Ezgo 295cc User manual

19
17
18
13
6
5
9
15
16
78
10
4
3
11
1-INCLUDESITEMS3 - 16
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.
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.
Engineexhaustfrom thisproduct containschemicalsknown, incertain 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 sec-
tion. 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

ENGINE DISASSEMBLY
Page A-ii Repair and Service Manual
Notes:

A
ENGINE DISASSEMBLY
Page A-1
Engine Shop Rebuild and Parts Manual
CYLINDER HEAD REMOVAL
Tool List Qty. Required
Extension, 3/8” drive, 4".............................................. 1
Mallet, medium wood or rubber .................................. 1
Puller, seal .................................................................. 1
Ratchet, 3/8” drive....................................................... 1
Screwdriver, small flat blade ....................................... 1
Screwdriver, medium flat blade................................... 1
Socket, 8 mm, 3/8” drive............................................. 1
Socket, 10 mm, 3/8” drive........................................... 1
Socket, 12 mm, 3/8” drive........................................... 1
Socket, 13/16” spark plug, 3/8” drive .......................... 1
Keep your work area clean and well organized
while performing the operations described in
this manual. This will help prevent accidents and reduce the
possibility of mistakes that could damage or impair the perfor-
mance of the engine.
Crankshaft and balancer shaft bearings should
be cleaned and inspected; and removed only if
they appear to be damaged or excessively worn. Remove bear-
ings that are pitted, nicked, burred, discolored or that rotate
roughly or noisily.
Because some mating parts with wear
surfaces were machined together when
the engine was manufactured, or have established wear patters
during operation, the reassembly of engine parts in their original
positions and orientations, with their original mating parts, is
critical to the performance and life expectancy of the engine.
Mark and sortall parts as they are disassembled so thatthey will
be reassembled and installed in their original positions.
Remove the Air Cleaner
A variety of air cleaner configurations exist. Refer to the
Technician’s Repair and Service Manual for removal/
installation instructions that are appropriate to the model
and year of your vehicle.
Remove the Carburetor
(See Fig. A-1 “Engine” on page A-4)
A. Remove the choke cable bracket plate (ITEM 12).
(DETAIL A)
B. Slide the carburetor (ITEM 11) off of its mounting
studs.
C. Remove the plastic carburetor insulator (ITEM 13).
Remove the Coil Mounting Bracket and Coil
(See Fig. A-1 “Engine” on page A-4)
A. Remove the spark plug wires (ITEM 1) from the
plugs.
B. Using a spark plug wrench, remove the spark plugs
(ITEM 2).
C. Using a 10mm socket, remove the nut (ITEM 3) and
the bolt (ITEM 4) attaching the coil bracket (ITEM 5)
to the engine.
Remove the Blower Housing
(See Fig. A-1 “Engine” on page A-4)
A. Using a 10mm socket, remove the three (3) remain-
ing bolts (ITEM 7) and remove the blower housing
(ITEM 6) from the engine.
Remove the Exhaust Manifold
(See Fig. A-1 “Engine” on page A-4)
(Later models have exhaust mainfold as part of the head)
A. Using a 12mm socket, remove the four (4) bolts
(ITEM 9) or nuts that attach the exhaust manifold
(ITEM 8) and gasket (ITEM 10) to the cylinder head.
Remove the Rear Cylinder Baffle
(See Fig. A-1 “Engine” on page A-4)
A. Using a 10mm socket, remove the four (4) bolts
(ITEM 12) that attach the baffle (ITEM 11) to the
engine. Lift the baffle from the engine.
Remove the Timing Belt Cover
(See Fig. A-1 “Engine” on page A-4)
A. Using a 10mm socket, remove the three (3) bolts
(ITEM 14) that attach the timing belt cover (ITEM 13)
to the engine.
Remove the Idler, Timing Belt, Drive and
Cam Pulleys
(See Fig. A-1 “Engine” on page A-4)
Do not twist, crimp or turn the belt
inside out. This will cause the belt to
fail.
A. Using a 12mm socket, loosen the idler and cam pul-
ley retaining bolts (ITEMS 15 AND 16).
B. Using a 10mm socket, loosen the drive pulley retain-
ing bolt (ITEM 17).
C. Remove the idler retaining bolt (ITEM 15), idler (ITEM
18), and idler spring (ITEM 19).

ENGINE DISASSEMBLY
Page A-2 Engine Shop Rebuild and Parts Manual
D. Remove the timing belt (ITEM 20). Do not twist the
belt or turn it inside out.
E. Remove the drive pulley retaining bolt (ITEM 17),
front belt retainer (ITEM 21), drive pulley (ITEM 22).
Rear belt retainer (ITEM 23) was present on early
production engines.
F. Remove the cam pulley retaining bolt (ITEM 16) and
the cam pulley (ITEM 24).
1. Remove the pulley alignment key. Using a non-fer-
rous (non-steel) punch, drive the back end of the
key down into the keyway, which will push the
front end up.
2. With the punch, gently drive the upraised key out
of the keyway.
Remove the Rear Timing Belt Cover
(See Fig. A-1 “Engine” on page A-4)
A. Using a 10mm socket, remove the two (2) bolts
(ITEM 26) that attach the rear timing belt cover (ITEM
25) to the engine.
Remove the Front Cylinder Baffle
(See Fig. A-1 “Engine” on page A-4)
A. Using a 10mm socket, remove the two (2) bolts
(ITEM 28) that attach the baffle (ITEM 27) to the
engine.
Remove the Valve Cover and Gasket
(See Fig. A-2 “Cylinder Head Components” on page A-5)
A. Using a 10mm socket, remove the six (6) bolts (ITEM
3) that attach the rocker cover (ITEM 1) to the cylin-
der head. Remove the rocker cover and gasket
(ITEM 2).
Remove the Rocker Assembly and Cam-
shaft
(See Fig. A-2 “Cylinder Head Components” on page A-5)
The rocker shafts in some early engines were
manufactured with a threaded hole in the end,
into which a blot is placed in order to pull the shaft from the cyl-
inder head.
Do not allow the camshaft lobes or
bearing surfaces to scrape against the
cylinder head. Because these parts have established wear pat-
terns during operation, mark and sort them as they are disas-
sembled so that they will be reassembled in their original
positions.
A. Remove the camshaft cover (ITEM 4).
1. Using a 10mm socket, remove the three (3) bolts
(ITEM 5) and one (1) stud (ITEM 6).
(Later models have four (4) bolts and no stud)
2. Using a rubber or wooden mallet, gently tap loose
the protruding edge of the camshaft cover and pull
it away from the engine.
B. Using a 10mm socket, loosen the four (4) rocker arm
nuts (ITEM 7).
C. With a medium flat blade screwdriver, turn the four (4)
rocker adjustment screws (ITEM 8) counterclockwise
until they no longer exert any force on the camshaft
(ITEM 9) and it can rotate freely.
D. Remove the rocker assembly.
1. Insert a small flat blade screwdriver into the
groove in the center of the rocker shaft (ITEM 10)
and push the shaft toward the fan side of the
engine. Tap lightly if required.
2. As the end of the rocker shaft slides out of the cyl-
inder head, remove the four (4) rocker arms (ITEM
11), two (2) spacers (ITEM 12), and one (1) spring
(ITEM 13) from the other end of the shaft. Mark or
sort parts as they are disassembled. Wear
parts must be reassembled in their original
positions.
E. Carefully pull the camshaft out through the fan side of
the cylinder head. Do not allow the wear surfaces of
the camshaft to scrape against the cylinder head, or
any part of the camshaft to scrape against the cylin-
der head bearing surfaces.
Remove the Cylinder Head and Gasket from
the Crankcase
(See Fig. A-2 “Cylinder Head Components” on page A-5)
Because this is an aluminum cylinder
head, it is important that the clamping
pressure of the mounting bolts be released evenly. Remove
them in the order shown in detail A (Ref Fig. A-2 on page A-5) by
loosening only 1/8 turn at a time.
A. Using a 12mm socket and extension, remove six (6)
cylinder head bolts (ITEM 16) in the sequence
shown. Remove the cylinder head (ITEM 14), gasket
(ITEM 15) and dowel pins (ITEM 19) from crankcase.

ENGINE DISASSEMBLY
Page A-3
Engine Shop Rebuild and Parts Manual
VALVE REMOVAL
Remove the Valves from the Cylinder Head
(See Fig. A-3 “Valves” on page A-6)
A. While supporting the valve (ITEM 1) from the bottom
to prevent its downward motion, push the valve
spring retainer (ITEM 2) down so that the valve stem
keys (ITEM 6) are released from the retainer. It may
be necessary to remove valve stem keys using a pair
of needle nose pliers. (DETAIL A)
B. Remove the spring retainer and spring (ITEM 3).
Then push the valve down and remove it from the
bottom of the cylinder head.
C. Repeat steps A and B to remove the remaining
valves.
D. Use a small flat blade screwdriver to GENTLY pry the
valve stem seals (ITEM 4) free. Remove them from
the valve guides. (DETAIL B)
Valve Guide Removal
A. If the valve guides (ITEM 5) are to be replaced, a
hydraulic press with an appropriate adaptor must be
used to remove them from cylinder head.

ENGINE DISASSEMBLY
Page A-4 Engine Shop Rebuild and Parts Manual
Fig. A-1 Engine
1
4
9
8
10
12
11
14
13
15
16
17
18
19
20
21
22
24 26
25
28
6
7
5
27
2
11 13
12
3
A
Newer Model
Newer Model
Newer Model

ENGINE DISASSEMBLY
Page A-5
Engine Shop Rebuild and Parts Manual
Fig. A-2 Cylinder Head Components
3
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
Crankcase
19
1
2
3
4
5
67
Follow numbers to remove cylinder head bolts in correct sequence
A
Groove

ENGINE DISASSEMBLY
Page A-6 Engine Shop Rebuild and Parts Manual
Fig. A-3 Valves
B
Pry valve stem seal loose
1
3
4
5
2
Push spring retainer down
to release valve keys
6
A

TABLE OF CONTENTS FOR SECTION ‘B’
SECTION TITLE PAGE NO.
Page B-i
Repair and Service Manual
B
ENGINE DISASSEMBLY
CRANKCASE DISASSEMBLY.........................................................................................................B - 1
Remove the Oil Filter.............................................................................................................B - 1
Remove the Fan Hub ............................................................................................................B - 1
Remove the Pulser Coil.........................................................................................................B - 1
Remove the Oil Pressure Switch...........................................................................................B - 1
Remove the Oil Pump ...........................................................................................................B - 1
Remove the Crankcase End Cover.......................................................................................B - 2
Remove the Balancer Shaft...................................................................................................B - 2
Remove the Pistons ..............................................................................................................B - 2
Remove the Crankshaft.........................................................................................................B - 2
Remove the Balancer Shaft Seal and the Crankshaft Seal...................................................B - 2
Inspect the Balancer Shaft Bearing and Crankshaft Bearing................................................B - 2
Remove the PCV Valve.........................................................................................................B - 3
Disassemble the Crankcase End Cover................................................................................B - 3
Remove the Piston From Connecting Rod............................................................................B - 3
Removal of Crankshaft Bearing.............................................................................................B - 3
LIST OF ILLUSTRATIONS
Fig. B-1 Engine Components..........................................................................................................B - 4
Fig. B-2 Engine Components con’t..................................................................................................B - 5
Fig. B-3 Crankshaft .........................................................................................................................B - 6
Fig. B-4 Balancer Shaft Bearing, Crankshaft Bearing and PCV Valve............................................B - 7
Fig. B-5 Crankcase End Cover and Crankshaft Bearing.................................................................B - 8
Fig. B-6 Piston.................................................................................................................................B - 9

ENGINE DISASSEMBLY
Page B-ii Repair and Service Manual
Notes:

B
ENGINE DISASSEMBLY
Page B-1
Engine Shop Rebuild and Parts Manual
CRANKCASE DISASSEMBLY
Tool List Qty. Required
Extension, 3/8” drive, 4".............................................. 1
Extension, 3/8” drive, 6".............................................. 1
Mallet, medium wood or rubber .................................. 1
Puller, (E-Z-GO P/N 27111-G01)................................. 1
Puller, seal .................................................................. 1
Punch, non-ferrous ..................................................... 1
Ratchet, 3/8” drive....................................................... 1
Screwdriver, small flat blade ....................................... 1
Screwdriver, medium flat blade................................... 1
Screwdriver, #2 phillips ............................................... 1
Screwdriver, #3 phillips ............................................... 1
Socket, 8 mm, 3/8” drive............................................. 1
Socket, 10 mm, 3/8” drive........................................... 1
Socket, 12 mm, 3/8” drive........................................... 1
Socket, Impact, 26 mm, 1/2” impact drive.................. 1
Socket, oil pressure switch ......................................... 1
Wrench, 7 mm combination ........................................ 1
Wrench, 10 mm combination ...................................... 1
Wrench 12 mm combination ....................................... 1
Remove the Oil Filter
(See Fig. B-1 “Engine Components” on page B-4)
A. Using a 10mm socket, remove the three (3) bolts
(ITEM 2) securing oil filter (ITEM 1) to the crankcase.
B. With a twisting motion, slowly pull the filter from the
crankcase and drain oil.
C. Remove the O-ring (ITEM 3).
D. Inspect filter for debris that could indicate an exces-
sive wear problem or contamination.
Remove the Fan Hub
(See Fig. B-1 “Engine Components” on page B-4)
(See Fig. B-2 “Engine Components con’t” on page B-5)
Do not exert pressure against the
crankshaft or fan.
A. Using and impact wrench and 30 mm (Later models
26MM) impact socket, remove the fan hub nut (ITEM
5)
B. Using and E-Z-GO Fan Hub Puller, remove the fan
hub (ITEM 4). (Later models do not require a
puller) Some models of puller have a sharp point that
could damage the crankshaft oil passage plug.
Modify per Fig. B-2, detail A.
1. Inspect puller. The end of the threaded portion
should not be pointed. Grind off 1/8” to provide a
taper. If desired, a nut may be used as a spacer
between the puller and crankshaft. Lubricate the
tip and threads of the puller shaft (ITEM 6) and
place it in the indention in the end of the crank-
shaft. (DETAIL A)
2. Install the three (3) puller bolts (ITEM 7) through
the puller collar (ITEM 8) and into the threaded
holes in the fan hub. Tighten the puller bolts until
each is snug against the puller collar, and the col-
lar face is at 90°to the crankshaft axis. This will
insure that the hub is pulled straight and does not
bind. (DETAIL A)
3. Insert a large screwdriver under the puller collar
and between two of the puller bolts as shown.
Insert another large screwdriver through the hole
in the top of the puller shaft. (DETAIL B)
4. Hold the first screwdriver against the two puller
bolts while turning the second screwdriver clock-
wise until the fan hub breaks free from the crank-
shaft. Do not exert pressure against the
crankshaft or fan blades.
5. Remove the fan hub and puller from the crank-
shaft.
6. Remove the puller from the fan hub.
Remove the Pulser Coil
(See Fig. B-1 “Engine Components” on page B-4)
A. Using an 8mm socket, remove two (2) bolts (ITEM
10) and the pulser coil (ITEM 9).
Remove the Oil Pressure Switch
(See Fig. B-1 “Engine Components” on page B-4)
(Later models may or may not have an oil pressure
switch)
A. Use a 7mm socket to remove the bolt (ITEM 12) and
the wire (ITEM 13).
B. Use an automotive oil pressure switch socket to
remove the switch (ITEM 11)
Remove the Oil Pump
(See Fig. B-1 “Engine Components” on page B-4)
A. Using a 10mm socket, remove three (3) bolts (ITEM
14) and the oil pump cover (ITEM 15).
B. Remove the oil pump O-ring (ITEM 16).
C. Carefully remove the oil pump rotors (ITEMS 17 and
18).