1992-2004 EZGO 295CC 350CC 4 Cycle Engine Service & Repair Manual

295cc and 350cc 4 CYCLE ENGINE STARTING MODEL YEAR: 1992 ENGINE SHOP REBUILD & SERVICE PARTS MANUAL 27615-G01 REVISED: 08/04

Page i Engine Shop Rebuild and Parts Manual ENGINE SHOP REBUILD & SERVICE PARTS MANUAL 295cc and 350cc ENGINE E-Z-GO Division of Textron, Inc. reserves the right to make design changes without obligation to make these changes on units previously sold and the informa- tion contained in this manual is subject to change without notice. E-Z-GO Division of Textron, Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. CUSTOMER SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855 FAX: 1-800-448-8124 OUTSIDE USA PHONE: 010-1-706-798-4311, FAX: 010-1-706-771-4609 E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA 30906

Page ii NOTES Transaxle Shop Rebuild and Parts Manual TO OBTAIN A COPY OF THE LIMITED WARRANTY THAT IS APPLICABLE TO THE VEHICLE, CALL OR WRITE THE LOCAL DISTRUBUTOR, E-Z-G0 BRANCH OR E-Z-G0 WARRANTY DEPARTMENT WITH VEHICLE SERIAL NUMBER AND MANUFACTURER’S CODE. THE USE OF NON E-Z-GO PARTS AND HARDWARE MAY VOID THE WARRANTY. TAMPERING WITH OR ADJUSTING GOVERNOR TO PERMIT VECLE TO OPERATE AT ABOVE FACTORY SETTINGS WILL VOID THE VEHICLE WARRANTY. IF APPLICABLE, REFER TO BACK COVER FOR CALIFORNIA AND/OR FEDERAL EMISSIONS CONTROL WARRANTY STATEMENT. Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm. The exhaust emissions of this vehicle’s engine complies with regulations set forth by the Environmental Protection Agency (EPA) of the United States of America (USA) at time of manufacture. Significant fines could result from mod- ifications or tampering with the engine, fuel, ignition or air intake systems. ! !

Page iii Engine Shop Rebuild and Parts Manual TABLE OF CONTENTS Section Page No. How to use the E-Z-GO Service Manual .............. ............................................. .......................................... vii Federal and California Emissions Warranty Statements .................................... .................................... Section G ENGINE DISASSEMBLY A CYLINDER HEAD REMOVAL • Air Cleaner ........................................... ............................................. ......................................... A-1 • Carburetor ............................................ ............................................. ......................................... A-1 • Coil and Bracket .................................. ............................................. ......................................... A-1 • Blower Housing.................................... ............................................. ......................................... A-1 • Exhaust Manifold ................................. ............................................. ......................................... A-1 • Rear Cylinder Baffle ............................. ............................................. ......................................... A-1 • Front Timing Belt Cover ....................... ............................................. ......................................... A-1 • Idler, Timing Belt and Cam Gear.......... ............................................. ......................................... A-1 • Rear Timing Belt Cover........................ ............................................. ......................................... A-2 • Front Cylinder Baffle ............................ ............................................. ......................................... A-2 • Rocker Cover and Gasket ................... ............................................. ......................................... A-2 • Rocker Assembly and Cam Shaft ........ ............................................. ......................................... A-2 • Cylinder Head and Gasket ................... ............................................. ......................................... A-2 • Valves .................................................. ............................................. ......................................... A-3 • Valve Guides ........................................ ............................................. ......................................... A-3 ENGINE DISASSEMBLY B CRANKCASE DISASSEMBLY • Oil Filter ............................................... ............................................. ......................................... B-1 • Fan Hub ............................................... ............................................. ......................................... B-1 • Pulser Coil ........................................... ............................................. ......................................... B-1 • Oil Pressure Switch ............................. ............................................. ......................................... B-1 • Oil Pump .............................................. ............................................. ......................................... B-1 • Crankcase End Cover .......................... ............................................. ......................................... B-2 • End Cover Gasket and Oil Feed O-Ring ........................................... ......................................... B-2 • Balancer Shaft ..................................... ............................................. ......................................... B-2 • Pistons ................................................. ............................................. ......................................... B-2 • Crankshaft............................................ ............................................. ......................................... B-2 • Balancer and Crankshaft Seals ........... ............................................. ......................................... B-2 • Balancer Shaft and Crankcase Bearings ........................................... ......................................... B-2 • PCV Valve ............................................ ............................................. ......................................... B-3 • Crankcase End Cover .......................... ............................................. ......................................... B-3 • Piston and Connecting Rod ................. ............................................. ......................................... B-3 • Crankshaft Bearing .............................. ............................................. ......................................... B-3

Page iv TABLE OF CONTENTS Engine Shop Rebuild and Parts Manual Section Page No. ENGINE MEASUREMENTS AND SPECIFICATIONS C ENGINE MEASUREMENTS AND SPECIFICATIONS • Check Flatness of Crankcase, End Cover and Cylinder Head .......... ......................................... C-1 • Crankcase Cylinder Bores ................... ............................................. ......................................... C-2 • Crankcase and End Cover Crankshaft Bearing Bores ...................... ......................................... C-2 • Crankshaft Journals and Gear ............. ............................................. ......................................... C-2 • Crankcase and End Cover Balancer Shaft Bearing Bores ................ ......................................... C-2 • Balancer Shaft Journals and Gear....... ............................................. ......................................... C-2 • Piston ................................................... ............................................. ......................................... C-2 • Wrist Pin .............................................. ............................................. ......................................... C-3 • Connecting Rod ................................... ............................................. ......................................... C-3 • Cylinder Head Cam and Rocker Shaft Bores .................................... ......................................... C-3 • Valves Guides and Seats..................... ............................................. ......................................... C-3 • Valves and Valve Springs .................... ............................................. ......................................... C-3 • Camshaft ............................................. ............................................. ......................................... C-3 • Rocker Shaft and Rocker Arms ........... ............................................. ......................................... C-3 • Piston Ring Gap................................... ............................................. ......................................... C-3 • Torque Specifications ........................... ............................................. ......................................... C-3 ENGINE REASSEMBLY D CRANKCASE ASSEMBLY • Honing the Cylinder Bores ................... ............................................. ......................................... D-1 • Pistons and Connecting Rods ............. ............................................. ......................................... D-1 • Piston Rings......................................... ............................................. ......................................... D-2 • Crankcase End Cover.......................... ............................................. ......................................... D-2 • Crankcase Bearings ............................ ............................................. ......................................... D-2 • Crankshaft Bearing .............................. ............................................. ......................................... D-3 • Crankshaft and Balancer Shaft Seals .. ............................................. ......................................... D-3 • Crankshaft ........................................... ............................................. ......................................... D-3 • Pistons ................................................. ............................................. ......................................... D-3 • Balancer Shaft ..................................... ............................................. ......................................... D-3 • Checking Crankshaft and Balancer Shaft Endplay ............................ ......................................... D-4 • End-Play Spacers ................................ ............................................. ......................................... D-4 • Oil Feed O-Ring ................................... ............................................. ......................................... D-4 • Crankcase End Cover Gasket ............. ............................................. ......................................... D-4 • Crankcase End Cover.......................... ............................................. ......................................... D-4 • Oil Pump Gear Rotors ......................... ............................................. ......................................... D-5

Page v TABLE OF CONTENTS Engine Shop Rebuild and Parts Manual Section Page No. • Oil Pressure Switch ............................. ............................................. ......................................... D-4 • Pulser Coil ........................................... ............................................. ......................................... D-4 • Fan Hub ............................................... ............................................. ......................................... D-4 • Pulser Coil and Air Gap ....................... ............................................. ......................................... D-5 • PCV Valve ............................................ ............................................. ......................................... D-5 • Oil Filter ............................................... ............................................. ......................................... D-5 ENGINE REASSEMBLY E CYLINDER HEAD ASSEMBLY • Valve Guides ........................................ ............................................. ......................................... E-1 • Cutting the Valve Seats........................ ............................................. ......................................... E-1 • Lapping the Valves............................... ............................................. ......................................... E-1 • Valve Stem Seals ................................. ............................................. ......................................... E-2 • Valves .................................................. ............................................. ......................................... E-2 • Cylinder Head ...................................... ............................................. ......................................... E-2 • Camshaft.............................................. ............................................. ......................................... E-2 • Rocker Assembly ................................. ............................................. ......................................... E-2 • Rear Timing Belt Cover........................ ............................................. ......................................... E-3 • Drive and Cam Pulleys, Idler and Timing Belt ................................... ......................................... E-3 • Front Timing Belt Cover ....................... ............................................. ......................................... E-4 • Front Cylinder Baffle ............................ ............................................. ......................................... E-4 • Rear Cylinder Baffle ............................. ............................................. ......................................... E-4 • Exhaust Manifold and Gasket .............. ............................................. ......................................... E-4 • Blower Housing.................................... ............................................. ......................................... E-4 • Coil and Mounting Bracket ................... ............................................. ......................................... E-4 • Valve Adjustment ................................. ............................................. ......................................... E-4 • Spark Plugs .......................................... ............................................. ......................................... E-4 • Rocker Cover ....................................... ............................................. ......................................... E-5 • Carburetor ............................................ ............................................. ......................................... E-5 ILLUSTRATED PARTS BREAKDOWN F ILLUSTRATED PARTS BREAKDOWN • Engine Illustrations .............................. ............................................. ......................................... F-1 • Engine Parts List .................................. ............................................. ......................................... F-6 SERVICE TOOLS • CYLINDER HEAD REMOVAL ............. ............................................. ......................................... A-1 • CRANKCASE DISASSEMBLY ............ ............................................. ......................................... B-1 • ENGINE MEASUREMENTS AND SPECIFICATIONS ...................... ......................................... C-1 • CRANKCASE ASSEMBLY .................. ............................................. ......................................... D-1 • CYLINDER HEAD ASSEMBLY............ ............................................. ......................................... E-1

Page vi TABLE OF CONTENTS Engine Shop Rebuild and Parts Manual Notes:

vii HOW TO USE THIS MANUAL Engine Shop Rebuild and Parts Manual This manual is designed to suit the needs of mechanics at all levels of experience with the E-Z-GO 4-cycle engine. The outline format will allow the mechanic to choose the level of instructional detail needed to completely disassemble, diag- nose, repair/overhaul and reassemble the engine. The manual is divided into four major operational sections, which are each divided into smaller operational sections. At the beginning of each major section is a list of tools that will be required to perform the operations desired in that section. Do not use non-specified tools (vise grips®, hammers, adjustable wrenches etc.). The use of these tools could cause permanent damage to the engine components. WE STRONGLY RECOMMEND that no matter what your experience level, you use this manual as a guide when disas- sembling, repairing/overhauling and reassembling the engine. Before working on the engine, read and understand the text and in particular each NOTE, CAUTION and WARNING. Some illustrations may show components that differ from your engine. This is the result of ongoing improvements to the engine design.

viii HOW TO USE THIS MANUAL Engine Shop Rebuild and Parts Manual

TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. Page A-i Repair and Service Manual A ENGINE DISASSEMBLY CYLINDER HEAD REMOVAL..........................................................................................................A - 1 Remove the Air Cleaner ........................................................................................................A - 1 Remove the Carburetor .........................................................................................................A - 1 Remove the Coil Mounting Bracket and Coil .........................................................................A - 1 Remove the Blower Housing .................................................................................................A - 1 Remove the Exhaust Manifold...............................................................................................A - 1 Remove the Rear Cylinder Baffle ..........................................................................................A - 1 Remove the Timing Belt Cover..............................................................................................A - 1 Remove the Idler, Timing Belt, Drive and Cam Pulleys.........................................................A - 1 Remove the Rear Timing Belt Cover .....................................................................................A - 2 Remove the Front Cylinder Baffle .........................................................................................A - 2 Remove the Valve Cover and Gasket ...................................................................................A - 2 Remove the Rocker Assembly and Camshaft .......................................................................A - 2 Remove the Cylinder Head and Gasket from the Crankcase................................................A - 2 VALVE REMOVAL ...........................................................................................................................A - 3 Remove the Valves from the Cylinder Head .........................................................................A - 3 Valve Guide Removal ............................................................................................................A - 3 LIST OF ILLUSTRATIONS Fig. A-1 Engine................................................................................................................................A - 4 Fig. A-2 Cylinder Head Components...............................................................................................A - 5 Fig. A-3 Valves ................................................................................................................................A - 6

1992-2004 EZGO 295CC 350CC 4 Cycle Engine Service & Repair Manual

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