Engine Top End; Tool List; Install Valve Mechanism; Cylinder Head - E-Z-GO Engine Shop Rebuild Manual

ENGINE TOP END REASSEMBLY

ENGINE TOP END

Tool List

Compression Gauge, 20 kgf/cm²:
E-Z-GO Part No. N/A .................................................. 1
Valve Seat Cutter, 45° - 32:
E-Z-GO Part No. 608665 ............................................ 1
Valve Seat Cutter, 45° - 35:
E-Z-GO Part No. 608666 ............................................ 1
Valve Seat Cutter, 32° - 35:
E-Z-GO Part No. 608667 ............................................ 1
Valve Seat Cutter, 32° - 38.5:
E-Z-GO Part No. 608668 ............................................ 1
Valve Seat Cutter Holder, 7:
E-Z-GO Part No. 608669 ............................................ 1
Valve Seat Cutter Holder Bar:
E-Z-GO Part No. 608670 ............................................ 1
Compression Gauge Adapter, M14 × 1.25:
E-Z-GO Part No. N/A .................................................. 1
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.
D. Install the valve retainer while pushing down the valve
retainer with the thumbs.
E. Install cylinder head. See Install Cylinder Head in
Section A.

CYLINDER HEAD

Install Cylinder Head

A. Clean the mating surface of the cylinder head and the
cylinder.
Qty. Required
Kawasaki Engine Shop Rebuild Manual
B.
Install the dowel pins [A].
C. Replace the gasket [B] with a new one.
D.
Install cylinder head and push rod guides [A].
E.
Tighten the cylinder head bolts following the tighten-
ing sequence as shown.
Torque - Cylinder Head Bolts: 37 N•m (3.8 kgf•m, 27
ft-lb)
E
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