Club Car Carryall 550 2019 Maintenance And Service Manual page 531

Disassembly/Inspection and Service
NOTE: Rings must be installed correctly. Use a piston
ring expander to install rings. Install bottom (oil
control) ring fi rst and top compression ring last.
To install new piston rings, proceed as follows:
1. Oil control ring (bottom groove): Install expander and
then rails. Make sure ends of expander are not
overlapped.
2. Middle compression ring (center groove): Install
center ring using a piston ring installation tool. Make
sure identifi cation mark is up or colored dye stripe (if
contained), is to left of end gap.
3. Top compression ring (top groove): Install top ring
using a piston ring expander. Make sure
identifi cation mark is up or colored dye stripe (if
contained), is to left of end gap.
Crankshaft Inspection and Service
Inspect gear teeth of crankshaft. If teeth are badly worn,
chipped, or some are missing, replacement of crankshaft
will be necessary.
Inspect crankshaft bearing surfaces for scoring,
grooving, etc. Measure running clearance between
crankshaft journals and their respective bearing bores.
Use an inside micrometer or telescoping gauge to
measure inside diameter of both bearing bores in vertical
and horizontal planes. Use an outside micrometer to
measure outside diameter of crankshaft main bearing
journals. Subtract journal diameters from their respective
bore diameters to get running clearances. Check results
against values in Specifi cations and Tolerances. If
running clearances are within specifi cation, and there
is no evidence of scoring, grooving, etc., no further
reconditioning is necessary. If bearing surfaces are worn
or damaged, crankcase and/or closure plate will need to
be replaced.
Inspect crankshaft keyways. If worn or chipped,
replacement of crankshaft will be necessary. Inspect
crankpin for score marks or metallic pickup. Slight score
marks can be cleaned with crocus cloth soaked in oil. If
wear limits are exceeded, as stated in Specifi cations, it
will be necessary to replace crankshaft.
Remove Oil Sentry System
™
1. Remove nut securing Oil Sentry
assembly in crankcase.
2. Pull grommet assembly from inside of crankcase.
3. Remove screws securing Oil Sentry
crankcase. Remove switch assembly.
Remove Crankcase and Closure Plate Seals and
Bearings
NOTE: Inspect bearings for signs of wear by rotating
inner race and examine for marring or cracks.
Check to make sure race moves easily and is
not sloppy. If bearing is tight and rotates
smoothly, removal is not necessary. If you feel
any roughness or chattering or bearing is sloppy,
it should be replaced.
1. Remove oil seal from crankcase.
2. Using a suitable press, push crankshaft bearing from
crankcase.
68
lead wire grommet
™
level switch to
™
KohlerEngines.com
3. Remove oil seal from closure plate.
4. Using a suitable press, push crankshaft bearing from
closure plate.
Crankcase Inspection and Service
Cylinder Bore Detail
NOTE: A 0.25 mm (0.010 in.) oversize piston is
available if resizing is selected. Initially, resize
using a boring bar, then follow procedures for
honing cylinder.
Check all gasket surfaces to make sure they are free of
gasket fragments. Gasket surfaces must also be free of
deep scratches or nicks.
Check cylinder bore for scoring. In severe cases,
unburned fuel can cause scuffi ng and scoring of cylinder
wall. It washes necessary lubricating oils off piston and
cylinder wall. As raw fuel seeps down cylinder wall,
piston rings make metal to metal contact with wall.
Scoring of cylinder wall can also be caused by localized
hot spots resulting from blocked cooling fi ns or from
inadequate or contaminated lubrication.
If cylinder bore is badly scored, excessively worn,
tapered, or out-of-round, resizing is necessary. Use an
inside micrometer to determine amount of wear (refer to
Specifi cations).
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