E-Z-GO Engine Shop Rebuild Manual page 6

ENGINE MEASUREMENTS AND SPECIFICATIONS
ENGINE MEASUREMENTS AND SPECIFICATIONS
• Tool List................................................ ............................................. ......................................... C-1
• Using Telescoping Gauges and Hole Gauges ................................... ......................................... C-1
CYLINDER HEAD
• Measure Cylinder Compression .......... ............................................. ......................................... C-1
• Inspect Push Rod ................................ ............................................. ......................................... C-3
• Inspect Rocker Arm ............................. ............................................. ......................................... C-3
• Measure Cylinder Head Warp ............. ............................................. ......................................... C-3
VALVES
• Inspect Valve Clearance ...................... ............................................. ......................................... C-4
• Adjust Valve Clearance........................ ............................................. ......................................... C-4
• Inspect Valve Seat ............................... ............................................. ......................................... C-4
• Repair Valve Seat ................................ ............................................. ......................................... C-4
• Operating Procedures.......................... ............................................. ......................................... C-5
• Measure Valve Spring Free Length ..... ............................................. ......................................... C-8
• Measure Valve Head Thickness .......... ............................................. ......................................... C-8
• Measure Valve Stem Bend ................. ............................................. ......................................... C-8
• Measure Valve Stem Diameter ........... ............................................. ......................................... C-9
• Measure Valve Guide Inside Diameter ............................................. ......................................... C-9
• Measure Valve/Guide Clearance (Wobble Method)........................... ......................................... C-9
CAMSHAFT AND TAPPETS
• Measure Camshaft Bearing/Journal Wear......................................... ........................................ C-10
CYLINDER AND PISTONS
• Clean Piston ........................................ ............................................. ........................................ C-11
• Check Piston Ring and Ring Groove Wear ....................................... ........................................ C-11
• Measure Piston Ring End Gap ............ ............................................. ........................................ C-12
• Measure Piston Pin, Piston Pin Hole, and Connecting Rod Wear..... ........................................ C-13
• Measure Piston Diameter .................... ............................................. ........................................ C-13
• Check Cylinder Inside Diameter .......... ............................................. ........................................ C-14
CRANKSHAFT AND CONNECTING RODS
• Clean/Inspect....................................... ............................................. ........................................ C-14
• Measure Connecting Rod Bend/Twist.. ............................................. ........................................ C-14
• Measure Connecting Rod Big End/Crankpin Width Wear ................. ........................................ C-15
• Measure Connecting Rod Big End Bearing/Crankpin Wear ............. ........................................ C-15
• 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
Page iv
TABLE OF CONTENTS
Kawasaki Engine Shop Rebuild Manual
Section
C
Page No.