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E-Z-GO 295cc User Manual
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1 - INCLUDES ITEMS 3 - 16
295cc and 350cc 4 CYCLE ENGINE
STARTI
NG MODEL Y
EAR: 199
2
ENGINE SHOP
REBUILD
&
SER
VICE P
AR
TS MANUAL
27615-G01
REVI
SED:
08
/04
2
Table of Contents
Table of Contents
4
How to Use this Manual
8
Table of Contents
10
Engine Disassembly
10
Remove the Blower Housing
12
Remove the Carburetor
12
Remove the Coil Mounting Bracket and Coil
12
Remove the Exhaust Manifold
12
Remove the Idler, Timing Belt, Drive and Cam Pulleys
12
Remove the Rear Cylinder Baffle
12
Remove the Timing Belt Cover
12
Remove the Cylinder Head and Gasket from the Crankcase
13
Remove the Front Cylinder Baffle
13
Remove the Rear Timing Belt Cover
13
Remove the Rocker Assembly and Camshaft
13
Remove the Valve Cover and Gasket
13
Remove the Valves from the Cylinder Head
14
Valve Guide Removal
14
Engine Diagram
15
Cylinder Head Components Diagram
16
Fig. A-2 Cylinder Head Components
16
Valves Diagram
17
Fig. A-1 Engine
18
Crankcase Disassembly
20
Remove the Fan Hub
20
Remove the Oil Filter
20
Remove the Oil Pressure Switch
20
Remove the Pulser Coil
20
Inspect the Balancer Shaft Bearing and Crankshaft Bearing
21
Remove the Balancer Shaft Seal and the Crankshaft Seal
21
Remove the Crankcase End Cover
21
Remove the Pistons
21
Disassemble the Crankcase End Cover
22
Removal of Crankshaft Bearing
22
Remove the PCV Valve
22
Remove the Piston from Connecting Rod
22
Engine Components Diagrams
23
Crankshaft Diagram
25
Balancer Shaft Bearing, Crankshaft Bearing and PCV Valve Diagram
26
Crankcase End Cover and Crankshaft Bearing Diagram
27
Piston Diagrams
28
Engine Measurements
30
Check Flatness of Crankcase, End Cover and Cylinder Head
32
Engine Measurements and Specifications
32
Using Telescoping Gauges and Hole Gauges
32
Crankcase and End Cover Balancer Shaft Bearing Bores Measurement
33
Crankcase Cylinder Bores Measurement
33
Crankshaft Journals and Gear Measurement
33
Piston Measurement
33
Camshaft
34
Connecting Rod Measurement
34
Cylinder Head Cam and Rocker Shaft Bores Measurement
34
Piston Ring Gap Measurement
34
Rocker Shaft and Rocker Arms Measurement
34
Torque Specifications (Wet)
34
Valve Guides and Seats
34
Valves and Valve Springs
34
Wrist Pin
34
Crankcase Cylinder Bores Diagram
35
Crankshaft Journals and Gear, and Bearing Bores Diagrams
36
Piston, Wrist Pin and Connecting Rod Diagrams
37
Balancer Shaft Journals, Gear and Bearing Bores Diagrams
38
Cylinder Head Cam and Camshaft Diagram
39
Valve Guides and Seats Diagram
40
Valve and Valve Springs Diagram
41
Rocker Shaft, Arms, and Bearing Bores Diagrams
42
Piston Ring Gap Diagram
43
Engine Reassembly
46
Crankcase Assembly
48
Hone the Crankcase Cylinder Bore
48
Reassemble the Pistons and Connecting Rods
48
Install New Crankcase Bearing
49
Install the Piston Rings
49
Reassemble the Crankcase End Cover
49
Install Crankshaft into Crankcase
50
Install New Crankshaft Bearing
50
Install the Balancer Shaft
50
Install the Pistons in the Crankcase
50
Set the Crankshaft and Balancer Shaft Endplay
50
Install Alignment Dowel Pins
51
Install Crankcase End Cover Gasket
51
Install Crankshaft Endplay Spacer and Balancer Endplay Spacer
51
Install New Oil Feed O-Ring
51
Install the Crankcase End Cover
51
Install the Fan Hub
51
Install the Oil Pressure Switch
51
Install the Oil Pump Gear Rotors
51
Install the Pulser Coil
51
Install the Oil Filter
52
Install the PVC Valve
52
Set the Pulser Coil Air Gap
52
Crankcase Cylinder Diagram
53
Piston and Connecting Rods Diagrams
54
Crankcase End Cover, PCV Valve and Oil Filter Diagrams
56
Crankshaft, Pistons and Balancer Shaft Diagram
57
Crankshaft and Balancer Shaft Endplay Diagram
59
Oil Pump Gear Rotors, Oil Pressure Switch/Pulser Coil/Fan Hub Diagram
60
Pulser Coil Air Gap Diagram
62
Cutting Valve Seats
66
Cylinder Head Assembly
66
Install Valve Guides
66
Lap the Valves
66
Fig. A-3 Valves
66
Install New Valve Stem Seals/Install the Valves
67
Install the Cylinder Head on the Crankcase
67
Install the Camshaft
67
Install the Rocker Assembly
67
Install the Drive and Cam Pulleys, Idler and Timing Belt
68
Install the Rear Timing Belt Cover
68
Adjust the Valves/Install the Spark Plugs
69
Install the Coil Mounting Bracket and Coil Assembly
69
Install the Front Timing Belt Cover
69
Install the Front/Rear Cylinder Baffle
69
Install the Blower Housing
69
Install the Exhaust Manifold and Gasket
69
Install the Carburetor
70
Install the Rocker Cover
70
Valves and Valve Clearance Diagrams
71
Cylinder Head, Cam Shaft and Rocker Assembly Diagram
73
Timing Belt Covers, Drive and Cam Pulleys, Idler, Timing Belt Diagram
75
E-8 Rocker Cover Diagram
78
Carburetor Diagram
79
Illustrated Parts Breakdown
81
Parts List
85
California Emission Control Warranty Statement(1995-1999
100
LIMITED WARRANTY on Emission Control Systems - California Only
100
Your Warranty Rights and Obligations
100
California Emission Control Warranty Statement (2000
103
LIMITED WARRANTY on Emission Control Systems - California Only
103
Your Warranty Rights and Obligations
103
California Emission Control Warranty Statement (2001
106
LIMITED WARRANTY on Emission Control Systems - California Only
106
Your Warranty Rights and Obligations
106
California Emission Control Warranty Statement (2004
109
LIMITED WARRANTY on Emission Control Systems - California Only
109
Your Warranty Rights and Obligations
109
4
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E-Z-GO 295cc Specifications
General
Displacement
295cc
Cooling System
Air-cooled
Fuel System
Carburetor
Horsepower
9 hp
Fuel Type
Gasoline
Engine Type
4-cycle, single cylinder
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