to head Clearance 0.4724~0.4731 0.4711~0.4718 0.4724~0.4731 (in) 0.0006~0.0020 0.0006~0.0020 STD. (0.016~0.052) (0.016~0.052) (mm) (12.000~12.018) (11.966~11.984) (12.000~12.018) (in) 0.0039 0.0041 0.4748 0.4704 0.4746 LIMIT (mm) (12.060) (11.950) (12.055) (0.100) (0.105) Fan side Measure each position in 2 places 90 apart Rocker shaft...
  • Page 43 ENGINE MEASUREMENTS 1" EH29C EH35C Recommended clearances 295 CC (64 MM BORE) 350 CC (67 MM BORE) for piston ring end gap (in) (0.008~0.016) (0.006~0.010) Top ring (mm) (0.20~0.40) (0.15~0.25) (in) (0.008~0.016) (0.006~0.012) 2nd Ring (mm) (0.20~0.40) (0.15~0.30) Oil ring (in) (0.008~0.028) (0.004~0.024)
  • Page 44 ENGINE MEASUREMENTS TIGHTENING TORQUE DESCRIPTION kg / cm ft / lb N / m Cylinder head bolts 16.6~19.5 230~270 22.5~26.5 170~200 Connecting rod cap bolts 12.3~14.5 16.7~19.6 600~650 58.8~63.7 Fan hub nut 43.4~47.0 5.8~7.2 80~100 7.8~9.8 Crankcase end-cover bolts 12.3~13.7 170~190 16.7~18.6 New plug...
  • Page 45 ENGINE MEASUREMENTS Notes: Engine Shop Rebuild and Parts Manual Page C-14...

  • Page 46: Piston And Connecting Rod

    ENGINE REASSEMBLY TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. CRANKCASE ASSEMBLY......................D - 1 Hone the Crankcase Cylinder Bore ..................D - 1 Reassemble the Pistons and Connecting Rods ..............D - 1 Install the Piston Rings ......................D - 2 Reassemble the Crankcase End Cover ................
  • Page 47 ENGINE REASSEMBLY Notes: Engine Shop Rebuild and Parts Manual Page D-ii...

  • Page 48: Pistons And Connecting Rods

    Gauge, feeler machined if applicable). We recommend that parts found to be acceptable but near limits be replaced if the engine will see high (E-Z-GO P/N 72525-G01) ........... 1 usage. Gauge, wire spark plug ..........1 Because some mating parts with wear surfaces were machined Flex Hone, ball, 240 grit, 2 1/2 “cylinder...

  • Page 49: Piston Rings

    ENGINE REASSEMBLY A. Apply a coat of assembly lube to the exterior surface D. Install the compression ring (ITEM 7), with the “N” facing up, in the top groove with the ring gap at 120° of the wrist pin (ITEM 1) and to the wrist pin bores in the connecting rod (ITEM 2) and piston (ITEM 3).

  • Page 50: Crankshaft Bearing

    ENGINE REASSEMBLY Install New Crankshaft Bearing C. Install a piston ring compressor on the piston, leaving enough of the piston skirt protruding below the com- (See Fig. D-6 “Crankshaft, Pistons and Balancer Shaft con’t” on page pressor to start into the cylinder. (DETAIL B) D-11) D.

  • Page 51: End-Play Spacers

    ENGINE REASSEMBLY C. Using a depth gauge and straight edge, measure the B. Install the end cover mounting bolts. distance from the gasket surface of the crankcase to 1. Start two (2) bolts (ITEM 4, M8x1.25x30L, 12mm the faces of both the crankshaft and balancer shaft socket) with lock washers (ITEM 5) and six (6) gears close to the shafts, then subtract the width of bolts (ITEM 6, M6x1.0x30L,10mm socket) with...
  • Page 52 ENGINE REASSEMBLY 1. Place key in the keyway on the crankshaft spindle. Install the Oil Filter Use a brass drift to tap it into position. (DETAIL B) (See Fig. D-4 “Crankcase End Cover, PCV Valve and Oil Filter” on page D-9) B.
  • Page 53 ENGINE REASSEMBLY An electric drill is used to rotate the honing tool while steadily moving it up and down inside the cylinder. Generally, the faster the rpm of tool, the faster the up and down motion in the cylinder. Beads should not be permitted to extend out of the cylinder, as uneven wearing of the beads may occur.
  • Page 54 ENGINE REASSEMBLY Service piston rings profile view at gap Compression ring (TOP) Wiper ring (MIDDLE) Oil ring (BOTTOM) "N" Faces up when installed Mandrel Insert a portion of the retaining ring into the ring groove. Use a flat blade screwdriver to Press the piston down onto the mandrel, push the remainder of the ring pushing the wrist pin in...
  • Page 55 ENGINE REASSEMBLY Compression ring gap 45 o Top of Wiper ring piston Wrist pin Rings 120 o Oil ring Note: Factory 3 piece oil ring is replaced by 1 piece oil ring. Start one end of ring into the groove, leaving the other end on top of the piston.
  • Page 56 ENGINE REASSEMBLY Newer Model Fig. D-4 Crankcase End Cover, PCV Valve and Oil Filter Engine Shop Rebuild and Parts Manual Page D-9...
  • Page 57 ENGINE REASSEMBLY Fig. D-5 Crankshaft, Pistons and Balancer Shaft Engine Shop Rebuild and Parts Manual Page D-10...
  • Page 58 ENGINE REASSEMBLY Fill crankshaft oil passages with engine oil Press against inner race only Use mallet handle to gently tap piston through compressor and into cylinder head Align single dot on crankshaft gear with two dots on balancer shaft gear Fig.
  • Page 59 ENGINE REASSEMBLY Make sure the gears are completely seated and that their faces are perfectly flush . Rest the straight edge on the gasket surface of the crankcase and measure to the face of the balancer gear and crankshaft gear with a depth gauge. Subtract the width of the straight edge from the measurements.

  • Page 60: Oil Pump Gear Rotors

    ENGINE REASSEMBLY Newer Model Crankcase Fig. D-8 Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil and Fan Hub Engine Shop Rebuild and Parts Manual Page D-13...
  • Page 61 ENGINE REASSEMBLY Follow numbers to tighten end cover bolts in correct sequence. Tighten to specified torque in two stages (Some models may have 8 or 9 or 10 bolts) Gently tap key into keyway Brass drift (Later models do not have a keyway) Crankshaft Fig.
  • Page 62 ENGINE REASSEMBLY NOTE: For clarity, the fan is shown pulled away from the hub, and the fan hub is partially cut-a-way. It is Press lightly with suitable mandrel not necessary to remove the fan or hub to set the air gap. Use the access holes provided. .020 - .039 Feeler gauge Insert phillips screwdriver...
  • Page 63 ENGINE REASSEMBLY Notes: Engine Shop Rebuild and Parts Manual Page D-16...
  • Page 64 ENGINE REASSEMBLY TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. CYLINDER HEAD ASSEMBLY......................E - 1 Install Valve Guides.......................E - 1 Cutting Valve Seats .......................E - 1 Lap the Valves........................E - 1 Install New Valve Stem Seals....................E - 2 Install the Valves ........................E - 2 Install the Cylinder Head on the Crankcase ................E - 2 Install the Camshaft.......................E - 2...
  • Page 65 ENGINE REASSEMBLY Notes: Engine Shop Rebuild and Parts Manual Page E-ii...

  • Page 66: Cylinder Head Assembly

    (E-Z-GO P/N 72525-G01) ........... 1 Cutting Valve Seats Gauge, wire spark plug ..........1 A. Using the E-Z-GO valve seat cutter, insert the reamer pilot tool in the valve guide and rotate in a clockwise Valve seat cutter direction only using firm consistent pressure.

  • Page 67: Valve Stem Seals

    ENGINE REASSEMBLY Install New Valve Stem Seals D. Install and hand tighten seven (7) cylinder head mounting bolts (ITEM 4, 1 each, M8x1.25x60L; ITEM (See Fig. E-2 “Valves con’t” on page D-7) 5, 4 each, M8x1.25x50L; and ITEM 6, 2 each, A.
  • Page 68 M6x1.0x12L) and one (1) stud (ITEM 17, M6x1.0). M8x1.25x20L) and washer (ITEM 8, 8.5x28x2.3t). The stud is mounted in the top right corner of the Do not tighten the bolt. (If the E-Z-GO CAM PUL- cover. LEY TOOL is being used, position it on the drive 2.

  • Page 69: Oil Pressure Switch

    ENGINE REASSEMBLY Install the Front Timing Belt Cover Install the Coil Mounting Bracket and Coil Assembly (See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and Timing Belt” on page D-10) (See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulleys, Idler and Timing Belt”...

  • Page 70: Rocker Cover

    ENGINE REASSEMBLY Install the Rocker Cover Install the Carburetor (See Fig. E-8 “Rocker Cover” on page D-13) (See Fig. E-9 “Carburetor” on page D-14) A. Install a new rocker cover gasket (ITEM 2) in the A. Install the gasket (ITEM 2), plastic insulator (ITEM 3), cover.
  • Page 71 ENGINE REASSEMBLY Lobe .004" Feeler guage Position heel of cam lobe as shown to measure valve clearance Fig. E-1 Valves and Valve Clearance Engine Shop Rebuild and Parts Manual Page E-6...
  • Page 72 ENGINE REASSEMBLY Push spring retainer down to install/release valve keys Fig. E-2 Valves con’t Engine Shop Rebuild and Parts Manual Page E-7...
  • Page 73 ENGINE REASSEMBLY Crankcase Fig. E-3 Cylinder Head, Cam Shaft and Rocker Assembly Engine Shop Rebuild and Parts Manual Page E-8...
  • Page 74 ENGINE REASSEMBLY Item Sequence Follow numbers to tighten cylinder head bolts in correct sequence Tighten to specified torque in two stages Lobes Rotate the cam lobes so that they will not exert pressure on the rocker arms as they are installed on the rocker shaft Fig.
  • Page 75 ENGINE REASSEMBLY Fig. E-5 Timing Belt Covers, Drive and Cam Pulleys, Idler and Timing Belt Engine Shop Rebuild and Parts Manual Page E-10...
  • Page 76 ENGINE REASSEMBLY Align notch and mark Spring stop Idler spring 1/8" - 1/4" Deflection Idler clamp bolt at 10 lbs tighten to 10 - 13 "push" ft lbs torque Idler Align key way with mark Fig. E-6 Timing Belt Covers, Drive and Cam Pulleys, Idler and Timing Belt con’t Engine Shop Rebuild and Parts Manual Page E-11...
  • Page 77 ENGINE REASSEMBLY Follow numbers to tighten manifold bolts in correct sequence Tighten to specified torque in two stages Some later models may or may not have an oil pressure switch, some models have location of the switch in a slightly different position. Route the oil pressure switch wire and the pulser coil wire through the groove in the blower housing...
  • Page 78 ENGINE REASSEMBLY Rocker cover tightening sequence Fig. E-8 Rocker Cover Engine Shop Rebuild and Parts Manual Page E-13...
  • Page 79 ENGINE REASSEMBLY Fig. E-9 Carburetor Engine Shop Rebuild and Parts Manual Page E-14...
  • Page 80 Illustrated Parts Breakdown ILLUSTRATED PARTS BREAKDOWN Engine Shop Rebuild and Parts Manual Page F-1...
  • Page 81 ENGINE Illustrated Parts Breakdown Newer Model Earlier Model 231 - 235 Engine Shop Rebuild and Parts Manual Page F-2...
  • Page 82 Illustrated Parts Breakdown ENGINE Engine Shop Rebuild and Parts Manual Page F-3...
  • Page 83 ENGINE Illustrated Parts Breakdown Newer Model Engine Shop Rebuild and Parts Manual Page F-4...
  • Page 84 Illustrated Parts Breakdown ENGINE Engine Shop Rebuild and Parts Manual Page F-5...
  • Page 85 ITEM PART NO. DESCRIPTION QTY. 72845-G01 SERVICE ENGINE, 295CC (INCLUDES ITEMS 5 - 197, 208 - 215)....72846-G02 SERVICE ENGINE, 350CC (INCLUDES ITEMS 4,6 - 197, 208 - 215)....72875-G01 CRANKCASE ASSEMBLY (INCLUDES ITEMS 6 - 12), 350 cc ENGINE ONLY(1 PIECE MAN/EXH) ..........
  • Page 86 Illustrated Parts Breakdown ENGINE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. DESCRIPTION QTY.
  • Page 87 CRANKSHAFT (INCLUDES ITEM 74) 295 cc ENGINE ONLY ....26739-G01 BEARING, BALL ..................26692-G01 WOODRUFF KEY, CRANKSHAFT .............. 601551 CRANKSHAFT (INCLUDES ITEM 74) 295cc ONLY(1 PIECE MAN/EXH) .. 26684-G01 SPACER, CRANKSHAFT (.6MM) ..............26685-G01 SPACER, CRANKSHAFT (.8MM) ..............26686-G01 SPACER, CRANKSHAFT (1MM) ..............
  • Page 88 Illustrated Parts Breakdown ENGINE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. DESCRIPTION QTY.
  • Page 89 ENGINE Illustrated Parts Breakdown When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. DESCRIPTION QTY.
  • Page 90 Illustrated Parts Breakdown ENGINE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. DESCRIPTION QTY.
  • Page 91 ENGINE Illustrated Parts Breakdown When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. DESCRIPTION QTY.
  • Page 92 GASKET, CAMSHAFT COVER (1 PIECE MAN/EXH) ......... 72869-G01 BRACKET, IGNITION COIL 350CC (1 PIECE MAN/EXH)......72885-G01 BRACKET, IGNITION COIL, 295CC (1 PIECE MAN/EXH)......72870-G01 FLANGED BOLT, M6 X 1 X 12MM (1 PIECE MAN/EXH) ......72871-G01 SCREW AND WASHER ASSEMBLY(1 PIECE MAN/EXH) ......
  • Page 93 ENGINE Illustrated Parts Breakdown When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO. DESCRIPTION QTY.
  • Page 94 LIMITED WARRANTY TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. FEDERAL EMISSION CONTROL WARRANTY STATEMENT ............G-1 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT(1995-1999)....... G-5 YOUR WARRANTY RIGHTS AND OBLIGATIONS .............. G-5 LIMITED WARRANTY on Emission Control Systems - California Only -....... G-5 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT (2000)........
  • Page 95 LIMITED WARRANTY Notes: Engine Shop Rebuild and Parts Manual Page G-ii...
  • Page 96 (iii) Filter lock assy (gaseous fuel, if applicable) OBTAINING WARRANTY SERVICE To obtain warranty service, take your engine to the nearest authorized E-Z-GO distributor, dealer, or service provid- er. Bring your sales receipts indicating date of purchase for this engine. The distributor, dealer, or service provider authorized by E-Z-GO will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order.
  • Page 97 As the engine owner, you should however be aware that E-Z-GO may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 98 LIMITED WARRANTY - FEDERAL (2001) EMISSION COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all states, except the State of California. Fuji Heavy Industries Ltd. and Textron Golf, Turf & Specialty Products Augusta, Georgia, (herein “Textron Golf, Turf &...
  • Page 99 LIMITED WARRANTY - FEDERAL (2001) You are responsible for presenting your engine to the nearest distributor, dealer, or service provider authorized by Textron Golf, Turf & Specialty Products when a problem exists. If you have any questions regarding your warranty rights and responsibilities, you should contact the Textron Golf, Turf &...
  • Page 100 The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact the E-Z-GO War- ranty Department at 1-800-241-5855.
  • Page 101 All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or distributors or warranty stations authorized by E-Z-GO. In the event that any emission-related part is found to be defective during the warranty period, you should notify E-Z-GO Warranty Department at 1-800- 241-5855 and you will be given the appropriate warranty service facilities where the warranty repair is per- formed.
  • Page 102 LIMITED WARRANTY - CALIFORNIA (1995-1999) (4) Exhaust Manifold (5) Miscellaneous Items Used in Above Systems (i) Fuel hoses, clamps and sealing gaskets I. MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 1995 and later Owner’s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended.
  • Page 103 The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact the E-Z-GO War- ranty Department at 1-800-241-5855.
  • Page 104 All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or distributors or warranty stations authorized by E-Z-GO. In the event that any emission-related part is found to be defective during the warranty period, you should notify E-Z-GO Warranty Department at 1-800- 241-5855 and you will be given the appropriate warranty service facilities where the warranty repair is per- formed.
  • Page 105 LIMITED WARRANTY - CALIFORNIA (2000) (4) Exhaust Manifold (5) Miscellaneous Items Used in Above Systems (i) Fuel hoses, clamps and sealing gaskets R. MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2000 and later Owner’s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended.
  • Page 106 LIMITED WARRANTY - CALIFORNIA (2001) CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd. (herein “FUJI”) are pleased to explain the emis- sion control system warranty on your 2001 and later small off-road engine (herein “engine”). In California, the engine must be designed, built and equipped to meet the State’s stringent anti-smog standards.
  • Page 107 LIMITED WARRANTY - CALIFORNIA (2001) part which is scheduled for replacement as required maintenance shall be warranted for the pe- riod of time up to the first scheduled replacement point for that part. 3. DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized dealer, distributor or service provider.
  • Page 108 LIMITED WARRANTY - CALIFORNIA (2001) (iii) Spark advance/retard system, if applicable (4) Exhaust Manifold, if applicable (5) Miscellaneous Items Used in Above Systems (i) Electronic controls, if applicable (ii) Hoses, belts, connectors, and assemblies (iii) Filter lock assembly (gaseous fuel, if applicable) I.
  • Page 109 The warranty repairs should be completed in a reasonable amount of time, not to ex- ceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact the E-Z-GO War- ranty Department at 1-800-241-5855.
  • Page 110 All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or distributors or service providers authorized by E-Z-GO. In the event that any emission-related part is found to be defective during the warranty period, you should notify E-Z-GO Warranty Department at 1-800- 241-5855 and you will be given the appropriate warranty service facilities where the warranty repair is per- formed.
  • Page 111 LIMITED WARRANTY - CALIFORNIA (2004) (ii) Magneto or electronic ignition system. (iii) Spark advance/retard system, if applicable (4) Exhaust manifold, if applicable (5) Miscellaneous Items Used in Above Systems (i) Electronic controls, if applicable (ii) Hoses, belts, connectors, and assemblies (iii) Filter lock assy (gaseous fuel, if applicable) R.
  • Page 112 E-Z-GO Division of Textron Inc. 1451 Marvin Griffin Rd. Augusta, Georgia 30906 USA Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc. Technical Communications Department...

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