<strong>ENGINE</strong> REASSEMBLY Notes: Page E-ii Engine Shop Rebuild and Parts Manual
<strong>ENGINE</strong> REASSEMBLY CYLINDER HEAD ASSEMBLY Tool List Qty. Required Compressor, piston ring .............................................. 1 Drill, electric ................................................................ 1 Gauge, feeler (E-Z-GO P/N 72525-G01) ........................................... 1 Gauge, wire spark plug ............................................... 1 Valve seat cutter (E-Z-GO P/N 72516-G01) ........................................... 1 Installer, piston ring (E-Z-GO P/N 72521-G01) ........................................... 1 Grinder, valve, cup type (E-Z-GO P/N 72522-G01) ........................................... 1 Compound, 4 oz. valve grinding (E-Z-GO P/N 72523-G01) ........................................ AR Extension, 3/8” drive, 4" .............................................. 1 Extension, 3/8” drive, 6" .............................................. 1 Mallet, Medium wood or rubber .................................. 1 Cam pulley alignment tool (E-Z-GO P/N 26850-G01) ........................................... 1 Punch, nonferrous....................................................... 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, oil pressure switch ......................................... 1 Socket, 13/16” spark plug, 3/8” drive .......................... 1 Wrench, 7 mm combination ........................................ 1 Wrench, 10 mm combination ...................................... 1 Wrench 12 mm combination ....................................... 1 Wrench, torque, Inch and Ft. Lbs............................... 1 Install Valve Guides (See Fig. E-1 “Valves and Valve Clearance” on page D-6) E A. If the valve guides (ITEM 1) were removed from the cylinder head (ITEM 2), use a mechanical press to install new over size valves guides. [If valve guides are replaced, valve seats must be resurfaced. (See Valve Guides and Seats in section C]). (DETAIL A) Cutting Valve Seats A. Using the E-Z-GO valve seat cutter, insert the reamer pilot tool in the valve guide and rotate in a clockwise direction only using firm consistent pressure. B. Remove no more material than is necessary to clean the valve seat. C. Refer to additional instructions included with cutter. Lap the Valves (See Fig. E-1 “Valves and Valve Clearance” on page D-6) (See Fig. E-2 “Valves con’t” on page D-7) A. Turn the cylinder head upside down. B. Lightly lubricate the stem of one of the intake valves (ITEM 4) with engine oil and insert it into one of the middle (intake) valve guides. The heads of the intake valves are larger in diameter than the heads of the exhaust valves (ITEM 5). (If the original valves are used, place them in the guides from which they came.) C. Moisten the suction cup on the valve lapping tool and attach it to the valve. D. Apply a small amount of valve grinding compound evenly around the valve seat. E. Grind the valve face against the seat by applying slight downward pressure on the lapping tool and rotating it back and forth between the palms of your hands five or six times. Lift the tool, turn it about 90° and repeat until both the valve and seat show even polished contact surfaces of. 040 to .050 wide. F. Repeat this process for each of the valves. G. Thoroughly clean the valves and the cylinder head to remove all of the lapping compound. H. Test the valve seat seal by installing the springs and keys. Stand the cylinder head on the exhaust port and pour a few ounces of clean solvent into the intake ports. Check the valve seats for any sign of wetness. If solvent seeps out, repeat the lapping process and retest. Pour out solvent, turn over, and repeat for the exhaust valves. Engine Shop Rebuild and Parts Manual Page E-1