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

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

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your engine. Read and print pages directly or copy the entire manual to your hard drive.

 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

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