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1. Page Kawasaki Engine Shop Rebuild Manual ENGINE TOP END REASSEMBLY ENGINE TOP END Tool List Qty Required Compression Gauge 20 kgf cm E Z GO Part No Ni 1 Valve Seat Cutter 45 32 E Z GO Part 608665 1 Valve Seat Cutter 45 35 E Z GO Part 608666 1 Valve Seat Cutter 32 35 E Z GO Part No 608667 1 Valve Seat Cutter 32 38 5 E Z GO Part 608668 1 Valve Seat Cutter Holder 7 E Z GO Part No 608669 1 Valve Seat Cutter Holder Bar E Z GO Part No 608670 1 Compression Gauge Adapter M14 x 1 25 E Z GO Part No 000 1 VALVES Install Valve Mechanism A Apply engine oil to the valve stems and install them B Check to see that the valve moves smoothly up and down in the guide C Install the spring and the valve retainer D Install the valve retainer while pushing down the valve retainer with the thumbs E Install cylinder head See Install Cylinder Head in Section A CYLINDER HEAD Install Cylinder Head A Clean the mating surface of the cylinder head and the cylinder Kawasaki Engine Shop Rebuild Manual Install the dowe
2. nennen niente tnnt thun tnde iaa nnn C 8 Measure Valve Stem Bend reete ner nter nennt nere in Fan rhet iin ENER ENN Measure Valve Stem Diameter e Measure Valve Guide Inside C 9 Measure Valve Guide Clearance Wobble C 9 CAMSHAFT AND TAPPETS ioa e tnt e REN REN EVERTI EROR T C 10 Measure Camshaft Bearing Journal Wear nere C 10 CYLINDER AND PISTONS ettet t SURE e PE RE ie TRE cel C 11 Cleam GT EE C 11 Check Piston Ring and Ring Groove Wear C 11 Measure Piston Ring End Gap ccscccsscccsscsecesccetessesessceneeneoecoeseseatscoeeneseessecsseesonseseaneeneenes C 12 Measure Piston Pin Piston Pin Hole and Connecting Rod Wear C 13 Measure Piston Diameter center nnne etta tenenti nennen C 13 Check Cylinder Inside Diameter C 14 CRANKSHAFT AND CONNECTING nnne nennen ie ilem Measure Connecting Rod Bend Twist Measure Connecting Rod Big End Crankpin Width C 15 Measure Connecting Rod Big Bearing Crankpin Wear C 15 Measure Crankshaft Runout Measure Crankshaft Main Bearing Journal esses C 16 See We EE 17 Measure Balancer Shaft Bearing Journal Wear BREATHER VALVE
3. Inspect Breather Valve Kawasaki Engine Shop Rebuild Manual Page C i Notes Page CH Kawasaki Engine Shop Rebuild Manual ENGINE MEASUREMENTS AND SPECIFICATIONS Tool List Qty Required Compression Gauge 20 kgf cm E Z GO Part No N A 1 Compression Gauge Adapter M14 x 1 25 2 00 1 Valve Seat Cutter 45 35 E Z GO Part 608666 1 Valve Seat Cutter 32 38 5 E Z GO Part 608668 1 Valve Seat Cutter 45 32 E Z GO Part No Gopeep 1 Valve Seat Cutter 32 35 E Z GO Part 608667 1 Valve Seat Cutter Holder 7 E Z GO Part No 608669 1 Valve Seat Cutter Holder Bar E Z GO Part 608670 1 engine parts must be thoroughly cleaned and free of all dirt oil grease carbon deposits or residue of any kind before begin ning this section It is especially important that your work area be clean and well organized while performing the operations described in this section In some cases time may be saved by setting measuring instru ments at limit specifications and using them as go no go fix tu
4. dades D 1 Install Balancer es er err rcv eA ees D 1 CRANKSHAFT AND CONNECTING 8 D 2 Install Crankshaft deviate Install Connecting LOG rer trn t eter en i re D 2 CYLINDERS AND PISTONS Install Piston CAMSHAFT AND PISTONS 5 terrier tete mero ePi ERR Te leer b Install Camshaft Tappet CRANKGOASEc 555 MN Ebo CUR I SL Raa Sa Sah ten cu tasca Assemble Crankcase Cover Install Crankcase Cover Kawasaki Engine Shop Rebuild Manual Page D i ENGINE BOTTOM END REASSEMBLY Notes Page D ii Kawasaki Engine Shop Rebuild Manual ENGINE BOTTOM END REASSEMBLY ENGINE BOTTOM END Tool List Qty Required Piston Ring Compressor Grip E Z GO Part No 0000 1 Piston Ring Compressor Belt 80 91 E Z GO Part No 1 Bearing Driver Set E Z GO Part No 1 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 Prior to engine reassembly all parts CAUTION 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 ar
5. csse C 17 BREATHER VALVE nspect Breather Valve eme pert eene E eats C 17 Page iv Kawasaki Engine Shop Rebuild Manual TABLE CONTENTS Section Page No ENGINE BOTTOM END REASSEMBLY D ENGINE BOTTOM END TOON E eae eee ENSE EMO ni Eme D 1 BREATHER VALVE e Install Breather Valve nite D eed reet ee Le RP ER Lr E Ee ER da eds D 1 BALANCER SHAFT Install BalanGer Shaft tinte ed ende dta Lebe d LEER d Ege x ed dea D 1 CRANKSHAFT AND CONNECTING RODS Install Crankshaft t d E ERR dL ren d n D 2 Insia E e ET RU D 2 CYLINDERS AND PISTONS nStall i ini D 2 CAMSHAFT AND PISTONS Install Camshatt Tappet eda eig reed der EE EEN EEN EE D 4 CRANKCASE e Assemble Crankcase Cover D 4 Install 5 ine D 4 ENGINE TOP END REASSEMBLY E ENGINE TOP END s Teo ts nee Say ay SRG atic at N ER RE SURE Funes 1 VALVES Install Valve Mecharisrm iniit ete ie td en teo e ce E ek eT d tet ns E 1 CYLINDER HEAD Install Cylinder Head eerie e E 1
6. Page A 6 Kawasaki Engine Shop Rebuild Manual ENGINE BOTTOM END DISASSEMBLY TABLE OF CONTENTS FOR SECTION B SECTION TITLE PAGE NO ENGINE BOTTOM END B 1 Tool m R tessa ans B 1 ees eebe geheie deeg iade br itu B 1 Remove Crankcase nnn n nnns B 1 CAMSHAET AND TAPPETS 2itsief tette e A a eee B 1 Remove Camshaft ET E B 1 CYLINDERS AND PISTONS 1 sete pee a de evene ee b ee an AT a B 2 Remove PISTON ec E 2 CRANKSHAFT AND CONNECTING RODS B 3 Remove Connecting Rod Ae ES Remove Crankshaft BALANCER SHARM tre rover tae ebd t sis cure t e sec cron Remove Balancer Shaft Ged Ghee ecd an ee EA oed ea die em B 3 Remove Breather varies 3 SPEGIFIGATIONS Al aes BAA ALARA ete ed 4 EXPLODED MEW RE B 6 LIST OF ILLUSTRATIONS FIG Mere B 6 Kawasaki Engine Shop Rebuild Manual Page B i ENGINE BOTTOM END DISASSEMBLY Notes Page B ii Kawasaki Engine Shop Rebuild Manual ENGINE BOTTOM END DISASSEMBLY ENGINE BOTTOM END Tool List Qty Required Piston Ring Compressor Grip E Z GO Pa
7. bd bte bref ct b too ss 4 LIST OF ILLUSTRATIONS Figs 1 Cylinder Head erede ete t de ide din ee tei a A 4 Kawasaki Engine Shop Rebuild Manual Page ENGINE END DISASSEMBLY Notes Page A ii Kawasaki Engine Shop Rebuild Manual ENGINE END DISASSEMBLY ENGINE TOP END Tool List Qty Required Compression Gauge 20 kgf cm E Z GO Part No 1 Valve Seat Cutter 45 32 E Z GO Part Goen 1 Valve Seat Cutter 45 35 E Z GO Part No Gong 1 Valve Seat Cutter 32 35 E Z GO Part No 608667 1 Valve Seat Cutter 32 38 5 E Z GO Part No 608668 1 Valve Seat Cutter Holder 7 E Z GO Part No 608669 1 Valve Seat Cutter Holder Bar E Z GO Part No 608670 1 Compression Gauge Adapter M14 x 1 25 E Z GO Part No 1 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 performance of the engine Crankshaft and balancer shaft bearings should be cleaned and inspected and removed only if they appear to be damaged or excessively worn Hemove bearings that
8. 608172 KAWASAKI ENGINE SHOP REBUILD MANUAL 4 STROKE AIR COOLED GASOLINE ENGINE STARTING MODEL YEAR 2008 KAWASAKI ENGINE SHOP REBUILD MANUAL 4 STROKE AIR COOLED GASOLINE 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 Kawasaki Engine Shop Rebuild Manual Page i OBTAIN COPY OF THE LIMITED WARRANTY THAT IS APPLICABLE TO THE VEHICLE CALL OR WRITE THE LOCAL DISTRIBUTOR E Z GO BRANCH OR E Z GO 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 VEHICLE TO OPERATE AT ABOVE FACTORY SETTINGS WILL VOID THE VEHICLE WARRANTY IF APPLICABLE REFER TO BACK COVER FOR CALIFORNIA AND OR FEDERAL EMISSIONS CONTROL WARRANTY STATEMENT Engine exhaust from this product contains chemicals known in certain quantitie
9. Crankshaft Runout Crankshaft Main Journal Diameter Crankcase Side Crankshaft Main Bearing Inside Diameter Crankcase Side Page B 4 Kawasaki Engine Shop Rebuild Manual 29 95 30 05 mm 1 179 1 183 in 29 95 30 05 mm 1 179 1 183 in 19 967 19 980 mm 0 78610 0 78661 in 49 959 49 975 mm 1 9669 1 9675 in 20 000 20 013 mm 0 78740 0 78791 in 50 000 50 025 mm 1 9685 1 9695 in 27 4 27 7 mm 1 08 1 09 in 28 0 28 2 mm 1 10 1 11 in 43 004 43 015 1 6931 1 6935 42 963 42 976 1 6915 1 6920 0 02 0 0008 or less 34 955 34 980 1 3762 1 3772 35 002 35 015 mm 1 3780 1 3785 in 29 86 mm 1 176 in 29 86 mm 1 176 in 19 94 mm 0 7850 in 49 93 mm 1 966 in 20 07 mm 0 7902 in 50 09 mm 1 972 in 0 15 100 mm 0 006 3 94 in 0 15 100 mm 0 006 3 94 in 27 0 mm 1 06 in 28 4 mm 1 12 in 43 04 mm 1 694 in 42 95 mm 1 691 in TIR 0 05 mm 0 002 in 34 93 mm 1 375 in 35 05 mm 1 380 in ENGINE BOTTOM END DISASSEMBLY tem enen Service iit Cylinder and Piston Piston Ring Groove Clearance Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second Oil Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Connecting Rod Small End Inside Diameter Piston Diameter Cylinder Inside Diameter Cyli
10. sse C 8 e Measure Valve Stem Bend 2 2 24 11 1 0 C 8 e Measure Valve Stem Diameter 2 enne C 9 e Measure Valve Guide Inside Diameter C 9 e Measure Valve Guide Clearance Wobble Meibod sese C 9 CAMSHAFT AND TAPPETS e Measure Camshaft Bearing Journal Wear enne nnne nnns C 10 CYLINDER AND PISTONS Clean Piston nec ec to dar n e Ede teft Pete ee itn C 11 e Check Piston Ring and Ring Groove VWear eene nennen nens C 11 e Measure Piston Ring End Gap C 12 Measure Piston Pin Piston Pin Hole and Connecting Rod C 13 Measure Piston Diameter 1 1 2 411 14 4 41 2 4116410 Aoa Aaina ien nni 13 e Check Cylinder Inside Diameter 4 2 01 EE C 14 CRANKSHAFT AND CONNECTING RODS v Glean Inspect rta pice e redu ient C 14 e Measure Connecting Rod Bend Twist eene nennen C 14 e Measure Connecting Rod Big End Crankpin Width Wear sse C 15 e Measure Connecting Rod Big End Bearing Crankpin Wear 2 C 15 Measure Crankshaft 2 2 40 EE C 16 e Measure Crankshaft Main Bearing Journal Wear senem C 16 BALANCER SHAFT e Measure Balancer Shaft Bearing Journal Wear
11. Measure the inside diameter A of the balancer shaft bearing on the crankcase cover at several points F If inside diameter is more than the service limit replace the crankcase cover with a new one Balancer Shaft Bearing Inside Diameter Crankcase cover Standard 32 000 32 016 mm 1 2598 1 2605 in Service Limit 32 06 mm 1 262 in BREATHER VALVE Inspect Breather Valve A Remove the breather valve see Remove Breather Valve B Inspect the reed valve for breakage hair cracks or distortion replace it if necessary C Inspect the back plate for damage or rough contact surface replace it if necessary D Inspect the valve seating surface The surface should be free of nicks or burrs E Align center of the valve seat with center of the reed valve and back plate then tighten the breather valve screw Page C 17 Notes Page C 18 Kawasaki Engine Shop Rebuild Manual ENGINE BOTTOM END REASSEMBLY TABLE OF CONTENTS FOR SECTION D SECTION TITLE PAGE NO 5 2 122 dacs AR Ten eR s D 1 ERE EA D 1 22 He cot ede RED RED D 1 Install Breather Valve dee nare en Fe nre Dee ed D 1 BALANCER SHAET toe der les e vdd
12. 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 Spark plugs i 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 ii 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 accessories 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 performi
13. necting rod big end B and cap C M Install the connecting rod big end cap in its original position on the connecting rod big end by matching the marks D Page D 3 ENGINE BOTTOM END REASSEMBLY N Apply a small amount of engine oil to the thread and seating surface of the cap bolts E O Tighten the cap bolts Torque Connecting Rod Big End Cap Bolts 5 9 Nem 0 60 52 in Ib P Install camshaft see Install Camshaft Tappet Instal lation and crankcase cover see Install Crankcase Cover CAMSHAFT AND PISTONS Install Camshaft Tappet A Apply engine oil to the tappet journal cam lobe sur face and camshaft gear B Apply molybdenum disulfide grease to the camshaft journal C Install the tappets in their original positions Align the punch marks A on the crankshaft gear and on the camshaft gear E Install the crankcase cover see Install Crankcase Cover F Install the push rods see Install Cylinder Head in Section A G Mount the rocker arms on the push rods and install the valve clearance adjusting nuts and the lock SCrews Torque Valve Adjusting Nut Lock Screws 6 9 Nem 0 70 kgf m 61 in b H Adjust the valve clearance see Adjust Valve Clear ance in Section C l Install the valve cover Page D 4 CRANKCASE Assemble Crankcase Cover A 1104000BS1 C Install the ball bearing A until it is bottomed Special Tool Bearing Driver Set E Z GO Par
14. 5 repairs performed outside of the authorized warranty service facilities 6 use of parts which are not authorized by 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 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 service 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 dealer distributor and service provider any where in the United States When warranty repair is needed the engine must be brought to an authorized dealer distributorship or service
15. EE B 3 BALANCER SHAFT eke eh eg een el ete el B 3 BREATHER VALVE Remove Breather Valve n RIS EE en ew Ge ee ee cies B 3 SPECIFICATIONS EE 4 EXPLODED VIEW it petite ameti et 6 Kawasaki Engine Shop Rebuild Manual Page iii TABLE CONTENTS Section Page No ENGINE MEASUREMENTS AND SPECIFICATIONS ENGINE MEASUREMENTS AND SPECIFICATIONS TOOWLISti a cp ru Pat a k ax ak E D en te C 1 Using Telescoping Gauges and Hole Gauges sss see ene C 1 CYLINDER HEAD e Measure Cylinder Compression 22 00 0000 rennen nennen nennen nennen C 1 Inspect Push Rod opi pte eet eei C 3 Inspect Rocker ATTI nied eatin Aiello aie ale ini ee ig RR e RR Re ee C 3 e Measure Cylinder Head 2 0 204 4 1 0 EEN C 3 VALVES Inspect Valve Clearance EEN EN CA s Adjust Valve Clearance Dead drei sieeve E bet ed reds CA Inspect Valve Seat rate ao e eR e E dee ED aan E ek doe P E C 4 Repair Valve Seat nei de oen aide uat ad ph ea ipe pete t Eee C 4 e Operating Procedures inre pedale Dd YE LESE LE ELE RI E C 5 Measure Valve Spring Free ener entere nnn nennen C 8 Measure Valve Head Thickness
16. Kawasaki Engine Shop Rebuild Manual Page v TABLE CONTENTS Section Page No ILLUSTRATED PARTS BREAKDOWN F 4 e Hd t bee o eters 2 PIST ON CRANKSHAPT sivas a dona iy a eat aetates ae E e F 4 VALVE CAMSHAF iste siete ecrit toi ne al c PE heed ate Mia pete idea eve F 6 LUBRICATION te ete ete eo tor Ae es deg RGU defi od te edis F 8 E 10 12 eren o te eb pee rati eect F 14 AIR INTAKE BREATHER EXHAUST e Ferne xe F 16 LIMITED WARRANTY G Federal Emissions Component Defect Warranty G 1 California Emission Control Warranty Statement 1995 1999 csse G 5 California Emission Control Warranty Statement 2000 G 8 California Emission Control Warranty Statement 2001 seems G 11 California Emission Control Warranty Statement 2004 G 14 Page vi Kawasaki Engine Shop Rebuild Manual HOW 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 allows the mechanic to choose the level of instructional detail neede
17. Valve Head Thickness Valve Stem Bend Valve Stem Diameter Inlet Exhaust Valve Guide Inside Diameter Valve guide Clearance wobble method Inlet Exhaust 0 10 0 15 mm 0 0039 0 0059 in 32 8 mm 1 29 in 27 6 mm 1 09 in 1 1 1 7 mm 0 043 0 067 1 0 1 5 mm 0 039 0 059 in 45 35 mm 1 38 in 0 4 mm 0 016 in Less than 0 01 mm 0 0004 in TIR 6 960 6 975 mm 0 2740 0 2746 in 6 945 6 960 mm 0 2734 0 2740 in 7 000 7 015 mm 0 2756 0 2762 in 0 06 0 13 mm 0 0024 0 0051 in 0 10 0 17 mm 0 0039 0 0067 in Kawasaki Engine Shop Rebuild Manual 32 6 mm 1 28 in 0 4 mm 0 016 in TIR 0 05 mm 0 0020 in 6 95 mm 0 274 in 6 93 mm 0 273 in 7 08 mm 0 279 in 0 29 mm 0 011 in 0 33 mm 0 013 in Page A 3 ENGINE END DISASSEMBLY Exploded View Fig 1 Cylinder Head Kawasaki Engine Shop Rebuild Manual Page A 4 ENGINE TOP END DISASSEMBLY et ES B 603523 Cylinder Head Cover Bolts 69 61 p s nave snows set eese vaesdesmmauskSoms sini EO Apply engine oil M Apply molybdenum disulfide grease R Replacement Parts S Follow the specific tightening sequence Kawasaki Engine Shop Rebuild Manual Page A 5 Notes
18. 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 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
19. 100 NOT SHOWN 607685 89 VALVE FLOAT 607686 1 1 90 FLOAT 607687 1 1 91 PIN FLOAT 607688 1 1 92 GASKET BOWEL 607689 1 1 93 ASSY FLOAT CHAMBER 607690 1 1 94 GASKET CHAMBER 607691 1 1 95 PLUG CHAMBER 607692 1 1 96 BUSHING THROTTLE ATTACH 608023 1 1 Kawasaki Engine Shop Rebuild Manual Page F 15 ILLUSTRATED PARTS BREAKDOWN AIR INTAKE BREATHER EXHAUST REF CYLINDER CRANKCASE Es 102 2 A KAWIPB8 Page F 16 Kawasaki Engine Shop Rebuild Manual ILLUSTRATED PARTS BREAKDOWN AIR INTAKE BREATHER Item Description E Z GO Part Number SUA GOLF UTILITY 97 GASKET CHOKE 603593 1 1 98 PIPE INTAKE 603594 1 1 99 NUT M6X1 0 V 603595 2 2 100 CLAMP INTAKE PIPE 603596 1 1 101 CLAMP CYLINDR HEAD 603597 1 1 102 TUBE BREATHER 603598 1 1 EXHAUST 103 SCREW EXHAUST 608022 2 2 Kawasaki Engine Shop Rebuild Manual Page F 17 ILLUSTRATED PARTS BREAKDOWN Notes Page F 18 Kawasaki Engine Shop Rebuild Manual LIMITED WARRANTY TABLE OF CONTENTS FOR SECTION SECTION TITLE PAGE NO FEDERAL EMISSION COMPONENT DEFECT G 1 CALIFORNIA EMISSION CONTROL WARRANTY 1995 1999 G 5 YOUR WARRANTY RIGHTS AND OBLIGATIONS 2 G 5 LIMITED WARRANTY o
20. 61 in lb 603524 Crankcase Cover Bolts 22 16 ft lb with crankcase EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts S Follow the specific tightening sequence Kawasaki Engine Shop Rebuild Manual Page B 7 Notes Page B 8 Kawasaki Engine Shop Rebuild Manual TABLE CONTENTS FOR SECTION C SECTION TITLE PAGE NO ENGINE MEASUREMENTS AND C 1 TOON C 1 Using Telescoping Gauges and Hole 2 C 1 CYEINDER HEAD tiroteo ed ada dedu ees C 1 Measure Cylinder rnnt tnnt enn C 1 Inspect Rebeet ene eek era Inspect Rocker Arm AE Measure Cylinder Head Warp cc cccsssscsesccsesssssessssccessevssseesseocersssersecsoseeensneetenoseesserseceeosen C 3 MAEVE Si Ciao AL E Ed Lai tne x C 4 Inspect Valve Clearance 2 GA Adjust Valve Clearance 2 04 Inspect Valve Seat CA Repair Vavle Seat 2 4 Operating Procedures wn 0 5 Measure Valve Spring Free Length 2 C 8 Measure Vavle Head
21. Magneto or Electronic Ignition System Page G 12 Kawasaki Engine Shop Rebuild 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 1 Hoses Belts Connectors and Assemblies iit 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 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 Kawasaki Engine Shop Rebuild 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 t
22. 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 1 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 Plug annual maintenance item il Ignition Coil Ignitor Complete iv Pulser Coil Kawasaki Engine Shop Rebuild 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 It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2000 and l
23. are pitted nicked burred discolored or that rotate roughly or noisily 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 Mark and sort all parts as they are disassembled so that they will be reassembled and installed in their original positions Kawasaki Engine Shop Rebuild Manual CYLINDER HEAD Remove Cylinder Head A Several components must be removed in order to gain access to the cylinder head for example carbu rator and exhaust Refer to the service manual of your vehicle for removal procedures 1 048013 Remove clamp and hose A bolts and engine shroud C Remove spark plug cap A dipstick B valve cover bolts C and valve cover D D Position the crankshaft at TDC of the end of the com pression stroke Page A 1 ENGINE END DISASSEMBLY 4 1 048015 P Loosen lock screws A Tag and mark push rods during removal Push rods should be installed in their original orientation and position during assem bly Remove valve clearance adjusting nuts B rocker arms C and push rods D 1E048016 P The cylinder head may be held in place by the gasket during removal Pry tabs are
24. 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 1 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 Plug annual maintenance item il Ignition Coil iii Ignitor Complete iv Pulser Coil Page G 6 Kawasaki Engine Shop Rebuild Manual LIMITED WARRANTY CALIFORNIA 1995 1999 4 Exhaust Manifold 5 Miscellaneous Items Used in Above Systems i Fuel Hoses Clamp
25. 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 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 dealer distributor and warranty station any where in the United States When warranty repair is needed the engine must be brought to an authorized dealer distributorship or warranty station s place of business during normal business hours In all cases 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 P MAINTENANCE REPLACEMENT AND
26. 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 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 8
27. 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 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 2000 and later engine that the engine 1
28. shaft see Remove Balancer Shaft Turn the crankshaft to expose the connecting rod cap bolts A C Remove the bolts and take off the connecting rod cap Note the position of the connecting rod cap for reinstalling the cap D Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder Page B 2 Remove one of the piston pin snap rings A with needle nose pliers Remove the piston by pushing the piston pin A out the side from which the snap ring was removed GE160606S1 C Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it H Remove the 3 piece oil ring with your thumbs in the same manner Kawasaki Engine Shop Rebuild Manual ENGINE BOTTOM END DISASSEMBLY CRANKSHAFT AND CONNECTING RODS Remove Connecting Rod A Refer to Remove Piston Remove Crankshaft A Drain the engine oil B Remove alternator rotor camshaft see Remove Camshaft Tappet balancer shaft see Remove Bal ancer Shaft and connecting rod cap see Remove Piston Pull the crankshaft A out of the crankcase Tap gen tly with a wooden or plastic mallet if necessary to loosen the crankshaft BALANCER SHAFT Remove Balancer Shaft A Remove crankcase cover see Remove Crankcase Cover and balancer shaft A Kawasaki Engine Shop Rebuild Manual BREATHER VALVE Remove Breather Valve Th
29. shall be warranted for the warranty period Any warranted Page G 8 Kawasaki Engine Shop Rebuild 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 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 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 2 Add on or modified parts This warranty does not cover any part which malfunctions
30. 00 241 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 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 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 sc
31. 25 150 HOURS 10W 30 10W 40 SF SG CC oil 9 Clean oil filter in solvent at oil change SEMIANNUAL 125 150 HOURS Replace O rings if required 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 ANNUAL 250 300 HOURS required k Check timing belt tension check for signs of wear ANNUAL 250 300 HOURS damage Replace only if worn or damaged Kawasaki Engine Shop Rebuild Manual 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 In California 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
32. 46 2 2 40 SEAL OIL 603547 2 2 41 SPRING NOT SHOWN 603548 1 1 42 BOLT 603549 2 2 Kawasaki Engine Shop Rebuild Manual Page F 7 ILLUSTRATED PARTS BREAKDOWN LUBRICATION KAWIPB4 Page F 8 Kawasaki Engine Shop Rebuild Manual ILLUSTRATED PARTS BREAKDOWN LUBRICATION Quantity Item Description E Z GO Part Number GOLF UTILITY 43 PLATE OIL RELIEF 603550 1 1 44 ASSY OIL PUMP 603552 1 1 45 COVER PUMP 603553 1 1 46 ROTOR PUMP OUTER 603554 1 1 47 PIPE 603555 1 1 48 FILTER OIL FJ400D 607454 1 1 49 DIPSTICK OIL LOW SUSP 606390 1 1 50 DIPSTICK OIL HIGH SUSP NOT SHOWN 606391 1 51 RING SNAP 603556 1 1 52 PLUG 603557 3 3 53 BALL 603558 1 1 54 SPRING OIL RELIEF 603559 1 1 55 BOLT 603560 2 2 56 BOLT FLANGED 603561 1 1 57 O RING 16MM 603562 3 3 58 SWITCH OIL PRESSURE NOT SHOWN 608398 1 Utility vehicles may be equipped with either high or low suspension Please be sure to select the correct dipstick P N for your model Kawasaki Engine Shop Rebuild Manual Page F 9 ILLUSTRATED PARTS BREAKDOWN COOLING KAWIPB5 Kawasaki Engine Shop Rebuild Manual Page F 10 ILLUSTRATED PARTS BREAKDOWN COOLING Quantity Item Description E Z GO Part Number GOLF UTILITY 59 SHROUD ENGINE 603563 1 60 GUARD 603564 1 1 61 FAN 603566 1 1 62 HOUSING FAN 603567 1 1 63 RIVET GUARD 603569 1 1 64
33. 6 in C 1105000BS1 C Measure both camshaft journals at several points around the journal circumference D If the journal diameter is less than the service limit replace the camshaft Crankcase Side Camshaft Journal Diameter Standard 19 967 19 980 mm 0 78610 0 78661 in Service Limit 19 94 mm 0 7850 in Page C 10 Crankcase Cover Side Camshaft Journal Diameter Standard 49 959 49 975 mm 1 9669 1 9675 in Service Limit 49 93 mm 1 966 in E Qr Y KGO5BO4I P Measure the inside diameter A of the camshaft bearing on the crankcase at several points F Replace the crankcase if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Standard 20 000 20 013 mm 0 78740 0 78791 in Service Limit 20 07 mm 0 7902 in Measure the inside diameter A of the camshaft bearing on the crankcase cover at several points H Replace the crankcase cover if the inside diameter is more than the service limit Camshaft Bearing Cover Inside Diameter Crankcase Standard 50 000 50 025 mm 1 9685 1 9695 Service Limit 50 09 mm 1 972 in Kawasaki Engine Shop Rebuild Manual CYLINDER AND PISTONS Clean Piston A Remove the piston and piston rings see Remove Piston in Section A B KE06037BS1 C Never clean the piston head with the engine assembled Carbon particles will fall between the piston and cylinder and damage t
34. 740 in as close as possible to the cylinder head upper sur i face Service Limit Inlet 6 95 mm 0 274 in D Move the stem back and forth C to measure valve Exhaust 6 93 mm 0 273 in guide clearance Measure Valve Guide Inside Diameter E Repeat the measurement in a direction at a right angle to the first F If the reading exceeds the service limit replace the cylinder head The reading is not actual valve guide clearance because the measuring point is above the guide Valve Guide Clearance Wobble Method KE05020BS1 Standard Measure the inside diameter A of the valve guide B A 9 Inlet 0 06 0 13 mm 0 0024 0 0051 B Ifthe valve guide has worn enough to exceed the ser Exhaust 0 10 0 17 mm 0 0039 0 0067 in vice limit replace the cylinder head Service Limit Valve Guide Inside Diameter Standard 7 000 7 015 mm 0 2756 0 2762 in Inlet 0 29 mm 0 011 in Service Limit 7 08 mm 0 279 in Exhaust 0 33 mm 0 013 in Kawasaki Engine Shop Rebuild Manual Page C 9 CAMSHAFT TAPPETS Measure Camshaft Bearing Journal Wear A KG05014BS1 C Measure the height of each cam lobe A B If the cam height is less than the service limit for either lobe replace the camshaft Cam Lobe Height Standard Inlet 29 95 30 05 mm 1 179 1 183 in Exhaust 29 95 30 05 mm 1 179 1 183 in Service Limit Inlet 29 86 mm 1 176 in Exhaust 29 86 mm 1 17
35. 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 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 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 o
36. BOLT 603560 5 5 Kawasaki Engine Shop Rebuild Manual Page F 11 ILLUSTRATED PARTS BREAKDOWN ELECTRICAL amp 69 KAWIPB6 Page F 12 Kawasaki Engine Shop Rebuild Manual ILLUSTRATED PARTS BREAKDOWN ELECTRICAL Quantity Item Description E Z GO Part Number GOLF UTILITY 65 PLATE FAN 603571 1 1 66 ASSY IGNITION COIL 603572 1 1 67 FLYWHEEL ASSEMBLY 607463 1 1 68 WIRE LEAD 603573 1 1 69 PLUG 603522 1 1 70 PLUG SPARK BPR2ES 607462 1 1 71 BOLT M12X39MM LG 603575 1 1 72 WASHER 603576 1 1 73 BOLT FLANGED 603577 2 2 74 SCREW PAN WP CROS NOT SHOWN 603578 4 4 75 KEY WOODRUFF 603579 1 1 Kawasaki Engine Shop Rebuild Manual Page F 13 ILLUSTRATED PARTS BREAKDOWN CARBURETOR CABLE BRACKETS KAWIPB7 Page F 14 Kawasaki Engine Shop Rebuild Manual ILLUSTRATED PARTS BREAKDOWN CARBURETOR CABLE BRACKETS Quantity Item Description E Z GO Part Number GOLF UTILITY 76 GASKET HD CARBURETOR 603580 3 3 77 INSULATOR 603581 1 1 78 BRACKET CHOKE CABLE 603583 1 1 79 BOLT STUD 603584 2 2 80 CARBURETOR ASO3 607954 1 81 CARBURETOR ASO7 SPEC NOT SHOWN 607955 1 82 PLUG PILOT JET 603585 1 1 83 JET PILOT 44 608021 1 84 JET PILOT 52 NOT SHOWN 607957 1 85 JET MAIN 106 607956 1 86 JET MAIN 104 607683 1 87 JET MAIN 102 607684 88 JET MAIN
37. M e edi F 2 5 dese tetro uen 4 eege EE Dou Tee a de F 6 LUBRICATION EE F 8 COOLING mds utn CL I AUT ELE F 10 EEECTRIGAL 5 1 ea Ie ete F 12 CARBURETOR CABLE F 14 AIR INTAKE BREATHER EXHAUST esee nnne innen tnn nennen nnne nentes ena F 16 Kawasaki Engine Shop Rebuild Manual Page Fi ILLUSTRATED PARTS BREAKDOWN Page Fii Kawasaki Engine Shop Rebuild Manual ILLUSTRATED PARTS BREAKDOWN F Notes Kawasaki Engine Shop Rebuild Manual Page F 1 ILLUSTRATED PARTS BREAKDOWN CYLINDER CRANKCASE KAWIPB1 Page F 2 Kawasaki Engine Shop Rebuild Manual ILLUSTRATED PARTS BREAKDOWN CYLINDER CRANKCASE Item Description E Z GO Part Number SUA GOLF UTILITY 1 GASKET HEAD 603510 1 1 2 CYL HEAD COMPLETE 603511 1 1 3 CASE ROCKER 607951 1 1 4 GASKET COVER CRANKCASE 603512 1 1 5 GASKET CAS COVER 603513 1 1 6 PLATE BREATHER 603514 1 1 7 VALVE BREATHER 603515 1 1 8 PIPE BREATHER 603516 1 1 9 COVER CRANKCASE 603517 1 1 10 CRANKCASE COMPLETE 603518 1 1 11 PIN DOWEL 603519 4 4 12 SEAL OIL
38. Ring End Gap Lower Steel Rail End Gap D F Apply engine oil to the piston pins Kawasaki Engine Shop Rebuild Manual ENGINE BOTTOM END REASSEMBLY KE06035BS1 C Assemble the piston onto the connecting rod so that the arrow mark A on the top of the piston can be aligned with MADE IN USA B on the connecting rod Fit a new piston pin snap ring into the side of the pis ton so that the ring opening A does not coincide with the notch B in the edge of the piston pin hole When installing a piston pin snap ring compress it only enough to install it and no more Do not reuse the snap rings as removal weakens and deforms them They could fall out and score the cylinder wall l Apply engine oil to the piston skirt and the cylinder bore Kawasaki Engine Shop Rebuild Manual geg pr Using the piston ring compressor grip A and the belt B lightly tap the top of the piston with a plastic mal let C to insert the piston and connecting rod into the cylinder Special Tools Piston Ring Compressor Grip E Z GO Part No N A Piston Ring Compressor Belt 80 91 E Z GO Part No N A K Position the arrow mark D on the top of the piston toward the alternator rotor side E The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state so they must be replaced together as a set L KE06036BS1 C Apply engine oil to the inner surface A of the con
39. SD35X48X8 603520 1 1 13 SEAL OIL 603521 1 1 14 PLUG 603522 2 2 15 BOLT FLANGED 603523 4 4 16 BOLT FLANGED 603524 8 8 17 BOLT FLANGED 603525 4 4 18 SCREW PAS CROS 603526 1 1 19 BEARING BALL 603527 1 1 Kawasaki Engine Shop Rebuild Manual Page F 3 ILLUSTRATED PARTS BREAKDOWN PISTON CRANKSHAFT 26 KAWIPB2 Page F 4 Kawasaki Engine Shop Rebuild Manual ILLUSTRATED PARTS BREAKDOWN PISTON CRANKSHAFT Quantity Item Description E Z GO Part Number GOLF UTILITY 20 PISTON ENGINE 603528 1 1 21 PIN PISTON 603529 1 1 22 RING SET PISTON 603530 1 1 23 CRANKSHAFT COMPLETE 603531 1 1 24 BALANCER COMPLETE 603532 1 1 25 ASSY CONNECT ROD 603533 1 1 26 RING SNAP 603534 2 2 27 BOLT M6X1 0X35 0 LG 603535 2 2 Kawasaki Engine Shop Rebuild Manual Page F 5 ILLUSTRATED PARTS BREAKDOWN VALVE CAMSHAFT wo pars 28 29 KAWIPB3 Page F 6 Kawasaki Engine Shop Rebuild Manual ILLUSTRATED PARTS BREAKDOWN VALVE CAMSHAFT Item Description E Z GO Part Number uy GOLF UTILITY 28 VALVE INTAKE 603536 1 1 29 VALVE EXHAUST 603537 1 1 30 RETAINER VALVE SPRING 603538 2 2 31 COLLECT 603539 4 4 32 ARM ROCKER 603540 2 2 33 TAPPET 603541 2 2 34 GUIDE PUSH ROD 603542 2 2 35 ROD PUSH 603543 2 2 36 SPRING ENGINE VALVE 603544 2 2 37 CAMSHAFT COMPLETE 607461 1 1 38 SCREW 603545 2 2 39 NUT 6035
40. 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 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 Rep
41. airs 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 Kawasaki Engine Shop Rebuild 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 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 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 inst
42. and tighten the bolts to the speci fied torque see Install Piston in Section D C KG06B023 P Measure the inside diameter A of big end at several points with a telescoping gauge or inside micrometer D If the inside diameter is more than the service limit replace the connecting rod with a new one Connecting Rod Big End Inside Diameter Standard 43 004 43 015 mm 1 6931 1 6935 in Service Limit 43 04 mm 1 694 in Page C 15 Measure Crankshaft Main Bearing Journal Wear A KG06019BS1 C Measure the crankpin outside diameter A F Use micrometer to measure several points around eee the crankpin circumference m MM Measure the diameter A of the crankshaft main jour G If the crankpin diameter is less than the service limit nal replace the crankshaft with a new one Crankpin Outside Diameter B If the journal has worn enough to exceed the service Standard 42 963 42 976 mm 1 6915 1 6920 in TEEN Service Limit 42 95 mm 1 691 Crankcase Side Crankshaft Main Journal Diameter Measure Crankshaft Runout Standard 34 955 34 980 mm 1 3762 1 3772 in A Measure the crankshaft runout B Service Limit 34 93 mm 1 375 in C ze 606020851 C v 1 d Set the crankshaft in a flywheel alignment jig A or on 2 blocks gauge Measure the inside diameter A of the crankshaft C Set a dial gauge B against both bearing journals main bearing crankcase si
43. ater 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 Page G 10 Kawasaki Engine Shop Rebuild 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 In California 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 rela
44. ct 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 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 ass
45. d 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 tools that will be required to perform the operations desired in that sec tion Do not use non specified tools vise grips 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 Kawasaki Engine Shop Rebuild Manual Page vii Notes Page viii Kawasaki Engine Shop Rebuild Manual ENGINE END DISASSEMBLY TABLE OF CONTENTS FOR SECTION A SECTION TITLE PAGE NO ie rer zara zip P A 1 gH A 1 CYLINDER Aum Remove Cylinder Head eene VALVES Remove Valve Mechanism SPECIFICATIONS wie de EXPLODED VIEW idiot tede tid
46. de D Turn slowly 9 rungut D Ifthe bearing has worn enough to exceed the service The difference between the highest and lowest dial limit replace the crankcase with a new gauge readings TIR is the amount of runout E Ifthe measurement exceeds the service limit replace Crankshaft Main Bearing Inside Diameter Crankcase the crankshaft Side Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 002 in Service Limit 35 05 mm 1 380 in Standard 35 002 35 015 mm 1 3780 1 3785 in Page C 16 Kawasaki Engine Shop Rebuild Manual BALANCER SHAFT Measure Balancer Shaft Bearing Journal Wear A 6078002 P Measure both balancer shaft journal diameters A at several points around the journal s circumference B If journal diameter is less than the service limit replace the balancer shaft with a new one Balancer Shaft Journal Diameter Standard 31 959 31 975 mm 1 2582 1 2589 in Service Limit 31 935 mm 1 2573 in C ow yl K 24 Measure the inside diameter of the balancer shaft bearing on the crankcase at several points D If inside diameter is more than the service limit replace the crankcase with a new one Balancer Shaft Bearing Inside Diameter Crankcase Standard 32 000 32 016 mm 1 2598 1 2605 in Service Limit 32 06 mm 1 262 in Kawasaki Engine Shop Rebuild Manual
47. e The seating area should be marked about in the mid dle of the valve face If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it Be sure to remove all grinding compound before assembly P When the engine is assembled be sure to adjust the valve clearances Kawasaki Engine Shop Rebuild Manual START Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec Tool small 45 Grind Tool 45 Cutter Purpose increase O D of seat area to spec Machinist s dye on seat 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Lap Valve Tools Valve lapper grinding compound Purpose perfectly match valve and seat area check valve head for damage FINISHED Kawasaki Engine Shop Rebuild Manual Page C 7 Measure Valve Spring Free Length Measure Valve Stem Bend A A 8 06060351 C GE15011281 C Measure the valve spring A free length Place the valve in V blocks at each end of the stem and set a dial gauge A on the stem at a point half way between the blocks Turn the valve to measure the bend The difference between the highest and the lowest dial readings is the amount of bend B Ifthe free
48. e 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 have 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 8096 of the speci fied torque of dry fasteners Kawasaki Engine Shop Rebuild Manual BREATHER Install Breather Valve A lt zr Install the reed valve A and back plate B then tighten the breather valve screw C Torque Breather Valve Screw 3 4 Nem 0 35 kgf m 30 in Ib B Install the cylinder head see Install Cylinder Head in Section A BALANCER SHAFT Install Balancer Shaft A Install the balancer shaft to the balancer shaft bear ing on the crankcase B Install the crankcase cover see In
49. e function of the breather is to create a negative pres sure in the crankcase which prevents oil from being forced out of the engine through the piston rings oil seals or gaskets A sealed type crankcase emission control system is used to prevent blow by gases from emitting in the air The blow by gases are drawn into the clean side of the air cleaner through the crankcase and the cylinder head and mixed with the clean airflow and subsequently come into the combustion chamber through the carbure tor Oil is primarily separated from the gases while pass ing through the inside of the rocker chamber from the crankcase and secondly separated from the gases in the breather chamber and then brought back to the crank case 2 Fresh Air Biow by gas 011 A Remove the cylinder head assembly see Remove Cylinder Head in Section A B Unscrew the breather valve screw A Page B 3 ENGINE BOTTOM END DISASSEMBLY SPECIFICATIONS m Suma Camshaft and Tappets Cam Lobe Height Inlet Exhaust Camshaft Journal Diameter Crankcase Side Crankcase Cover Side Camshaft Bearing Inside Diameter Crankcase Side Crankcase Cover Side Crankshaft and Connecting Rods Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Width Crankpin Width Connecting Rod Big End Inside Diameter Crankpin Outside Diameter
50. earance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clear ance and the cylinder head must be replaced F Measure the outside diameter O D of the seating surface with a vernier caliper G If the O D of the seating surface is too small repeat the 45 grind until the diameter is within the specified range H If the O D of the seating surface is too large make the 32 grind described below Page C 5 To make the 32 grind fit a 32 cutter to the holder and slide it into the valve guide 1 Grind the seat at a 32 angle until the seat O D is within the specified range 2 Turn the holder one turn at a time while pressing down very lightly Check the seat after each turn The 32 cutter removes material very quickly A Page C 6 3 Check the seat outside diameter frequently to pre vent overgrinding After making the 32 grind return to the seat O D measurement step above Lap the valve to the seat once the seat width and O D are within the ranges specified above Put a little coarse grinding compound on the face of the valve in a number of places around the valve head Spin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve Repeat the process with a fine grinding compound GE15012081 C A Lapping Tool B Valve Seat C Valv
51. ession reading obtainable Cylinder Compression Usable Range 880 1 080 kPa 9 11 kgf cm 128 156 psi 2500 700 r min rpm Page C 1 The following table should be consulted if the obtainable compression reading is not within the usable range Problem Diagnosis Remedy Action Cylinder compression higher than usable range Carbon accumulation on piston and cylinder head and in combustion chamber possibly due to damaged valve stem oil seal and or damaged piston oil rings Remove the carbon deposits and replace damaged parts if necessary Incorrect cylinder head gasket thickness Replace with a gasket of the proper thick ness Cylinder compression lower than usable range Gas leakage around cylinder head Replace damaged gas ket and check cylin der head warp Bad condition of valve seating Repair if possible Incorrect valve piston cylinder clearance Adjust Piston seizure Inspect cylinder and liner and replace repair as necessary Page C 2 Bad condition of piston ring and or piston ring grooves Kawasaki Engine Shop Rebuild Manual Replace Inspect Push Rod Measure Cylinder Head Warp A A B KE04016BS1 C Place the rocker arm push rod on V blocks that are as far apart as possible and set a dial gauge A on the rod at a point halfway between the blocks Turn the rod to measure the runout The difference between highest and
52. exceeds the service limit the connecting rod must be replaced Connecting Rod Bend Service Limit 0 15 100 mm 0 006 3 94 in Kawasaki Engine Shop Rebuild Manual G Measure connecting rod twist H KGO6017BS1 C With the big end arbor still on the V blocks A hold the connecting rod horizontally Use a height gauge B to measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist L If connecting rod twist exceeds the service limit the connecting rod must be replaced Connecting Rod Twist Service Limit 0 15 100 mm 0 006 3 94 in Measure Connecting Rod Big End Crankpin Width Wear A 6068022 P Measure the connecting rod big end width A with a micrometer or dial caliper B If the measurement is less than the service limit replace the connecting rod Connecting Rod Big End Width Standard 27 4 27 7 mm 1 08 1 09 in Service Limit 27 0 mm 1 06 in Kawasaki Engine Shop Rebuild Manual KGO6018BS1 C Measure the crankpin width A with a dial caliper D If the crankpin width is more than the service limit replace the crankshaft Crankpin Width Standard 28 0 28 2 mm 1 10 1 11 in Service Limit 28 4 mm 1 12 in Measure Connecting Rod Big End Bearing Crankpin Wear A Apply a thin film of oil on the thread of the cap bolts B Install the cap bolts
53. f 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 Kawasaki Engine Shop Rebuild 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 operating 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
54. 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 defective 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 Kawasaki Engine Shop Rebuild 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 Indu
55. he crankshaft bearings Use the scraping tools carefully Do not gouge the piston head To avoid gouging use scrapers that are made of a material that will not cause damage Scrape the carbon off the piston head with a scraper A Kawasaki Engine Shop Rebuild Manual KE06038BS1 C Be careful not to widen the ring grooves Damaged ring grooves will require piston replacement D Clean the piston ring grooves A with a broken piston ring or other suitable tools Check Piston Ring and Ring Groove Wear A Clean the piston see Clean Piston Visually inspect the piston rings and ring grooves B If the piston rings are worn unevenly or damaged replace them C If the ring grooves are worn unevenly or damaged replace both the piston and piston rings 06039851 C Measure the clearance between the top and second rings and their grooves using a thickness gauge A Page C 11 E If the piston ring groove clearance is greater than the specified value replace the piston Piston Ring Groove Clearance Standard Top Second 0 04 0 08 mm 0 002 0 003 in Service Limit Top Second 0 18 mm 0 0071 in The oil ring is a three piece assembled ring It is difficult to measure the ring groove clearance and thickness visually inspect only 06010851 C Measure the piston ring thickness A G Use a micrometer to measure at several points around the rings H If any of the measurement
56. he emis sion control system warranty on your 2004 and later small off road engine herein engine In California new 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 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
57. heduled 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 Kawasaki Engine Shop Rebuild 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 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 1995 and later Owner s Manual 5 repairs performed outside of
58. ial 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 atno 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 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 injection 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 Miscellaneou
59. l pins A C Replace the gasket B with a new one D Tighten the cylinder head bolts following the tighten ing sequence as shown Torque Cylinder Head Bolts 37 Nem 3 8 kgf m 27 ft lb Page E 1 ENGINE TOP END REASSEMBLY F l Be sure the ends of the push rods are correctly seated on the tappets J Apply engine oil to the rocker arms K Install rocker arms and valve clearance adjusting nuts L Check and adjust the valve clearance see Inspect Valve Clearance and Adjust Valve Clearance M Install new gasket and valve cover N Tighten 1 048009 Torque Cylinder Head Cover Bolts 6 9 Nem 0 70 kgf m 61 in Ib Apply engine oil to the push rods A and install them Engine Shroud Bolts 5 9 Nem 0 60 kgf m 52 in Ib onto the tappets B 040178 52 C To install the push rods A in the correct positions on the tappets B insert the push rod so that the end of the push rod is sliding down along inside wall C of the crankcase and position the push rod end onto the tappet H Check that both inlet and exhaust push rods on each cylinder are at the lowest position on the cam lobes D If not turn the alternator rotor clockwise one turn and position the crankshaft at TDC of the compres sion stroke Page E 2 Kawasaki Engine Shop Rebuild Manual ILLUSTRATED PARTS BREAKDOWN TABLE OF CONTENTS FOR SECTION F SECTION TITLE PAGE NO CYLINDER CRANKGMASE enin Omen ep ER ener
60. length is less than the service limit replace the valve spring with a new one Valve Spring Free Length Standard 35 mm 1 38 in B If the valve stem bend is greater than the service Service Limit 32 6 mm 1 28 in limit replace the valve with a new one Measure Valve Head Thickness Valve Stem Bend A Standard Less than 0 01 mm 0 0004 in TIR Service Limit TIR 0 05 mm 0 0020 in 6 15011151 C Measure the thickness A of the valve head B If the valve head thickness is less than the service limit replace the valve with a new one Valve Head Thickness Standard 0 4 mm 0 016 in Service Limit 0 4 mm 0 016 in Page C 8 Kawasaki Engine Shop Rebuild Manual Measure Valve Stem Diameter Measure Valve Guide Clearance Wobble A Method A KEO5008BS1 C 1 05002851 C Measure the diameter of the valve stem A in two directions at right angles and at four different posi If a small bore gauge is not available inspect the tions on the stem valve guide wear by measuring the valve guide clear B If any single measurement is less than the service ance with the wobble method as indicated below limit replace the valve with a new one B Insert a new valve A into the guide B from the to Valve Stem Diameter A g B p of the head Standard Inlet 6 960 6 975 mm 0 2740 0 2746 in C Set a dial gauge against the stem perpendicular to it Exhaust 6 945 6 960 mm 0 2734 0 2
61. located on the cylinder head to allow the head to be removed without damaging the fins Do not pry on the cylinder head fins during removal Damage to the fins will occur if they are used as pry points Remove cylinder head bolts A push rod guides B and cylinder head C Page 2 VALVES Remove Valve Mechanism A Remove cylinder head see Remove Cylinder Head B Support the valve head in the combustion chamber with a folded shop towel C Wear eye protection while removing collets Valve springs are under tension and may propel collets during removal causing injury to eyes To remove the collets A push down the valve retainer with thumbs and remove the collets D Remove the valve retainer spring C and valve D It is not necessary to remove the stem seal unless it is being replaced Stem seals should be replaced during a top end overhaul Valve guide B is not replaceable do not remove it E Remove the stem seals A Kawasaki Engine Shop Rebuild Manual ENGINE END DISASSEMBLY SPECIFICATIONS a Cylinder Head 880 1 080 kPa 9 11 kgf cm 128 156 psi Cylinder Compression 500 700 r min rpm Rocker Arm Push Rod Runout TIR 0 5 mm 0 02 in Cylinder Head Warp 0 03 mm 0 001 in Valves Valve Clearance when cold Valve Seating Surface Outside Diameter Inlet Exhaust Width Inlet Exhaust Valve Seat Cutting Angle Valve Spring Free Length
62. n Emission Control Systems California Only G 5 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT 2000 G 8 YOUR WARRANTY RIGHTS AND OBLIGATIONS eee G 8 LIMITED WARRANTY on Emission Control Systems California Only G 8 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT 2001 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 Kawasaki Engine Shop Rebuild Manuall Page G i LIMITED WARRANTY Notes Page G ii Kawasaki Engine Shop Rebuild Manual LIMITED WARRANTY FEDERAL FEDERAL EMISSIONS COMPONENT 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 init
63. nder Bore Out Round Piston Cylinder Clearance Balancer Shaft Balancer Shaft Journal Diameter Balancer Shaft Bearing Inside Diameter Crankcase Side Crankcase Cover Side 0 04 0 08 mm 0 002 0 003 in 1 47 1 49 mm 0 0579 0 0587 in 0 15 0 40 mm 0 0059 0 016 in 0 23 0 48 mm 0 0091 0 019 in 0 25 0 75 mm 0 0098 0 030 in 18 995 19 000 mm 0 74783 0 74803 in 19 004 19 015 mm 0 74819 0 74862 in 19 010 19 021 mm 0 74842 0 74886 in 81 935 81 955 mm 3 2258 3 2266 in 81 97 81 99 mm 3 227 3 228 in 0 015 0 055 mm 0 00059 0 0022 in 31 959 31 975 mm 1 2582 1 2589 in 32 000 32 016 mm 1 2598 1 2605 in 32 000 32 016 mm 1 2598 1 2605 in Kawasaki Engine Shop Rebuild Manual 0 18 mm 0 0071 in 1 40 mm 0 0551 in 0 7 mm 0 03 in 0 8 mm 0 03 in 1 0 mm 0 039 in 18 96 mm 0 7465 in 19 08 mm 0 7512 in 19 06 mm 0 7504 in 81 79 mm 3 220 in 82 10 mm 3 232 in 0 05 mm 0 002 in 31 935 mm 1 2573 in 32 06 mm 1 262 in 32 06 mm 1 262 in Page B 5 ENGINE BOTTOM END DISASSEMBLY Exploded View Fig 1 Crankcase Page B 6 Kawasaki Engine Shop Rebuild Manual ENGINE BOTTOM END DISASSEMBLY Torque E Z GO Nem ft Ib in Ib Connecting Rod Big End Cap Bolts 060 52imbb EO s ww 2 F 603518 Oil Filter Joint 0 70
64. ng 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 abuse neglect improper maintenance or unapproved modifications Kawasaki Engine Shop Rebuild 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 conta
65. provider s place of business during normal business hours In all cases 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 and or pressure regulator or fuel injection system it 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 il Air Filter 3 Ignition System i Spark Plugs ii
66. r valve seat repair Therefore the cutter must not be used for other purposes 2 Do not drop or hit the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cut ter before grinding the seat surface Also use washing oil to wash off ground particles sticking to the cutter Do not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles Setting the valve seat cutter holder A in position operate the cutter B with one hand C Do not apply too much force to the diamond portion Prior to grinding apply oil to the cutter and during the operation use washing oil to wash off any ground particles sticking to the cutter 5 After use wash the cutter with washing oil and apply a thin layer of engine oil before storing Kawasaki Engine Shop Rebuild Manual Marks Stamped on the Cutter 6 15011851 C The marks stamped on the back of the cutter A repre sent the following GO e Cutter angle B Outer diameter of cutter C Operating Procedures A Clean the seat area carefully B Coatthe seat with machinist s dye C Fita 45 cutter to the holder and slide it into the valve guide D Press down lightly on the handle and turn it right or left E Grind the seating surface only until it is smooth Do not grind the seat too much Overgrinding will reduce valve cl
67. res 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 this section Using Telescoping Gauges Hole Gauges Kawasaki Engine Shop Rebuild Manual Telescoping gauges and hole gauges are transfer type measuring instruments They are not calibrated and are used to record a distance which 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 CYLINDER HEAD Measure Cylinder Compression A Thoroughly warm up the engine so that the engine oil between the piston and the cylinder wall will help seal compression as it does during normal running 1 048012 P Stop the engine remove the spark plug and attach a compression gauge A firmly into the spark plug hole B Special Tools Compression Gauge 20 kgf cm E Z GO Part No N A Compression Gauge Adapter M14 x 1 25 B E Z GO Part No N A C Using the starter turn the engine over with the throt tle fully open until the compression gauge stops ris ing this is the highest compr
68. rmal engine operating schedule Page G 16 Kawasaki Engine Shop Rebuild 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
69. rmance 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 Kawasaki Engine Shop Rebuild 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 a 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 engine You should keep all receipts and maintenance re cords 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
70. rt No 000 0 1 Piston Ring Compressor Belt 80 91 E Z GO Part No Ni 1 Bearing Driver Set E Z GO Part No 1 Use clutch puller bolt E Z GO Part No 608429 to remove the drive clutch if it has not yet been removed from the PTO of the crankshatt CRANKCASE Remove Crankcase Cover A Drain the engine oil If the crankcase cover sticks tap lightly with a wooden or plastic mallet near the dowel pins C 11048002 P C Remove crankcase cover bolts A and crankcase cover B CAMSHAFT AND TAPPETS Remove Camshaft Tappet A Drain the engine oil B Remove crankcase cover see Remove Crankcase Cover Kawasaki Engine Shop Rebuild Manual KGO5B036 P Remove valve cover A D Position the piston TDC at the end of the compres sion stroke Remove the lock screws A and the valve clearance adjusting nuts B which fasten the rocker arm C and pull the rocker arm off the push rods D F Remove the push rods and mark them so they can be installed in their original positions during assembly ub NER KG058038 P 4 Pull the camshaft A out of the crankcase Page B 1 ENGINE BOTTOM END DISASSEMBLY Remove the tappets A and mark them so they can be installed in their original positions during assem bly CYLINDERS AND PISTONS Remove Piston A Remove crankcase cover see Remove Crankcase Cover camshaft see Remove Camshaft Tappet Removal and balancer
71. ructions 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 must be performed by a dealer who sold you the engine or distributors or service providers authorized 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 tha
72. s to cause cancer birth defects or other reproductive harm The exhaust emissions of this vehicle s engine comply with regulations set forth by the Environmental Protection Agency EPA of the United States of America USA at time of manufacture Significant fines could result from modifications or tampering with the engine fuel ignition or air intake systems Page ii Kawasaki Engine Shop Rebuild Manual TABLE CONTENTS Section Page No HOW TO USE THIS S rien ine ro ree IR vii ENGINE TOP END DISASSEMBLY A ENGINE TOP END EUG M PD A 1 CYLINDER HEAD Hemove Cylinder Head ede eee pe ae aed oA A 1 VALVES Remove Valve Mechantem nemen aai A 2 SPEGIFIGATIONS EE A 3 EXPEODEDB VIEW ete roten 4 ENGINE BOTTOM END DISASSEMBLY B ENGINE BOTTOM END PUB BT PIE B 1 CRANKCASE Remove Crankcase Cover sennior i eee Io ede e ee idee de e eS B 1 CAMSHAFT AND TAPPETS Remove Camshaft B 1 CYLINDERS AND PISTONS Remove PISTON Sage B 2 CRANKSHAFT AND CONNECTING RODS Remove Connecting t eeu pie dA teehee elena nen B 3 s Hemove Gratikshalt
73. s Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies ii 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 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 perfo
74. s and Sealing Gaskets MAINTENANCE STATEMENTS 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 recommended FUJI will not deny a warranty claim solely because you have no record of maintenance however FUJI may deny a warranty claim if your failure to perform re quired 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 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 Check for sealing of fuel and proper operation of WEEKLY fuel gauge at each fueling Check that fuel cap vent is free of dirt b Check engine for unusual noise vibration acceleration MONTH 20 HOURS Check engine electrical system for coil spark plug wire 3 MONTH 50 HOURS for cracks loose connections d Check fuel system for leaks at tank cap lines filters 3 MONTH 50 HOURS pump carburetor Check lines for cracks deterioration Check air cleaner filter element SEMIANNUAL 125 HOURS f Replace engine oil DO NOT OVERFILL Use SAE SEMIANNUAL 1
75. s are less than the service limit replace the entire set of rings Piston Ring Thickness Standard Top Second 1 47 1 49 mm 0 0579 0 0587 Service Limit Top Second 1 40 mm 0 0551 in When using new rings in a used piston check for uneven groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Measure Piston Ring End Gap A Remove the piston rings Page C 12 B Push each ring one at a time into the cylinder bore to a point close to the bottom of the cylinder bore C Use the piston to push it in to be sure it is square KE06040BS1 C Measure the gap A between the ends of the ring B with a thickness gauge E If the end gap of any ring is greater than the service limit replace the entire set of rings Piston Ring End Gap Standard 0 15 0 40 mm 0 0059 0 016 Second 0 23 0 48 mm 0 0091 0 019 in Oil 0 25 0 75 mm 0 0098 0 030 in Service Limit Top 0 7 mm 0 03 in Second 0 8 mm 0 03 in Oil 1 0 mm 0 039 in Kawasaki Engine Shop Rebuild Manual Measure Piston Pin Piston Pin Hole and Connecting Rod Wear A Remove the piston pin B KE06012BS1 C Measure the outside diameter of the piston pin with a micrometer at several points C If the outside diameter is less than service limit replace the piston pin Piston Pin Outside Diameter Standard 18 995 19 000 mm 0 74783 0 74803 in Ser
76. stall Crankcase Cover Align the punch marks A the crankshaft gear and on the balancer shaft gear Page D 1 ENGINE BOTTOM END REASSEMBLY CRANKSHAFT AND CONNECTING RODS Install Crankshaft A Clean the crankshaft and crankcase thoroughly especially at the bearing contact surfaces B Pack grease to 60 volume between the lips of the oil seal on the crankcase Press in the new oil seal 0 1 mm 0 0 04 in below the crankcase surface C Apply molybdenum disulfide grease to the alternator side journal D Apply engine oil to the crank pin and bearing E Insert the crankshaft into the crankcase Install Connecting Rod A Refer to Install Piston CYLINDERS AND PISTONS Install Piston A KE06045BS1 C Install the expander A in the piston oil ring groove so that the expander ends B touch never overlap B There is no up or down to the rails They can be installed either Way Install the upper and lower steel rails Page D 2 Do not mix the top and second rings Install the second ring so that the notched edge A faces down The rings should turn freely in the grooves D Install the top ring KE06033BS1 C Piston Head B Top Ring C Second Ring D E KE06034BS1 C Align the piston and rings with the piston ring end gap as shown Arrow Match Marks A Top Ring End Gap Upper Steel Rail End Gap B About 45 C Second
77. stries 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 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 period 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
78. sure regulator or fuel injection system ii Air fuel ratio feedback and control system if applicable iit 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 Kawasaki Engine Shop Rebuild 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 1 Hoses Belts Connectors and Assemblies iit 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 warranty 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 no
79. t No N A B Apply grease to 60 volume between seal lips C Install the oil seal B at specified position as shown C Crankcase Cover D 4 0 4 5 mm 0 16 0 18 in Install Crankcase Cover A 11048001 P Check to see that the dowel pins A are in place on the crankcase B Install the new gasket on the crankcase Kawasaki Engine Shop Rebuild Manual ENGINE BOTTOM END REASSEMBLY 1104001BS1 C Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown Torque Crankcase Cover Bolts 22 Nem 2 2 kgf m 16 ft lb Kawasaki Engine Shop Rebuild Manual Page D 5 Notes Page D 6 Kawasaki Engine Shop Rebuild Manual ENGINE TOP END REASSEMBLY TABLE OF CONTENTS FOR SECTION E SECTION TITLE PAGE NO 5 noe Fa dee Ra ck Avani etr ied Erde ere e E 1 Him eeh 1 WALES m TIU E 1 Install Valve 1 CYLINDER HEAD i ices uie oett eee en e tel Atul 1 Install CylinderiHea x erret ter eti qe en e ere ren debe aetna ese 1 Kawasaki Engine Shop Rebuild Manual Page E i ENGINE TOP END REASSEMBLY Notes
80. t be in good condition or this check will not be valid G If the valve seating pattern is not correct repair the seat H Measure the outside diameter D of the seating pat tern on the valve seat If the outside diameter of the valve seating pattern is too large or too small repair the seat Valve Seating Surface Outside Diameter Inlet 32 8 mm 1 29 in Exhaust 27 6 mm 1 09 in J Measure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F Too Wide G Too Narrow H e Uneven J K Ifthe width is too wide too narrow or uneven repair the seat see Repair Valve Seat Valve Seating Surface Width Standard Inlet 1 1 1 7 mm 0 043 0 067 in Exhaust 1 0 1 5 mm 0 039 0 059 in Repair Valve Seat A Follow the manufacturer s instructions for use of valve seat cutters Special Tools Valve Seat Cutter 45 35 E Z GO Part No 608666 Valve Seat Cutter 32 38 5 E Z GO Part No 608668 Valve Seat Cutter 45 32 E Z GO Part No 608665 Valve Seat Cutter 32 35 E Z GO Part No 608667 Valve Seat Cutter Holder 7 E Z GO Part No 608669 Valve Seat Cutter Holder Bar E Z GO Part No 608670 Kawasaki Engine Shop Rebuild Manual If the manufacture s instructions not available use the following procedure Seat Cutter Operating Cares 1 The valve seat cutter is designed only fo
81. t warranty service be performed by the authorized dealer who sold you the engine although warranty service will be performed by any authorized dealer distributor and service provider any where in the United States When warranty repair is needed the engine must be brought to an authorized dealer distributorship or service provider s place of business during normal business hours In all cases 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 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 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 pres
82. ted 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 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
83. the authorized warranty service facilities 6 use of parts which are not authorized by 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 service be performed by the authorized dealer who sold you the engine although warranty service will be performed by any authorized dealer distributor and warranty station any where in the United States When warranty repair is needed the engine must be brought to an authorized dealer distributorship or warranty station s place of business during normal business hours In all cases a reasonable time not to exceed 30
84. the lowest dial readings is the amount of runout If the runout exceeds the service limit replace the rod Rocker Arm Push Rod Runout Service Limit TIR 0 5 mm 0 02 in Inspect Rocker Arm A KE04003BS1 C Clean and inspect the rocker arm where it touches the push rod and valve stem If the contact points A are worn or damaged replace the rocker arm Kawasaki Engine Shop Rebuild Manual Lay a straightedge A across the lower surface of the head at several different points and measure warp by inserting a thickness gauge B between the straight edge and the head If warp exceeds the service limit repair the mating surface Replace the cylinder head if the mating sur face is badly damaged Cylinder Head Warp Service Limit 0 03 mm 0 001 in Page C 3 VALVES Inspect Valve Clearance A Refer to the Specifications table in Section A Adjust Valve Clearance A Refer to the Specifications table in Section A Inspect Valve Seat A Remove the valve See Remove Valve Mechanism in Section A B GE15011782 C Check the valve seating surface A between the valve B and valve seat C C Coat the valve seat with machinist s dye D Push the valve into the guide E Rotate the valve against the seat with a lapping tool F Pull the valve out and check the seating pattern on the valve head It must be the correct width and even all the way around Page C 4 The valve stem and guide mus
85. ure 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 Kawasaki Engine Shop Rebuild 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 later specialty vehicle engine herein 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
86. vice Limit 18 96 mm 0 7465 in D KE06041BS1 C Measure the inside diameter A of the piston pin hole at several points on both sides Use a dial bore gauge E If the inside diameter is more than the service limit replace the piston Piston Pin Hole Inside Diameter Standard 19 004 19 015 mm 0 74819 0 74862 in Service Limit 19 08 mm 0 7512 in Kawasaki Engine Shop Rebuild Manual KE06042BS1 C Measure the inside diameter A of the small end of the connecting rod at several points Use a dial bore gauge G If the inside diameter is more than the service limit replace the connecting rod Connecting Rod Small End Inside Diameter Standard 19 010 19 021 mm 0 74842 0 74886 in Service Limit 19 06 mm 0 7504 in Measure Piston Diameter A KE06043BS1 C Measure the outside diameter A of the piston 18 mm 0 71 in up B from the bottom of the piston at a right angle to the direction of the piston pin hole B If the measurement is less than the service limit replace the piston Piston Diameter Standard 81 935 81 955 mm 3 2258 3 2266 Service Limit 81 79 mm 3 220 in Page C 13 Check Cylinder Inside Diameter A Clean and measure the cylinder inside diameter B Use a dial bore gauge to measure front to back and side to side at the points as shown in the figure C KE06044BS1 C If any of the cylinder bore measurements is greater than the ser
87. vice limit replace the crankcase 10 mm 0 39 in A 35 mm 1 38 in B Cylinder Inside Diameter Standard 81 97 81 99 mm 3 227 3 228 in Service Limit 82 10 mm 3 232 in Cylinder Bore Out Round Service Limit 0 05 mm 0 002 in Page C 14 CRANKSHAFT AND CONNECTING RODS Clean Inspect A After removing clean the crankshaft and connecting rods with a high flash point solvent and dry them with compressed air B Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and evidence of improper tooth contact C Replace the gear if necessary D Inspect the crankshaft and connecting rods espe cially at the bearing surfaces for wear scratches evi dence of improper contact or other damages E Replace them if necessary Measure Connecting Rod Bend Twist A Measure connecting rod bend B Select an arbor of the same diameter as the connect ing rod big end and insert the arbor through the con necting rod big end C Select an arbor of the same diameter as the piston pin and at least 100 mm long and insert the arbor through the connecting rod small end KGO6016BS1 C On a surface plate set the big end arbor on V blocks With the connecting rod held vertically use a height gauge B to measure the difference in the height of the small end arbor above the surface plate over a 100 mm length to determine the amount of connect ing rod bend F If connecting rod bend

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