Club Car Carryall 500 2019 Maintenance And Service Manual page 515

Valve Guides
If a valve guide is worn beyond specifi cations, it will not guide valve in a straight line. This may result in burnt valve
faces or seats, loss of compression, and excessive oil consumption.
To check valve guide-to-valve stem clearance, thoroughly clean valve guide and, using a split-ball gauge, measure
inside diameter of guide. Then, using an outside micrometer, measure diameter of valve stem at several points on
stem where it moves in valve guide. Use largest stem diameter to calculate clearance by subtracting stem diameter
from guide diameter. If intake or exhaust clearance exceeds specifi cations in Valve Specifi cation table, determine
whether valve stem or guide is responsible for excessive clearance.
If guides are within limits but valve stems are worn beyond limits, install new valves.
Valve Seat Inserts
Hardened steel alloy intake and exhaust valve seat inserts are press-fi tted into cylinder head. Inserts are not
replaceable but can be reconditioned if not too badly pitted or distorted. If cracked or badly warped, cylinder head
should be replaced.
Recondition valve seat inserts following instructions provided with valve seat cutter being used. Final cut should be
made with a 44.5° cutter as specifi ed for valve seat angle. Cutting proper 45° valve face angle, as specifi ed, and
proper valve seat angle (44.5°) will achieve desired 0.5° (1.0° full cut) interference angle where maximum pressure
occurs on outside diameters of valve face and seat.
Lapping Valves
Reground or new valves must be lapped in, to provide proper fi t. Use a hand valve lapping tool with suction cup
for fi nal lapping. Lightly coat valve face with fi ne grade of grinding compound, then rotate valve on seat with tool.
Continue lapping until smooth surface is obtained on seat and on valve face. Thoroughly clean cylinder head in soap
and hot water to remove all traces of grinding compound. After drying cylinder head, apply a light coating of SAE 10
oil to prevent rusting.
Valve Stem Seals
These engines use valve stem seals on intake and exhaust valves.
Always use new seals when valves are removed from cylinder head. Seals should also be replaced if deteriorated or
damaged in any way. Never reuse old seals.
Valve Details
D
E
Item Dimension
Head Diameter
A
Valve Length
B
Stem Diameter
C
D Face/Seat Width - Maximum
E Face/Seat Angle
17 690 15 Rev. --
B
C
A
E
Valve Specifi cations
35.875-36.125 mm
(1.4124-1.4222 in.)
86.175-86.375 mm
(3.3927-3.4006 in.)
(0.2583-0.2589 in.)
1.5 mm (0.059 in.)
KohlerEngines.com
Disassembly/Inspection and Service
D
Intake
6.560-6.575 mm
45°-44.5°
D
Exhaust
32.875-33.125 mm
(1.2943-1.3041 in.)
86.341-86.541 mm
(3.3993-3.4071 in.)
6.545-6.560 mm
(0.2577-0.2583 in.)
1.5 mm (0.059 in.)
45°-44.5°
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