Club Car EX40D Einrichtungshandbuch
Manual Number 105062943
Edition Code 0114A00000
EX40 EFI Engine
Service, Repair, and
Rebuild Manual
1. SPECIFICATIONS............................................... 1
2. GENERAL DESCRIPTION OF ENGINE COMPONENTS ................ 2
3. DISASSEMBLY AND REASSEMBLY ............................... 6
3-1 PREPARATIONS AND PRECAUTIONS ........................... 6
3-2 SPECIAL TOOLS............................................. 6
3-3 DISASSEMBLY PROCEDURE .................................. 7
3-4 REASSEMBLY PROCEDURE ................................... 19
4. ENGINE OIL ................................................... 32
5. IGNITION SYSTEM .............................................. 33
6. WIRING DIAGRAM .............................................. 33
7. OIL SENSOR................................................... 34
8. TROUBLESHOOTING ........................................... 35
9. ELECTRIC FUEL INJECTION SYSTEM ............................. 41
10. STANDARD REPAIR TABLES .................................... 49
10-1 STANDARD DIMENSIONS AND LIMITS OF USE .................. 49
10-2 SERVICE DATA (The following are only for your reference.)........... 54
10-3 TIGHTENING TORQUE....................................... 55
10-4 AIR GAP AND CLEARANCE ................................... 55
11.PERIODIC MAINTENANCE ....................................... 56
CONTENTS
Section Title Page
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1
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1. SPECIFICATIONS
*Specifications are subject to change without notice.
Model EX40D
Type Air-Cooled, 4-Cycle, Slant Single-Cylinder,
Horizontal P.T.O. Shaft, OHC Gasoline Engine
Bore & Stroke mm (in.) 89 × 65 (3.50 × 2.56)
Piston Displacement ml (cu.in.) 404 (24.65)
Compression Ratio 8.3
Maximum Output kW(HP)/r.p.m. per SAE J 1940 10.4 (14)/3600
Maximum Torque
N・m / r.p.m.
(kgf・m / r.p.m.)
(ft・lb. / r.p.m.)
27/2400
(2.8/2400)
(19.91/2400)
Direction of Rotation Counterclockwise as viewed from the P.T.O. shaft side
Cooling System Forced air cooling system
Lubrication System Splash lubrication system
Lubricant
Automobile engine oil ; Grade SE or higher (SG,SH or SJ in recomended)
SAE 10W-30-----Under ordinary atmospheric temperatures
SAE 5W-30-------In cold areas
Capacity of Lubricant L 1.2 (1.3 qt.)
Fuel system Throttle body single point injection
Fuel type Automobile unleaded gasoline
Fuel Supply System Regulated pressure with electric fuel pump type
Ignition System Flywheel magneto digital C.D.I.
Spark Plug NGK BR-6HS
Starting System Starter / Generator
Governor System None (Vehicle speed control)
Dry Weight kg (lb.) Approx. 24.4 (53.6)
Dimensions (L x W x H) mm (in.) 351 x 451 x 340 (13.8 x 17.8 x 13.4)
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2
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2. GENERAL DESCRIPTION OF ENGINE COMPONENTS
2-1 CYLINDER AND CRANKCASE
The cylinder and crankcase are aluminum die-casting
as a single piece. A special cast iron cylinder liner is
molded into the aluminum die-casting.
The crankcase has a mounting surface on the output
shaft side to which the main bearing cover is attached.
The cylinder is inclined to the right at an angle of 25
degrees from the horizontal as viewed from the output
shaft side.
2-2 MAIN BEARING COVER
The main bearing cover is an aluminum die-casting,
which is mounted on the output shaft side of the
crankcase. By removing the main bearing cover,
the
inside of the engine can be inspected with ease.
Pilots and bosses are machined into the cover
to facilitate the direct coupling of the engine with
machines such as generators and pumps.
Oil gauges (fillers) are on both sides of the cover for
easy maintenance.
2-3 CRANKSHAFT
The crankshaft is forged carbon steel, and the crank
pin is high-frequency inductionhardened.
The crank sprocket used to drive the chain and the
gear used to drive the governor gear are pressed into
the output end of the shaft.
2-4 CONNECTING ROD AND PISTON
The connecting rod is a specially heat-treated
aluminum alloy die-casting. Its large and small ends
function as bearings. A splasher built into the
connecting rod lubricates by splashing engine oil.
The piston is an aluminum alloy casting with grooves
for mounting one compression ring and one oil ring.
Fig.2-1
Fig.2-2
Fig.2-3
25°
Fig.2-4
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3
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2-6 CAMSHAFT
The camshaft and the sprocket are made of special
sintered alloy. They are constructed as a single
piece. The camshaft is provided with intake and
exhaust cam, and the decompression release lever is
mounted on the sprocket shaft end side.
2-7 VALVE ARRANGEMENT
This engine has a chain-driven overhead cam and
overhead valve construction, with a single cam which
has individual profile for intake and exhaust to
perform high output.
Fig.2-6
Fig.2-5
TOP
RING
SECOND
RING
OIL
RING
1
2
3
BARREL
TAPER
TAPER
1
2
3
THREE-PIECE
CONSTRUCTION
EXHAUST VALVEINTAKE VALVE
2-5 PISTON RINGS
The piston rings are made of special cast iron. The profile of the top ring is a tapered face.
The oil ring is designed for better sealing and less oil consumption, in combination with 3 pieces.
Fig.2-7
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4
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2-11 TIMING CHAIN
Timing chain system is adopted and designed for
lubricating for the upper portion of cylinder head.
The timing chain is engaged between the sprocket
portion of integrated camshaft in the cylinder head and
the crankshaft gear sprocket.
The sprocket teeth in particular shape are adopted to
enhance the durability and to realize low noise level.
Fig.2-9
2-10 LUBRICATION SYSTEM
The rotating parts, sliding parts and valves of the engine are lubricated with oil in the crankcase.
The oil is splashed onto the parts by the oil splasher on the connecting rod.
2-9 COOLING SYSTEM
The engine uses a forced air-cooling system in which a synthetic resin cooling fan (which is separate from the
flywheel), reduce noise and forces cooling air into the cylinder and cylinder head.
Baffles are provided to guide the flow of cooling air.
TIMING CHAIN
OIL SPLASHER
2-8 CYLINDER HEAD
The cylinder head is on aluminum die-casting with a
dome-shaped combustion chamber. The intake and
exhaust ports are arranged in a cross direction to
improve combustion efficiency.
Fig.2-8
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5
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2-13 BALANCER
Unbalanced inertia force is cancelled by the balancer
which rotates at the same speed as the crankshaft to
effectively reduce vibration.
Fig.2-11
2-12 IGNITION SYSTEM
The ignition system is a flywheel magneto digital
C.D.I. system. The magneto consists of a flywheel
and ignition coil. The flywheel (cooling fan is
separete from the flywheel) is directly mounted on
the crankshaft and the ignition coil is directly
mounted on the crankcase.
Fig.2-10
IGNITION COIL
FAN
FLYWHEEL
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6
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Fig.3-1
3. DISASSEMBLY AND REASSEMBLY
3-1 PREPARATIONS AND PRECAUTIONS
(1)
When disassembling the engine, memorize the location of each part so that you can reassemble the engine
correctly. If necessary, attach identification tags with the required assembly information to the parts.
(2) Store groups of parts in separate boxes. This will make reassembly easier.
(3) To prevent parts from being mislaid, keep each group provisionally assembled after removing the parts
from the engine.
(4) Handle the disassembled parts with the utmost care. Clean them with cleaning oil if necessary.
(5) Use the correct tools in the correct way when disassembling and reassembling the engine.
3-2 SPECIAL TOOLS
Tool name Use
Commercially available product Flywheel puller For pulling off the ywheel
Commercially available product Chain wrench For locking the ywheel
FLYWHEEL PULLER
675$3:5(1&+
Inhaltsverzeichnis
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