Ezgo EXPRESS L4 Technician'S Repair And Service Manual Download

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TABLE OF CONTENTS FOR SECTION ‘G’

SECTION TITLE

PAGE NO.

Page G-i

Repair and Service Manual

ENGINE

POWERTRAIN MAINTENANCE ............................................................................... G - 1

Checking the Oil Level ..................................................................................... G - 1
Changing the Oil .............................................................................................. G - 1

AIR FILTER INSPECTION/REPLACEMENT ............................................................ G - 3

Cleaning the Air Filter Element......................................................................... G - 4

STARTER/GENERATOR BELT TENSION ...............................................................G - 4

Adjusting the Belt ............................................................................................. G - 4

STARTER/GENERATOR REPLACEMENT .............................................................. G - 5

COOLING SYSTEM CLEANING ............................................................................... G - 6

SPARK PLUG ........................................................................................................... G - 6

FOUR CYCLE ENGINE............................................................................................. G - 7

Engine Specifications ....................................................................................... G - 7
Engine Description ...........................................................................................G - 7

CYLINDER HEAD ..................................................................................................... G - 7

Compression Measurement .............................................................................G - 7
Rocker Cover Removal .................................................................................... G - 8
Valve Clearance Inspection.............................................................................. G - 8
Valve Clearance Adjustment ............................................................................ G - 8

ENGINE REMOVAL .................................................................................................. G - 9

Controls and Wiring........................................................................................ G - 10
Removing the Engine from the Vehicle .......................................................... G - 10
Engine Installation.......................................................................................... G - 10

DRIVE CLUTCH REMOVAL ................................................................................... G - 10

LIST OF ILLUSTRATIONS

Fig. 1 Oil Dipstick ................................................................................................. G - 1
Fig. 2 Check Oil Level on Dipstick ........................................................................ G - 1
Fig. 3 Oil Viscosity Chart ...................................................................................... G - 2
Fig. 4 Cleaning Top of Engine .............................................................................. G - 2
Fig. 5 Oil Drain Plug ............................................................................................. G - 2
Fig. 6 Remove Oil Filter ........................................................................................ G - 2
Fig. 7 Inspect Oil Filter.......................................................................................... G - 3
Fig. 8 Add Engine Oil ............................................................................................ G - 3
Fig. 9 Air Filter Assembly ...................................................................................... G - 3
Fig. 10 Checking Belt Tension with Gauge ............................................................. G - 4
Fig. 11 Checking Belt Tension with Finger............................................................... G - 4
Fig. 12 Starter/Generator ...................................................................................... G - 5
Fig. 13 Adjusting the Belt Tension ........................................................................ G - 5
Fig. 14 Starter/Generator Wire Connections ......................................................... G - 6
Fig. 15 Starter/Generator Wiring Table ................................................................. G - 6
Fig. 16 Cleaning Cooling System with Air ............................................................. G - 6
Fig. 17 Gapping the Spark Plug ............................................................................ G - 6
Fig. 18 Compression Gauge .................................................................................. G -7
Fig. 19 Rocker Cover ............................................................................................ G - 8
Fig. 20 Measure Valve Clearance ......................................................................... G - 8
Fig. 21 Valve Clearance Adjustment ..................................................................... G - 8