Ezgo TE5 PDS Service Manual

191718136591516781043111 - INCLUDES ITEMS 3 - 16295cc and 350cc 4 CYCLE ENGINESTARTING MODEL YEAR: 1992ENGINE SHOP REBUILD&SERVICE PARTS MANUAL 27

viiiHOW TO USE THIS MANUALEngine Shop Rebuild and Parts Manual

Page G-4LIMITED WARRANTY - FEDERAL (2001)Engine Shop Rebuild and Parts ManualYou are responsible for presenting your engine to the nearest distributor

Page G-5LIMITED WARRANTY - CALIFORNIA (1995-1999)Engine Shop Rebuild and Parts ManualCALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHT

Page G-6LIMITED WARRANTY - CALIFORNIA (1995-1999)Engine Shop Rebuild and Parts Manualpart which is scheduled for replacement as required maintenance s

Page G-7LIMITED WARRANTY - CALIFORNIA (1995-1999)Engine Shop Rebuild and Parts Manual(4) Exhaust Manifold(5) Miscellaneous Items Used in Above Systems

Page G-8LIMITED WARRANTY - CALIFORNIA (2000)Engine Shop Rebuild and Parts ManualCALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND

Page G-9LIMITED WARRANTY - CALIFORNIA (2000)Engine Shop Rebuild and Parts Manualpart which is scheduled for replacement as required maintenance shall

Page G-10LIMITED WARRANTY - CALIFORNIA (2000)Engine Shop Rebuild and Parts Manual(4) Exhaust Manifold(5) Miscellaneous Items Used in Above Systems(i)

Page G-11LIMITED WARRANTY - CALIFORNIA (2001)Engine Shop Rebuild and Parts ManualCALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AN

Page G-12LIMITED WARRANTY - CALIFORNIA (2001)Engine Shop Rebuild and Parts Manualpart which is scheduled for replacement as required maintenance shall

Page G-13LIMITED WARRANTY - CALIFORNIA (2001)Engine Shop Rebuild and Parts Manual(iii) Spark advance/retard system, if applicable(4) Exhaust Manifold,

TABLE OF CONTENTS FOR SECTION ‘A’SECTION TITLE PAGE NO.Page A-iRepair and Service ManualAENGINE DISASSEMBLYCYLINDER HEAD REMOVAL...

Page G-14LIMITED WARRANTY - CALIFORNIA (2004)Engine Shop Rebuild and Parts ManualCALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AN

Page G-15LIMITED WARRANTY - CALIFORNIA (2004)Engine Shop Rebuild and Parts Manualpart which is scheduled for replacement as required maintenance shall

Page G-16LIMITED WARRANTY - CALIFORNIA (2004)Engine Shop Rebuild and Parts Manual(ii) Magneto or electronic ignition system. (iii) Spark advance/retar

Copyrighted MaterialThis manual may not be reproduced in whole orin part without the express permission ofE-Z-GO Division of Textron Inc.Technical Com

ENGINE DISASSEMBLYPage A-iiRepair and Service ManualNotes:

AENGINE DISASSEMBLYPage A-1Engine Shop Rebuild and Parts ManualCYLINDER HEAD REMOVALTool List Qty. RequiredExtension, 3/8” drive, 4" ...

ENGINE DISASSEMBLYPage A-2Engine Shop Rebuild and Parts ManualD. Remove the timing belt (ITEM 20). Do not twist thebelt or turn it inside out.E. Remov

ENGINE DISASSEMBLYPage A-3Engine Shop Rebuild and Parts ManualVALVE REMOVAL Remove the Valves from the Cylinder Head(See Fig. A-3 “V

ENGINE DISASSEMBLYPage A-4Engine Shop Rebuild and Parts ManualFig. A-1 Engine149810121114131516171819202122242625286752721113123ANewer ModelNewer Mod

ENGINE DISASSEMBLYPage A-5Engine Shop Rebuild and Parts ManualFig. A-2 Cylinder Head Components31245678910111213141516Crankcase191234567Follow number

ENGINE DISASSEMBLYPage A-6Engine Shop Rebuild and Parts ManualFig. A-3 ValvesBPry valve stem seal loose13452Push spring retainer downto release valve

TABLE OF CONTENTS FOR SECTION ‘B’SECTION TITLE PAGE NO.Page B-iRepair and Service ManualBENGINE DISASSEMBLYCRANKCASE DISASSEMBLY...

ENGINE DISASSEMBLYPage B-iiRepair and Service ManualNotes:

BENGINE DISASSEMBLYPage B-1Engine Shop Rebuild and Parts ManualCRANKCASE DISASSEMBLYTool List Qty. RequiredExtension, 3/8” drive, 4" ...

ENGINE DISASSEMBLYPage B-2Engine Shop Rebuild and Parts ManualRemove the Crankcase End Cover(See Fig. B-1 “Engine Components” on page B-4)(See Fig. B-

ENGINE DISASSEMBLYPage B-3Engine Shop Rebuild and Parts ManualC. To remove a bearing, turn the crankcase on its side,PTO (clutch) side up, and gently

ENGINE DISASSEMBLYPage B-4Engine Shop Rebuild and Parts ManualFig. B-1 Engine Components45910111213141516171821222423252627Crankcase19123 30Newer Mod

ENGINE DISASSEMBLYPage B-5Engine Shop Rebuild and Parts ManualFig. B-2 Engine Components con’t900 Crankshaft786Fan hub(shown without fan)Grind offCra

ENGINE DISASSEMBLYPage B-6Engine Shop Rebuild and Parts ManualFig. B-3 Crankshaft123456ASeal puller

ENGINE DISASSEMBLYPage B-7Engine Shop Rebuild and Parts ManualFig. B-4 Balancer Shaft Bearing, Crankshaft Bearing and PCV Valve1245667893104ATo drive

ENGINE DISASSEMBLYPage B-8Engine Shop Rebuild and Parts ManualFig. B-5 Crankcase End Cover and Crankshaft Bearing123456781CrankshaftAB

ENGINE DISASSEMBLYPage B-9Engine Shop Rebuild and Parts ManualFig. B-6 Piston12334567Insert a suitable mandrel into the pin boreof the piston Press t

Page iEngine Shop Rebuild and Parts ManualENGINE SHOP REBUILD &SERVICE PARTS MANUAL295cc and 350cc ENGINEE-Z-GO Division of Textron, Inc. reserves

ENGINE DISASSEMBLYPage B-10Engine Shop Rebuild and Parts ManualNotes:

TABLE OF CONTENTS FOR SECTION ‘C’SECTION TITLE PAGE NO.Page C-iCENGINE MEASUREMENTSEngine Shop Rebuild and Parts ManualENGINE MEASUREMENTS AND SPECIFI

ENGINE MEASUREMENTSPage C-iiEngine Shop Rebuild and Parts ManualNotes:

CENGINE MEASUREMENTSPage C-1Engine Shop Rebuild and Parts ManualENGINE MEASUREMENTS AND SPECIFICATIONSTool List Qty. RequiredCalipers, dial ...

ENGINE MEASUREMENTSPage C-2Engine Shop Rebuild and Parts ManualF. Turn the cylinder head so that the valve cover gasketsurface rests on the surface pl

ENGINE MEASUREMENTSPage C-3Engine Shop Rebuild and Parts ManualWrist Pin(See Fig. C-5 “Piston, Wrist Pin and Connecting Rod” on page C-6)A. Measure wr

ENGINE MEASUREMENTSPage C-4Engine Shop Rebuild and Parts ManualABCA11A2C1C22B11B22Measure each position inthe cylinder bore at 2 placesCutaway view of

ENGINE MEASUREMENTSPage C-5Engine Shop Rebuild and Parts ManualFig. C-4 Crankshaft Journals and Gear, and Bearing BoresABCCutaway view of crankcase a

ENGINE MEASUREMENTSPage C-6Engine Shop Rebuild and Parts ManualFig. C-5 Piston, Wrist Pin and Connecting RodMeasure each positionin 2 places 90 apar

ENGINE MEASUREMENTSPage C-7Engine Shop Rebuild and Parts ManualFig. C-6 Balancer Shaft Journals, Gear and Bearing BoresCutaway view of crankcase and

Page iiNOTESTransaxle Shop Rebuild and Parts ManualTO OBTAIN A COPY OF THE LIMITED WARRANTY THAT IS APPLICABLE TO THE VEHICLE, CALL OR WRITE THE LOCAL

ENGINE MEASUREMENTSPage C-8Engine Shop Rebuild and Parts ManualFig. C-7 Cylinder Head Cam and CamshaftCutaway view of cylinder head through camshaftA

ENGINE MEASUREMENTSPage C-9Engine Shop Rebuild and Parts ManualFig. C-8 Valve Guides and SeatsABCDValve guideValve seatMeasure each positionin 2 plac

ENGINE MEASUREMENTSPage C-10Engine Shop Rebuild and Parts ManualFig. C-9 Valve and Valve SpringsABCEDFValveA B CIntakeSTD.LIMITD(5.40)0.2143~0.21

ENGINE MEASUREMENTSPage C-11Engine Shop Rebuild and Parts ManualFig. C-10 Rocker Shaft, Arms, and Bearing BoresCCFan sideCylinder headSPECSSTD.LIMITC

ENGINE MEASUREMENTSPage C-12Engine Shop Rebuild and Parts ManualFig. C-11 Piston Ring Gap1"(Top)Ringend gapSTD.LIMIT(Middle)(0.2~0.4)(1.0)Compre

ENGINE MEASUREMENTSPage C-13Engine Shop Rebuild and Parts ManualFig. C-12 Torque SpecificationsCrankcase end-cover bolts6mm8mm230~270 22.5~26.516.6~1

ENGINE MEASUREMENTSPage C-14Engine Shop Rebuild and Parts ManualNotes:

TABLE OF CONTENTS FOR SECTION ‘D’SECTION TITLE PAGE NO.Page D-iDENGINE REASSEMBLYEngine Shop Rebuild and Parts ManualCRANKCASE ASSEMBLY...

ENGINE REASSEMBLYPage D-iiEngine Shop Rebuild and Parts ManualNotes:

DENGINE REASSEMBLYPage D-1Engine Shop Rebuild and Parts Manual‘CRANKCASE ASSEMBLYTool List Qty. RequiredCompressor, piston ring ...

Page iiiEngine Shop Rebuild and Parts ManualTABLE OF CONTENTSSection Page No.How to use the E-Z-GO Service Manual... ...

ENGINE REASSEMBLYPage D-2Engine Shop Rebuild and Parts ManualA. Apply a coat of assembly lube to the exterior surfaceof the wrist pin (ITEM 1) and to

ENGINE REASSEMBLYPage D-3Engine Shop Rebuild and Parts ManualInstall New Crankshaft Bearing(See Fig. D-6 “Crankshaft, Pistons and Balancer Shaft con’t

ENGINE REASSEMBLYPage D-4Engine Shop Rebuild and Parts ManualC. Using a depth gauge and straight edge, measure thedistance from the gasket surface of

ENGINE REASSEMBLYPage D-5Engine Shop Rebuild and Parts Manual1. Place key in the keyway on the crankshaft spindle.Use a brass drift to tap it into pos

ENGINE REASSEMBLYPage D-6Engine Shop Rebuild and Parts ManualFig. D-1 Crankcase CylinderAn electric drill is used to rotate the honing toolwhile stea

ENGINE REASSEMBLYPage D-7Engine Shop Rebuild and Parts ManualFig. D-2 Piston and Connecting Rods32441765"N" Faces upwhen installedCompressi

ENGINE REASSEMBLYPage D-8Engine Shop Rebuild and Parts ManualFig. D-3 Pistons and Connecting Rods con’t120oCompressionring gapWiper ringgapOil ringga

ENGINE REASSEMBLYPage D-9Engine Shop Rebuild and Parts ManualFig. D-4 Crankcase End Cover, PCV Valve and Oil Filter4566789310418345627576BANewer Mode

ENGINE REASSEMBLYPage D-10Engine Shop Rebuild and Parts ManualFig. D-5 Crankshaft, Pistons and Balancer Shaft2847614121311341109

ENGINE REASSEMBLYPage D-11Engine Shop Rebuild and Parts ManualFig. D-6 Crankshaft, Pistons and Balancer Shaft con’tUse mallet handle to gently tap pi

Page ivTABLE OF CONTENTSEngine Shop Rebuild and Parts ManualSection Page No.ENGINE MEASUREMENTS AND SPECIFICATIONS CENGINE MEASUREMENTS AND SPECIFICAT

ENGINE REASSEMBLYPage D-12Engine Shop Rebuild and Parts ManualFig. D-7 Crankshaft and Balancer Shaft EndplayMake sure the gears are completelyseated

ENGINE REASSEMBLYPage D-13Engine Shop Rebuild and Parts ManualFig. D-8 Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil and Fan Hub202217181315

ENGINE REASSEMBLYPage D-14Engine Shop Rebuild and Parts ManualFig. D-9 Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil and Fan Hub con’t21Cran

ENGINE REASSEMBLYPage D-15Engine Shop Rebuild and Parts ManualFig. D-10 Pulser Coil Air GapFor clarity, the fan is shown pulled away fromthe hub, and

ENGINE REASSEMBLYPage D-16Engine Shop Rebuild and Parts ManualNotes:

TABLE OF CONTENTS FOR SECTION ‘E’SECTION TITLE PAGE NO.Page E-iEENGINE REASSEMBLYEngine Shop Rebuild and Parts ManualCYLINDER HEAD ASSEMBLY...

ENGINE REASSEMBLYPage E-iiEngine Shop Rebuild and Parts ManualNotes:

EENGINE REASSEMBLYPage E-1Engine Shop Rebuild and Parts ManualCYLINDER HEAD ASSEMBLYTool List Qty. RequiredCompressor, piston ring ...

ENGINE REASSEMBLYPage E-2Engine Shop Rebuild and Parts ManualInstall New Valve Stem Seals(See Fig. E-2 “Valves con’t” on page D-7)A. Place a new seal

ENGINE REASSEMBLYPage E-3Engine Shop Rebuild and Parts ManualF. Install the camshaft cover (ITEM 14) and new gasket(ITEM 15).1. With the flanged side

Page vTABLE OF CONTENTSEngine Shop Rebuild and Parts ManualSection Page No.• Oil Pressure Switch ... ...

ENGINE REASSEMBLYPage E-4Engine Shop Rebuild and Parts ManualInstall the Front Timing Belt Cover(See Fig. E-5 “Timing Belt Covers, Drive and Cam Pulle

ENGINE REASSEMBLYPage E-5Engine Shop Rebuild and Parts ManualInstall the Rocker Cover(See Fig. E-8 “Rocker Cover” on page D-13)A. Install a new rocker

ENGINE REASSEMBLYPage E-6Engine Shop Rebuild and Parts ManualFig. E-1 Valves and Valve Clearance7635412B.004" FeelerguageLobePosition heel of ca

ENGINE REASSEMBLYPage E-7Engine Shop Rebuild and Parts ManualFig. E-2 Valves con’t231BA87CPush spring retainer down to install/releasevalve keys

ENGINE REASSEMBLYPage E-8Engine Shop Rebuild and Parts ManualFig. E-3 Cylinder Head, Cam Shaft and Rocker Assembly1315168761091112134 Crankcase521417

ENGINE REASSEMBLYPage E-9Engine Shop Rebuild and Parts ManualFig. E-4 Cylinder Head, Cam Shaft, Rocker Assembly con’tLobesRotate the cam lobes so tha

ENGINE REASSEMBLYPage E-10Engine Shop Rebuild and Parts ManualFig. E-5 Timing Belt Covers, Drive and Cam Pulleys, Idler and Timing Belt34323125232422

ENGINE REASSEMBLYPage E-11Engine Shop Rebuild and Parts ManualFig. E-6 Timing Belt Covers, Drive and Cam Pulleys, Idler and Timing Belt con’tIdlerIdl

ENGINE REASSEMBLYPage E-12Engine Shop Rebuild and Parts ManualFig. E-7 Timing Belt Covers, Drive and Cam Pulleys, Idler and Timing Belt con’tRoute th

ENGINE REASSEMBLYPage E-13Engine Shop Rebuild and Parts ManualFig. E-8 Rocker Cover1234Rocker cover tightening sequenceA

Page viTABLE OF CONTENTSEngine Shop Rebuild and Parts ManualNotes:

ENGINE REASSEMBLYPage E-14Engine Shop Rebuild and Parts ManualFig. E-9 Carburetor5761432

FPage F-1ILLUSTRATED PARTS BREAKDOWNEngine Shop Rebuild and Parts ManualIllustrated Parts Breakdown

Page F-2ENGINE Illustrated Parts BreakdownEngine Shop Rebuild and Parts Manual191898107633141316174243484140474645373836393534312928499712112122232324

Page F-3Illustrated Parts Breakdown ENGINEEngine Shop Rebuild and Parts Manual57 19358 19459 19553 18954 19055 191626251615152747778798094

Page F-4ENGINE Illustrated Parts BreakdownEngine Shop Rebuild and Parts Manual114116115126123124134 111113 110109112125121120118119122133Newe

Page F-5Illustrated Parts Breakdown ENGINEEngine Shop Rebuild and Parts Manual198229199200201204203205206136140138139137141146148153221135130183184186

Page F-6ENGINE Illustrated Parts BreakdownWhen ordering parts, please specify the model and serial number of the product.* Indicates a component that

When ordering parts, please specify the model and serial number of the product.* Indicates a component that is not available as an individual part.G**

Page F-8ENGINE Illustrated Parts BreakdownWhen ordering parts, please specify the model and serial number of the product.* Indicates a component that

When ordering parts, please specify the model and serial number of the product.* Indicates a component that is not available as an individual part.G**

viiHOW TO USE THIS MANUALEngine Shop Rebuild and Parts ManualThis manual is designed to suit the needs of mechanics at all levels of experience with t

Page F-10ENGINE Illustrated Parts BreakdownWhen ordering parts, please specify the model and serial number of the product.* Indicates a component that

When ordering parts, please specify the model and serial number of the product.* Indicates a component that is not available as an individual part.G**

Page F-12ENGINE Illustrated Parts BreakdownWhen ordering parts, please specify the model and serial number of the product.* Indicates a component that

When ordering parts, please specify the model and serial number of the product.* Indicates a component that is not available as an individual part.G**

Page F-14ENGINE Illustrated Parts BreakdownWhen ordering parts, please specify the model and serial number of the product.* Indicates a component that

TABLE OF CONTENTS FOR SECTION ‘G’SECTION TITLE PAGE NO.Page G-iGLIMITED WARRANTYEngine Shop Rebuild and Parts ManualFEDERAL EMISSION CONTROL WARRANTY

LIMITED WARRANTYPage G-iiEngine Shop Rebuild and Parts ManualNotes:

Page G-1LIMITED WARRANTY - FEDERALEngine Shop Rebuild and Parts ManualFEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY

Page G-2LIMITED WARRANTY - FEDERALEngine Shop Rebuild and Parts Manualdeny warranty solely for the lack of receipts or for your failure to ensure the

Page G-3LIMITED WARRANTY - FEDERAL (2001)Engine Shop Rebuild and Parts ManualEMISSION COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is a