ENGINE SHOP REBUILD & SERVICE PARTS MANUAL - Jacobsen

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NOTES 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 modifications or tampering with the engine, fuel, ignition or air intake systems. Page ii Transaxle 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 Engine Shop Rebuild and Parts Manual Page iii
Page 1: 19 13 17 9 11 16 15 7 18 3 4 6 5 8
Page 6 and 7: TABLE OF CONTENTS Section Page No.
Page 8 and 9: TABLE OF CONTENTS Notes: Page vi En
Page 10 and 11: HOW TO USE THIS MANUAL viii Engine
Page 12 and 13: ENGINE DISASSEMBLY Notes: Page A-ii
Page 14 and 15: ENGINE DISASSEMBLY D. Remove the ti
Page 16 and 17: 14 13 18 15 16 17 20 21 19 22 25 27
Page 18 and 19: ENGINE DISASSEMBLY A 2 6 3 Push spr
Page 20 and 21: ENGINE DISASSEMBLY Notes: Page B-ii
Page 22 and 23: ENGINE DISASSEMBLY Remove the Crank
Page 24 and 25: ENGINE DISASSEMBLY 1 3 2 Crankcase
Page 26 and 27: ENGINE DISASSEMBLY 1 5 4 6 3 2 A Se
Page 28 and 29: ENGINE DISASSEMBLY A 1 2 4 5 6 8 3
Page 30 and 31: ENGINE DISASSEMBLY Notes: Page B-10
Page 32 and 33: ENGINE MEASUREMENTS Notes: Page C-i
Page 34 and 35: ENGINE MEASUREMENTS F. Turn the cyl
Page 36 and 37: ENGINE MEASUREMENTS Measure each po
Page 38 and 39: 0 ENGINE MEASUREMENTS C 10 20 30 40
Page 40 and 41: ENGINE MEASUREMENTS Cylinder head C
Page 42 and 43: 0 50 0 50 ENGINE MEASUREMENTS Valve
Page 44 and 45: ENGINE MEASUREMENTS 1" Recommended
Page 46 and 47: ENGINE MEASUREMENTS Notes: Page C-1
Page 48 and 49: ENGINE REASSEMBLY Notes: Page D-ii
Page 50 and 51: ENGINE REASSEMBLY A. Apply a coat o
Page 52 and 53: ENGINE REASSEMBLY C. Using a depth
Page 54 and 55:
ENGINE REASSEMBLY An electric drill
Page 56 and 57:
ENGINE REASSEMBLY C 120 o Compressi
Page 58 and 59:
ENGINE REASSEMBLY 14 12 8 2 13 4 7
Page 60 and 61:
ENGINE REASSEMBLY Make sure the gea
Page 62 and 63:
ENGINE REASSEMBLY A Follow numbers
Page 64 and 65:
ENGINE REASSEMBLY Notes: Page D-16
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ENGINE REASSEMBLY Notes: Page E-ii
Page 68 and 69:
ENGINE REASSEMBLY Install New Valve
Page 70 and 71:
ENGINE REASSEMBLY Install the Front
Page 72 and 73:
ENGINE REASSEMBLY A 8 7 6 1 3 2 5 B
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ENGINE REASSEMBLY 7 17 10 12 9 8 13
Page 76 and 77:
ENGINE REASSEMBLY 29 31 27 28 25 23
Page 78 and 79:
ENGINE REASSEMBLY B 3 2 1 4 Follow
Page 80 and 81:
ENGINE REASSEMBLY 7 6 1 4 3 2 5 Fig
Page 82 and 83:
ENGINE Illustrated Parts Breakdown
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Page 94 and 95:
Page 96 and 97:
LIMITED WARRANTY Notes: Page G-ii E
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LIMITED WARRANTY - FEDERAL deny war
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LIMITED WARRANTY - FEDERAL (2001) Y
Page 102 and 103:
LIMITED WARRANTY - CALIFORNIA (1995
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