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E-Z-GO Engine User Manual

E-Z-GO Engine
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1 - INCLUDES ITEMS 3 - 16
4-STROKE AIR-COOLED GASOLINE
ENGINE
STARTING MODEL YEAR: 2008
KAWASAKI ENGINE
SHOP REBUILD MANUAL
608172

Table of Contents

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E-Z-GO Engine Specifications

General IconGeneral
BrandE-Z-GO
ModelEngine
CategoryEngine
LanguageEnglish

Summary

How to Use This Manual

Engine Top End Disassembly

Tool List

Lists tools required for top end disassembly.

Remove Cylinder Head

Step-by-step guide to removing the cylinder head.

Remove Valve Mechanism

Procedures for removing valve components.

Specifications

Technical data and limits for top end components.

Engine Bottom End Disassembly

Tool List

Lists tools needed for bottom end disassembly.

Remove Crankcase Cover

Guide to removing the crankcase cover.

Remove Piston

Procedure for removing the piston from the cylinder.

Remove Crankshaft

Steps to remove the crankshaft from the crankcase.

Specifications

Technical data and limits for bottom end components.

Engine Measurements

Tool List

Lists tools for engine measurements.

Measure Cylinder Compression

Procedure to check engine cylinder compression.

Measure Cylinder Head Warp

Checking cylinder head for flatness.

Inspect Valve Seat

Inspecting the valve seat for proper condition.

Repair Valve Seat

Steps to repair valve seats using cutters.

Engine Bottom End Reassembly

Tool List

Lists tools required for bottom end reassembly.

Install Breather Valve

Steps for installing the breather valve.

Install Crankshaft

Procedure for installing the crankshaft.

Install Piston

Guide for installing the piston and connecting rod.

Install Crankcase Cover

Steps for installing the crankcase cover.

Engine Top End Reassembly

Tool List

Lists tools required for top end reassembly.

Install Valve Mechanism

Steps to install valve components.

Install Cylinder Head

Procedure for installing the cylinder head.

Illustrated Parts Breakdown

Cylinder/Crankcase

Illustrated parts for cylinder and crankcase.

Piston/Crankshaft

Illustrated parts for piston and crankshaft.

Lubrication

Illustrated parts for the lubrication system.

Cooling

Illustrated parts for the cooling system.

Limited Warranty

Federal Emission Component Defect Warranty

Details federal warranty for emission components.

California Emission Control Warranty Statement (1995-1999)

California emission warranty terms for 1995-1999.

California Emission Control Warranty Statement (2000)

California emission warranty terms for 2000.

California Emission Control Warranty Statement (2001)

California emission warranty terms for 2001.

California Emission Control Warranty Statement (2004)

California emission warranty terms for 2004.

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