E-Z-GO Engine Shop Rebuild Manual Download

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Page iv

TABLE OF CONTENTS

Kawasaki Engine Shop Rebuild Manual

Section

Page No.

ENGINE MEASUREMENTS AND SPECIFICATIONS

ENGINE MEASUREMENTS AND SPECIFICATIONS

• Tool List................................................ ............................................. .........................................C-1
• Using Telescoping Gauges and Hole Gauges ................................... .........................................C-1

CYLINDER HEAD

• Measure Cylinder Compression .......... ............................................. .........................................C-1
• Inspect Push Rod ................................ ............................................. .........................................C-3
• Inspect Rocker Arm ............................. ............................................. .........................................C-3
• Measure Cylinder Head Warp ............. ............................................. .........................................C-3

VALVES

• Inspect Valve Clearance ...................... ............................................. .........................................C-4
• Adjust Valve Clearance........................ ............................................. .........................................C-4
• Inspect Valve Seat ............................... ............................................. .........................................C-4
• Repair Valve Seat ................................ ............................................. .........................................C-4
• Operating Procedures.......................... ............................................. .........................................C-5
• Measure Valve Spring Free Length ..... ............................................. .........................................C-8
• Measure Valve Head Thickness .......... ............................................. .........................................C-8
• Measure Valve Stem Bend ................. ............................................. .........................................C-8
• Measure Valve Stem Diameter ........... ............................................. .........................................C-9
• Measure Valve Guide Inside Diameter ............................................. .........................................C-9
• Measure Valve/Guide Clearance (Wobble Method)........................... .........................................C-9

CAMSHAFT AND TAPPETS

• Measure Camshaft Bearing/Journal Wear......................................... ........................................C-10

CYLINDER AND PISTONS

• Clean Piston ........................................ ............................................. ........................................C-11
• Check Piston Ring and Ring Groove Wear ....................................... ........................................C-11
• Measure Piston Ring End Gap ............ ............................................. ........................................C-12
• Measure Piston Pin, Piston Pin Hole, and Connecting Rod Wear..... ........................................C-13
• Measure Piston Diameter .................... ............................................. ........................................C-13
• Check Cylinder Inside Diameter .......... ............................................. ........................................C-14

CRANKSHAFT AND CONNECTING RODS

• Clean/Inspect....................................... ............................................. ........................................C-14
• Measure Connecting Rod Bend/Twist.. ............................................. ........................................C-14
• Measure Connecting Rod Big End/Crankpin Width Wear ................. ........................................C-15
• Measure Connecting Rod Big End Bearing/Crankpin Wear ............. ........................................C-15
• Measure Crankshaft Runout................ ............................................. ........................................C-16
• Measure Crankshaft Main Bearing/Journal Wear ............................. ........................................C-16

BALANCER SHAFT

• Measure Balancer Shaft Bearing/Journal Wear ............................... ........................................C-17

BREATHER VALVE

• Inspect Breather Valve......................... ............................................. ........................................C-17