Home

engine shop rebuild & service parts manual 27615-g01

1. Page C 14 Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY TABLE OF CONTENTS FOR SECTION D SECTION TITLE PAGE NO CRANKCASE ASSEMBBLY esses enee emen enne D 1 Hone the Crankcase Cylinder Bore sse nnne D 1 Reassemble the Pistons and Connecting 0 5 D 1 Installthe Piston Rings oet rre tle erento deed eon P nne D 2 Reassemble the Crankcase End Cover sss rennen D 2 Install New Crankcase Bearing Install New Crankshaft Bearing Install New Crankshaft Seal nnne Install Crankshaft into Crankcase Install the Pistons in the Crankcase Install the Balancer m Set the Crankshaft and Balancer Shaft Endplay sse Install Crankshaft Endplay Spacer and Balancer Endplay Install Alignment Dowel Pins Install New Oil Feed O Ring Install Crankcase End Cover Gasket is Install the Crankcase End Install the Oil Pump Gear Rotors ssssseseeeeeneeeeeneeenren ennemi Install the Oil Pressure Switch a Install the Pulser Coll
2. Page D ii Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY CRANKCASE ASSEMBLY Tool List Qty Required Compressor piston ring 1 DrillzelecttiQus ret Peru ree EE 1 Gauge feeler E Z GO P N 72525 901 1 Gauge wire spark plug 1 Flex Hone ball 240 grit 2 1 2 cylinder E Z GO P N 72517 901 1 Installer piston ring E Z GO P N 72521 G01 sse 1 Engine assembly lube 8 oz E Z GO P N 72515 G01 AR Brush cylinder cleaning 2 1 2 E Z GO P N 72519 901 1 Oil cylinder honing E Z GO P N 72518 901 1 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 27851 901 1 PUNCH nonsferroUus x i tie tert race RR 1 Ratchet 3 8 1 Screwdriver small flat blade 1 Screwdriver mediu
3. 1 Screwdriver medium flat 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 NOTE 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 NOTE Crankshaft and balancer 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 CAUTION 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 sort all parts as they are disassembled so that they 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
4. Cylinder Head Cam and Rocker Shaft Valve Guides and Seats Valves and Valve Springs enn TIME Rocker Shaft and Rocker Arms Piston Ring Gap aote respete paene in eee tena ete au Torque Specifications Wet LIST OF ILLUSTRATIONS C 1 Using Telescoping and Hole Gauges C 2 Flatness of Mating Surfaces Crankcase Cylinder C 4 Crankshaft Journals and Gear and Bearing Bores C 5 Piston Wrist Pin and Connecting Rod caeococococoocoao C 8 Valve Guides and Seats C 11 Piston Ring Gap Engine Shop Rebuild and Parts Manual C 6 Balancer Shaft Journals Gear and Bearing C 7 Cylinder Head Cam and Camshaft esses C 9 Valve and Valve Springs C 10 Rocker Shaft Arms and Bearing C 12 Torque Specifications PAGE NO Page C i ENGINE MEASUREMENTS Notes Page C ii Engine Shop Rebuild and Parts Manual ENGINE MEASUREMENTS ENGINE
5. AR Extension 3 8 drive 4 Extension 3 8 drive 6 Mallet Medium wood or rubber Cam pulley alignment tool E Z GO P N 26850 G01 PUNCH nonf rrous ii tar i ec rectore Ratchet 3 8 Screwdriver small flat blade Screwdriver medium flat Screwdriver 2 phillips seeseesssss Screwdriver 3 phillips sesessessss Socket 8 mm 3 8 drive Socket 10 mm 3 8 drive Socket 12 mm 3 8 drive Socket oil pressure switch Socket 13 16 spark plug 3 8 drive Wrench 7 mm combination Wrench 10 mm combination Wrench 12 mm combination Wrench torque Inch and Ft Lbs Qty Required Install Valve Guides See Fig E 1 Valves and Valve Clearance on page D 6 A If the valve guides ITEM 1 were removed from the cy
6. induce t ce euer a ue Prid n iv eet eee A E 5 A T M 5 ILLUSTRATED PARTS BREAKDOWN F ILLUSTRATED PARTS BREAKDOWN Engine lll strations 2 iine cemeterio cente tiere tite F 1 Engine Parts Elst i eise rte Dee EIDEM PSI F 6 SERVICE TOOLS OYLINDER HEAD REMOVAL EROR EPIRI Hoa Rx A 1 GRANKGASE DISASSEMBLY etd Do dE eed edere ee oou uada B 1 ENGINE MEASUREMENTS AND SPECIFICATIONS seen C 1 CRANKCASE ASSEMBLY D 1 CYLINDER HEAD ASSEMBLY ente dte eite hid nier E 1 Engine Shop Rebuild and Parts Manual Page v TABLE OF CONTENTS Notes Page vi Engine Shop Rebuild and Parts Manual HOW TO USE THIS 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 t
7. terree tree e Pres Nicer re era cese set entera Installthe Fan Elub 2 oio db P Pd o S dee e ete dede bcr Set the Pulser Coil Air Gap ec secessccsesseesseessescseeesseesecescscesseeeseeccecessnsssaeseseessneessnesseess lristall thie PVG 2 cete tere ener ette ree e E deo cese Install the Oil Filter eerie e exert lev i ne edes cene emer ep nta ce enn Dao roc 3 3 RR LIST OF ILLUSTRATIONS D 1 i Crankcase Cylinder uu oerte deer erdt era eue X te eemper des gens D 2 Piston and Connecting Rods nennen nennen D 3 Pistons and Connecting Rods con t sessssssssssssesseeeneeeneeeneen nennen D 4 Crankcase End Cover PCV Valve and Oil Filter D 5 Crankshaft Pistons and Balancer Shaft D 6 Crankshaft Pistons and Balancer Shaft con t D 7 Crankshaft and Balancer Shaft D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub D 9 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub con t D 10 Pulser Coil Air Gap ere ottenere inet trice Ente ore deer ded dede cocooocoocoao Tp Tp TID Engine Shop Rebuild and Parts Manual Page D i ENGINE REASSEMBLY Notes
8. 2 exceeds C by 0 004 1mm rebore the cylinder 295cc 350cc 2 519 2 520 STD 2 6378 2 6385 STD 64 000mm 64 019mm 67 000mm 67 019mm Oylinder bore dimension is determined by size of the piston to be used If over size piston is used C represents specified bore for that piston Relative dimension for A remains valid telescoping gauge 25mm and 50mm oversize pistons are available Cutaway view of crankcase at cylinder bores Fig C 3 Crankcase Cylinder Bores Engine Shop Rebuild and Parts Manual Page C 4 ENGINE MEASUREMENTS Measure each bore in 2 places 90 apart Crankcase and Endcover 0 Cutaway view of crankcase and endcover through crankshaft bearing bores Recommended press Ball bearings onto Ball bearings into fits crankshaft crankcase in 0 00024 0 00067 0 00067 0 0024 Measure each position mm 0 006 0 017 0 017 0 060 in 2 places 90 apart SPECS A B C STD in 2 4386 2 4398 2 8347 2 8359 2 8322 2 8334 mm 61 940 61 970 72 002 72 032 71 938 71 968 2 4405 2 8340 LIMIT mm 61 99 71 985 SPECS ABCD G F STD in 1 3767 1 3774 1 3774 1 3778 1 3782 1 3786 mm 34 968 34 985 34 9
9. rnnt err entrer ree rr ne t e i rele n YR arn E 2 Install the Rocker Assembly eese nennen enne nnne nennen nene E 2 Install the Rear Timing Belt Cover nennen nennen E 3 Install the Drive and Cam Pulleys Idler and Timing E 3 Install the Front Timing Belt Cover esssseesseeseeeeeneneenee nnne enne E 4 Install the Front Cylinder Baffle E 4 Install the Rear Cylinder E 4 Install the Exhaust Manifold and Gasket sese E 4 Install The Blower Housirig etn rtt nente entente racine o E 4 Install the Coil Mounting Bracket and Coil Assembly E 4 Adjust the Valves ccscsssssscessseessneneneseceeceonesseessseceoneeseesssnscsseseneessecescesssesesessseeseneeseneseeees Install the Spark Plugs Install the Rocker Cover rhet tren treten rrr Prnt Pri arena rn ront E 5 11 2 ete ettet tenore etes epo dei eite deg E 5 LIST OF ILLUSTRATIONS Fig E 1 Valves and Valve Clearance esee nnne nnne nnn nnne nennen nennen E 6 Fig E 2 Valves CON tio eni oer oe derer fe Ed eee dr err rp EE ei pene Fra rein E 7 Fig E 3 Cylinder Head Cam Shaft and Rocker Assembly sse
10. 26663 G01 PISTON RING SET 50MM OVERSIZE 295 cc ENGINE ONLY 26609 G01 PIN PISTON 26610 G01 CLIP PISTON PIN 72861 G01 GASKET BEARING COVER 1 PIECE MAN EXH 72553 G01 GASKET BEARING COVER 26611 G01 BALANCER SHAFT 26689 G01 SPACER BLANCER SHAFT 1MM 26690 G01 SPACER BALANCER SHAFT 1 2MM 26688 G01 SPACER BALANCER SHAFT 8MM 601550 CRANKSHAFT INCLUDES ITEM 74 350cc ONLY 1 PIECE MAN EXH 26693 G01 WOODRUFF KEY BALANCER SHAFT 72503 G01 CRANKSHAFT INCLUDES ITEM 74 350 cc ENGINE ONLY 26605 G01 CRANKSHAFT INCLUDES ITEM 74 295 cc ENGINE ONLY 26739 G01 BEARING BALL 26692 G01 WOODRUFF KEY CRANKSHAFT 601551 CRANKSHAFT INCLUDES ITEM 74 295cc ONLY 1 PIECE MAN EXH 26684 G01 SPACER CRANKSHAFT 6MM 26685 G01 SPACER CRANKSHAFT 8MM 26686 G01 SPACER CRANKSHAFT 1MM 26687 G01 SPACER CRANKSHAFT 1 2MM 72886 G01 CRANKCASE END COVER ASSEMBLY INCLUDES ITEMS 84 86 295cc ONLY 1 PIECE MAN EXH 72858 G01 CRANKCASE END COVER ASSEMBLY INCLUDES ITEMS 84 86 350cc ONLY 1 PIECE MAN EXH INCLUDES ITEMS 84 86 72513 G01 CRANKCASE END COVER ASSEMBLY S N 1074503 AND LATER WITHOUT DIPSTICK OPENING INCLUDES ITEMS 84 86 26738 G01 BEARING BALL 26739 G01 BEARING BALL 26742 G01 OIL SEAL Page F 8 Engine Shop Rebuild and Parts Manual Illustrated Parts Breakdown ENGINE When ordering parts please specify the model and serial number of the product Indicates a component that is not availab
11. A Textron Company ENGINE SHOP REBUILD amp SERVICE PARTS MANUAL 295cc and 350cc 4 CYCLE ENGINE STARTING MODEL YEAR 1992 REVISED 08 04 ENGINE SHOP REBUILD amp 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 Engine Shop Rebuild and Parts Manual Page i NOTES TO OBTAIN A COPY OF THE LIMITED WARRANTY THAT IS APPLICABLE TO THE VEHICLE CALL OR WRITE THE LOCAL DISTRUBUTOR E Z GO 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 kno
12. A Remove the cap ITEM 9 from the PTO clutch side connecting rod ITEM 10 Apply a coat of assembly lube to the rod and cap bearing surfaces and lightly oil the sides of the piston rings ITEM 8 and cylin der bore KEEP LUBRICANT OFF OF THE MATING SURFACES OF THE ROD AND ROD B Make sure that the piston ring gaps are correctly positioned on the piston DETAIL C Engine Shop Rebuild and Parts Manual C Install a piston ring compressor on the piston leaving enough of the piston skirt protruding below the com pressor to start into the cylinder DETAIL B D With the word FAN on the connecting rod oriented toward the open side of the crankcase and the crankshaft at bottom dead center insert the piston into the PTO clutch side cylinder E Reach into the crankcase and guide the rod onto the crankshaft journal while lightly tapping the piston head through the ring compressor and into the cylin der with a small wooden or rubber mallet F Seat the rod on the crankshaft journal and attach the rod cap ITEM 9 1 Lubricate the wear surface of the cap with assem bly lube 2 With the alignment notch on the cap facing out snap the cap onto the rod 3 Install and tighten to specified torque two 2 bolts ITEM 11 10mm socket G Repeat steps A F to install the second piston Install the Balancer Shaft See Fig D 6 Crankshaft Pistons and Balancer Shaft con t on page D 11 CAUTION The cr
13. AE aaO C 3 Torque Specificationss ee aeree tem gta eite tr aya see tee shes C 3 ENGINE REASSEMBLY D CRANKCASE ASSEMBLY Honing the Cylinder Bores ne ine ee rete eta ae even ddd attain D 1 e Pistons and Connecting Rods sse D 1 Piston ings cir oed ce eere euo Eee ae ener Ene D 2 lt CrankCase End C OVON D 2 Grankcase Bearings vestes is D 2 4 Grankshaft Bearing cet teet aet eae icd eet D 3 e Crankshaft and Balancer Shaft Seals D 3 p CRAMKSNAM OPEM MEM D 3 s A AELA E tall toe Beas decks Madball dere tere A eO Rex e lud D 3 s Balancetr Slhiatb b t reed rd OR Fan a e eg aea T D 3 e Checking Crankshaft and Balancer Shaft sess D 4 End Play Spaeers feri ho aee P E m eine D 4 eu edu D 4 GrankeaseEnd Gover Gasket eoe HO ep fea ei uris D 4 s CrankGase End K070 7 MT D 4 s Oil Pump ROtOFS iie peer erede Euer a ai D 5 Page iv Engine Shop Rebuild and Parts Manual TABLE OF CONTENTS Section Page No Oil Pressure bte e ER HU e E ee D 4 uiae ERN D 4 auxi I EUMDEM D 4 Pulser and ti eed ae eria epe d
14. F Recheck rocker arm locknut torque Install the Spark Plugs See Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt on page D 10 A With a wire gauge set the spark plug gaps at 030 and install them in the engine Tighten them to speci fied torque B Install the plug wires ITEM 34 on the plugs ENGINE REASSEMBLY Install the Rocker Cover See Fig E 8 Rocker Cover on page D 13 A Install a new rocker cover gasket ITEM 2 in the cover Match the shape of the gasket to the shape of the cover for proper orientation Match the shape of the rocker cover ITEM 1 to the shape of the mounting surface for proper orientation and position the cover on the cylinder head Make certain that the six 6 spacers sleeves ITEM 4 are installed in rocker cover DETAIL A Using a 10mm socket install and tighten six 6 bolts ITEM 3 M6x1 0x23L to specified torque in two stages in the order shown Install the Carburetor See Fig E 9 Carburetor on page D 14 A Engine Shop Rebuild and Parts Manual Install the gasket ITEM 2 plastic insulator ITEM 3 and gasket ITEM 4 on the carburetor mounting studs Place the carburetor on the mounting studs with the choke side out Insert one carburetor vent hose ITEM 5 through the hole in the PCV cover plate Be certain that it is not crimped or blocked in any way Install new gasket ITEM 6 and the air cleaner car buretor sea
15. Fig A 3 Valves Page A 6 Engine Shop Rebuild and Parts Manual ENGINE DISASSEMBLY TABLE OF CONTENTS FOR SECTION B SECTION TITLE CRANKCASE 5 59 Remove the Oil Filler Remove the Fan H b ep riae rid eed Tio rae oae edad Remove the Pulser Coil Remove the Oil Pressure Switch sssssssseeenenneee Remove the Oil Pump Remove the Crankcase End Cover Remove the Balancer Shaft nennen Remove th Pistons 2 2 oH eo ll a PD ee Remove the Crankshaft Remove the Balancer Shaft Seal and the Crankshaft Seal Inspect the Balancer Shaft Bearing and Crankshaft Bearing Remove the PCV Valve Disassemble the Crankcase End Remove the Piston From Connecting Removal of Crankshaft Bearing sse LIST OF ILLUSTRATIONS Fig B 1 Engine Fig B 2 Engine Components con t Fig B 3 Crankshaft 0 0 cece cece eee eee eeee sees sees Fig B 4 Balancer Shaft Bearing Crankshaft Bearing and PCV Valve Fig 5 Crankcase End Cover and Crankshaft Bearing Fig B 6 PISIOTT
16. amp SPECIALTY PRODUCTS THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EF FECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUT COME OF A WARRANTY CLAIM If other than the parts authorized by Textron Golf Turf amp Specialty Products are used for maintenance replacements or for the repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by Textron Golf Turf amp Specialty Products in their performance and durability HOW TO MAKE A CLAIM All repairs qualifying under this limited warranty must be performed by a distributor dealer or service provider au thorized by Textron Golf Turf amp Specialty Products In the event that any emission related part is found to be defec tive during the warranty period you shall notify Textron Golf Turf amp Specialty Products Warranty Department at 1 800 241 5855 and you will be advised of the appropriate warranty service providers where the warranty repair can be performed Page G 4 Engine Shop Rebuild and Parts Manual LIMITED WARRANTY CALIFORNIA 1995 1999 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd herein FUJI are pleased to explain the emis sion control system warranty on your 1995 and
17. wrist pin retaining clips ITEM 3 1 Insert a small flat blade screwdriver into one of the slots as shown Push in and up to dislodge the clip from the connecting rod ITEM 2 DETAIL A B Remove the wrist pin ITEM 4 1 Use a suitable mandrel to carefully push the wrist pin out of the piston ITEM 1 DETAIL B C Remove the piston rings ITEMS 5 6 and 7 Removal of Crankshaft Bearing See Fig B 1 Engine Components on page B 4 A f the bearing ITEM 1 is to be removed from the crankshaft use a mechanical press or bearing puller to remove it Discard bearing DETAIL B Page B 3 ENGINE DISASSEMBLY me gt gt 2 Crankcase Fig B 1 Engine Components Page B 4 Engine Shop Rebuild and Parts Manual ENGINE DISASSEMBLY Grind off Crankshaft Hold against puller screws not against Fan hub the crankshaft or fan shown without fan Crankshaft Drive end of key down and gently drive Lightly tap flanged edge of cover with a key up and out wooden or rubber mallet Fig B 2 Engine Components con t Engine Shop Rebuild and Parts Manual Page B 5 ENGINE DISASSEMBLY 0 999255 4 Fig B 3 Crankshaft Engine Shop Rebuild and Parts Manual Page B 6 ENGINE DISASSEMBLY To drive bearing out straight move drift side to side while tapping Fig B 4 Balancer Shaft Bearing Crankshaft Bearing and PCV Valve Engine Shop Rebuild and
18. 0 6313 63 960 63 980 2 515 63 870 2 6327 63 870 0 0650 1 65 0 1043 2 65 0 6283 15 960 0 6331 16 080 1 3819 35 100 16 035 0 6296 0 6300 15 991 16 002 2 528 2 529 64 210 64 230 2 6461 2 6469 67 210 67 230 0 6313 16 035 2 525 64 120 2 6425 67 120 0 6296 0 6300 2 538 2 539 64 460 64 480 2 6559 2 6567 67 460 67 480 15 991 16 002 0 6313 16 035 2 535 64 370 2 6524 67 370 Page C 6 Fig C 5 Piston Wrist Pin and Connecting Rod Engine Shop Rebuild and Parts Manual ENGINE MEASUREMENTS Balancer shaft B C D Recommended press fit for balance 1 6516 1 6526 0 7869 0 7873 shaft bearing Se 19 988 19 997 in 0 0006 0 0020 1 6531 0 7864 mm 0 014 0 050 41 990 19 975 Cutaway view of crankcase and endcover through balancer shaft bearing bores Measure each bore in 2 places 90 apart ESES i Measure each position in 2 places 90 apart C2 Fig C 6 Balancer Shaft Journals Gear and Bearing Bores Engine Shop Rebuild and Parts Manual Page C 7 ENGINE MEASUREMENTS Camshaft Recommended clearance for camshaft to cylinder head Fan side PTO Side 0 00098
19. 1 800 241 5855 to get the nearest appropriate location where your warranty repairs are performed 2 WARRANTY PERIOD This warranty continues for a period of two 2 years and shall apply only to the repair replace ment or adjustment of the component parts which are not scheduled for replacement as required maintenance Further component parts which are scheduled only for regular inspection to the ef fect of repair or replace as necessary shall be warranted for the warranty period Any warranted Page G 8 Engine Shop Rebuild and Parts Manual LIMITED WARRANTY CALIFORNIA 2000 part which is scheduled for replacement as required maintenance shall be warranted for the pe riod of time up to the first scheduled replacement point for that part 3 DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective if the diagnostic work is performed at an authorized dealer distributor or warranty station 4 CONSEQUENTIAL DAMAGES If a warranted part failed causing damages to other engine components consult a warranty sta tion M WHAT IS NOT COVERED 1 This limited warranty does not cover any part which malfunctions fails or is damaged due to failure to follow the maintenance and operating instructions set forth in the 2000 and later Owner s Manual in cluding 1 improper or inadequate scheduled engine inspection and maintenance 2 improper or inadequate maintenance of any warran
20. 72541 G01 72542 G01 72543 G01 72544 G01 72545 G01 72857 G01 72508 G01 26728 G01 26727 G01 72840 G02 72840 G03 26706 G01 72854 G01 26726 G01 CYLINDER BAFFLE EXHAUST 1 PIECE MAN EXH CYLINDER BAFFLE EXHAUST BOLT FLANGED M6 X 1 X 8MM BOLT FLANGED M8 X 1 25 X 50MM VALVE INTAKE BOLT FLANGED M8 X 1 25 X 40MM BOLT FLANGED M8 X 1 25 X 50MM BOLT FLANGED M8 X 1 25 X 60MM GASKET CYLINDER HEAD 295 cc ENGINE ONLY GASKET CYLINDER HEAD 350 cc ENGINE ONLY PISTON STANDARD 350 cc ENGINE ONLY PISTON 25MM OVERSIZE 350 cc ENGINE ONLY PISTON 50MM OVERSIZE 350 cc ENGINE ONLY PISTON RING SET STANDARD 350 cc ENGINE ONLY PISTON RING SET 25MM OVERSIZE 350 cc ENGINE ONLY PISTON RING SET 50MM OVERSIZE 350 cc ENGINE ONLY VALVE EXHAUST 1 PIECE MAN EXH VALVE EXHAUST BRACKET CHOKE CABLE GASKET AIR CLEANER CARBURETOR STANDARD 295 cc ENGINE ONLY CARBURETOR STANDARD 350 cc ENGINE ONLY FLANGE NUT MOX 1 0 erede iet echec title INSULATOR 350 cc ENGINE ONLY GASKET CARBURETOR Engine Shop Rebuild and Parts Manual Illustrated Parts Breakdown ENGINE When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION ES 72883 G01 26726 G01 72656 G01 72655 G01 72654 G01 72653 G01
21. D E AND G in two 2 places each 90 apart If rod journals are excessively rough scored or out of round replace the crankshaft Minor scratches on journals can be carefully polished using extra fine emery cloth Thoroughly clean crank shaft after polishing and reinspect journal diameters B Measure the oil seal surface diameters DIMEN SIONS AND J in two places each 90 apart Inspect for wear roughness or pitting Replace crankshaft if below specified limit C If the bearing was removed from the crankshaft mea sure the bearing journal DIMENSION F in two places 90 apart D Inspect gear teeth and oil seal areas for excessive wear or damage E Inspect oil passage plug in end of crankshaft for dam age Crankcase and End Cover Balancer Shaft Bearing Bores See Fig C 6 Balancer Shaft Journals Gear and Bearing Bores on page C 7 A Use a telescoping gauge to measure the balancer shaft bearing bore in the crankcase DIMENSION A in two 2 places 90 apart B Use a telescoping gauge to measure the balancer shaft bearing bore in the end cover DIMENSION B in two places 90 apart Balancer Shaft Journals and Gear See Fig C 6 Balancer Shaft Journals Gear and Bearing Bores on page C 7 A Measure the bearing journal diameters DIMEN SIONS A AND B in two places each 90 apart Inspect gear teeth and oil seal areas for excessive wear or damage Piston See Fig C 5 Piston Wrist Pin an
22. 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 cove
23. Fuel filter annual maintenance item 2 Air Induction System i Air filter element semi annual maintenance item 3 Ignition System i Spark plug annual maintenance item il Ignition Coil iii Ignitor Complete iv Pulser Coil Page G 6 Engine Shop Rebuild and Parts Manual 4 Exhaust Manifold 5 Miscellaneous Items Used in Above Systems i Fuel hoses clamps and sealing gaskets I MAINTENANCE STATEMENTS LIMITED WARRANTY CALIFORNIA 1995 1999 It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 1995 and later Owner s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended FUJI will not deny a warranty claim solely be cause you have no record of maintenance however FUJI may deny a warranty claim if your failure to per form required maintenance resulted in the failure of warranted part The proof which you maintain should be given to each subsequent owner of the engine You are responsible for performing the scheduled main tenance described below based on the procedures specified in the 1995 and later Owner s Manual The scheduled maintenance below is based on the normal engine operating schedule PROCEDURE INTERVAL a Check for sealing of fuel cap and proper operation of fuel gauge at each fueling Check that fuel cap vent is free of dirt WEEKLY b Check engine for unusual
24. Install the Coil Mounting Bracket and Coil Assembly See Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt on page D 10 Later models have a slightly different mounting A Position the bracket ITEM 30 on the mounting stud as shown B Install the bracket blower housing mounting bolt ITEM 31 M6x1 0x23L 10mm socket and nut ITEM 32 M6x10 10mm socket C Tighten the bolts ITEMS 27 28 29 and 31 and nut ITEM 32 to specified torques Adjust the Valves See Fig E 1 Valves and Valve Clearance on page D 6 A Rotate the camshaft so that the intake and exhaust cam lobes for one cylinder are oriented downward and the rocker arms rest on the heels of the lobes as shown DETAIL B B Adjust the exhaust valve clearance 1 Insert a 004 feeler gauge between the cam lobe heel and the rocker arm 2 Using a medium flatblade screwdriver turn the adjusting screw until the feeler gauge slides between the lobe heel and rocker arm with very slight resistance 3 Hold the adjusting screw at this position and tighten the rocker arm locknut to specified torque with a 10mm box end wrench 4 Check the valve with the feeler gauge again and readjust if necessary C Adjust the intake valve clearance the same as the exhaust valve clearance D Rotate the camshaft so that the cam lobes for the second cylinder are oriented downward for adjust ment E Adjust the intake and exhaust valve clearances
25. Owner s Manual FUJI recommends that you retain all receipts covering maintenance on your engine but FUJI cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that FUJI may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to a dealer distributor or service provider authorized by E Z GO Division of Textron Augusta Georgia herein E Z GO to which FUJI supplies the engine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to ex ceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the E Z GO War ranty Department at 1 800 241 5855 LIMITED WARRANTY on Emission Control Systems California Only FUJI Tokyo Japan warrants to the owner of the 2004 and later engine that the engine 1 has been designed built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Re sources Board and 2 is free from defects in materials and workmanship which could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below J WARRANTY COMMENCEMENT DATE The warranty period begins
26. Parts Manual Page B 7 ENGINE DISASSEMBLY Page B 8 Crankshaft Fig 5 Crankcase End Cover and Crankshaft Bearing Engine Shop Rebuild and Parts Manual ENGINE DISASSEMBLY Insert a suitable mandrel into the pin bore of the piston Press the piston down onto the mandrel pushing the wrist pin out Insert screwdriver into slot and push to compress ring Pry ring up and out of the retainer groove Remove the piston from the connecting rod Fig B 6 Piston Engine Shop Rebuild and Parts Manual Page B 9 ENGINE DISASSEMBLY Notes Page B 10 Engine Shop Rebuild and Parts Manual ENGINE MEASUREMENTS TABLE OF CONTENTS FOR SECTION C SECTION TITLE ENGINE MEASUREMENTS AND SPECIFICATIONS seen Using Telescoping Gauges and Hole Gauges Check flatness of Crankcase End Cover and Cylinder Head Crankcase Cylinder Bores Crankcase and End Cover Crankshaft Bearing Crankshaft Journals and Gear sse Crankcase and End Cover Balancer Shaft Bearing Bores Balancer Shaft Journals and Pistons pae e Ren E eth o ete ed de eae ide dee ecd Wrist Pin Connecting Odi irte teh ror PE
27. Parts Manual Page D 9 ENGINE REASSEMBLY Fig 5 Crankshaft Pistons and Balancer Shaft Page D 10 Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY Use mallet handle to gently tap piston through compressor and into cylinder head Align single dot on crankshaft gear with two dots on balancer shaft gear Fig D 6 Crankshaft Pistons and Balancer Shaft con t Engine Shop Rebuild and Parts Manual Page D 11 ENGINE REASSEMBLY Make sure the gears are completely seated and that their faces are perfectly flush Rest the straight edge on the gasket surface of the crankcase and measure to the face of the balancer gear and crankshaft gear with a depth gauge Subtract the width of the straight edge from the measurements Rest the straight edge on the gasket surface of the end cover and across the centers of the bearings The straight edge should sit solidly on the gasket surface without rocking Measure to the face of the balancer and crankshaft bearing inner races then subtract the width of the straight edge from the measurements Fig D 7 Crankshaft and Balancer Shaft Endplay Page D 12 Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY Fig D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub Engine Shop Rebuild and Parts Manual Page D 13 ENGINE REASSEMBLY Follow numbers to tighten end cover bolts in correct sequence Tighten to specified torque in two st
28. 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 Page A 1 ENGINE DISASSEMBLY 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
29. abuse neglect improper maintenance or unapproved modifications Engine Shop Rebuild and Parts Manual Page G 3 LIMITED WARRANTY FEDERAL 2001 You are responsible for presenting your engine to the nearest distributor dealer or service provider authorized by Textron Golf Turf amp Specialty Products when a problem exists If you have any questions regarding your warranty rights and responsibilities you should contact the Textron Golf Turf amp Specialty Products Warranty Department at 1 800 241 5855 for the information THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper use and maintenance of the engine You should keep all receipts and mainte nance records covering the performance of regular maintenance in the event questions arise These receipts and maintenance records should be transferred to each subsequent owner of the engine Textron Golf Turf amp Specialty Products reserves the right to deny warranty coverage if the engine has not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep mainte nance records MAINTENANCE REPLACEMENT OR REPAIR OF EMISSSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DISTRIBUTOR DEALER OR SERVICE PROVIDER AUTHO RIZED BY TEXTRON GOLF TURF
30. dealer distributor or warranty station authorized by E Z GO DIVISION OF TEXTRON INC Augusta Georgia herein E Z GO to which FUJI supplies the en gine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the E Z GO War ranty Department at 1 800 241 5855 LIMITED WARRANTY on Emission Control Systems California Only FUJI Tokyo Japan warrants to the owner of the 1995 and later engine that the engine 1 has been designed built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Re sources Board and 2 is free from defects in materials and workmanship which could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below A WARRANTY COMMENCEMENT DATE The warranty period begins on the date the engine is delivered to a first retail purchaser B LENGTH OF COVERAGE FUJI warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship which could cause the failure of a warranted emission related part for a pe riod of two 2 years after the date of delivery to the first retail purchaser C WHAT IS COVERED 1 REPAIR OR REPLACEMENT PARTS Repairs and replacement of any warranted part wi
31. engine You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise These receipts and mainte nance records should be transferred to each subsequent owner of the engine E Z GO reserves the right to deny warranty coverage if the engine has not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep maintenance records MAINTENANCE REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DISTRIBUTOR DEALER OR SERVICE PROVIDER AUTHO RIZED BY E Z GO THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DU RABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CON TROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM If other than the parts authorized by E Z GO are used for maintenance replacements or for the repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by E Z GO in their performance and durability HOW TO MAKE A CLAIM All repair qualifying under this limited warranty must be performed by a distributor dealer or service provider autho rized by E Z GO In the event that any emission related part is found to be defecti
32. 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 Engine Shop Rebuild and Parts Manual 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
33. hn ie UR bs cies ats ieu nai ties B 3 Engine Shop Rebuild and Parts Manual Page iii TABLE OF CONTENTS Section Page No ENGINE MEASUREMENTS AND SPECIFICATIONS C ENGINE MEASUREMENTS AND SPECIFICATIONS Check Flatness of Crankcase End Cover and Cylinder Head C 1 e Crankcase Cylinder C 2 e Crankcase and End Cover Crankshaft Bearing Bores sss C 2 Crankshaft Journals and Gear irr a e E qued gets E dete ii Fu C 2 e Crankcase and End Cover Balancer Shaft Bearing Bores sss C 2 e Balancer Shaft Journals and nennen nennen C 2 SCPISIOD iue eet tea ote c EE Et ee fe motam etes C 2 V AWEISD PAD ERES DuC C 3 Connecting ROO ute etit C 3 e Cylinder Head Cam and Rocker Shaft enne C 3 e Valves Guides and C 3 Valves and Valve Springs 52 eed ete eer eode HD eT ete C 3 estia suas LOREM Y x TE Dese teur UR C 3 Rocker Shaft and Rocker Arms C 3 Piston Ring Gap denti cabs veh ac esas deat nh ue
34. inspected before removing the valve guides If other parts in the head show excessive wear it may be more cost effective to replace the entire head than to replace parts If the valve guides are to be replaced the valve seats must be resurfaced with an appropriate cutter A total dif ference of 1 between the finish angles of the valve and valve seat is desirable A Measure the inside diameter at each end of the valve guides DIMENSIONS A AND B in two 2 places each 90 apart If a valve guide is worn beyond ser vice limits it may be removed with a mechanical press See NOTE above B Measure angle DIMENSION C and width DIMEN SION D of the valve seat contact surface If valve seats are worn beyond service limits they may be resurfaced with an appropriate cutter Valves and Valve Springs See Fig C 8 Valve Guides and Seats on page C 9 x Engine Shop Rebuild and Parts Manual A Measure the valve stem at three 3 positions DIMENSIONS A B and C in two 2 places each 90 apart B Measure angle D and widths DIMENSION E AND F of the valve face C Measure valve spring free length DIMENSION G Camshaft See Fig C 7 Cylinder Head Cam and Camshaft on page C 8 A Measure the camshaft diameter at four 4 positions DIMENSIONS A B AND in two 2 places each B Measure the height of all four cam lobes DIMEN SIONS C D E AND F Rocker Shaft and Rocker Arms See Fig C
35. noise vibration acceleration MONTH 20 HOURS C Check engine electrical system for coil spark plug wire for cracks loose connections 3 MONTH 50 HOURS d Check fuel system for leaks at tank cap lines filters pump carburetor Check lines for cracks deterioration 3 MONTH 50 HOURS Check air cleaner filter element SEMIANNUAL 125 HOURS f Replace engine oil DO NOT OVERFILL SAE 10W 30 10W 40 SF SG CC oil SEMIANNUAL 125 150 HOURS 9 Clean oil filter in solvent at oil change Replace O rings if required SEMIANNUAL 125 150 HOURS h Replace air cleaner filter element if required ANNUAL 250 300 HOURS i Check fuel filter for dirt build up Replace as required ANNUAL 250 300 HOURS j Check the spark plugs for gap 0 030 Replace if required ANNUAL 250 300 HOURS k Check timing belt tension signs of wear damage Replace only if worn or damaged Engine Shop Rebuild and Parts Manual ANNUAL 250 300 HOURS Page G 7 LIMITED WARRANTY CALIFORNIA 2000 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd herein FUJI are pleased to explain the emis sion control system warranty on your 2000 and later small off road engine herein engine In California the engine must be designed built and equipped to meet the State s stringent anti
36. product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 23 4 5 DESCRIPTION be 72845 G01 SERVICE ENGINE 295CC INCLUDES ITEMS 5 197 208 215 72846 G02 SERVICE ENGINE 350CC INCLUDES ITEMS 4 6 197 208 215 Page F 6 72875 G01 72884 G01 26743 G01 26741 G01 26737 G01 26738 G01 26708 G01 72539 G01 72559 G01 26591 G01 26710 G01 26680 G01 26678 G01 26712 G01 26669 G01 72555 G01 72657 G01 72554 G01 72658 G01 72676 G01 72659 G01 72680 G01 72860 G01 CRANKCASE ASSEMBLY INCLUDES ITEMS 6 12 350 cc ENGINE ONLY 1 PIECE MAN EXH CRANKCASE ASSEMBLY INCLUDES ITEMS 6 12 295 cc ENGINE ONLY 1 PIECE MAN EXH OIL SEAL BALANCER SHAFT OIL SEAL CRANKSHAFT BEARING BALL FILTER OIL O RING OIL FILTER BOLT AND WASHER ASSEMBLY M6 X 1 X 12MM FLANGED BOLT M6 X 1 12MM 1 PIECE MAN EXH O RING CYLINDER HEAD DOWEL PIN BREATHER COVER GASKET THICK INNER BREATHER PLATE LONG SLOT BREATHER COVER GASKET THIN BREATHER BOX OUTER BREATHER PLATE SHORT SLOT BREATHER COVER FLANGED BOLT M6 X 1 X 40 MM LG REAR BELT COVER Engine Shop Rebuild and Parts Manual Illustrated Parts Breakdown ENGINE When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Dep
37. remaining valves in the same manner Install the Cylinder Head on the Crankcase See Fig E 3 Cylinder Head Cam Shaft and Rocker Assembly on page D 8 See Fig E 4 Cylinder Head Cam Shaft Rocker Assembly con t on page D 9 CAUTION Because this is an aluminum cylinder head it is important that the clamping pressure of the mounting bolts be applied evenly Install and tighten the bolts to specified torque as directed A Install the two 2 cylinder head alignment dowels ITEM 2 B Install a new head gasket ITEM 3 The head gasket is specially coated for the alu NOTE minum cylinder head Do not use additional sealants or other material on gasket mating surfaces 1 Match the contours of the gasket to the contours of the gasket boss surrounding the cylinders ITEM 1 The word UP is cut into the gasket 2 Place the gasket on the alignment dowels on the crankcase C Match the features on the bottom of the head to the features of the crankcase gasket surface Position the head on the alignment dowels and lower it gently onto the crankcase Page E 2 Engine Shop Rebuild and Parts Manual D Install and hand tighten seven 7 cylinder head mounting bolts ITEM 4 1 each M8x1 25x60L ITEM 5 4 each M8x1 25x50L and ITEM 6 2 each M8x1 25x40L tighten to specified torque in two stages in the order shown DETAIL A Install the Camshaft See Fig E 3 Cylinder Head Cam Shaft and Rocker Asse
38. see high usage Because some mating parts with wear surfaces were machined together when the engine was manufactured or have estab lished wear patterns during operation the reassembly of engine parts in their original positions and orientations with their origi nal mating parts is critical to the performance and life expectan cy of the engine When tightening torquing a number of screws or bolts in a giv en pattern tighten them in two stages Tighten them to 1 2 of specified torque in one pass through the pattern and then to specified torque on the second pass All 4 cycle engine fasteners are plated and NOTE some are lubricated when installed They are considered wet and require approximately 80 of the speci fied torque of dry fasteners Hone the Crankcase Cylinder Bore See Fig D 1 Crankcase Cylinder on page D 6 A Hone the cylinder bores only if new piston rings are to be installed CAUTION Make sure that all carbon residue has been removed from the cylinder walls before honing B Install the crankcase end cover as shown in Fig D 9 Secure the crankcase to the work surface C D Lightly coat the cylinder bore with honing oil E Insert the hone and adjust the speed and stroke rate until a 30 50 cross hatch angle is achieved F Allow the hone to stop within the bore before remov ing the hone G Clean the bore with a brush and shop solvent H Measure the bore Reassemble the Pistons and Con
39. 0 0030 0 00079 0 0024 0 025 0 075 0 020 0 062 SPECS C D E F STD in 1 9780 1 3789 0 9843 0 9851 1 3760 1 3770 1 048 1 052 0 9826 0 9835 mm 35 000 35 025 25 000 25 021 34 950 34 975 26 620 26 720 24 959 24 980 LIMIT 1 3805 0 9865 1 375 1 040 0 9816 mm 35 065 25 057 34 925 26 420 24 935 Cutaway view of cylinder head through camshaft Typical measure each bore in 2 places 90 apart a Fan side n am Fan side Fig C 7 Cylinder Head Cam and Camshaft Page C 8 Engine Shop Rebuild and Parts Manual ENGINE MEASUREMENTS SPECS A B D stp in 0 2165 0 2172 0 0118 0 0295 mm 5 500 5 518 0 30 0 75 in 0 2175 0 0591 SE mm 5 525 1 5 d total difference of 1 between the finish angles of the valve and valve seat is required Measure each position i in 2 places 90 apart Valve guide Valve seat Fig C 8 Valve Guides and Seats Engine Shop Rebuild and Parts Manual Page C 9 ENGINE MEASUREMENTS Page C 10 Recommended clearance for valve to valve guide Intake Exhaust 0 0018 0 0030 0 045 0 075 0 0022 0 0036 0 056 0 092 A Intake BC
40. 10 Rocker Shaft Arms and Bearing Bores on page C 11 A Measure the rocker arm shaft bore in two 2 places 90 apart at each end of the bore DIMENSION A B At positions along its length including the rocker arm contacts measure the outside diameter of the rocker shaft DIMENSIONS B AND J in two 2 places 90 apart C Replace shaft if there are any signs of wear or abra sion Piston Ring Gap See Fig C 11 Piston Ring Gap on page C 12 A Place the compression top ring in the cylinder bore as shown B Usean inverted piston to push the ring approximately one inch into the cylinder make sure the ring is flat against its top before withdrawing the piston This will leave the ring at 90 to the axis of the cylinder C Use a feeler gauge to measure the ring gap as shown D Measure each of the remaining rings in the same manner Torque Specifications Wet See Fig C 12 Torque Specifications on page C 13 NOTE The torque table provided on Page 5 specifies lubricated torque figures Fasteners that are plated or are lubricated when installed are considered wet and require approximately 80 of the torque required for dry fas teners Page C 3 ENGINE MEASUREMENTS Measure each position in the cylinder bore at 2 places M A fine cross hatched surface is the proper finish for a cylinder bore Crankcase Detail A If al exceeds or if
41. 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 CAUTION 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 NOTE Some models of puller have a sharp point that could damage the crankshaft oil passage plug Modify per Fig B 2 detail A Engine Shop Rebuild and Parts Manual 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
42. 72677 G01 72678 G01 72679 G01 601556 601557 601558 601563 26599 G01 72869 G01 72885 G01 72870 G01 72871 G01 601559 72863 G01 72859 G01 72862 G01 INSULATOR 295 cc ENGINE ONLY GASKET ENGINE ALUMINUM GASKET BANJO UNION BANJO BOLT RUBBER RETURN HOSE INCLUDES ITEMS 213 215 RUBBER HOSE 6 MM ID X 12 MM OD X 145 MM LG MESH PROTECTIVE COVER HOSE CLAMP ROCKER ARM ASSEMBLY INCLUDES ITEMS 218 219 1 PIECE MAN EXH SCREW 5 X 5 X 18 5MM 1 PIECE MAN EXH NUT M5 X 5 1 PIECE MAN EXH CAMSHAFT 1 PIECE MAN EXH GASKET CAMSHAFT COVER 1 PIECE MAN EXH BRACKET IGNITION COIL 350CC 1 PIECE MAN EXH BRACKET IGNITION COIL 295CC 1 PIECE MAN EXH FLANGED BOLT M6 X 1 X 12MM 1 PIECE MAN EXH SCREW AND WASHER ASSEMBLY 1 PIECE MAN EXH BRACKET CHOKE CABLE 1 PIECE MAN EXH GASKET BREATHER COVER INNER 1 PIECE MAN EXH PLATE BREATHER 1 PIECE MAN EXH GASKET BREATHER COVER OUTER 1 PIECE MAN EXH Engine Shop Rebuild and Parts Manual Page F 13 ENGINE Illustrated Parts Breakdown When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 12 345 DESCRIPTION QTY 234 72877 G01 COVER BREATHER COMPLETE 1 PIECE MAN EXH 235 72879 G01 BOLT FLANGED M6 X 1 X 40MM 1 PIECE MAN EXH Page F 14 Engine Shop
43. 86 34 997 35 006 35 017 in 1 3757 1 3771 1 3779 LIMIT mm 34 945 34 980 35 001 ul Plug Fig C 4 Crankshaft Journals and Gear and Bearing Bores Engine Shop Rebuild and Parts Manual Page C 5 ENGINE MEASUREMENTS Measure the width and depth of each ring groove Piston wrist pin and connecting rod Measure each position in 2 places 90 apart E O Maximum wear limit A Recommended clearance New engine for piston to cylinder wall in mm 0 0039 0 0008 0 0023 0 100 0 020 0 059 Recommended clearance for connecting rod to crankshaft in mm 0 0039 0006 0019 0 100 0 015 0 047 Recommended press fit for piston wrist pin in mm 0 0019 Loose 00039 Loose 00035 Tight 0 050 Loose 0 010 Loose 0 009 Tight C D K B J A B 295 cc 350 cc ALL TOP MIDDLE BOTTOM OIL E F G 0 6303 0 6307 1 3780 1 3786 0 6296 0 6300 2 518 2 519 2 6362 2 6370 66 960 66 980 0 1043 0 1122 2 65 2 85 0 0598 0 0608 1 520 1 545 0 0988 1 0000 2 510 2 540 0 6296 0 6299 15 992 16 000 16 010 16 021 35 000 35 016 15 991 16 002
44. E 8 Fig E 4 Cylinder Head Cam Shaft Rocker Assembly 9 Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt E 10 Fig E 6 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt con t E 11 Fig E 7 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt con t E 12 Fig E 8 Rocker Cover rene etienne ttai deti Eck ee eta aac E 13 Eig E 9 Garb retor intere er P tree tertie ee terres eet ia E 14 Engine Shop Rebuild and Parts Manual Page E i ENGINE REASSEMBLY Notes Page E ii Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY CYLINDER HEAD ASSEMBLY Tool List Compressor piston ring Dril electi Ca tai ER Gauge feeler E Z GO P N 72525 901 Gauge wire spark plug Valve seat cutter E Z GO P N 72516 901 Installer piston ring E Z GO P N 72521 901 Grinder valve cup type E Z GO P N 72522 901 Compound 4 oz valve grinding E Z GO P N 72523 01
45. EM PART NO 23 4 5 DESCRIPTION be 72865 G01 PULSER COIL 1 PIECE MAN EXH 72556 G01 BLOWER ASSEMBLY INCLUDES ITEMS 118 121 26703 G01 FAN COOLING BLOWER 72557 G01 FLYWHEEL 26705 G01 WASHER LOCK 26638 G01 BOLT AND WASHER ASSEMBLY M6 X 1 X 16MM 601548 FAN COOLING BLOWER 1 PIECE MAN EXH 26704 G01 BOLT FLANGED M6 X 1 X 18MM 26641 G01 BLOWER HOUSING 26691 G01 NUT FLANGED M22 X 1 5 enne nre 26676 G01 BOLT FLANGED M6 X 1 X 23MM 72391 G01 CYLINDER HEAD ASSEMBLY INCLUDES ITEMS 129 132 350 cc ENGINE ONLY 72390 G01 CYLINDER HEAD ASSEMBLY INCLUDES ITEMS 129 132 295 cc ENGINE ONLY 26715 G01 OIL SEAL CAMSHAFT 72307 G01 STUD M6 X 1 X 115MM 26659 G01 VALVE GUIDE OVERSIZE 72392 G01 SEAL VALVE STEM 601555 NUT FLANGED M18 x 1 5 1 PIECE MAN EXH 72880 G01 BLOWER HOUSING 1 PIECE MAN EXH 72882 G01 CYLINDER BAFFLE INTAKE 72851 G01 BOLT FLANGED M6 X 1 X 14MM 26600 G01 ROCKER COVER 26601 G01 CAP OIL FILTER 26720 G01 O RING OIL FILTER 26676 G01 BOLT FLANGED M6 X 1 X 23MM 72848 G01 ROCKER COVER 1 PIECE MAN EXH 72509 G01 RETAINER VALVE SPRING 72510 G01 KEYS VALVE COLLET Page F 10 Engine Shop Rebuild and Parts Manual Illustrated Parts Breakdown ENGINE When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional informat
46. Exhaust E F 0 2143 0 2148 0 2136 0 2143 5 443 5 455 5 426 5 444 0 0891 0 1281 2 263 3 253 0 0276 0 0354 0 7 0 9 0 2125 5 40 0 2125 5 40 0 1392 3 536 0 0197 0 5 Measure each position Y in 2 places 90 apart A Fig C 9 Valve and Valve Springs Engine Shop Rebuild and Parts Manual ENGINE MEASUREMENTS D Clearance to head Clearance 0 4724 0 4731 0 4711 0 4718 0 4724 0 4731 0 0006 0 0020 0 0006 0 0020 12 000 12 018 11 966 11 984 12 000 12 018 0 016 0 052 0 016 0 052 0 4748 0 4704 0 4746 0 0039 0 0041 12 060 11 950 12 055 0 100 0 105 Fan side Measure each position in 2 places 90 apart Y Rocker shaft Shaft arm clearance Fig C 10 Rocker Shaft Arms and Bearing Bores Engine Shop Rebuild and Parts Manual Page C 11 ENGINE MEASUREMENTS Page C 12 Recommended clearances for piston ring end gap EH29C 295 CC 64 MM BORE EH35C 350 CC 67 MM BORE Top ring 0 008 0 016 0 20 0 40 0 006 0 010 0 15 0 25 2nd Ring 0 008 0 016 0 20 0 40 0 006 0 012 0 15 0 30 Oil ring 3 Pi
47. Golf Turf amp Specialty Products Augusta Georgia herein Textron Golf Turf amp Specialty Prod ucts to which FUJI supplies the engine as soon as a problem exists The warranty repairs should be com pleted in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the Textron Golf Turf amp Specialty Products Warranty Department at 1 800 241 5855 LIMITED WARRANTY on Emission Control Systems California Only FUJI Tokyo Japan warrants to the owner of the 2001 and later engine that the engine 1 has been designed built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Re sources Board and 2 is free from defects in materials and workmanship which could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below A WARRANTY COMMENCEMENT DATE The warranty period begins on the date the engine is delivered to a first retail purchaser B LENGTH OF COVERAGE FUJI warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship which could cause the failure of a warranted emission related part for a pe riod of two 2 years after the date of delivery to the first retail purchaser C WHAT IS COVERED 1 REPAIR OR REPLACEMENT PARTS Repairs and replacement of a
48. MEASUREMENTS AND SPECIFICATIONS Tool List Qty Required Calipers eiit dens 1 Gauge 1 Gauge Set 1 Gauge Set 1 MiGrOmeter 1 Micrometer 2 5o velt evecta rerba de eer as 1 Micrometer 9 1 Surface plate oh eee ei date E ee RR 1 CAUTION All engine parts must be thoroughly cleaned and free of all dirt oil grease carbon deposits or residue of any kind before beginning this section It is especially important that your work area be clean and well organized while performing the operations described in this section NOTE In some cases time may be saved by setting measuring instruments at limit specifications and using them as go no go fixtures Check preset instrument fit in bores on shafts etc to determine part acceptability We recommend that parts bound to be acceptable but near limits be replaced if the engine will see high usage Check micrometers for proper calibration before beginning the operations described in NOTE this section Using Telescoping Gauges and Hole Gauges See Fig C 1 Using Telescoping and Hole Gauges on page C 1 Telescoping gauges and hole gauges are transfer type measuring instruments They are not calibrated and are used to record a distance wh
49. ONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE This emission warranty is applicable in all States except the State of California Fuji Heavy Industries Ltd and E Z GO Division of Textron Augusta Georgia herein E Z GO warrant s to the initial retail purchaser and each subsequent owner that this Non road engine herein engine has been designed built and equipped to conform at the time of initial sale to all applicable regulations of the U S Environmental Pro tection Agency EPA and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period For the components listed under PARTS COVERED the distributor dealer or service provider authorized by E Z GO will at no cost to you make the necessary diagnosis repair or replacement necessary to ensure that the engine complies with applicable U S EPA regulations EMISSISON COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of 2 years PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel inject
50. Original oil rings are three piece design A sin gle oil ring is provided as a service replace CAUTION Piston ring grooves must be clean Reassemble the pistons with new pis ton rings Position the top ring gap at 45 to the axis of the wrist pin A Apply a light coat of engine oil to the piston rings and lands B Install the oil ring ITEM 5 1 If desired use piston ring installer or insert one end of the oil ring into the bottom groove on the piston leaving the other end resting on top of the piston Work the rest of the ring into the groove while rotating the piston DETAIL D C Install the wiper ring ITEM 6 with the facing up in the middle groove with the ring gap at 120 to the top scraper of the oil ring DETAIL C Page D 2 Engine Shop Rebuild and Parts Manual D Install the compression ring ITEM 7 with the N facing up in the top groove with the ring gap at 120 Fahrenheit to the wiper ring DETAIL C Reassemble the Crankcase End Cover See Fig D 4 Crankcase End Cover PCV Valve and Oil Filter on page D 9 Reassemble the end cover with new CAUTION balancer shaft and crankshaft bearings if the original bearings were removed If the bearings can be installed in the end cover by hand without heating the end cov er the end cover and crankcase must be replaced A If the original crankshaft bearing ITEM 2 and bal ancer shaft bearing ITEM 3 have been removed install NEW on
51. Rebuild and Parts Manual LIMITED WARRANTY TABLE OF CONTENTS FOR SECTION G SECTION TITLE PAGE NO FEDERAL EMISSION CONTROL WARRANTY STATEMENT eese G 1 CALIFORNIA EMISSION CONTROL WARRANTY 1995 1999 G 5 YOUR WARRANTY RIGHTS AND OBLIGATIONS sese G 5 LIMITED WARRANTY on Emission Control Systems California Only G 5 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT 2000 G 8 YOUR WARRANTY RIGHTS AND OBLIGATIONS G 8 LIMITED WARRANTY on Emission Control Systems California Only G 8 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT 2001 G 11 YOUR WARRANTY RIGHTS AND OBLIGATIONS LIMITED WARRANTY on Emission Control Systems California Only G 11 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT 2004 G 14 YOUR WARRANTY RIGHTS AND OBLIGATIONS LIMITED WARRANTY on Emission Control Systems California Only G 14 Engine Shop Rebuild and Parts Manual Page G i LIMITED WARRANTY Notes Page G ii Engine Shop Rebuild and Parts Manual LIMITED WARRANTY FEDERAL FEDERAL EMISSIONS COMP
52. Timing Belt on page D 10 A Hold the baffle ITEM 21 in place and install and tighten four 4 bolts ITEM 22 M6x1 0x8L 10mm Socket to specified torque Later models have five 5 bolts Install the Exhaust Manifold and Gasket See Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt on page D 10 See Fig E 7 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt con t on page D 12 Later models have exhaust manifold as part of head Some early model engines were assembled NOTE with two small gaskets These have been replaced with a one piece gasket A Insert four 4 bolts ITEM 25 M8x1 25x50L 12mm Socket through the manifold and position the gasket over the bolts B Hold the manifold in place and start the bolts into the cylinder head Tighten the bolts to specified torque in two stages in the order shown DETAIL B Install the Blower Housing See Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt on page D 10 See Fig E 7 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt con t on page D 12 A Hold the housing in place and route the oil pressure switch wire and pulser coil wire from behind the hous ing through the groove as shown DETAIL C B Install three 3 mounting bolts ITEMS 27 28 AND 29 M6x1 0x18L 10mm socket Do not tighten them at this time Page E 4 Engine Shop Rebuild and Parts Manual
53. UNDER THE CALIFORNIA EMISSIONS WARRANTY 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system il Air fuel ration feedback and control system if applicable iil Cold start enrichment system if applicable iv Regulator assembly gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable il Air filter 3 Ignition System i Spark plugs il Magneto or electronic ignition system Page G 12 Engine Shop Rebuild and Parts Manual LIMITED WARRANTY CALIFORNIA 2001 iii Spark advance retard system if applicable 4 Exhaust Manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable il Hoses belts connectors and assemblies iil Filter lock assembly gaseous fuel if applicable MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2001 and later Owner s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended FUJI will not deny a warranty claim solely be cause you have no record of maintenance however FUJI may deny a warranty claim if your failure to per form required maintenance resulted in the failure of warranted part The proof which you maintain should be given to each subsequent owner of the engine You are responsible for performing the sch
54. ages Some models may have 8 or 9 or 10 bolts Gently tap key into keyway Later models do not have a keyway Fig D 9 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub con t Page D 14 Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY For clarity the fan is shown pulled away from the hub and the fan hub is partially cut a way It is not necessary to remove the fan or hub to set the air gap Use the access holes provided Press lightly with suitable mandrel 020 039 Feeler gauge Insert phillips screwdriver through fan hub Fig D 10 Pulser Coil Air Gap Engine Shop Rebuild and Parts Manual Page D 15 ENGINE REASSEMBLY Notes Page D 16 Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY TABLE OF CONTENTS FOR SECTION E SECTION TITLE PAGE NO CYLINDER HEAD ASSEMBU Y Aa aa E 1 Install Valve eee ten rede ne PG De deren te deae E 1 Cutting Valve Seats sinure aur nne nri ee eH Ri e nilo gonna E 1 Lapthe ELE E 1 Install New Valve Stem Seals ce seesccessnesecceeseeceseeeseessscessesseceecsceseeesseeseseeosneseaeeceneoees E 2 Install the Valves Install the Cylinder Head on the Crankcase E 2 Installithie Garnshaft
55. ankshaft and balancer shaft gears must be aligned properly when assembled in order to set engine valve timing A Lubricate the balancer shaft gear with assembly lube B Insert the keyway end of the balancer shaft into the balancer shaft bearing in the crankcase Position the single dot on the crankshaft gear face between the two dots on the balancer gear face before meshing the gears and seating the balancer shaft in the bal ancer shaft bearing DETAIL C Set the Crankshaft and Balancer Shaft End play See Fig D 7 Crankshaft and Balancer Shaft Endplay on page D 12 A Position the crankcase with the open end up on a box or other surface that will leave the PTO clutch end of the crankshaft free from any contact or pres sure B Make sure the crankshaft and balancer shaft are completely seated and that their gear faces are per fectly flush Page D 3 ENGINE REASSEMBLY C Using a depth gauge and straight edge measure the distance from the gasket surface of the crankcase to the faces of both the crankshaft and balancer shaft gears close to the shafts then subtract the width of the straight edge from each measurement D Using a depth gauge and straight edge measure the distance from the gasket surface of the end cover to the inner races of both end cover bearings then sub tract the width of the straight edge from each mea surement E Add the figures from steps C and D plus 005 gas ket thickness for ea
56. anner D Place the crankcase end cover on the surface plate with the gasket surface down and check for flatness E Place the cylinder head on the surface plate with the crankcase mating surface down and check for flat ness Page C 1 ENGINE MEASUREMENTS F Turn the cylinder head so that the valve cover gasket surface rests on the surface plate Check for flatness surface plate Fig C 2 Flatness of Mating Surfaces Crankcase Cylinder Bores See Fig C 3 Crankcase Cylinder Bores on page C 4 A Use a telescoping gauge to measure each cylinder bore at three 3 positions DIMENSIONS A B AND C in two 2 places each 90 apart as shown B Inspect the cylinder wall surfaces for proper cross hatched finish DETAIL A Crankcase and End Cover Crankshaft Bear ing Bores See Fig C 4 Crankshaft Journals and Gear and Bearing Bores on page C 5 A Using a telescoping gauge measure the crankshaft bearing bores in the crankcase DIMENSION A B in two 2 places 90 apart B Using a telescoping gauge measure the crankshaft bearing bore in the end cover DIMENSION C in two 2 places 90 apart Crankshaft Journals and Gear See Fig C 4 Crankshaft Journals and Gear and Bearing Bores on page C 5 NOTE Measure crankshaft rod journals away from the oil holes in the journals Page C 2 Engine Shop Rebuild and Parts Manual A Measure the rod and bearing journal diameters DIMENSIONS B C
57. artment for additional information ITEM PART NO 12 345 DESCRIPTION 30 72536 G01 26681 G01 26626 G01 26627 G01 601554 26628 G01 26639 G01 26696 G01 26640 G01 26699 G01 26638 G01 26695 G01 72908 G01 26631 G01 26678 G01 26613 G01 26614 G01 26606 G01 26683 G01 72393 G01 72395 G01 72396 G01 26608 G01 26662 G01 IDLER SPRING BOLT FLANGED M6 X 1 X 8MM TIMING BELT PULLEY CAM BOLT FLANGED BOLT AND WASHER ASSEMBLY M8 X 1 25 X 20 WASHER 8 5MM X 28MM X 2 3MM BOLT IDLER PIVOT WASHER 8 5MM X 16MM X 1 2MM THK BOLT AND WASHER ASSEMBLY M6 X 1 X 16MM WASHER 6 5MM X 22MM X 2MM THK ese COVER FRONT TIMING BELT GROMMET TIMING BELT COVER BOLT FLANGED M6 X 1 X 12MM 3 4 RETAINER PULLEY PULLEY DRIVE CONNECTING ROD 2 MATCHED COMPONENTS BOLT CONNECTING ROD PISTON STANDARD 295 cc ENGINE ONLY PISTON 25MM OVERSIZE 295 cc ENGINE ONLY PISTON 50MM OVERSIZE 295 cc ENGINE ONLY PISTON RING SET STANDARD 295 cc ENGINE ONLY PISTON RING SET 25MM OVERSIZE 295 cc ENGINE ONLY Engine Shop Rebuild and Parts Manual ENGINE Illustrated Parts Breakdown When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 23 4 5 DESCRIPTION ES
58. ce be performed by the authorized dealer who sold you the engine although warranty service will be performed by any authorized dealers distributors and warranty stations anywhere in the United States When warranty repair is needed the engine must be brought to an autho rized dealer distributorship or warranty station s place of business during normal business hours In all cas es a reasonable time not to exceed 30 days must be allowed for the warranty repair to be completed after the engine is received by the authorized dealer distributor or service station G MAINTENANCE REPLACEMENT AND REPAIR OF EMISSION RELATED PARTS Only warranted engine replacement parts approved by FUJI should be used in the performance of any war ranty maintenance or repairs on emission related parts If other than authorized parts are used for mainte nance replacement or repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to authorized parts in performance and durability FUJI however assumes no liability under this warranty with respect to parts other than autho rized parts The use of non authorized replacement parts does not invalidate the warranty on other com ponents unless the non authorized parts cause damage to warranted parts H PARTS COVERED UNDER THE CALIFORNIA EMISSIONS WARRANTY 1 Fuel Metering System i Carburetor and internal parts il Choke System iil
59. cessories replaced under this warranty become the property of Textron Golf Turf amp Specialty Products WHAT IS NOT COVERED Conditions resulting from tampering misuse improper adjustment unless they were made by the distributor dealer or service provider authorized by Textron Golf Turf amp Specialty Products during a warranty repair alter ation accident failure to use the recommended fuel and oil or not performing required maintenance services The replacement parts used for required maintenance services Consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc Diagnosis and inspection charges that do not result in warranty eligible service being performed Any non authorized replacement part or malfunction of authorized parts due to use of non authorized parts OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual Textron Golf Turf amp Specialty Products recommends that you retain all receipts covering maintenance on your engine but Textron Golf Turf amp Specialty Products cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that Textron Golf Turf amp Specialty Products may deny you warranty coverage if your engine or a part has failed due to
60. ch shaft Subtract from each fig ure the thickness of its spacer to find the clearance for each shaft If either clearance is not between 003 and 015 replace the spacer to achieve correct end play Install Crankshaft Endplay Spacer and Bal ancer Endplay Spacer See Fig D 5 Crankshaft Pistons and Balancer Shaft on page D 10 A Place the Crankshaft endplay spacer ITEM 13 on the crankshaft and the balancer endplay spacer ITEM 14 on the balancer shaft Install Alignment Dowel Pins See Fig D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub on page D 13 Install alignment dowel pins ITEM 25 Install New Oil Feed O Ring See Fig D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub on page D 13 A Install a new oil feed O ring ITEM 1 Install Crankcase End Cover Gasket See Fig D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub on page D 13 A Place a new crankcase end cover gasket ITEM 2 on the end cover alignment dowel pins ITEM 25 Install the Crankcase End Cover See Fig D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub on page D 13 See Fig D 9 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub con t on page D 14 A Lift the crankcase end cover into position and with the balancer shaft and crankshaft started into their bearings in the cover place the end cover on the crankcase a
61. citro ntn dert te edere P nete eterne aee reserare eate Repair and Service Manual PAGE NO v w U Um U UO Page B i ENGINE DISASSEMBLY Notes Page B ii Repair and Service Manual ENGINE DISASSEMBLY 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 901 1 P lletr Sealz ti tei eee eae 1 Punch non ferrous cccccce ee eseeeeeeceeeeeseeeeeaeeaaeeseeeees 1 Ratchet 3 8 1 Screwdriver small flat blade 1 Screwdriver medium flat 1 Screwdriver 2 phillips 1 Screwdriver 3 phillips seessessss 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
62. d Connecting Rod on page C 6 A Measure wrist pin bore DIMENSION at two 2 places 90 apart B Measure piston skirt DIMENSION B as shown C Measure piston ring grooves DIMENSIONS C AND D at several positions around the piston ENGINE MEASUREMENTS Wrist Pin See Fig C 5 Piston Wrist Pin and Connecting Rod on page C 6 A Measure wrist pin outside diameter at three 3 posi tions DIMENSIONS E F AND G in two 2 places each 90 apart Connecting Rod See Fig C 5 Piston Wrist Pin and Connecting Rod on page C 6 CAUTION Do not measure connecting rod wrist pin bore at oil hole measure at each end of bore Do not measure crankshaft journal at rod cap joint A Measure connecting rod pin bore DIMENSION J at each end in two 2 places each 90 apart B Tighten the rod cap bolts to specified torque and measure the crankshaft journal DIMENSION K in two 2 places 120 apart as shown Cylinder Head Cam and Rocker Shaft Bores See Fig C 7 Cylinder Head Cam and Camshaft on page C 8 See Fig C 10 Rocker Shaft Arms and Bearing Bores on page C 11 A Measure the camshaft bores at four 4 positions DIMENSIONS B C and D in two 2 places each 90 apart B Measure the rocker shaft bores DIMENSIONS E AND F in two 2 places each 90 apart Valve Guides and Seats See Fig C 8 Valve Guides and Seats on page C 9 x It is recommended that the cylinder head be NOTE carefully
63. d warranty stations anywhere in the United States When warranty repair is needed the engine must be brought to an autho rized dealer distributorship or warranty station s place of business during normal business hours In all cas es areasonable time not to exceed 30 days must be allowed for the warranty repair to be completed after the engine is received by the authorized dealer distributor or service station P MAINTENANCE REPLACEMENT AND REPAIR OF EMISSION RELATED PARTS Only warranted engine replacement parts approved by FUJI should be used in the performance of any war ranty maintenance or repairs on emission related parts If other than authorized parts are used for mainte nance replacement or repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to authorized parts in performance and durability FUJI however assumes no liability under this warranty with respect to parts other than autho rized parts The use of non authorized replacement parts does not invalidate the warranty on other com ponents unless the non authorized parts cause damage to warranted parts Q PARTS COVERED UNDER THE CALIFORNIA EMISSIONS WARRANTY 1 Fuel Metering System i Carburetor and internal parts i Choke System iii Fuel filter annual maintenance item 2 Air Induction System i Air filter element semi annual maintenance item 3 Ignition System i Spark plu
64. ds should not be permitted to extend out 9 Oo c Ren s o e o 2 o 2 2 o o c lt while steadily moving it up down inside the cylinder Generally the faster the rpm of tool occur The desired result is a finely cross surface pattern as shown above ENGINE REASSEMBLY Fig D 1 Crankcase Cylinder Engine Shop Rebuild and Parts Manual Page D 6 ENGINE REASSEMBLY Service piston rings profile view at gap NS Compression ring TOP RES Wiper ring MIDDLE S Oil ring BOTTOM N Faces up when installed Insert a portion of the retaining ring into the ring groove Use a flat blade screwdriver to push the remainder of the ring Press the piston down onto the mandrel into the groove pushing the wrist pin in Fig D 2 Piston and Connecting Rods Engine Shop Rebuild and Parts Manual Page D 7 ENGINE REASSEMBLY Compression ring gap Top of Wiper ring piston gap Oil ring gap Note Factory 3 piece oil ring is replaced by 1 piece oil ring Start one end of ring into the groove leaving the other end on top of the piston Rotate piston while working rest of ring into groove Fig D 3 Pistons and Connecting Rods con t Page D 8 Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY Fig D 4 Crankcase End Cover PCV Valve and Oil Filter Engine Shop Rebuild and
65. e en gine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the E Z GO War ranty Department at 1 800 241 5855 LIMITED WARRANTY on Emission Control Systems California Only FUJI Tokyo Japan warrants to the owner of the 2000 and later engine that the engine 1 has been designed built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Re sources Board and 2 is free from defects in materials and workmanship which could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below J WARRANTY COMMENCEMENT DATE The warranty period begins on the date the engine is delivered to a first retail purchaser K LENGTH OF COVERAGE FUJI warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship which could cause the failure of a warranted emission related part for a pe riod of two 2 years after the date of delivery to the first retail purchaser L WHAT IS COVERED 1 REPAIR OR REPLACEMENT PARTS Repairs and replacement of any warranted part will be performed at no charge to you by an au thorized dealer distributor or a warranty station You may contact the E Z GO Warranty Depart ment at
66. ebet tete eus D 5 eA T H D 5 E 0 5 ENGINE REASSEMBLY E CYLINDER HEAD ASSEMBLY Valve G de S E E 1 Cutting the Valve sn tetris nennen E 1 capping the Valves iui ete dt eee e egt ER ueee tion E 1 s Valve Stem Seals nies n dieti an E 2 VANOS uie ade diee ER De ede ed aed eed E 2 s Gylinder Head cede ce a te tede tud E 2 te oit E 2 Rocker ASSOMDIY cT E 2 Rear Timing Belt Cover 3 Drive and Cam Pulleys Idler and Timing 2 2 seen E 3 Front Timing Belt GOVerz ince eb tee Pete tede es E 4 Front Cylinder Baffle a a ena a aa nnns nnne E 4 Rear Cylinder ea a quede cue uad e dne ee cud E 4 s Exhaust Manifold and Gasket e eer debe etaed oid E 4 Blower Housirig x 5 odere eI ene enne ei to E 4 e Coil and Mounting essere entente E 4 Valve AdjustiTient i ehe b Sati a ute ee BE See pa be E 4 SPANK PUGS s 53i ettari teer eite E ere aUe e c E EIE E 4 s Rocker
67. ece 0 008 0 028 0 20 0 70 0 004 0 024 0 10 0 60 1 Piece in mm 0 008 0 016 0 20 0 40 Ring Compression end gap Top Wiper Middle Oil Bottom 3 Piece 1 Piece in 0 008 0 016 STD mm 0 2 0 4 0 008 0 016 0 2 0 4 0 008 0 028 0 2 0 7 0 008 0 016 0 2 0 4 in 0 040 LIMIT mm 1 0 0 040 1 0 0 040 0 040 1 0 1 0 Note Engines are shipped from the factory with three piece oil rings Rebuild rings are special one piece design for convenience Fig C 11 Piston Ring Gap Engine Shop Rebuild and Parts Manual ENGINE MEASUREMENTS TIGHTENING TORQUE DESCRIPTION ft Ib kg cm N m Cylinder head bolts 16 6 19 5 230 270 22 5 26 5 Connecting rod cap bolts 12 3 14 5 170 200 16 7 19 6 Fan hub nut 43 4 47 0 600 650 58 8 63 7 5 8 7 2 80 100 7 8 9 8 Crankcase end cover bolts 12 3 13 7 170 190 16 7 18 6 New plug 8 7 10 9 120 150 11 8 14 7 Retightening 16 6 19 5 230 270 22 5 26 5 Spark plug Oil drain plug 14 5 16 6 200 230 19 6 22 5 Drive gear bolt 5 8 7 2 80 100 7 8 9 8 Cam gear bolt 16 6 19 5 230 270 22 5 26 5 Rocker arm nut 5 8 7 2 80 100 7 8 9 8 4 3 5 8 60 80 5 9 7 8 Others 10 1 13 0 140 180 13 7 17 6 Fig C 12 Torque Specifications Engine Shop Rebuild and Parts Manual Page C 13 ENGINE MEASUREMENTS Notes
68. eduled main tenance described in the Periodic Service Schedule of this manual The scheduled maintenance is based on the normal engine operating schedule Engine Shop Rebuild and Parts Manual Page G 13 LIMITED WARRANTY CALIFORNIA 2004 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd herein FUJI are pleased to explain the emis sion control system warranty on your 2004 and later small off road engine herein engine In California new en gine must be designed built and equipped to meet the State s stringent anti smog standards FUJI must warrant the emission control system on your engine for the period of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor and the ignition system Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists FUJI will repair your engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 2004 and later engines are warranted for two 2 years If any emission related part on your engine is defective the part will be repaired or replaced by FUJI OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your
69. enne nennen nnne Remove the Idler Timing Belt Drive and Cam A 1 Remove the Rear Timing Belt Cover Remove the Front Cylinder Baffle sess Remove the Valve Cover and eene nennen nnne Remove the Rocker Assembly and Camshaft Remove the Cylinder Head and Gasket from the VALVE REMOVAL herein etr MR MU Pcr tera tete eee Remove the Valves from the Cylinder Head ret cans ah LIST OF ILLUSTRATIONS Eig Ast te e totem E Te e LIA de ties A 4 Fig A 2 Cylinder Head 1 A 5 3 6 Repair and Service Manual Page A i ENGINE DISASSEMBLY Notes Page A ii Repair and Service Manual ENGINE DISASSEMBLY CYLINDER HEAD REMOVAL Tool List Qty Required Extension 3 8 drive 4 1 Mallet medium wood or rubber 1 ei nte ttn 1 Ratchet 3 8 1 Screwdriver small flat blade
70. es DETAIL A 1 Use an oven to evenly heat the end cover to 200 Fahrenheit 2 Before the end cover ITEM 1 cools install a new crankshaft bearing ITEM 2 and new balancer shaft bearing ITEM 3 into the cover 3 Allow the cover to cool then lubricate the bearing races with assembly lube B Reassemble the oil pump check valve 1 Coat the check ball ITEM 4 with engine oil and install it into the cover 2 Install the spring ITEM 5 over the check ball 3 Set the valve cover plate ITEM 6 in place with the bleed hole over the spring Hold the plate down and install and tighten the bolt ITEM 7 M6x1 0x8L 10mm socket to specified torque Use 262 Loctite on the bolt do not allow any to get on the ball or spring C Using a seal installation tool install a NEW crank shaft seal ITEM 8 Install New Crankcase Bearing See Fig D 5 Crankshaft Pistons and Balancer Shaft on page D 10 CAUTION If the bearings can be installed by hand without a press or heating the crank case the crankcase and end cover must be replaced A If the original bearings were removed use a mechan ical press or heat the crankcase in an oven to 200 Fahrenheit to install a new crankshaft bearing ITEM 1 and new balancer shaft bearing ITEM 2 into the crankcase ITEM 3 ENGINE REASSEMBLY Install New Crankshaft Bearing See Fig D 6 Crankshaft Pistons and Balancer Shaft con t on page D 11 CAUTION Press only against t
71. evenly in an oven DO NOT USE DIRECT HEAT FLAME OR HOT LIQUID Remove the PCV Valve See Fig B 4 Balancer Shaft Bearing Crankshaft Bearing and PCV Valve on page B 7 NOTE It may be necessary to gently pry the valve cover and valve free before they can be removed from the crankcase A Using a 10mm socket remove two 2 bolts ITEM 3 Later models have four 4 bolts B Remove the PCV cover valve gaskets and hose ITEMS 4 10 Disassemble the Crankcase End Cover See Fig B 1 Engine Components on page B 4 A Using a seal puller remove the crankshaft seal ITEM 2 from the fan side of the cover ITEM 1 DETAIL A B Remove the oil pump check valve from the engine side of the cover 1 Using a 10mm socket remove the bolt ITEM 3 and check valve cover ITEM 4 2 Remove the spring ITEM 5 and check ball ITEM 6 Engine Shop Rebuild and Parts Manual C Clean and inspect the crankshaft bearing ITEM 7 and the balancer shaft bearing ITEM 8 for damage If there is any doubt about a bearing remove it 1 If a bearing is to be removed tap it out with a brass drift and discard or use an oven to evenly heat the end cover to 200 Fahrenheit This will expand the aluminum cover and release the bear ings Crankcase must be heated evenly in an oven DO NOT USE DIRECT HEAT FLAME OR HOT LIQUID Remove the Piston From Connecting Rod See Fig B 1 Engine Components on page B 4 A Remove two 2
72. faces of 040 to 050 wide Repeat this process for each of the valves G Thoroughly clean the valves and the cylinder head to Engine Shop Rebuild and Parts Manual remove all of the lapping compound 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 pro cess and retest Pour out solvent turn over and repeat for the exhaust valves Page E 1 ENGINE REASSEMBLY Install New Valve Stem Seals See Fig E 2 Valves on page D 7 A Place a new seal on a valve guide large diameter down and push until it snaps into place Repeat to install the remaining guides DETAIL B Install 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 Lightly coat the valve stems with engine oil B From the bottom of the head insert one of the valves into its mating seat and guide C Install the valve spring ITEM 6 spring retainer ITEM 7 and keys ITEM 8 DETAIL C 1 While supporting the valve from the bottom place the valve spring over the valve stem from the top 2 Place the spring retainer over the spring Push the retainer down and install the keys It may be nec essary the install keys using a pair of needle nose pliers DETAIL C D Install the
73. ft does not align with the crankcase mark rotate the fan hub until it is aligned 2 Align the key slot in the rear belt retainer ITEM 5 with the key in the crankshaft and install it onto the shaft 3 Align the keyslot in the drive pulley ITEM 3 with the key in the crankshaft and slide the pulley onto the shaft flange side toward the engine B Install the cam pulley ITEM 6 1 Align the notch on the rear of the cam pulley with the pin on the cam shaft and slide the pulley onto the shaft 2 1 1 Engine Shop Rebuild and Parts Manual Rotate the cam pulley until the smallest of the three holes on the face of the gear aligns with the notch at the top of the rear timing belt cover Install the mounting bolt with lock washer ITEM 7 M8x1 25x20L and washer ITEM 8 8 5x28x2 3t Do not tighten the bolt f the E Z GO CAM PUL LEY TOOL is being used position it on the drive and cam pulleys See NOTE above Install the idler ITEM 9 Insert the short extension of the idler spring ITEM 10 into the small hole on the rear face of the idler and position the spring on the raised surface of the face DETAIL A Place the washer ITEM 11 8 5x16x1 2t on the idler mounting bolt ITEM 12 M8x1 25x30L and insert the bolt through the idler While holding the short spring extension in place position the idler against the crankcase Hand tighten the bolt into the crankcase Rotate the spring into the sprin
74. g annual maintenance item il Ignition Coil iit Ignitor Complete iv Pulser Coil Engine Shop Rebuild and Parts Manual Page G 9 LIMITED WARRANTY CALIFORNIA 2000 4 Exhaust Manifold 5 Miscellaneous Items Used in Above Systems i Fuel hoses clamps and sealing gaskets R MAINTENANCE STATEMENTS Page G 10 It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2000 and later Owner s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended FUJI will not deny a warranty claim solely be cause you have no record of maintenance however FUJI may deny a warranty claim if your failure to per form required maintenance resulted in the failure of warranted part The proof which you maintain should be given to each subsequent owner of the engine You are responsible for performing the scheduled main tenance described in the Periodic Service Schedule of this manual The scheduled maintenance is based on the normal engine operating schedule Engine Shop Rebuild and Parts Manual LIMITED WARRANTY CALIFORNIA 2001 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd herein FUJI are pleased to explain the emis sion control system warranty on your 2001 and later small off road engine herein engine In Calif
75. g stop Install a newtiming belt ITEM 13 DETAIL A If the E Z GO CAM PULLEY TOOL is not being used check that the drive and cam pulleys are aligned with their marks Position the belt on the drive pulley Do not twist crimp or turn the belt inside out Rotate the idler counterclockwise until it the belt can be placed on the cam pulley Place the belt on the cam pulley then snug the bolt If the E Z GO CAM PULLEY TOOL is being used remove it Install the drive pulley front belt guide ITEM 14 washer ITEM 15 6 5x22x2t and retaining bolt with lock washer ITEM 16 M6x1 0x16L Torque to specification Loosen the idler bolt and allow the idler to tension the belt Rotate the crankshaft two turns and tighten the bolt to specified torque Page E 3 ENGINE REASSEMBLY Install the Front Timing Belt Cover See Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt on page D 10 A Hold the cover ITEM 17 in place and install three 3 bolts ITEM 18 M6x1 0x12L 10mm socket Tighten the bolts to specified torque Install the Front Cylinder Baffle See Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt on page D 10 A Hold the baffle ITEM 19 in place and install and tighten two 2 bolts ITEM 20 M6x1 0x8L 10mm Socket to specified torque Install the Rear Cylinder Baffle See Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and
76. he PVC Valve See Fig D 4 Crankcase End Cover PCV Valve and Oil Filter on page D 9 A Install the gaskets PCV plate valve and PCV cover ITEMS 4 9 into the PCV port in the crankcase Match the contour of the plate with the contour of the port for correct orientation B Hold the PCV cover ITEM 9 in place and start two 2 bolts ITEM 3 M6x10x18L Tighten the bolts to specified torque using a 10mm socket Install return hose ITEM 10 Engine Shop Rebuild and Parts Manual Install the Oil Filter See Fig D 4 Crankcase End Cover PCV Valve and Oil Filter on page D 9 Later models have a new mesh design for the oil fil ter it is not necessary to replace the oil filter unless damage has occurred to the existing filter A Lubricate the small O ring in the tip of the filter with engine oil B Install a new O ring ITEM 6 in the ring groove C Insert the filter ITEM 5 and with a twisting motion gently push the tip onto the guide boss inside the crankcase until the plate is flush against the crank case Do not use the mounting bolts to pull it into position against the crankcase D Align the mounting holes with the holes in the crank case and start three 3 bolts with washers ITEM 7 M6x1 0x12L Tighten the bolts to specified torque with 10mm socket Page D 5 hatched V M QW of the cylinder as uneven wearing of the beads may the faster the up and down motion in the cylinder Bea
77. he inner race of the bearing when installing it on the shaft A lf the bearing ITEM 4 was removed from the crank shaft ITEM 5 use a mechanical press to install a new bearing DETAIL A Install New Crankshaft Seal See Fig D 5 Crankshaft Pistons and Balancer Shaft on page D 10 A Using a seal installation tool install a new crankshaft seal ITEM 6 and new balancer shaft seal ITEM 7 into the crankcase Lubricate the rubber inside diam eters of the seals with engine oil Install Crankshaft into Crankcase See Fig D 6 Crankshaft Pistons and Balancer Shaft con t on page D 11 CAUTION Be careful not to damage the seal while installing crankshaft A Insert the crankshaft PTO end first through the inte rior of the crankcase into the bearing and through the seal DO NOT DAMAGE THE SEAL Seat the shaft bearing in the bearing bore and make sure that the shaft rotates freely B Lubricate the crankshaft journals and gear with engine oil use a squirt type oil can to fill the crank shaft oil passages with engine oil DETAIL A Install the Pistons in the Crankcase See Fig D 3 Pistons and Connecting Rods con t on page D 8 See Fig D 5 Crankshaft Pistons and Balancer Shaft on page D 10 See Fig D 6 Crankshaft Pistons and Balancer Shaft con t on page D 11 CAUTION It is critical that piston assemblies are properly oriented and installed in their original positions on the crankshaft
78. ice facilities where the warranty repair is performed F WHERE TO GET WARRANTY SERVICE It is recommended that warranty service be performed by the authorized dealer who sold you the engine although warranty service will be performed by any authorized dealers distributors and service providers anywhere in the United States When warranty repair is needed the engine must be brought to an autho rized dealer distributorship or service provider s place of business during normal business hours In all cas es areasonable time not to exceed 30 days must be allowed for the warranty repair to be completed after the engine is received by the authorized dealer distributor or service station G MAINTENANCE REPLACEMENT AND REPAIR OF EMISSION RELATED PARTS Only warranted engine replacement parts approved by FUJI should be used in the performance of any war ranty maintenance or repairs on emission related parts If other than authorized parts are used for mainte nance replacement or repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to authorized parts in performance and durability FUJI however assumes no liability under this warranty with respect to parts other than autho rized parts The use of non authorized replacement parts does not invalidate the warranty on other com ponents unless the non authorized parts cause damage to warranted parts H PARTS COVERED
79. ich is then transferred to a micrometer for measurement Position the gauge in the hole or bore and set the tele scoping arms or ball to its true diameter Make sure that the handle of the gauge is in line with the centerline of the hole or bore Lock and remove the gauge Measure its setting with a micrometer Check flatness of Crankcase End Cover and Cylinder Head See Fig C 1 Using Telescoping and Hole Gauges on page C 1 CAUTION If flatness of a surface is found to be out of tolerance the part must be machined or replaced No more than 010 may be machined from Engine Shop Rebuild and Parts Manual Fig C 1 Using Telescoping and Hole Gauges a surface If warpage is in excess of 004 the part must be replaced A Place the crankcase on a surface plate with the mat ing surface for the end cover down Be sure that all gasket material and dowel pins are removed B Use a 004 feeler gauge to determine if surface is within tolerance 1 Try inserting the feeler gauge into all visible gaps between the crankcase and surface plate If the gauge can be inserted the surface is out of toler ance and must be machined or replaced No more than 010 may be machined from the surface If warpage is in excess of 004 the crankcase must be replaced C Turn the crankcase so that the mating surface for the cylinder head rests on the surface plate and check for flatness in the same m
80. ing screw ITEM 15 M4x 4x6L with lock washer ITEM 16 Install the Pulser Coil See Fig D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub on page D 13 A Hold the pulser coil ITEM 17 in place and start the two 2 mounting screws ITEM 18 M5x0 8x10L 8mm socket with lock washers ITEM 19 B Snug the mounting screws using an 8mm socket Install the Fan Hub See Fig D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub on page D 13 See Fig D 9 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub con t on page D 14 A Install the fan hub alignment key ITEM 21 ENGINE REASSEMBLY 1 Place key in the keyway on the crankshaft spindle Use a brass drift to tap it into position DETAIL B B Align the slot in the fan hub with the key and slide the fan hub onto the crankshaft C Install the fan hub nut ITEM 22 M22x1 5 Tighten the nut to specified torque using a 30mm socket Set the Pulser Coil Air Gap See Fig D 10 Pulser Coil Air Gap on page D 15 A Insert a 2 phillips screwdriver through the one of the holes in the fan as shown and loosen the pulser coil mounting screws B From the side insert a long 020 039 feeler gauge between the pulser coil and fan hub C Press the pulser coil lightly until the feeler gauge is snug between it and the fan hub Hold the pulser coil in this position and tighten the mounting screws Install t
81. iod of 2 years PARTS COVERED Listed below are the parts covered by the Emission Component Defect Warranty Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system ii Air fuel ration feedback and control system if applicable iii Cold start enrichment system if applicable iv Regulator assembly gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance retard system if applicable 4 Exhaust Manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assembly gaseous fuel if applicable OBTAINING WARRANTY SERVICE To obtain warranty service take your engine to the nearest authorized Textron Golf Turf amp Specialty Products dis tributor dealer or service provider Bring your sales receipts indicating date of purchase for this engine The distrib utor dealer or service provider authorized by Textron Golf Turf amp Specialty Products will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order All parts and ac
82. ion ITEM PART NO 2 3 4 5 DESCRIPTION E 72511 G01 SPRING VALVE 26719 G01 GASKET ROCKER COVER 26624 G01 SPACER ROCKER SHAFT 72876 G01 GASKET ROCKER COVER 1 PIECE MAN EXH 26621 G01 ROCKER ARM ASSEMBLY INCLUDES ITEMS 150 151 26622 G01 SCREW M6 X 75 X 20MM 26623 G01 NUT M6 X 75 26625 G01 SPRING ROCKER SHAFT 72394 G01 CAMSHAFT 26709 G01 PIN DOWEL 26620 G01 SHAFT ROCKER 26718 G01 GASKET CAMSHAFT COVER 26599 G01 COVER CAMSHAFT 26678 001 BOLT FLANGED M6 X 1 X 12MM 26679 G01 BOLT M6 X 1 72866 G01 IGNITION COIL 1 PIECE MAN EXH 26657 G01 BRACKET IGNITION COIL 26706 G01 NUT FLANGED M6 X 1 26652 G01 IGNITION COIL 13632 G1 NUT M6 X 1 26733 G01 PLUG WIRE SET 26733 G02 PLUG WIRE SET IGNITION SUPRESSOR OPTIONAL 25523 G3 SPARK PLUG BPR4ES 295 25523 G4 SPARK PLUG NGK BPR5ES 350 26724 G01 GASKET EXHAUST 26633 G01 MANIFOLD EXHAUST 25531 G1 GASKET MUFFLER 25532 G1 BOLT AND WASHER 8 X 1 25 X 18MM Engine Shop Rebuild and Parts Manual Page F 11 ENGINE Illustrated Parts Breakdown When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 23 4 5 DESCRIPTION be Page F 12 601560 26642 G01 26681 G01 26673 G01 72507 G01 26675 G01 26673 G01 26674 G01 26716 G01 72512 G01 72540 G01
83. ion system ii XAir fuel ratio feedback and control system if applicable iii Cold start enrichment system if applicable iv Regulator assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable OBTAINING WARRANTY SERVICE To obtain warranty service take your engine to the nearest authorized E Z GO distributor dealer or service provid er Bring your sales receipts indicating date of purchase for this engine The distributor dealer or service provider authorized by E Z GO will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order All parts and accessories replaced under this warranty become the prop erty of E Z GO WHAT IS NOT COVERED Conditions resulting from tampering misuse improper adjustment unless they were made by the distributor dealer or service provider authorized by E Z GO during a warranty repair alteration accident failure to use the recommended fuel and oil or not performing required maintenance services The replacement parts used for
84. l plate ITEM 7 Page E 5 ENGINE REASSEMBLY 004 Feeler Lobe guage Position heel of cam lobe as shown to measure valve clearance Fig E 1 Valves and Valve Clearance Page E 6 Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY Push spring retainer down to install release valve keys Fig E 2 Valves con t Engine Shop Rebuild and Parts Manual Page E 7 ENGINE REASSEMBLY Fig E 3 Cylinder Head Cam Shaft and Rocker Assembly Page E 8 Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY 7 u 8 Follow numbers to tighten cylinder head bolts in correct sequence Tighten to specified torque in two stages Rotate the cam lobes so that they will not exert pressure on the rocker arms as they are installed on the rocker shaft Fig E 4 Cylinder Head Cam Shaft Rocker Assembly con t Engine Shop Rebuild and Parts Manual Page E 9 ENGINE REASSEMBLY Newer Model gt gt 2 Spring stop Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt Page E 10 Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY Align notch and mark Spring stop Idler spring 1 8 1 4 Deflection Idler clamp bolt tighten to 10 13 at 10 Ibs ft Ibs torque push Align key way with mark Fig E 6 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt c
85. later specialty vehicle engine herein engine In California the en gine must be designed built and equipped to meet the State s stringent anti smog standards FUJI must warrant the emission control system on your engine for the period of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor and the ignition system Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists FUJI will repair your engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 1995 and later engines are warranted for two 2 years If any emission related part on your engine is defective the part will be repaired or replaced by FUJI OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual FUJI recommends that you retain all receipts covering maintenance on your engine but FUJI cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that FUJI may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to a
86. le as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 12 345 DESCRIPTION 87 26713 G01 26666 G01 26681 G01 26597 G01 26664 G01 26665 G01 72538 G01 26595 G01 26594 G01 26711 G01 26596 G01 26680 G01 26678 G01 601552 72850 G01 26671 G01 601553 26655 G01 26656 G01 72863 G01 26651 G02 26707 G01 GASKET PLUG PLUG CRANKCASE BOLT FLANGED M6 X 1 X 8MM PLATE RELIEF VALVE SPRING OIL PUMP RELIEF VALVE STEEL BALL OIL PUMP DIPSTICK STRAIGHT ROTOR OUTER OIL PUMP ROTOR INNER OIL PUMP O RING OIL PUMP COVER COVER OIL PUMP BOLT AND WASHER ASSEMBLY M6 X 1 X 12MM BOLT FLANGED M6 X 1 X 12MM 1 PIECE MAN EXH BOLT FLANGED M8 X 1 25 X 28MM 1 PIECE MAN EXH BOLT AND WASHER ASSEMBLY 8 X 1 25 X 30MM BOLT AND WASHER ASSEMBLY M6 X 1 X 30MM BOLT FLANGED M6 X 1 0 X 28MM 1 PIECE MAN EXH OIL PRESSURE SWITCH ASSEMBLY INCLUDES ITEMS 109 111 WASHER LOCK SWITCH OIL PRESSURE WIRE OIL PRESSURE SWITCH OIL PRESSURE SWITCH ASSEMBLY INCLUDES ITEMS 109 111 1 PIECE MAN EXH PULSER COIL BOLT AND WASHER ASSEMBLY M5 X 8 X 10MM Engine Shop Rebuild and Parts Manual ENGINE Illustrated Parts Breakdown When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information IT
87. lem G Remove dowel pins ITEM 30 H Remove the end cover gasket ITEM 25 and the oil feed O ring ITEM 26 Remove the Balancer Shaft See Fig B 1 Engine Components on page B 4 A While pushing the shaft from the PTO clutch side of the engine gently work the balancer shaft gear free from the crankshaft balancer gear and remove the shaft ITEM 27 from the crankcase Remove the Pistons See Fig B 3 Crankshaft on page B 6 Remove any carbon deposits from the top of NOTE the cylinder wall These might damage the pis ton or prevent it from being removed Page B 2 Engine Shop Rebuild and Parts Manual Because the pistons rods and caps CAUTION were machined and have established wear patterns as assemblies it is critical to the life expectancy and performance of the engine that they are reassembled with their original mates and in their original positions Mark and sort mating parts as they are disassembled A Rotate the crankshaft until the pistons ITEM 1 are at bottom dead center or are positioned to allow best access to the connecting rod bolts ITEM 2 B Using a 10mm socket remove the connecting rod bolts and cap ITEM 3 from the fan side piston assembly C Reposition the crankshaft at top dead center and push the piston and rod out through the top of the block Reattach the connecting rod cap to the rod to insure correct match of mating parts D Repeat steps A B and C to remo
88. lignment dowels and gently work it down until it rests against the crankcase Be careful not to damage oil seals Page D 4 Engine Shop Rebuild and Parts Manual B Install the end cover mounting bolts 1 Start two 2 bolts ITEM 4 M8x1 25x30L 12mm Socket with lock washers ITEM 5 and six 6 bolts ITEM 6 M6x1 0x30L 10mm socket with lock washers ITEM 7 and snug them in the order shown DETAIL A 2 In the same order tighten the bolts to 1 2 of speci fied torque Repeat the sequence tightening the bolts to specified torque Install the Oil Pump Gear Rotors See Fig D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub on page D 13 A Coat the internal gear rotor ITEM 8 with engine oil and place it on the rotor shaft in the pump bore B Lubricate the external gear rotor ITEM 9 with engine oil and place it in the pump bore C Install a new O ring ITEM 10 in the ring groove D Hold the oil pump cover ITEM 11 in place Install and tighten three 3 mounting bolts with lock wash ers ITEM 12 M6x1 0x12L 10mm socket to speci fied torque Install the Oil Pressure Switch See Fig D 8 Oil Pump Gear Rotors Oil Pressure Switch Pulser Coil and Fan Hub on page D 13 A Apply a small amount of pipe sealer or teflon tape to the switch threads B Use an oil pressure switch socket to install and snug the switch C Use a 7mm socket to attach the switch wire ITEM 14 and mount
89. linder 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 B C 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 Remove no more material than is necessary to clean the valve seat 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 B Turn the cylinder head upside down 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 Moisten the suction cup on the valve lapping tool and attach it to the valve Apply a small amount of valve grinding compound evenly around the valve seat 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 sur
90. ll be performed at no charge to you by an au thorized dealer distributor or a warranty station You may contact the E Z GO Warranty Depart ment at 1 800 241 5855 to get the nearest appropriate location where your warranty repairs are performed 2 WARRANTY PERIOD This warranty continues for a period of two 2 years and shall apply only to the repair replace ment or adjustment of the component parts which are not scheduled for replacement as required maintenance Further component parts which are scheduled only for regular inspection to the ef fect of repair or replace as necessary shall be warranted for the warranty period Any warranted Engine Shop Rebuild and Parts Manual Page G 5 LIMITED WARRANTY CALIFORNIA 1995 1999 part which is scheduled for replacement as required maintenance shall be warranted for the pe riod of time up to the first scheduled replacement point for that part 3 DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective if the diagnostic work is performed at an authorized dealer distributor or warranty station 4 CONSEQUENTIAL DAMAGES If a warranted part failed causing damages to other engine components consult a warranty sta tion D WHAT IS NOT COVERED 1 This limited warranty does not cover any part which malfunctions fails or is damaged due to failure to follow the maintenance and operating instructions set forth in the 1995 and later O
91. longer exert any force on the camshaft ITEM 9 and it can rotate freely D Remove the rocker assembly 1 Insert 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 CAUTION 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 VALVE REMOVAL Remove the Valves fr
92. m flat 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 NOTE If the engine is not going to be put back into service immediately completely coat all inter nal engine components with assembly lube Tape intake and exhaust openings Engine Shop Rebuild and Parts Manual CAUTION Prior to engine reassembly parts must be thoroughly cleaned free of dirt oil grease carbon deposits or residue of any kind free of nicks burrs or damage of any kind to wear surfaces and inspected for excessive wear Parts that are damaged or are not within dimensional specifications should be replaced or machined if applicable We recommend that parts found to be acceptable but near limits be replaced if the engine will
93. mbly on page D 8 Do not allow the wear surfaces of the CAUTION camshaft to scrape against the cylinder head during installation A Lubricate the camshaft lobes and journals with engine oil B Insert the camshaft ITEM 7 small end first into the head through the camshaft bore in the fan side of the cylinder head Seat the shaft journals in the bores in each side of the head Do not allow the lobes or jour nals of the shaft to scrape against the head Install the Rocker Assembly See Fig E 3 Cylinder Head Cam Shaft and Rocker Assembly on page D 8 See Fig E 4 Cylinder Head Cam Shaft Rocker Assembly con t on page D 9 It is critical to the performance and life CAUTION expectancy of the engine that mating parts that have established wear patterns are reassembled in their original positions A If the rocker adjustment screws ITEM 8 and lock nuts ITEM 9 were removed from the rocker arms ITEM 10 re install them DETAIL B B Lubricate the rocker shaft ITEM 11 and rocker arm bearing surfaces with engine oil C Rotate the camshaft until all of the lobes are posi tioned so that they will not interfere with the motion of the rocker arms DETAIL C D Install the rocker shaft through the bore on the fan side of the engine with the ends of the shaft oriented as they were originally E Install the four 4 rocker arms two 2 spacers ITEM 12 and spring ITEM 13 on the leading end of the shaf
94. nation that a warranted part is defective if the diagnostic work is performed at an authorized dealer distributor or service provider 4 CONSEQUENTIAL DAMAGES If a warranted part failed causing damages to other engine components consult a service provid er M WHAT IS NOT COVERED 1 This limited warranty does not cover any part which malfunctions fails or is damaged due to failure to follow the maintenance and operating instructions set forth in the 2004 and later Owner s Manual in cluding 1 improper scheduled engine inspection and maintenance 2 improper maintenance of any warranted parts 3 improper installation adjustment or repair of the engine or of any warranted part unless per formed by an authorized dealer 4 failure to follow recommendations on fuel use contained in the 2004 and later Owner s Manual 5 repairs performed outside of the authorized warranty service facilities 6 use of parts which are not authorized by FUJI 2 Add on or modified parts This warranty does not cover any part which malfunctions fails or is damaged due to alterations by changing adding to or removing parts from the engine 3 Expenses incurred by processing warranty claims FUJI any authorized dealer distributors and service providers shall not be liable for any loss of use of the engine for any alternative usage for any damage to goods loss of time or inconve nience N HOW TO FILE A CLAIM All repairs qualifying under this Limited Warranty mu
95. necting Rods See Fig D 2 Piston and Connecting Rods on page D 7 CAUTION It is critical to the performance and life expectancy of the engine that parts be assembled in their original positions with their original mating parts Page D 1 ENGINE REASSEMBLY A Apply a coat of assembly lube to the exterior surface of the wrist pin ITEM 1 and to the wrist pin bores in the connecting rod ITEM 2 and piston ITEM 3 B Insert the wrist pin through the pin bore on one side of the piston allowing it to protrude slightly into the interior of the piston C With the word FAN on the connecting rod oriented toward the letters DF on the top of the piston slide the rod onto the end of the wrist pin protruding into the interior of the piston Continue pushing the wrist pin through the piston and into the opposing bore D Install the wrist pin retaining rings ITEM 4 1 Insert a portion of a wrist pin retaining ring into the groove at the mouth of the wrist pin bore in the pis ton Use a flat blade screwdriver to push the remainder of the ring into the groove DETAIL A 2 Use a suitable mandrel to push the wrist pin against the retaining ring from the opposite side of the piston DETAIL B 3 Repeat step 1 to install the second wrist pin retain ing ring Install the Piston Rings See Fig D 2 Piston and Connecting Rods on page D 7 See Fig D 3 Pistons and Connecting Rods on page D 8 NOTE ment
96. nty claim solely because you have no record of maintenance however FUJI may deny a warranty claim if your failure to perform required maintenance resulted in the failure of warranted part The proof which you maintain should be given to each subsequent owner of the engine You are responsible for performing the scheduled maintenance described in the Periodic Service Schedule of this manual The scheduled maintenance is based on the normal engine operating schedule Page G 16 Engine Shop Rebuild and Parts Manual EZGO A Textron Company E Z GO Division of Textron Inc 1451 Marvin Griffin Rd Augusta Georgia 30906 USA Inside 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 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department
97. ny warranted part will be performed at no charge to you by an au thorized dealer distributor or a service provider You may contact the Textron Golf Turf amp Spe cialty Products Warranty Department at 1 800 241 5855 to get the nearest appropriate location where your warranty repairs are performed 2 WARRANTY PERIOD This warranty continues for a period of two 2 years and shall apply only to the repair replace ment or adjustment of the component parts which are not scheduled for replacement as required maintenance Further component parts which are scheduled only for regular inspection to the ef fect of repair or replace as necessary shall be warranted for the warranty period Any warranted Engine Shop Rebuild and Parts Manual Page G 11 LIMITED WARRANTY CALIFORNIA 2001 part which is scheduled for replacement as required maintenance shall be warranted for the pe riod of time up to the first scheduled replacement point for that part 3 DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective if the diagnostic work is performed at an authorized dealer distributor or service provider 4 CONSEQUENTIAL DAMAGES If a warranted part failed causing damages to other engine components consult a service provid er D WHAT IS NOT COVERED 1 This limited warranty does not cover any part which malfunctions fails or is damaged due to failure to follow the maintenance and ope
98. om 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 Shop Rebuild and Parts Manual Page A 3 ENGINE DISASSEMBLY Newer Model gt gt amp z ewer Model Fig 1 Engine Page A 4 Engine Shop Rebuild and Parts Manual ENGINE DISASSEMBLY Follow numbers to remove cylinder head bolts in correct sequence y 0 v lt M ofp I y 5 y E Fig 2 Cylinder Head Components Engine Shop Rebuild and Parts Manual Page A 5 ENGINE DISASSEMBLY Push spring retainer down to release valve keys Pry valve stem seal loose
99. on t Engine Shop Rebuild and Parts Manual Page E 11 ENGINE REASSEMBLY Follow numbers to tighten manifold bolts in correct sequence Tighten to specified torque in two stages Some later models may or may not have an oil pressure switch some models have location of the switch in a slightly different position Route the oil pressure switch wire and the pulser coil wire through the groove in the blower housing Fig E 7 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt con t Page E 12 Engine Shop Rebuild and Parts Manual ENGINE REASSEMBLY Rocker cover tightening sequence Fig E 8 Rocker Cover Engine Shop Rebuild and Parts Manual Page E 13 ENGINE REASSEMBLY Fig E 9 Carburetor Page E 14 Engine Shop Rebuild and Parts Manual Illustrated Parts Breakdown EF ILLUSTRATED PARTS BREAKDOWN Engine Shop Rebuild and Parts Manual Page F 1 ENGINE Illustrated Parts Breakdown e Newer Model Earlier Model Page F 2 Engine Shop Rebuild and Parts Manual ENGINE Illustrated Parts Breakdown Page F 3 Engine Shop Rebuild and Parts Manual ENGINE Illustrated Parts Breakdown Newer Model Page F 4 Engine Shop Rebuild and Parts Manual Illustrated Parts Breakdown ENGINE Newer Model Newer Model Engine Shop Rebuild and Parts Manual Page F 5 ENGINE Illustrated Parts Breakdown When ordering parts please specify the model and serial number of the
100. on the date the engine is delivered to a first retail purchaser K LENGTH OF COVERAGE FUJI warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship which could cause the failure of a warranted emission related part for a pe riod of two 2 years after the date of delivery to the first retail purchaser L WHAT IS COVERED 1 REPAIR OR REPLACEMENT PARTS Repairs and replacement of any warranted part will be performed at no charge to you by an au thorized dealer distributor or a service provider You may contact the E Z GO Warranty Depart ment at 1 800 241 5855 to get the nearest appropriate location where your warranty repairs are performed 2 WARRANTY PERIOD This warranty continues for a period of two 2 years and shall apply only to the repair replace ment or adjustment of the component parts which are not scheduled for replacement as required maintenance Further component parts which are scheduled only for regular inspection to the ef fect of repair or replace as necessary shall be warranted for the warranty period Any warranted Page G 14 Engine Shop Rebuild and Parts Manual LIMITED WARRANTY CALIFORNIA 2004 part which is scheduled for replacement as required maintenance shall be warranted for the pe riod of time up to the first scheduled replacement point for that part 3 DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determi
101. ools that will be required to perform the operations desired in that sec tion Do not use non specified tools vise grips amp 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 Engine Shop Rebuild and Parts Manual vii HOW TO USE THIS MANUAL viii Engine Shop Rebuild and Parts Manual ENGINE DISASSEMBLY TABLE OF CONTENTS FOR SECTION A SECTION TITLE PAGE NO CYLINDER HEAD REMOQOVAL n ES r e AER ERR entree n rena e ere eer arenas Remove the Air Cleaner ote dere hee dt dto debo dene fe v de odds Remove the Carb retor 5 aene ed trei ie re DHT e t Ed Remove the Coil Mounting Bracket and Coil f Remove the Blower Housing cscssccsssesssessssseseseseseeceseesneesssecsceseseeeseecseeeoeessanseseeoes Remove the Exhaust Manifold sesssssessessseseseseseseeee eterne nnne nennen nennen Remove the Rear Cylinder Baffle Remove the Timing Belt
102. ornia the engine must be designed built and equipped to meet the State s stringent anti smog standards FUJI must warrant the emission control system on your engine for the period of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor and the ignition system Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists FUJI will repair your engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 2001 and later engines are warranted for two 2 years If any emission related part on your engine is defective the part will be repaired or replaced by FUJI OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual FUJI recommends that you retain all receipts covering maintenance on your engine but FUJI cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that FUJI may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to a dealer distributor or service provider authorized by Textron
103. r ITEM 15 B Remove the oil pump O ring ITEM 16 C Carefully remove the oil pump rotors ITEMS 17 and 18 Page B 1 ENGINE DISASSEMBLY Remove the Crankcase End Cover See Fig B 1 Engine Components on page B 4 See Fig B 2 Engine Components con t on page B 5 Do not lose the crankshaft and balancer shaft NOTE end play spacers These are individually fitted to each engine and are likely to fall from the engine when the cover is removed If the end cover must be tapped loose CAUTION use a wooden or rubber mallet Gently tap only the place shown in Detail D A Remove the fan hub alignment key ITEM 20 DETAIL C Later models do not have a hub key 1 Using a non ferrous 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 B Using a 12mm socket remove two 2 bolts ITEM 21 C Using a 10mm socket remove the six 6 remaining bolts ITEM 22 attaching the cover to the crankcase D Using a wooden or rubber mallet lightly tap the cover to break it loose from the crankcase TAP ONLY THE PLACE SHOWN DETAIL D E Remove the cover from the crankcase Do not lose the crankshaft and balancer shaft spacers ITEMS 23 and 24 that could fall from the engine when the cover is removed F Drain any remaining oil from the crankcase Note any unusual debris that might identify a prob
104. rating instructions set forth in the 2001 and later Owner s Manual in cluding 1 improper or inadequate scheduled engine inspection and maintenance 2 improper or inadequate maintenance of any warranted parts 3 improper installation adjustment or repair of the engine or of any warranted part unless per formed by an authorized dealer 4 failure to follow recommendations on fuel use contained in the 2001 and later Owner s Manual 5 repairs performed outside of the authorized warranty service facilities 6 use of parts which are not authorized by FUJI 2 Add on or modified parts This warranty does not cover any part which malfunctions fails or is damaged due to alterations by changing adding to or removing parts from the engine 3 Expenses incurred by processing warranty claims FUJI any authorized dealer distributors and service providers shall not be liable for any loss of use of the engine for any alternative usage for any damage to goods loss of time or inconve nience E HOW TO FILE A CLAIM All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or distributors or service providers authorized by Textron Golf Turf amp Specialty Products In the event that any emission related part is found to be defective during the warranty period you should notify Textron Golf Turf amp Specialty Products Warranty Department at 1 800 241 5855 and you will be given the appro priate warranty serv
105. required maintenance services Consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc Diagnosis and inspection charges that do not result in warranty eligible service being performed Any non authorized replacement part or malfunction of authorized parts due to use of non authorized parts OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your owner s manual E Z GO recommends that you retain all receipts covering maintenance on your engine but E Z GO cannot Engine Shop Rebuild and Parts Manual Page G 1 LIMITED WARRANTY FEDERAL deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled mainte nance As the engine owner you should however be aware that E Z GO may deny warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to the nearest distributor dealer or service provider authorized by E Z GO when problem exists If you have any questions regarding your warranty rights and responsibilities you should contact the E Z GO War ranty Department at 1 800 241 5855 for the information THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper maintenance of the
106. ressu ves 2 Rocker Cover and Gaskets A 2 e Rocker Assembly and Cam seen A 2 Cylinder Head and Gasket irre etes tueeipe ute eitis A 2 82 ValV8S csset ente CSI A A 3 x Aiea aed Meee a e A 3 ENGINE DISASSEMBLY B CRANKCASE DISASSEMBLY 1 E inn aUo ME I B 1 Pulser Coll EE B 1 Gil Pressure Switch ciii ee nen leaded Ex een ben ege aed B 1 EON Uo EI II TIU B 1 Crankcase Erid COVer a Dy dade ege Vana e oT pane aUe dad eue eaae eua nere RUE daga B 2 End Cover Gasket and Oil Feed O Ring essere nennen nens B 2 gt Balancer Shaft dete n ende ei Vc tee Ie Ma IER ERR REPE Leak B 2 s PISTONS s nie ees eines B 2 s Grankshatt a eI E NE Lee B 2 e Balancer and Crankshaft Seals ssssssssssssssssssssessseeeeeee nre nennen nnns B 2 e Balancer Shaft and Crankcase B 2 IP OV Valve d b mea tras se auntie tacere edente enden betonte B 3 Crankcase End 0107 1 TTE B 3 e Piston and Connecting Rod sse nennen trennen sinensis B 3 sGrankshaft Bearirig s m
107. rts in performance and durability FUJI however assumes no liability under this warranty with respect to parts other than autho rized parts The use of non authorized replacement parts does not invalidate the warranty on other com ponents unless the non authorized parts cause damage to warranted parts Q PARTS COVERED UNDER THE CALIFORNIA EMISSIONS WARRANTY 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system il Air fuel ratio feedback and control system if applicable iil Cold start enrichment system if applicable iv Regulator assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs Engine Shop Rebuild and Parts Manual Page G 15 LIMITED WARRANTY CALIFORNIA 2004 ii Magneto or electronic ignition system iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable il Hoses belts connectors and assemblies iil Filter lock assy gaseous fuel if applicable R MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recom mended in the 2004 and later Owner s Manual and to retain proof that inspection and maintenance services are per formed at the times when recommended FUJI will not deny a warra
108. smog standards FUJI must warrant the emission control system on your engine for the period of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor and the ignition system Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists FUJI will repair your engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 2000 and later engines are warranted for two 2 years If any emission related part on your engine is defective the part will be repaired or replaced by FUJI OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual FUJI recommends that you retain all receipts covering maintenance on your engine but FUJI cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that FUJI may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to a dealer distributor or warranty station authorized by E Z GO DIVISION OF TEXTRON INC Augusta Georgia herein E Z GO to which FUJI supplies th
109. 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 NOTE 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 CAUTION 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 Page A 2 Engine Shop Rebuild and Parts Manual 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
110. st be performed by a dealer who sold you the engine or distributors or service providers authorized by E Z GO In the event that any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855 and you will be given the appropriate warranty service facilities where the warranty repair is per formed O WHERE TO GET WARRANTY SERVICE It is recommended that warranty service be performed by the authorized dealer who sold you the engine although warranty service will be performed by any authorized dealers distributors and service providers anywhere in the United States When warranty repair is needed the engine must be brought to an autho rized dealer distributorship or service provider s place of business during normal business hours In all cas es areasonable time not to exceed 30 days must be allowed for the warranty repair to be completed after the engine is received by the authorized dealer distributor or service station P MAINTENANCE REPLACEMENT AND REPAIR OF EMISSION RELATED PARTS Only warranted engine replacement parts approved by FUJI should be used in the performance of any war ranty maintenance or repairs on emission related parts If other than authorized parts are used for mainte nance replacement or repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to authorized pa
111. t in their original positions as the shaft is inserted into the head Seat the shaft in the bore on the PTO side of the head ENGINE REASSEMBLY F Install the camshaft cover ITEM 14 and new gasket ITEM 15 1 With the flanged side of the cover oriented away from the engine hold the cover and gasket in place and install three 3 bolts ITEM 16 M6x1 0x12L and one 1 stud ITEM 17 M6x1 0 The stud is mounted in the top right corner of the cover 2 Tighten the mounting bolts and stud to specified torque Install the Rear Timing Belt Cover See Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt on page D 10 See Fig E 6 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt con t on page D 11 A Hold the cover in place and install two 2 bolts ITEM 2 M6x1 0x8L 10mm socket Later models have only one 1 bolt B Tighten the mounting bolts to specified torque Install the Drive and Cam Pulleys Idler and Timing Belt See Fig E 5 Timing Belt Covers Drive and Cam Pulleys Idler and Timing Belt on page D 10 NOTE A special tool for holding the drive and cam pul leys in proper timing position while installing the timing belt is available from the E Z GO Service Parts Department See Tool list Do not twist crimp or turn the belt CAUTION inside out This will cause the belt to fail A Install the drive pulley ITEM 3 1 If the key ITEM 4 in the cranksha
112. ted parts 3 improper installation adjustment or repair of the engine or of any warranted part unless per formed by an authorized dealer 4 failure to follow recommendations on fuel use contained in the 2000 and later Owner s Manual 5 repairs performed outside of the authorized warranty service facilities 6 use of parts which are not authorized by FUJI 2 Add on or modified parts This warranty does not cover any part which malfunctions fails or is damaged due to alterations by changing adding to or removing parts from the engine 3 Expenses incurred by processing warranty claims FUJI any authorized dealer distributors and warranty station shall not be liable for any loss of use of the engine for any alternative usage for any damage to goods loss of time or inconve nience N HOW TO FILE A CLAIM All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or distributors or warranty stations authorized by E Z GO In the event that any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855 and you will be given the appropriate warranty service facilities where the warranty repair is per formed O WHERE TO GET WARRANTY SERVICE It is recommended that warranty service be performed by the authorized dealer who sold you the engine although warranty service will be performed by any authorized dealers distributors an
113. ve during the warranty period you shall notify E Z GO Warranty Department at 1 800 241 5855 and you will be advised of the appropriate warranty service providers where the warranty repair can be performed Page G 2 Engine Shop Rebuild and Parts Manual LIMITED WARRANTY FEDERAL 2001 EMISSION COMPONENT DEFECT WARRANTY COVERAGE This emission warranty is applicable in all states except the State of California Fuji Heavy Industries Ltd and Textron Golf Turf amp Specialty Products Augusta Georgia herein Textron Golf Turf amp Specialty Products warrant s to the initial retail purchaser and each subsequent owner that this Nonroad engine herein engine has been designed built and equipped to conform at the time of initial sale to all applicable regu lations of the U S Environmental Protection Agency EPA and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period For the components listed under PARTS COVERED the distributor dealer or service provider authorized by Tex tron Golf Turf amp Specialty Products will at no cost to you make the necessary diagnosis repair or replacement necessary to ensure that the engine complies with applicable U S EPA regulations EMISSION COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a per
114. ve the PTO clutch side piston assembly Remove the Crankshaft See Fig B 3 Crankshaft on page B 6 On engines with many hours of operation it NOTE may be necessary to gently tap the crankshaft on the PTO clutch end to dislodge it Use a light wooden or rubber mallet handle only Remove the Balancer Shaft Seal and the Crankshaft Seal See Fig B 3 Crankshaft on page B 6 CAUTION Do not scratch or score the seal bore A Using a seal puller pry the shaft seal ITEM 5 and crankshaft seal ITEM 6 from the block DETAIL A Inspect the Balancer Shaft Bearing and Crankshaft Bearing See Fig B 4 Balancer Shaft Bearing Crankshaft Bearing and PCV Valve on page B 7 A Remove the balancer shaft bearing ITEM 1 and crankshaft bearing ITEM 2 only if they appear to be worn or damaged Do not use direct heat flame or hot liq CAUTION uid to expand parts Parts must be heat ed evenly in an oven B Clean the bearings and inspect for damage blue dis coloration pitting rough or noisy rotation etc If there is any doubt about a bearing remove it and discard ENGINE DISASSEMBLY C To remove a bearing turn the crankcase on its side PTO clutch side up and gently tap the bearing out with a brass drift DETAIL A Discard the bearing The bearings can also be removed by heating the crankcase to 200 Fahrenheit This will expand the aluminum crankcase and release the bearings Crankcase must be heated
115. wn in certain quantities to cause cancer birth defects or other reproductive harm NOTE 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 ii Transaxle Shop Rebuild and Parts Manual TABLE OF CONTENTS Section Page No How to use the E Z GO Service Manual sse enne nennen vii Federal and California Emissions Warranty sse Section G ENGINE DISASSEMBLY A CYLINDER HEAD REMOVAL SAI GIeanetzs ooi 1 Gaure pere ED 1 5 Goil and Bracke tsa 2 ei el ete et eee E E eee A 1 x Blower HOUSING e i ete E EROR a Sab E A 1 ExhaustManlltold deem ur pete tbe ee atio d tcd A 1 Bear Gylinder s iie deti err tee PT PO a Edo Re e SR cod neas A 1 Front Timing Belt sse entere nennen A 1 Idler Timing Belt and Cam Geoar ien a ene nnne nnns A 1 Rear Timing aa 2 Front Cylinder Baffle reisais ins epe ia tee g
116. wner s Manual in cluding 1 improper or inadequate scheduled engine inspection and maintenance 2 improper or inadequate maintenance of any warranted parts 3 improper installation adjustment or repair of the engine or of any warranted part unless per formed by an authorized dealer 4 failure to follow recommendations on fuel use contained in the 1995 and later Owner s Manual 5 repairs performed outside of the authorized warranty service facilities 6 use of parts which are not authorized by FUJI 2 Add on or modified parts This warranty does not cover any part which malfunctions fails or is damaged due to alterations by changing adding to or removing parts from the engine 3 Expenses incurred by processing warranty claims FUJI any authorized dealer distributors and warranty station shall not be liable for any loss of use of the engine for any alternative usage for any damage to goods loss of time or inconve nience E HOW TO FILE A CLAIM All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or distributors or warranty stations authorized by E Z GO In the event that any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855 and you will be given the appropriate warranty service facilities where the warranty repair is per formed F WHERE TO GET WARRANTY SERVICE It is recommended that warranty servi

engine shop rebuild & service parts manual 27615-g01

Contents

Download Pdf Manuals

Related Search

Related Contents

engine shop rebuild &amp; service parts manual 27615-g01

Contents

Download Pdf Manuals

Related Search

Related Contents

engine shop rebuild & service parts manual 27615-g01