E-Z-GO Engine Manuals

Manuals and User Guides for E-Z-GO Engine. We have 1 E-Z-GO Engine manual available for free PDF download: Shop Rebuild Manual

E-Z-GO Engine Shop Rebuild Manual

E-Z-GO Engine Shop Rebuild Manual (100 pages)

Starting Model Year 2008

Brand: E-Z-GO | Category: Engine | Size: 2 MB

Table of Contents

Table of Contents

5
- How to Use this Manual
  9
Engine Top End Disassembly

11
- Cylinder Head
  13
  - Remove Cylinder Head
    13
  - Valves
    13
  - Fig. 1 Cylinder Head
    13
- Engine Top End
  13
  - Tool List
    13
- Valves
  14
  - Remove Valve Mechanism
    14
  - Engine Top End
    14
    
    Remove Cylinder Head
    14
- Specifications
  15
- Exploded View
  16
  - Cylinder Head
    16
Engine Bottom End Disassembly

19
- Engine Bottom End Disassemblyb
  19
  - Engine Bottom End
    21
    
    Tool List
    21
  - Crankcase
    21
    
    Remove Crankcase Cover
    21
  - Camshaft and Tappets
    21
    
    Remove Camshaft, Tappet
    21
  - Cylinders and Pistons
    22
    
    Remove Piston
    22
  - Crankshaft and Connecting Rods
    23
    
    Remove Connecting Rod
    23
    
    Remove Crankshaft
    23
  - Balancer Shaft
    23
    
    Remove Balancer Shaft
    23
  - Breather Valve
    23
    
    Remove Breather Valve
    23
  - Specifications
    24
  - Exploded View
    26
Engine Measurements

29
- Engine Measurements and Specifications Engine Measurements and Specifications
  31
  - Tool List
    31
  - Using Telescoping Gauges and Hole Gauges
    31
  - Cylinder Head
    31
    
    Measure Cylinder Compression
    31
    
    Inspect Push Rod
    33
    
    Inspect Rocker Arm
    33
    
    Measure Cylinder Head Warp
    33
  - Valves
    34
    
    Inspect Valve Clearance
    34
    
    Adjust Valve Clearance
    34
    
    Inspect Valve Seat
    34
    
    Repair Valve Seat
    34
    
    Operating Procedures
    35
    
    Measure Valve Spring Free Length
    38
    
    Measure Valve Head Thickness
    38
    
    Measure Valve Stem Bend
    38
    
    Measure Valve Stem Diameter
    39
    
    Measure Valve Guide Inside Diameter
    39
    
    Measure Valve/Guide Clearance (Wobble Method
    39
  - Camshaft and Tappets
    40
    
    Measure Camshaft Bearing/Journal Wear
    40
  - Cylinder and Pistons
    41
    
    Clean Piston
    41
    
    Check Piston Ring and Ring Groove Wear
    41
    
    Measure Piston Ring End Gap
    42
    
    Measure Piston Pin, Piston Pin Hole, and Connecting Rod Wear
    43
    
    Measure Piston Diameter
    43
    
    Check Cylinder Inside Diameter
    44
  - Crankshaft and Connecting Rods
    44
    
    Clean/Inspect
    44
    
    Measure Connecting Rod Bend/Twist
    44
    
    Measure Connecting Rod Big End/Crankpin Width Wear
    45
    
    Measure Connecting Rod Big End Bearing/Crankpin Wear
    45
    
    Measure Crankshaft Runout
    46
    
    Measure Crankshaft Main Bearing/Journal Wear
    46
  - Balancer Shaft
    47
    
    Measure Balancer Shaft Bearing/Journal Wear
    47
  - Breather Valve
    47
    
    Inspect Breather Valve
    47
Engine Bottom End Reassembly

49
- Engine Bottom End Reassembly
  
  51
  - Engine Bottom End
    51
    
    Tool List
    51
    
    Install Breather Valve
    51
  - Balancer Shaft
    51
    
    Install Balancer Shaft
    51
  - Crankshaft and Connecting Rods
    52
    
    Install Crankshaft
    52
    
    Install Connecting Rod
    52
  - Cylinders and Pistons
    52
    
    Install Piston
    52
  - Camshaft and Pistons
    54
    
    Install Camshaft, Tappet
    54
  - Crankcase
    54
    
    Assemble Crankcase Cover
    54
    
    Install Crankcase Cover
    54
- Engine Top End Reassembly
  
  57
  - Engine Top End
    59
    
    Tool List
    59
    
    Install Valve Mechanism
    59
  - Cylinder Head
    59
    
    Install Cylinder Head
    59
Illustrated Parts Breakdown

61
- Illustrated Parts Breakdown
  64
  - Cylinder/Crankcase
    64
  - Piston/Crankshaft
    66
  - Valve/Camshaft
    68
  - Lubrication
    70
  - Cooling
    72
  - Electrical
    74
  - Carburetor/Cable Brackets
    76
  - Air Intake/Breather - Exhaust
    78
Limited Warranty

81

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