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E-Z-GO Engine User Manual
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ILLUSTRA
TED P
AR
TS BREAKDOWN
Page F-1
1
Kawasaki Engine Shop Rebuild Manual
COOLING
Item
Description
E-Z-GO Part Number
Quantity
GOLF
UTILITY
59
SHRO
UD
, ENGINE
603563
1
60
GU
ARD
603564
1
1
61
F
AN
603566
1
1
62
HOUSI
NG, F
AN
60356
7
1
1
63
RIVET
, GU
ARD
603569
1
1
64
BOL
T
603560
5
5
72
74
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
Federal Emissions Component Defect Warranty
83
California Emission Control Warranty Statement (1995-1999
87
California Emission Control Warranty Statement(1995-1999
87
Your Warranty Rights and Obligations
87
California Emission Control Warranty Statement (2000
90
Your Warranty Rights and Obligations
90
California Emission Control Warranty Statement (2001
93
Your Warranty Rights and Obligations
93
California Emission Control Warranty Statement (2004
96
LIMITED WARRANTY on Emission Control Systems - California Only
96
Your Warranty Rights and Obligations
96
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E-Z-GO Engine Specifications
General
Brand
E-Z-GO
Model
Engine
Category
Engine
Language
English
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