E-Z-GO Engine Shop Rebuild Manual
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E-Z-GO Engine Shop Rebuild Manual

E-Z-GO Engine Shop Rebuild Manual

Starting model year 2008
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KAWASAKI ENGINE
SHOP REBUILD MANUAL
4-STROKE AIR-COOLED GASOLINE
STARTING MODEL YEAR: 2008
ENGINE
608172
6
5
9
1 1
1 6
1 3
1 5
7
8
1 8
1 7
1 - I N C L U D E S I T E M S 3 - 1 6
1 9
3
1 0
4

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Summary of Contents for E-Z-GO Engine

  • Page 1 608172 1 - I N C L U D E S I T E M S 3 - 1 6 KAWASAKI ENGINE SHOP REBUILD MANUAL 4-STROKE AIR-COOLED GASOLINE ENGINE STARTING MODEL YEAR: 2008...
  • Page 3 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. CUSTOMER SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855 FAX: 1-800-448-8124 OUTSIDE USA PHONE: 010-1-706-798-4311, FAX: 010-1-706-771-4609 E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA 30906 Kawasaki Engine Shop Rebuild Manual Page i...
  • Page 4 The exhaust emissions of this vehicle’s engine comply with regulations set forth by the Environmental Protection Agency (EPA) of the United States of America (USA) at time of manufacture. Significant fines could result from modifications or tampering with the engine, fuel, ignition or air intake systems.

  • Page 5: Table Of Contents

    • Remove Crankshaft ........................B-3 BALANCER SHAFT • Remove Balancer Shaft ......................B-3 BREATHER VALVE • Remove Breather Valve ......................B-3 SPECIFICATIONS............................B-4 EXPLODED VIEW ............................. B-6 Kawasaki Engine Shop Rebuild Manual Page iii...
  • Page 6 • Measure Crankshaft Runout..................... C-16 • Measure Crankshaft Main Bearing/Journal Wear ..............C-16 BALANCER SHAFT • Measure Balancer Shaft Bearing/Journal Wear ............... C-17 BREATHER VALVE • Inspect Breather Valve......................C-17 Kawasaki Engine Shop Rebuild Manual Page iv...
  • Page 7 • Install Crankcase Cover ......................D-4 ENGINE TOP END REASSEMBLY ENGINE TOP END • Tool List............................E-1 VALVES • Install Valve Mechanism ......................E-1 CYLINDER HEAD • Install Cylinder Head........................E-1 Kawasaki Engine Shop Rebuild Manual Page v...
  • Page 8 Federal Emissions Component Defect Warranty..................G-1 California Emission Control Warranty Statement (1995-1999) ..............G-5 California Emission Control Warranty Statement (2000) ................G-8 California Emission Control Warranty Statement (2001) ................G-11 California Emission Control Warranty Statement (2004) ................G-14 Kawasaki Engine Shop Rebuild Manual Page vi...

  • Page 9: 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 allows the mechanic to choose the level of instructional detail needed to completely disassemble, diag- nose, repair/overhaul and reassemble the engine.
  • Page 10 Notes: Kawasaki Engine Shop Rebuild Manual Page viii...
  • Page 11 SECTION TITLE PAGE NO. ENGINE TOP END..........................A-1 Tool List ...........................A-1 CYLINDER HEAD ..........................A-1 Remove Cylinder Head ......................A-1 VALVES .............................A-2 Remove Valve Mechanism......................A-2 SPECIFICATIONS ..........................A-3 EXPLODED VIEW..........................A-4 LIST OF ILLUSTRATIONS Fig. 1 Cylinder Head..........................A-4 Kawasaki Engine Shop Rebuild Manual Page A-i...
  • Page 12 ENGINE TOP END DISASSEMBLY Notes: Kawasaki Engine Shop Rebuild Manual Page A-ii...

  • Page 13: Engine Top End

    Mark and sort all parts as they are disassembled so that they will be reassembled and installed in their original positions.

  • Page 14: Valves

    Damage to the fins will occur if they are used as pry points. Remove cylinder head bolts [A], push rod guides [B], and cylinder head [C]. Remove the stem seals [A]. Kawasaki Engine Shop Rebuild Manual Page A-2...

  • Page 15: Specifications

    7.08 mm (0.279 in.) Valve/guide Clearance (wobble method): Inlet 0.06 ~ 0.13 mm (0.0024 ~ 0.0051 in.) 0.29 mm (0.011 in.) Exhaust 0.10 ~ 0.17 mm (0.0039 ~ 0.0067 in.) 0.33 mm (0.013 in.) Kawasaki Engine Shop Rebuild Manual Page A-3...

  • Page 16: Exploded View

    ENGINE TOP END DISASSEMBLY Exploded View Fig. 1 Cylinder Head Kawasaki Engine Shop Rebuild Manual Page A-4...
  • Page 17 603545 Valve Adjusting Nut Lock Screws 0.70 61 in-lb 603549 Rocker Arm Bolts 21 ft-lb EO: Apply engine oil. M: Apply molybdenum disulfide grease. R: Replacement Parts S: Follow the specific tightening sequence. Kawasaki Engine Shop Rebuild Manual Page A-5...
  • Page 18 Notes: Kawasaki Engine Shop Rebuild Manual Page A-6...

  • Page 19: Engine Bottom End Disassemblyb

    CRANKSHAFT AND CONNECTING RODS..................B-3 Remove Connecting Rod ......................B-3 Remove Crankshaft.........................B-3 BALANCER SHAFT ...........................B-3 Remove Balancer Shaft......................B-3 BREATHER VALVE ...........................B-3 Remove Breather Valve ......................B-3 SPECIFICATIONS ..........................B-4 EXPLODED VIEW..........................B-6 LIST OF ILLUSTRATIONS Fig. 1 Crankcase ..........................B-6 Kawasaki Engine Shop Rebuild Manual Page B-i...
  • Page 20 ENGINE BOTTOM END DISASSEMBLY Notes: Kawasaki Engine Shop Rebuild Manual Page B-ii...

  • Page 21: Engine Bottom End

    CRANKCASE Remove Crankcase Cover A. Drain the engine oil. If the crankcase cover sticks, tap lightly with a wooden or plastic mallet near the dowel pins [C]. Remove the lock screws [A] and the valve clearance adjusting nuts [B], which fasten the rocker arm [C], and pull the rocker arm off the push rods [D].

  • Page 22: Cylinders And Pistons

    H. Remove the 3-piece oil ring with your thumbs in the D. Push the connecting rod end into the cylinder, and pull the piston and connecting rod out of the cylinder. same manner. Kawasaki Engine Shop Rebuild Manual Page B-2...

  • Page 23: Crankshaft And Connecting Rods

    The function of the breather is to create a negative pres- A. Refer to Remove Piston. sure in the crankcase, which prevents oil from being forced out of the engine through the piston rings, oil seals Remove Crankshaft or gaskets. A sealed-type crankcase emission control system is used to prevent blow-by gases from emitting in A.

  • Page 24: Specifications

    Crankcase Side 34.955 ~ 34.980 mm 34.93 mm (1.3762 ~ 1.3772 in.) (1.375 in.) Crankshaft Main Bearing Inside Diameter: Crankcase Side 35.002 ~ 35.015 mm 35.05 mm (1.3780 ~ 1.3785 in.) (1.380 in.) Kawasaki Engine Shop Rebuild Manual Page B-4...
  • Page 25 Balancer Shaft Bearing Inside Diameter: Crankcase Side 32.000 ~ 32.016 mm 32.06 mm (1.2598 ~ 1.2605 in.) (1.262 in.) Crankcase Cover Side 32.000 ~ 32.016 mm 32.06 mm (1.2598 ~ 1.2605 in.) (1.262 in.) Kawasaki Engine Shop Rebuild Manual Page B-5...

  • Page 26: Exploded View

    ENGINE BOTTOM END DISASSEMBLY Exploded View Fig. 1 Crankcase Kawasaki Engine Shop Rebuild Manual Page B-6...
  • Page 27 603524 16 ft-lb * with crankcase EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. R: Replacement Parts S: Follow the specific tightening sequence. Kawasaki Engine Shop Rebuild Manual Page B-7...
  • Page 28 Notes: Kawasaki Engine Shop Rebuild Manual Page B-8...
  • Page 29 ENGINE MEASUREMENTS TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. ENGINE MEASUREMENTS AND SPECIFICATIONS..............C-1 Tool List ..........................C-1 Using Telescoping Gauges and Hole Gauges ............... C-1 CYLINDER HEAD ..........................C-1 Measure Cylinder Compression ..................... C-1 Inspect Push Rod ........................C-3 Inspect Rocker Arm ........................
  • Page 30 ENGINE MEASUREMENTS Notes: Kawasaki Engine Shop Rebuild Manual Page C-ii...

  • Page 31: Engine Measurements And Specifications Engine Measurements And Specifications

    Valve Seat Cutter Holder Bar E-Z-GO Part No. 608670 ..........1 All engine parts must be thoroughly cleaned, and free of all dirt, oil, grease, carbon deposits or residue of any kind before begin- ning this section. It is especially important that your work area be clean and well organized while performing the operations described in this section.
  • Page 32 Repair if possible. Cylinder compression Incorrect valve, piston/cylinder clearance Adjust. lower than usable range Inspect cylinder and Piston seizure liner and replace/ repair as necessary. Bad condition of piston ring and/or piston ring Replace. grooves Kawasaki Engine Shop Rebuild Manual Page C-2...

  • Page 33: Inspect Push Rod

    Service Limit: TIR 0.5 mm (0.02 in.) Inspect Rocker Arm Clean and inspect the rocker arm where it touches the push rod and valve stem. B. If the contact points [A] are worn or damaged, replace the rocker arm. Kawasaki Engine Shop Rebuild Manual Page C-3...

  • Page 34: Valves

    F. Pull the valve out, and check the seating pattern on the valve head. It must be the correct width and even Valve Seat Cutter Holder Bar all the way around. E-Z-GO Part No. 608670 Kawasaki Engine Shop Rebuild Manual Page C-4...

  • Page 35: Operating Procedures

    2. Do not drop or hit the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cut- ter before grinding the seat surface. Also, use The marks stamped on the back of the cutter [A] repre-...
  • Page 36 To make the 32° grind, fit a 32° cutter to the holder, and slide it Be sure to remove all grinding compound before assembly into the valve guide. P. When the engine is assembled, be sure to adjust the 1. Grind the seat at a 32° angle until the seat O.D. is valve clearances.
  • Page 37 ENGINE MEASUREMENTS Kawasaki Engine Shop Rebuild Manual Page C-7...

  • Page 38: Measure Valve Spring Free Length

    B. If the valve head thickness is less than the service limit, replace the valve with a new one. Valve Head Thickness Standard: 0.4 mm (0.016 in.) Service Limit: 0.4 mm (0.016 in.) Kawasaki Engine Shop Rebuild Manual Page C-8...

  • Page 39: Measure Valve Stem Diameter

    Service Limit: Valve Guide Inside Diameter Inlet 0.29 mm (0.011 in.) Standard: 7.000 ~ 7.015 mm (0.2756 ~ 0.2762 in.) Service Limit: 7.08 mm (0.279 in.) Exhaust 0.33 mm (0.013 in.) Kawasaki Engine Shop Rebuild Manual Page C-9...

  • Page 40: Camshaft And Tappets

    Crankcase Side Camshaft Journal Diameter Standard: 50.000 ~ 50.025 mm (1.9685 ~ 1.9695 in.) Standard: 19.967 ~ 19.980 mm (0.78610 ~ 0.78661 in.) Service Limit: 19.94 mm (0.7850 in.) Service Limit: 50.09 mm (1.972 in.) Kawasaki Engine Shop Rebuild Manual Page C-10...

  • Page 41: Cylinder And Pistons

    D. Clean the piston ring grooves [A] with a broken piston ring or other suitable tools. Never clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder, and damage Check Piston Ring and Ring Groove Wear the crankshaft bearings.

  • Page 42: Measure Piston Ring End Gap

    When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston. Measure Piston Ring End Gap A. Remove the piston rings. Kawasaki Engine Shop Rebuild Manual Page C-12...

  • Page 43: Measure Piston Pin, Piston Pin Hole, And Connecting Rod Wear

    Piston Pin Hole Inside Diameter Standard: 81.935 ~ 81.955 mm (3.2258 ~ 3.2266 in.) Standard: 19.004 ~ 19.015 mm (0.74819 ~ 0.74862 in.) Service Limit: 19.08 mm (0.7512 in.) Service Limit: 81.79 mm (3.220 in.) Kawasaki Engine Shop Rebuild Manual Page C-13...

  • Page 44: Check Cylinder Inside Diameter

    100 mm length to determine the amount of connect- ing rod bend. F. If connecting rod bend exceeds the service limit, the connecting rod must be replaced. Connecting Rod Bend Service Limit: 0.15/100 mm (0.006/3.94 in.) Kawasaki Engine Shop Rebuild Manual Page C-14...

  • Page 45: Measure Connecting Rod Big End/Crankpin Width Wear

    Connecting Rod Big End Width Standard: 43.004 ~ 43.015 mm (1.6931 ~ 1.6935 in.) Standard: 27.4 ~ 27.7 mm (1.08 ~ 1.09 in.) Service Limit: 27.0 mm (1.06 in.) Service Limit: 43.04 mm (1.694 in.) Kawasaki Engine Shop Rebuild Manual Page C-15...

  • Page 46: Measure Crankshaft Runout

    Side) Crankshaft Runout Standard: 35.002 ~ 35.015 mm (1.3780 ~ 1.3785 in.) Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.002 in.) Service Limit: 35.05 mm (1.380 in.) Kawasaki Engine Shop Rebuild Manual Page C-16...

  • Page 47: Balancer Shaft

    D. If inside diameter is more than the service limit, replace the crankcase with a new one. Balancer Shaft Bearing Inside Diameter (Crankcase) Standard: 32.000 ~ 32.016 mm (1.2598 ~ 1.2605 in.) Service Limit: 32.06 mm (1.262 in.) Kawasaki Engine Shop Rebuild Manual Page C-17...

  • Page 48: Kawasaki Engine Shop Rebuild Manual

    Notes: Kawasaki Engine Shop Rebuild Manual Page C-18...
  • Page 49 Install Connecting Rod ......................D-2 CYLINDERS AND PISTONS ......................D-2 Install Piston ........................... D-2 CAMSHAFT AND PISTONS ......................D-4 Install Camshaft, Tappet......................D-4 CRANKCASE ............................ D-4 Assemble Crankcase Cover ....................D-4 Install Crankcase Cover ......................D-4 Kawasaki Engine Shop Rebuild Manual Page D-i...
  • Page 50 ENGINE BOTTOM END REASSEMBLY Notes: Kawasaki Engine Shop Rebuild Manual Page D-ii...

  • Page 51: Engine Bottom End Reassembly

    E-Z-GO Part No. N/A ..........1 Bearing Driver Set: E-Z-GO Part No. N/A ..........1 If the engine is not going to be put back into service immediately, completely coat all inter- nal engine components with assembly lube. Tape intake and exhaust openings.

  • Page 52: Crankshaft And Connecting Rods

    The rings should turn freely in the grooves. side journal. D. Install the top ring. D. Apply engine oil to the crank pin and bearing. E. Insert the crankshaft into the crankcase. Install Connecting Rod A. Refer to Install Piston.
  • Page 53 When installing a piston pin snap ring, compress it only enough to install it and no more. Apply engine oil to the inner surface [A] of the con- Do not reuse the snap rings, as removal weakens and deforms necting rod big end [B] and cap [C].

  • Page 54: Camshaft And Pistons

    ENGINE BOTTOM END REASSEMBLY CRANKCASE N. Apply a small amount of engine oil to the thread and seating surface of the cap bolts [E]. Assemble Crankcase Cover O. Tighten the cap bolts. Torque - Connecting Rod Big End Cap Bolts: 5.9 N•m (0.60 kgf•m, 52 in-lb)
  • Page 55 ENGINE BOTTOM END REASSEMBLY Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown. Torque - Crankcase Cover Bolts: 22 N•m (2.2 kgf•m, 16 ft-lb) Kawasaki Engine Shop Rebuild Manual Page D-5...
  • Page 56 Notes: Kawasaki Engine Shop Rebuild Manual Page D-6...

  • Page 57: Engine Top End Reassembly

    ENGINE TOP END REASSEMBLY TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. ENGINE TOP END..........................E-1 Tool List ...........................E-1 VALVES .............................E-1 Install Valve Mechanism......................E-1 CYLINDER HEAD ..........................E-1 Install Cylinder Head .......................E-1 Kawasaki Engine Shop Rebuild Manual Page E-i...
  • Page 58 ENGINE TOP END REASSEMBLY Notes: Kawasaki Engine Shop Rebuild Manual Page E-ii...

  • Page 59: Engine Top End

    Install cylinder head and push rod guides [A]. VALVES Install Valve Mechanism A. Apply engine oil to the valve stems and install them. B. Check to see that the valve moves smoothly up and down in the guide. C. Install the spring and the valve retainer.
  • Page 60 N. Tighten: Torque - Cylinder Head Cover Bolts: 6.9 N•m (0.70 kgf•m, 61 in-lb) Apply engine oil to the push rods [A] and install them Engine Shroud Bolts: 5.9 N•m (0.60 kgf•m, 52 in-lb) onto the tappets [B]. To install the push rods [A] in the correct positions on...
  • Page 61 ILLUSTRATED PARTS BREAKDOWN TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. CYLINDER/CRANKCASE........................F-2 PISTON/CRANKSHAFT........................F-4 VALVE/CAMSHAFT ...........................F-6 LUBRICATION ...........................F-8 COOLING............................F-10 ELECTRICAL ...........................F-12 CARBURETOR/CABLE BRACKETS ....................F-14 AIR INTAKE/BREATHER - EXHAUST.....................F-16 Kawasaki Engine Shop Rebuild Manual Page Fi...
  • Page 62 ILLUSTRATED PARTS BREAKDOWN Kawasaki Engine Shop Rebuild Manual Page Fii...
  • Page 63 ILLUSTRATED PARTS BREAKDOWN Notes: Kawasaki Engine Shop Rebuild Manual Page F-1...

  • Page 64: Illustrated Parts Breakdown

    ILLUSTRATED PARTS BREAKDOWN CYLINDER/CRANKCASE Kawasaki Engine Shop Rebuild Manual Page F-2...
  • Page 65 603516 COVER CRANKCASE 603517 CRANKCASE COMPLETE 603518 PIN, DOWEL 603519 SEAL-OIL, SD35X48X8 603520 SEAL OIL 603521 PLUG 603522 BOLT FLANGED 603523 BOLT FLANGED 603524 BOLT FLANGED 603525 SCREW, PAS, CROS 603526 BEARING-BALL 603527 Kawasaki Engine Shop Rebuild Manual Page F-3...

  • Page 66: Piston/Crankshaft

    ILLUSTRATED PARTS BREAKDOWN PISTON/CRANKSHAFT Kawasaki Engine Shop Rebuild Manual Page F-4...
  • Page 67 Item Description E-Z-GO Part Number GOLF UTILITY PISTON, ENGINE 603528 PIN, PISTON 603529 RING SET, PISTON 603530 CRANKSHAFT, COMPLETE 603531 BALANCER, COMPLETE 603532 ASSY, CONNECT ROD 603533 RING-SNAP 603534 BOLT, M6X1.0X35.0 LG. 603535 Kawasaki Engine Shop Rebuild Manual Page F-5...

  • Page 68: Valve/Camshaft

    ILLUSTRATED PARTS BREAKDOWN VALVE/CAMSHAFT Kawasaki Engine Shop Rebuild Manual Page F-6...
  • Page 69 603538 COLLECT 603539 ARM, ROCKER 603540 TAPPET 603541 GUIDE, PUSH ROD 603542 ROD, PUSH 603543 SPRING, ENGINE VALVE 603544 CAMSHAFT-COMPLETE 607461 SCREW 603545 603546 SEAL OIL 603547 SPRING (NOT SHOWN) 603548 BOLT 603549 Kawasaki Engine Shop Rebuild Manual Page F-7...

  • Page 70: Lubrication

    ILLUSTRATED PARTS BREAKDOWN LUBRICATION Kawasaki Engine Shop Rebuild Manual Page F-8...
  • Page 71 O RING, 16MM 603562 SWITCH, OIL PRESSURE (NOT SHOWN) 608398 * Utility vehicles may be equipped with either high or low suspension. Please be sure to select the correct dipstick P/N for your model. Kawasaki Engine Shop Rebuild Manual Page F-9...

  • Page 72: Cooling

    ILLUSTRATED PARTS BREAKDOWN COOLING Kawasaki Engine Shop Rebuild Manual Page F-10...
  • Page 73 ILLUSTRATED PARTS BREAKDOWN COOLING Quantity Item Description E-Z-GO Part Number GOLF UTILITY SHROUD, ENGINE 603563 GUARD 603564 603566 HOUSING, FAN 603567 RIVET, GUARD 603569 BOLT 603560 Kawasaki Engine Shop Rebuild Manual Page F-11...

  • Page 74: Electrical

    ILLUSTRATED PARTS BREAKDOWN ELECTRICAL Kawasaki Engine Shop Rebuild Manual Page F-12...
  • Page 75 PLATE, FAN 603571 ASSY, IGNITION COIL 603572 FLYWHEEL-ASSEMBLY 607463 WIRE-LEAD 603573 PLUG 603522 PLUG-SPARK, BPR2ES 607462 BOLT, M12X39MM LG. 603575 WASHER 603576 BOLT, FLANGED 603577 SCREW, PAN WP CROS (NOT SHOWN) 603578 KEY-WOODRUFF 603579 Kawasaki Engine Shop Rebuild Manual Page F-13...

  • Page 76: Carburetor/Cable Brackets

    ILLUSTRATED PARTS BREAKDOWN CARBURETOR/CABLE BRACKETS Kawasaki Engine Shop Rebuild Manual Page F-14...
  • Page 77 607683 JET-MAIN #102 607684 JET-MAIN #100 (NOT SHOWN) 607685 VALVE-FLOAT 607686 FLOAT 607687 PIN, FLOAT 607688 GASKET, BOWEL 607689 ASSY, FLOAT CHAMBER 607690 GASKET, CHAMBER 607691 PLUG, CHAMBER 607692 BUSHING, THROTTLE ATTACH. 608023 Kawasaki Engine Shop Rebuild Manual Page F-15...

  • Page 78: Air Intake/Breather - Exhaust

    ILLUSTRATED PARTS BREAKDOWN AIR INTAKE/BREATHER - EXHAUST Kawasaki Engine Shop Rebuild Manual Page F-16...
  • Page 79 ILLUSTRATED PARTS BREAKDOWN AIR INTAKE/BREATHER Quantity Item Description E-Z-GO Part Number GOLF UTILITY GASKET, CHOKE 603593 PIPE-INTAKE 603594 NUT-M6X1.0 V 603595 CLAMP-INTAKE PIPE 603596 CLAMP CYLINDR HEAD 603597 TUBE, BREATHER 603598 EXHAUST SCREW, EXHAUST 608022 Kawasaki Engine Shop Rebuild Manual Page F-17...
  • Page 80 ILLUSTRATED PARTS BREAKDOWN Notes: Kawasaki Engine Shop Rebuild Manual Page F-18...

  • Page 81: Limited Warranty

    LIMITED WARRANTY on Emission Control Systems - California Only -......G-11 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT (2004)........G-14 YOUR WARRANTY RIGHTS AND OBLIGATIONS ............G-14 LIMITED WARRANTY on Emission Control Systems - California Only -......G-14 Kawasaki Engine Shop Rebuild Manuall Page G-i...
  • Page 82 LIMITED WARRANTY Notes: Kawasaki Engine Shop Rebuild Manual Page G-ii...

  • Page 83: Federal Emissions Component Defect Warranty

    GO will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine complies with applicable U.S. EPA regulations. EMISSION COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of 2 years. PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty.
  • Page 84 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 85 U.S. EPA regulations. EMISSION COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of 2 years.
  • Page 86 THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper use and maintenance of the engine. You should keep all receipts and mainte- nance records covering the performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred to each subsequent owner of the engine.

  • Page 87: California Emission Control Warranty Statement (1995-1999

    - California Only - FUJI, Tokyo, Japan, warrants to the owner of the 1995 and later engine that the engine (1) has been designed, built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Re- sources Board, and (2) is free from defects in materials and workmanship which could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below.
  • Page 88 3. Expenses incurred by processing warranty claims FUJI, any authorized dealer, distributors and warranty station shall not be liable for any loss of use of the engine, for any alternative usage, for any damage to goods, loss of time or inconve- nience.
  • Page 89 The proof which you maintain should be given to each subsequent owner of the engine. You are responsible for performing the scheduled maintenance described below based on the procedures specified in the 1995 and later Owner’s Manual. The scheduled maintenance below is based on the normal engine operating schedule.

  • Page 90: California Emission Control Warranty Statement (2000

    - California Only - FUJI, Tokyo, Japan, warrants to the owner of the 2000 and later engine that the engine (1) has been designed, built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Re- sources Board, and (2) is free from defects in materials and workmanship which could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below.
  • Page 91 3. Expenses incurred by processing warranty claims FUJI, any authorized dealer, distributors and warranty station shall not be liable for any loss of use of the engine, for any alternative usage, for any damage to goods, loss of time or inconve- nience.
  • Page 92 The proof which you maintain should be given to each subsequent owner of the engine. You are responsible for performing the scheduled main- tenance described in the Periodic Service Schedule of this manual. The scheduled maintenance is based on the normal engine operating schedule.

  • Page 93: California Emission Control Warranty Statement (2001

    - California Only - FUJI, Tokyo, Japan, warrants to the owner of the 2001 and later engine that the engine (1) has been designed, built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Re- sources Board, and (2) is free from defects in materials and workmanship which could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below.
  • Page 94 3. Expenses incurred by processing warranty claims FUJI, any authorized dealer, distributors and service providers shall not be liable for any loss of use of the engine, for any alternative usage, for any damage to goods, loss of time or inconve- nience.
  • Page 95 The proof which you maintain should be given to each subsequent owner of the engine. You are responsible for performing the scheduled main- tenance described in the Periodic Service Schedule of this manual. The scheduled maintenance is based on the normal engine operating schedule.

  • Page 96: California Emission Control Warranty Statement (2004

    - California Only - FUJI, Tokyo, Japan, warrants to the owner of the 2004 and later engine that the engine (1) has been designed, built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Re- sources Board, and (2) is free from defects in materials and workmanship which could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below.
  • Page 97 3. Expenses incurred by processing warranty claims FUJI, any authorized dealer, distributors and service providers shall not be liable for any loss of use of the engine, for any alternative usage, for any damage to goods, loss of time or inconve- nience.
  • Page 98 FUJI may deny a warranty claim if your failure to perform required maintenance resulted in the failure of warranted part. The proof which you maintain should be given to each subsequent owner of the engine. You are responsible for performing the scheduled maintenance described in the Periodic Service Schedule of this manual.
  • Page 100 E-Z-GO Division of Textron Inc. 1451 Marvin Griffin Rd. Augusta, Georgia 30906 USA Inside USA Phone: 1-800-241-5855, FAX: 1-800-448-8124 Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 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.

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