Ezgo EXPRESS L4 Technician's Repair And Service Manual page 104

ENGINE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
the vehicle and using a 19mm combo wrench, remove
the bolt from the driven clutch.
20. Install the clutch puller bolt in clockwise position until it
bottoms out.
21. Using a impact tool and an impact socket on the clutch
puller bolt, remove the clutch then remove the clutch
puller bolt.
22. To remove the drive clutch, use a 19mm impact socket
with an impact tool remove the 19 mm bolt from the
center of the drive clutch.
23. Raise the powertrain with the floor jack so that the
clutch puller bolt clears the spring hanger. Remove the
front eyebolt from the spring hanger using a 15 mm
socket and a 15 mm wrench. Install the clutch puller
bolt in a clockwise position and using the impact tool
remove the drive clutch from the shaft. Remove the
clutch puller bolt.
24. Remove the four 15 mm bolts from the engine support
bracket connecting the engine to the differential and
the engine to the inner frame.
25. Remove the 15 mm bolts from the bottom of the skid
plate. Access the forward two nuts through the oil
drain access hole.
Controls and Wiring
Unplug the wiring harness from the engine and cut the
wire tie securing the accelerator cable to the engine.
Removing the Engine from the Vehicle
Place suitable blocks under the engine frame for support.
Although the blocks are not required for engine removal, they
will help maintain the alignment of the frames and simplify
engine installation.
It is not necessary to remove the muffler as part of the engine
removal.
Engine Installation
When installing the fuel and pulse lines, pay particular
attention to assure that the lines are not confused.
It is important to follow the assembly sequence recom-
Page G-10
NOTICE
NOTICE
Repair and Service Manual
mended for mounting hardware.
With the assistance of a hoist or another person, lower
the engine into position over the engine support cast-
ings.
Install one rear horizontal and one front bottom engine
bolt through the casting and engine and lightly snug in
place.
Install the remaining horizontal engine bolts and finger
tighten. Remove the front bottom bolt and reinstall the
skid plate finger tight.
Tighten the bottom and horizontal mounting bolts to 45
ft. lbs. (60 Nm) torque.
The remaining installation is in the reverse order of dis-
assembly using standard torque specifications.
DRIVE CLUTCH REMOVAL
To prevent possibility of personal injury, use
only impact sockets when using an impact
wrench.
Insert a clutch puller bolt (p/n 608429) into the clutch
and hand tighten for several turns. Remove the clutch by
driving it off with the impact wrench and the clutch puller
bolt.It is not necessary to remove the engine to remove
the clutch. Refer to the CONTINUOUSLY VARIABLE
TRANSMISSION (CVT) section for removal and installa-
tion.
NOTICE
In some extreme cases, the clutch will be resistant to removal.
In stubbon cases, the clutch removal tool should be removed
and the cavity filled with grease. Install the clutch puller and
use the impact wrenchto drive off the clutch. The combination
of hydraulic pressure (grease) and the impact wrench will
remove the most stubborn clutch. To prevent damage to the
clutch, be sure to remove all grease from the body of the
clutch since grease penetrating the seal may cause premature
clutch failure.
It is not necessary to remove the engine to remove the
clutch. Refer to the CONTINUOUSLY VARIABLE
TRANSMISSION (CVT) section for removal and installa-
tion.