E-Z-GO 295cc User Manual

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1 - INCLUDES ITEMS 3 - 16

295cc and 350cc 4 CYCLE ENGINE

STARTING MODEL YEAR: 1992

ENGINE SHOP REBUILD

&

SERVICE PARTS MANUAL

27615-G01

REVISED: 08/04

Table of Contents

Table of Contents4
How to Use this Manual8
Table of Contents10
Engine Disassembly10
Remove the Blower Housing12
Remove the Carburetor12
Remove the Coil Mounting Bracket and Coil12
Remove the Exhaust Manifold12
Remove the Idler, Timing Belt, Drive and Cam Pulleys12
Remove the Rear Cylinder Baffle12
Remove the Timing Belt Cover12
Remove the Cylinder Head and Gasket from the Crankcase13
Remove the Front Cylinder Baffle13
Remove the Rear Timing Belt Cover13
Remove the Rocker Assembly and Camshaft13
Remove the Valve Cover and Gasket13
Remove the Valves from the Cylinder Head14
Valve Guide Removal14
- Engine Diagram15
- Cylinder Head Components Diagram16
Fig. A-2 Cylinder Head Components16
Valves Diagram17
Fig. A-1 Engine18
- Crankcase Disassembly20
- Remove the Fan Hub20
- Remove the Oil Filter20
- Remove the Oil Pressure Switch20
- Remove the Pulser Coil20
- Inspect the Balancer Shaft Bearing and Crankshaft Bearing21
- Remove the Balancer Shaft Seal and the Crankshaft Seal21
- Remove the Crankcase End Cover21
- Remove the Pistons21
- Disassemble the Crankcase End Cover22
- Removal of Crankshaft Bearing22
- Remove the PCV Valve22
- Remove the Piston from Connecting Rod22
  - Engine Components Diagrams23
  - Crankshaft Diagram25
  - Balancer Shaft Bearing, Crankshaft Bearing and PCV Valve Diagram26
  - Crankcase End Cover and Crankshaft Bearing Diagram27
  - Piston Diagrams28
  - Engine Measurements30
- Check Flatness of Crankcase, End Cover and Cylinder Head32
- Engine Measurements and Specifications32
- Using Telescoping Gauges and Hole Gauges32
  - Crankcase and End Cover Balancer Shaft Bearing Bores Measurement33
  - Crankcase Cylinder Bores Measurement33
  - Crankshaft Journals and Gear Measurement33
  - Piston Measurement33
- Camshaft34
  - Connecting Rod Measurement34
  - Cylinder Head Cam and Rocker Shaft Bores Measurement34
  - Piston Ring Gap Measurement34
  - Rocker Shaft and Rocker Arms Measurement34
- Torque Specifications (Wet)34
- Valve Guides and Seats34
- Valves and Valve Springs34
- Wrist Pin34
  - Crankcase Cylinder Bores Diagram35
  - Crankshaft Journals and Gear, and Bearing Bores Diagrams36
  - Piston, Wrist Pin and Connecting Rod Diagrams37
  - Balancer Shaft Journals, Gear and Bearing Bores Diagrams38
  - Cylinder Head Cam and Camshaft Diagram39
  - Valve Guides and Seats Diagram40
  - Valve and Valve Springs Diagram41
  - Rocker Shaft, Arms, and Bearing Bores Diagrams42
  - Piston Ring Gap Diagram43
  - Engine Reassembly46
- Crankcase Assembly48
- Hone the Crankcase Cylinder Bore48
- Reassemble the Pistons and Connecting Rods48
- Install New Crankcase Bearing49
- Install the Piston Rings49
- Reassemble the Crankcase End Cover49
- Install Crankshaft into Crankcase50
- Install New Crankshaft Bearing50
- Install the Balancer Shaft50
- Install the Pistons in the Crankcase50
- Set the Crankshaft and Balancer Shaft Endplay50
- Install Alignment Dowel Pins51
- Install Crankcase End Cover Gasket51
- Install Crankshaft Endplay Spacer and Balancer Endplay Spacer51
- Install New Oil Feed O-Ring51
- Install the Crankcase End Cover51
- Install the Fan Hub51
- Install the Oil Pressure Switch51
- Install the Oil Pump Gear Rotors51
- Install the Pulser Coil51
- Install the Oil Filter52
- Install the PVC Valve52
- Set the Pulser Coil Air Gap52
  - Crankcase Cylinder Diagram53
  - Piston and Connecting Rods Diagrams54
  - Crankcase End Cover, PCV Valve and Oil Filter Diagrams56
  - Crankshaft, Pistons and Balancer Shaft Diagram57
  - Crankshaft and Balancer Shaft Endplay Diagram59
  - Oil Pump Gear Rotors, Oil Pressure Switch/Pulser Coil/Fan Hub Diagram60
  - Pulser Coil Air Gap Diagram62
- Cutting Valve Seats66
- Cylinder Head Assembly66
- Install Valve Guides66
- Lap the Valves66
Fig. A-3 Valves66
Install New Valve Stem Seals/Install the Valves67
Install the Cylinder Head on the Crankcase67
- Install the Camshaft67
- Install the Rocker Assembly67
- Install the Drive and Cam Pulleys, Idler and Timing Belt68
- Install the Rear Timing Belt Cover68
- Adjust the Valves/Install the Spark Plugs69
- Install the Coil Mounting Bracket and Coil Assembly69
- Install the Front Timing Belt Cover69
- Install the Front/Rear Cylinder Baffle69
Install the Blower Housing69
Install the Exhaust Manifold and Gasket69
Install the Carburetor70
Install the Rocker Cover70
- Valves and Valve Clearance Diagrams71
- Cylinder Head, Cam Shaft and Rocker Assembly Diagram73
- Timing Belt Covers, Drive and Cam Pulleys, Idler, Timing Belt Diagram75
- E-8 Rocker Cover Diagram78
- Carburetor Diagram79
- Illustrated Parts Breakdown81
- Parts List85
- California Emission Control Warranty Statement(1995-1999100
- LIMITED WARRANTY on Emission Control Systems - California Only100
- Your Warranty Rights and Obligations100
- California Emission Control Warranty Statement (2000103
- LIMITED WARRANTY on Emission Control Systems - California Only103
- Your Warranty Rights and Obligations103
- California Emission Control Warranty Statement (2001106
- LIMITED WARRANTY on Emission Control Systems - California Only106
- Your Warranty Rights and Obligations106
- California Emission Control Warranty Statement (2004109
- LIMITED WARRANTY on Emission Control Systems - California Only109
- Your Warranty Rights and Obligations109

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E-Z-GO 295cc Specifications

General

Brand	E-Z-GO
Model	295cc
Category	Engine
Language	English

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