Ezgo EXPRESS L4 Technician's Repair And Service Manual page 103

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Do NOT overtighten.
Remeasure any clearance that was adjusted. Readjust if
necessary.
Replace the Rocker Cover (6), gasket and the four bolts
(5). Tighten the bolts to secure the cover in place.
ENGINE REMOVAL
Tool List
Torque Wrench, ft. lbs ................................................. 1
Socket, 10 mm ............................................................ 1
Socket, 12 mm ............................................................ 1
Socket, 14 mm ............................................................ 1
Socket, 1/2" ................................................................. 1
Socket, 5/8" ................................................................. 1
Impact Socket, 19 mm................................................. 1
Wrench, 8 mm ............................................................. 1
Wrench, 10 mm ........................................................... 1
Wrench, 12 mm ........................................................... 1
Wrench, 13 mm ........................................................... 1
Wrench, 14 mm ........................................................... 2
Wrench, 15 mm ........................................................... 1
Wrench, 19 mm ........................................................... 1
Combo Wrench, 19 mm .............................................. 1
Pliers ........................................................................... 1
Extension 6" ................................................................ 1
Ratchet ........................................................................ 1
Flat Ratchet ................................................................. 1
Impact Tool .................................................................. 1
Straight Blade Screwdriver .......................................... 1
Drip Pan ...................................................................... 1
This section covers the removal and installation of the
engine, for information on rebuilding the engine please
see the Engine Shop Rebuild Manual for this vehicle.
NOTICE
In the following text, there are references to removing/installing
bolts etc. Additional hardware (nuts, washers etc.) that are
removed must always be installed in their original positions
unless otherwise specified. Non specified torque specifications
are as shown in the table contained in Section "A".
This operation will remove the engine through the top of
the engine compartment. The weight of the engine
exceeds normal OSHA limits for one person; therefore,
a second person or an engine hoist will be needed to
remove the engine. If a hoist is employed, it will be nec-
essary to remove the sun top.
1. Disconnect Battery ground wire.
2. Disconnect air hose at carburetor.
3. Jack up rear of vehicle as directed in Section B of this
manual. Use jack stands for stability.
4. Remove the drive belt by rotating clutch toward rear of
vehicle when the belt is slipped off the top of the
clutch. Remove belt from vehicle.
5. Disconnect the 'DF' wire from starter using 8mm
wrench, lay harness out of the way
6. Remove the ground strap from the Starter/Generator
using a 10 mm socket.
Qty.
7. Remove the Starter/Generator (See Starter/Generator
Replacement in this section).
8. Remove the two bolts between muffler and Starter/
Generator bracket using a flat ratchet.
9. Remove the ground strap at the crankcase using the
10 mm socket. Route ground strap through bracket
and under the throttle rod and cover.
10. Remove the bracket holding the pulse line with a 6"
extension and a 10 mm socket. Remove bracket and
unsnap the ignition wire from the harness.
11. Disconnect the pulse line from the fuel pump using pli-
ers.
12. Disconnect the fuel line from the carburetor inlet, use
drip pan to catch any fuel leakage.
13. Remove throttle rod cover using a 6" extension and a
12 mm socket. Remove the throttle rod at the carbure-
tor butterfly using a flat blade screwdriver to pop the
retaining tab from the throttle rod and lift throttle rod
out of hole. Remove throttle rod at rear by rotating 45
degrees from the bracket and lift through the bracket
slot and remove rod from vehicle.
14. Loosen nuts on the choke cable using a 10 mm
wrench. Close choke butterfly and remove cable from
slot.
15. Remove both bolts from starter/generator bracket
using a 15 mm wrench. Move throttle bracket away
from engine.
16. Remove muffler bolts from muffler stack using a 10
mm and a 13 mm wrench.
17. Remove the passenger side hub cap if equipped and
using a 3/4" lug wrench, remove the wheel and tire
assembly.
18. Set Park Brake and place direction selector in For-
ward to place tension on the clutches.
19. Access the driven clutch from the passenger side of
Repair and Service Manual
ENGINE
B
B
Page G-9