EZ-GO 295CC 350CC 4Cycle Engine Factory Service Repair Manual + Parts Manual

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EZ-GO 295CC 350CC 4Cycle Engine Factory Service Repair Manual + Parts Manual

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Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your EZ-GO.

112 Pages

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EZ-GO 295CC 350CC 4Cycle Engine Factory Service Repair Manual + Parts Manual

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your engine.

112 Pages

MANUAL COVERS:

295cc – 4cycle

350cc – 4cycle

Starting Model Year: 1992

Revised: 08/04

CD COVERS:

ENGINE DISASSEMBLY A

CYLINDER HEAD REMOVAL

Air Cleaner……………………………………. ……………………………………… …………………………………..A-1
Carburetor…………………………………….. ……………………………………… …………………………………..A-1
Coil and Bracket ……………………………. ……………………………………… …………………………………..A-1
Blower Housing……………………………… ……………………………………… …………………………………..A-1
Exhaust Manifold …………………………… ……………………………………… …………………………………..A-1
Rear Cylinder Baffle……………………….. ……………………………………… …………………………………..A-1
Front Timing Belt Cover ………………….. ……………………………………… …………………………………..A-1
Idler, Timing Belt and Cam Gear………. ……………………………………… …………………………………..A-1
Rear Timing Belt Cover…………………… ……………………………………… …………………………………..A-2
Front Cylinder Baffle ………………………. ……………………………………… …………………………………..A-2
Rocker Cover and Gasket ………………. ……………………………………… …………………………………..A-2
Rocker Assembly and Cam Shaft …….. ……………………………………… …………………………………..A-2
Cylinder Head and Gasket………………. ……………………………………… …………………………………..A-2
Valves ………………………………………….. ……………………………………… …………………………………..A-3
Valve Guides…………………………………. ……………………………………… …………………………………..A-3

ENGINE DISASSEMBLY B

CRANKCASE DISASSEMBLY

Oil Filter ……………………………………….. ……………………………………… …………………………………..B-1
Fan Hub ……………………………………….. ……………………………………… …………………………………..B-1
Pulser Coil ……………………………………. ……………………………………… …………………………………..B-1
Oil Pressure Switch ……………………….. ……………………………………… …………………………………..B-1
Oil Pump………………………………………. ……………………………………… …………………………………..B-1
Crankcase End Cover…………………….. ……………………………………… …………………………………..B-2
End Cover Gasket and Oil Feed O-Ring ……………………………………. …………………………………..B-2
Balancer Shaft ………………………………. ……………………………………… …………………………………..B-2
Pistons …………………………………………. ……………………………………… …………………………………..B-2
Crankshaft…………………………………….. ……………………………………… …………………………………..B-2
Balancer and Crankshaft Seals ……….. ……………………………………… …………………………………..B-2
Balancer Shaft and Crankcase Bearings……………………………………. …………………………………..B-2
PCV Valve…………………………………….. ……………………………………… …………………………………..B-3
Crankcase End Cover…………………….. ……………………………………… …………………………………..B-3
Piston and Connecting Rod …………….. ……………………………………… …………………………………..B-3
Crankshaft Bearing ………………………… ……………………………………… …………………………………..B-3

ENGINE MEASUREMENTS AND SPECIFICATIONS C

ENGINE MEASUREMENTS AND SPECIFICATIONS

Check Flatness of Crankcase, End Cover and Cylinder Head………. …………………………………..C-1
Crankcase Cylinder Bores ………………. ……………………………………… …………………………………..C-2
Crankcase and End Cover Crankshaft Bearing Bores …………………. …………………………………..C-2
Crankshaft Journals and Gear…………. ……………………………………… …………………………………..C-2
Crankcase and End Cover Balancer Shaft Bearing Bores ……………. …………………………………..C-2
Balancer Shaft Journals and Gear……. ……………………………………… …………………………………..C-2
Piston…………………………………………… ……………………………………… …………………………………..C-2
Wrist Pin ………………………………………. ……………………………………… …………………………………..C-3
Connecting Rod…………………………….. ……………………………………… …………………………………..C-3
Cylinder Head Cam and Rocker Shaft Bores ……………………………… …………………………………..C-3
Valves Guides and Seats………………… ……………………………………… …………………………………..C-3
Valves and Valve Springs ……………….. ……………………………………… …………………………………..C-3
Camshaft ……………………………………… ……………………………………… …………………………………..C-3
Rocker Shaft and Rocker Arms ……….. ……………………………………… …………………………………..C-3
Piston Ring Gap…………………………….. ……………………………………… …………………………………..C-3
Torque Specifications……………………… ……………………………………… …………………………………..C-3

ENGINE REASSEMBLY D

CRANKCASE ASSEMBLY

Honing the Cylinder Bores………………. ……………………………………… …………………………………..D-1
Pistons and Connecting Rods …………. ……………………………………… …………………………………..D-1
Piston Rings………………………………….. ……………………………………… …………………………………..D-2
Crankcase End Cover…………………….. ……………………………………… …………………………………..D-2
Crankcase Bearings ………………………. ……………………………………… …………………………………..D-2
Crankshaft Bearing ………………………… ……………………………………… …………………………………..D-3
Crankshaft and Balancer Shaft Seals.. ……………………………………… …………………………………..D-3
Crankshaft ……………………………………. ……………………………………… …………………………………..D-3
Pistons …………………………………………. ……………………………………… …………………………………..D-3
Balancer Shaft ………………………………. ……………………………………… …………………………………..D-3
Checking Crankshaft and Balancer Shaft Endplay ………………………. …………………………………..D-4
End-Play Spacers ………………………….. ……………………………………… …………………………………..D-4
Oil Feed O-Ring…………………………….. ……………………………………… …………………………………..D-4
Crankcase End Cover Gasket …………. ……………………………………… …………………………………..D-4
Crankcase End Cover…………………….. ……………………………………… …………………………………..D-4
Oil Pump Gear Rotors ……………………. ……………………………………… …………………………………..D-5
Oil Pressure Switch ……………………….. ……………………………………… …………………………………..D-4
Pulser Coil ……………………………………. ……………………………………… …………………………………..D-4
Fan Hub ……………………………………….. ……………………………………… …………………………………..D-4
Pulser Coil and Air Gap ………………….. ……………………………………… …………………………………..D-5
PCV Valve…………………………………….. ……………………………………… …………………………………..D-5
Oil Filter ……………………………………….. ……………………………………… …………………………………..D-5

ENGINE REASSEMBLY E

CYLINDER HEAD ASSEMBLY

Valve Guides…………………………………. ……………………………………… …………………………………..E-1
Cutting the Valve Seats…………………… ……………………………………… …………………………………..E-1
Lapping the Valves…………………………. ……………………………………… …………………………………..E-1
Valve Stem Seals…………………………… ……………………………………… …………………………………..E-2
Valves ………………………………………….. ……………………………………… …………………………………..E-2
Cylinder Head ……………………………….. ……………………………………… …………………………………..E-2
Camshaft………………………………………. ……………………………………… …………………………………..E-2
Rocker Assembly…………………………… ……………………………………… …………………………………..E-2
Rear Timing Belt Cover…………………… ……………………………………… …………………………………..E-3
Drive and Cam Pulleys, Idler and Timing Belt …………………………….. …………………………………..E-3
Front Timing Belt Cover ………………….. ……………………………………… …………………………………..E-4
Front Cylinder Baffle ………………………. ……………………………………… …………………………………..E-4
Rear Cylinder Baffle……………………….. ……………………………………… …………………………………..E-4
Exhaust Manifold and Gasket ………….. ……………………………………… …………………………………..E-4
Blower Housing……………………………… ……………………………………… …………………………………..E-4
Coil and Mounting Bracket………………. ……………………………………… …………………………………..E-4
Valve Adjustment …………………………… ……………………………………… …………………………………..E-4
Spark Plugs…………………………………… ……………………………………… …………………………………..E-4
Rocker Cover ………………………………… ……………………………………… …………………………………..E-5
Carburetor…………………………………….. ……………………………………… …………………………………..E-5

ILLUSTRATED PARTS BREAKDOWN F

ILLUSTRATED PARTS BREAKDOWN

Engine Illustrations ………………………… ……………………………………… ………………………………….. F-1
Engine Parts List……………………………. ……………………………………… ………………………………….. F-6

SERVICE TOOLS

CYLINDER HEAD REMOVAL …………. ……………………………………… …………………………………..A-1
CRANKCASE DISASSEMBLY ………… ……………………………………… …………………………………..B-1
ENGINE MEASUREMENTS AND SPECIFICATIONS …………………. …………………………………..C-1
CRANKCASE ASSEMBLY ……………… ……………………………………… …………………………………..D-1
CYLINDER HEAD ASSEMBLY………… ……………………………………… …………………………………..E-1

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

Language: English
Format: PDF

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.)

Windows/Mac/Tablet/Phone Friendly

EZ-GO used 295cc and 350cc 4-cycle Fuji-Robin engines in its gas-powered golf carts, including models like the Marathon, Medalist, and TXT, from 1991 through the 2000s. The 350cc engine replaced the earlier 295cc engine around 1996 and provided more power. Both engines were used in carts before and after 2003, when EZ-GO introduced some changes to the design, most notably the exhaust manifold.

Engine features and history

295cc 4-cycle engine

Production years: The 295cc engine was used in EZ-GO carts from 1991 to 2002.
Performance: This engine provided about 9 horsepower.
Models: It was featured in gas-powered EZ-GO Marathon, Medalist, and TXT models from the early 1990s and other vehicles like the Workhorse.

350cc 4-cycle engine

Production years: The 350cc engine was introduced in 1996 to replace the 295cc engine. It was used through 2008 and beyond.
Performance: The increase in displacement resulted in a noticeable bump in power compared to the 295cc, making for a faster and stronger cart.
Models: It was featured in later EZ-GO Marathon, Medalist, and TXT models, as well as the Workhorse and other utility vehicles.

How to distinguish between 295cc and 350cc engines

While visually similar, you can determine which engine is in an EZ-GO cart by checking the engine block or the exhaust manifold.

Check the engine block

Look for a tag or stamp at the bottom of the engine block.
A tag that reads “29” indicates a 295cc engine.
A tag that reads “35” indicates a 350cc engine.

Check the exhaust manifold

Pre-MCI engines (pre-2003): On older models, the exhaust manifold is a separate piece that bolts to the cylinder head, and the muffler bolts to the manifold.
MCI engines (2003 and later): On newer models (with the Multi-port Cylinder Induction system), the exhaust port is molded directly into the head, and the muffler bolts directly to it.

Common problems

Owners of carts with the Fuji-Robin engines frequently encounter issues related to:

Performance issues: Power loss, poor acceleration, and stalling can result from common problems like a dirty carburetor, clogged fuel filter, or valves that are out of adjustment.
Engine wear: Lowered compression test readings on older engines can point to worn rings or valves.
Ignition system failures: Some EZ-GO ignition systems can fail, requiring replacement of the coil or ignitor.
Starter/generator problems: The starter/generator on these carts is a common failure point and can cause problems with starting or charging the battery.
Valve lash issues: A common problem on older 295cc engines is that the valve lash can tighten up over time, which affects compression and performance.