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Honda HRA536, Manual, Page: 76 / 119

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Honda HRA536 Manual Download Page 76

BALL BEARING REPLACEMENT

Oil a new bearing to ease installation and drive in evenly.
Drive the bearing in squarely with the driver and attachment.

[1]

DRIVER HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07749-0010000

[2]

ATTACHMENT, 52 x 55 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07746-0010400

HRD535/K1/K2

[3]

PILOT, 22 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07746-0041000

HRA536 - HRD536/K1/K2

[3]

PILOT, 25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07746-0040600

OIL SEAL REASSEMBLY

Apply grease to the oil seal lip and drive it in squarely with the driver and attachment.

[4]

DRIVER HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07749-0010000

HRD535/K1/K2

[5]

ATTACHMENT, 37 x 40 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07746-0010200

HRA536 - HRD536/K1/K2

[5]

ATTACHMENT, 42 x 47 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07746-0010300

- 77 -

HRA536 - HRD535 - HRD536

- OIL PAN / DRIVE SHAFT / GOVERNOR

S.TOOL

S.TOOL

[2]

[1]

[3]

S.TOOL

S.TOOL

S.TOOL

[5]

[4]

S.TOOL

S.TOOL

Summary of Contents for HRA536

Page 1: ...assembly 55 8 3 carburetor 59 9 FLYWHEEL STARTER MOTOR 61 9 1 Flywheel 61 9 2 Starter motor Charging coil 62 10 CYLINDER HEAD VALVES 66 10 1 Removal Installation 66 10 2 Disassembly Reassembly 67 10 3...

Page 2: ...lutch Dog clutch Neutral valve Dog clutch A cones Dog clutch Shift control Manual remote control Transmission oil NLGI 2 grease HST Honda SAE 90 oil NLGI 2 grease 15W30 oil API SD SF SAE 90 oil Oil ca...

Page 3: ...tem Forced air Ignition system Transistorized magneto Ignition timing 25 BTDC Spark plug NGK BPR 5 ES carburetor Horizontal butterfly valve type Air cleaner Double element dry type Governor Centrifuga...

Page 4: ...t Clutch Neutral valve Shift control Manual remote control Transmission oil NLGI 2 grease HST Honda Oil capacity 85 g 140 cm3 Blade stopping system Rotostop Drive wheel Rear Driving speed with engine...

Page 5: ...r Ignition system Transistorized magneto Ignition timing 20 BTDC Spark plug NGK BPR 5 ES NIPPONDENSO Co Ltd W16 EPR U carburetor Horizontal butterfly valve type Air cleaner Dual type semi dry Governor...

Page 6: ...utral valve Shift control Manual remote control Transmission oil HST Honda Oil capacity 350 cm3 Blade stopping system ROTOSTOP Drive wheel Rear Driving speed with engine speed at 3100 rpm m s 0 85 1 6...

Page 7: ...em Transistorized magneto Ignition timing 20 BTDC Spark plug NGK BPR 5 ES NIPPONDENSO Co Ltd W16 EPR U carburetor Horizontal butterfly valve type Air cleaner Dual element type Governor Centrifugal mec...

Page 8: ...RD536K1 HRD536K1 Types SXE HXE HME HXE HME HXE HME A mm 1694 B mm 574 C mm 1018 D mm 476 E mm 512 F mm 625 Model HRA536 Type HXE A mm 1665 B mm 565 C mm 1020 D mm 480 E mm 500 F mm 635 The models show...

Page 9: ...relay 12 Main fuse 1A 13 Combination switch 14 Control box block with starter motor model 15 Combination switch continuity Bk Black Y Yellow BI Blue G Green R Red W White Br Brown O Orange Lb Light b...

Page 10: ...th larger diameter or inner bolts first and tighten to the specified torque diagonally unless a particular sequence is specified 5 Clean parts in cleaning solvent upon disassembly Lubricate any slidin...

Page 11: ...5 K1 K2 13 000 mm 12 954 mm HRA536 HRD536 K1 K2 18 000 mm 17 954 mm Piston ring Thickness Top Second 1 5 mm 1 37 mm Oil 2 5 mm 2 37 mm Side clearance Top Second Oil 0 015 0 045 mm 0 15 mm End gap Top...

Page 12: ...1 0 8 5 Air cleaner elbow nut HRA536 HRD536 K1 K2 M6 X 1 0 8 5 Recoil starter cover tapping screw 4 mm 0 8 Recoil starter nut M6 X 1 0 8 5 Air cleaner cover screw M6 X 1 0 2 Muffler nut M6 X 1 0 10 B...

Page 13: ...ng HRA536 HRD536 K1 K2 9 Valve seat cutter 32 07780 0012800 07780 0012100 Valve seat reconditioning HRD535 K1 K2 Valve seat reconditioning HRA536 HRD536 K1 K2 10 Valve seat cutter 60 07780 0014300 077...

Page 14: ...Poor performance at low speed VALVE CLEARANCE incorrect Readjust ch 3 8 Engine lacks power VALVE or VALVE SEAT worm or damaged Disassemble and inspect ch 10 2 and 10 3 Correct ch 10 5 CYLINDER PISTON...

Page 15: ...he valve clearance is correct Check for defective cylinder head gasket valves or valve seats Check that the cylinder head is correctly tightened Check for worn piston rings piston or cylinder 8 Instal...

Page 16: ...STOP CABLE too loose Adjust ch 3 6 CLUTCH LINING worn Check ch 4 1 or 4 2 CLUTCH SPRING too weak Q type Check ch 4 2 BLADE BRAKE CLUTCH ASSEMBLY faulty Replace ch 4 1 or 4 2 Blade does not stop turnin...

Page 17: ...rk plug lead with wet hands while performing this test Make sure that no fuel has been spilled on the engine and that the plug is not wet with fuel To avoid fire hazards do not allow sparks near the p...

Page 18: ...Check 2 Shift cable 3 Check Adjust Throttle cable Check Adjust Valve clearance Check Adjust 2 Fuel tank and filter Clean 2 Fuel lines Check replace if necessary Every 2 years 2 Battery 3 Recharge 4 D...

Page 19: ...l Recommended engine oil Use Honda 4 stroke oil Service classification SF SG Viscosity 10W30 b Engine oil change NOTE Draining can be performed rapidly and completely when the engine is still warm 1 S...

Page 20: ...ion oil NOTE When checking hydrostatic transmission oil level screw in the oil level gauge Incorrect oil level will result if the oil level gauge is not screwed in Check the hydrostatic transmission o...

Page 21: ...K2 BPR 5ES NGK HRA536 HRD536 K1 K2 BPR 5ES NGK W16 EPR U NIPPONDENSO Co Ltd 7 Make sure the sealing washer is in good condition Thread the spark plug in by hand to prevent cross threading 8 After spa...

Page 22: ...nt in clean engine oil and squeeze out all the excess oil Excess oil will restrict air flow through the foam element and may transfer to paper element soaking and clogging it Paper element blow low pr...

Page 23: ...nkage adjustment make sure that the maximum engine speed is in the specified range b Maximum engine speed adjustment NOTE adjust the throttle cable linkage before maximum engine speed adjustment 1 Run...

Page 24: ...osen the lock nuts and adjust as required Retighten the lock nuts securely 1 CLEARANCE 2 LOCK NUTS 3 DRIVE CLUTCH CABLE 3 6 ROTOSTOP cable a HRD535 K1 8106639 HRD536 K1 8107479 1 Stop the engine and d...

Page 25: ...nd the right hand edge of the light Distance 1 2 6 If necessary adjust the cable using the adjusting nuts 3 7 Once the adjustment is complete check the play on the Rotostop lever 4 Play at lever 4 5 t...

Page 26: ...of the shift lever s positions must correspond to the three positions of the transmission s selector arm 6 4 If adjustement is required turn the adjustment nuts 7 accordingly NOTE Install the spark p...

Page 27: ...st be performed with the engine cold a Inspection 1 Remove the cylinder head cover 2 Turn the crankshaft until the piston is at top dead center on its compression stroke both valves fully closed 3 Che...

Page 28: ...e speed until it reaches normal operating temperature 3 Turn the pilot screw in or out to obtain the highest idle speed Generally the correct adjustment is obtained by using the values provided above...

Page 29: ...hands when handling the blade 1 Move the throttle lever to STOP position and turn the fuel shut off valve HRA536 HRD535K1 K2 HRD536 K1 K2 drain the carburetor 2 Tilt the mower so the carburetor side u...

Page 30: ...vicing the spark arrester 1 Remove the two nuts remove the muffler protector and muffler 2 Remove the spark arrester from the muffler 3 Use a wire brush to remove carbon deposits from the spark arrest...

Page 31: ...ough detents located around the edge of the lining 5 The blade starts to rotate Rotostop lever released right hand section of the drawing 1 The Rotostop return spring pivots the control plate 1 clockw...

Page 32: ...BLY Remove the cable stay REASSEMBLY Connect the Rotostop cable before tightening the stop screw 3 BBC BOTTOM PLATE INSPECTION ch 4 2b 4 STOP SCREW TIGHTNING TORQUE 22 N m 5 BLADE HOLDER SCREW DISASSE...

Page 33: ...mm Replace the bottom plate if the lining thickness is under than the service limit 1 CLUTCH LINING THICKNESS 2 BRAKE LINING THICKNESS RETURN SPRING Measure the return spring free length Service limi...

Page 34: ...ENING TORQUE 55 N m WRENCH SIZE 14 mm 5 SPRING WASHER 10 mm 2 REASSEMBLY Fit the washer with the OUT mark facing outwards 6 BLADE INSPECTION ch 3 12 SHARPENING ch 4 6 7 BLADE HOLDER SCREW 25 mm M10 TI...

Page 35: ...should be between Distance 2 Measuring the wear on the clutch Engage the Rotostop lever The distance between the brake anchor plate 2 and the lining 3 should be greater than Distance 0 5 mm 3 Measurin...

Page 36: ...crankshaft key way 2 DRIVE DISC 3 DRIVEN DISC INSPECTION ch 4 4b 4 WASHER 10 mm 5 BLADE HOLDER SCREW DISASSEMBLY REASSEMBLY Loosen or tighten the blade holder screw with holding the Rotostop lever TIG...

Page 37: ...the driven disc if the lining thickness is under than the service limit 1 BRAKE LINING THICKNESS 2 CLUTCH LINING THICKNESS 3 DRIVEN DISC CLUTCH SPRING Measure the clutch spring free length Service li...

Page 38: ...NG 3 5 SPECIAL SCREW 6 mm 3 6 BRAKE DISC 7 BALL CONTROL ASSEMBLY REASSEMBLY Connect the Rotostop cable before securing the brake disc 8 SCREW 6 x 14 mm 2 9 COLLAR 10 BALL CONTROL RETURN SPRING REASSEM...

Page 39: ...le the upper surface of the blade only The cutting edge must be even with the lower surface of the blade Taper the blade profile with the maximum amount of material removed at the blade tip and no mat...

Page 40: ...tostop ch 4 4 Loosen the throttle cable holder screw and disconnect the throttle cable from the control arm 5 HRD535 K1 K2 HRD536 K1 K2 Remove the 6 x 32 mm flange screw and 6 mm washer and remove the...

Page 41: ...only Remove screws HRD535 K1 K2 5 x 8 mm screw and 4 x 6 mm screw HRD536 K1 K2 5 x 8 mm screw and 6 x 12 mm flange screw and disconnect the wire harness from the starter motor Disconnect the ignition...

Page 42: ...the woodruff key on the crankshaft except Q type and HRA536 Connect the throttle cable to the throttle arm then secure the cable holder with the screw Adjust the throttle cable after engine installati...

Page 43: ...2 x 23 mm 2 6 ENGINE HRA536 HRD536 K1 K2 GCV160 HRD535 K1 K2 GXV140 7 ENGINE MOUNTING STUD 4 HRA536 HRD536 K1 K2 HRD535 K1 K2 THICKNESS 3 5 mm 5 5 mm 8 ADIABATIC BUSH 4 9 ROTOSTOP CABLE BRACKET 10 WAS...

Page 44: ...INSPECTION ch 3 3 6 FOAM ELEMENT INSPECTION ch 3 3 7 AIR CLEANER COVER SCREW TIGHTENING TORQUE 2 N m 8 AIR CLEANER COVER REASSEMBLY Set the tabs of the cover into the groove of the air cleaner case 9...

Page 45: ...gine to cool before servicing the spark arrester NOTE Muffler servicing can be accomplished with the engine installed 1 MUFFLER REASSEMBLY When reassembly remove the carbon deposits from the muffler b...

Page 46: ...eitfromthehandle INSTALLATION Secure the recoil starter rope through the rope guides as shown DISASSEMBLY REASSEMBLY ch 7 2 4 FUEL FILLER CAP INSTALLATION Make sure the air vent is clean and not clogg...

Page 47: ...by pushing from outside INSTALLATION Set the three tabs into the fuel tank groove securely 4 FUEL FILLER CAP INSTALLATION Make sure the air vent is clean and not clogged Blow clean with compressed ai...

Page 48: ...r case and starter reel 7 1 PIN DRIVER 5 mm 07744 0010500 7 2 STARTER PIN 7 3 BASE O D 35 40 mm I D 20 30 mm Height 30 mm or more 8 WASHER RESIN 9 RATCHET SPRING 2 10 RETURN SPRING DISASSEMBLY Be care...

Page 49: ...nd the rope around the starter reel approx 6 turns 4 Apply grease to the starter case tab Install the starter reel to the starter case hooking the inner hook of the return spring onto the tab on the s...

Page 50: ...until the starter pin head is flat with the reel cover as shown CAUTION Take care not to damage the starter case and starter reel 12 Check the operation of the recoil starter by pulling the starter ro...

Page 51: ...SCREW 4 x 8 mm 6 SWITCH SPRING 7 SPARK PLUG CAP INSPECTION ch 8 1b HRA536 HRD536 K1 K2 8 IGNITION COIL INSPECTION ch 8 1b ADJUSTMENT ch 8 1c 9 FUEL TANK STUD BOLT TIGHTNING TORQUE 10 N m 10 SCREW 6 x...

Page 52: ...s are not obtained 1 ENGINE STOP SWITCH 2 NO CONTINUITY 3 CONTINUITY 4 ARM 5 BUTTON IGNITION COIL PRIMARY COIL Measure the resistance of the primary coil by touching ohmmeter leads to the ignition coi...

Page 53: ...nd stud bolt of the ignition coil 2 Insert a long thickness gauge or piece of paper of the proper thickness between the ignition coil and flywheel Both gaps should be adjusted simultaneously Avoid the...

Page 54: ...INSULATOR INSTALLATION Note the installation direction 5 1 GASKET 5 2 INSULATOR 5 3 INSULATOR GASKET 6 FUEL SHUT OFF VALVE INSTALLATION Inserttheshaftofthevalvetothegrooveofthelever Connectthefuel tu...

Page 55: ...HROTTLE CABLE 13 3 THROTTLE ARM 14 SCREW 15 SCREW 6 x 10 mm 2 16 PROTECTOR 17 ADJUSTING SCREW A INSTALLATION Install the stopper collar as shown ADJUSTMENT ch 3 4 17 1 STOPPER COLLAR 17 2 ADJUSTING SC...

Page 56: ...E 10 N m 10 GOVERNOR SPRING INSTALLATION Hook to the lower hole on the control arm 10 1 CONTROL ARM 10 2 LOWER HOLE 11 CABLE HOLDER INSTALLATION Introduce the throttle cable end in the throttle arm no...

Page 57: ...ASKET b Inspection FUEL SHUT OFF VALVE HRD535 8035905 only Connect pressure tester to the fuel supply fitting Apply pressure to the circuit Pressure should be blocked with valve rod ON position and sh...

Page 58: ...Check for smooth movement after assembly FLOAT LEVEL INSPECTION ch 8 3b 4 FLOAT GASKET 5 FLOAT CHAMBER 6 GASKET 7 SET SCREW CAUTION After assembly check that no fuel leaks 8 DRAIN SCREW 9 MAIN JET RE...

Page 59: ...float top and carburetor body when the float just contacts the float valve Standard float height 13 7 mm If the height is out of specification replace the float Check the float operation 1 FLOAT LEVE...

Page 60: ...ROTOR PULLER HRD535 K1 K2 QME SME HRD536 K1 K2 HME 07935 8050004 INSTALLATION Make sure there are no metal objects stuck to the magnet Adjust the ignition coil air gap after installation ch 8 1c 4 SC...

Page 61: ...ACK WHITE 10 GREY 11 CHARGING COIL WIRE GREY 12 COLLAR 2 13 SCREW 6 x 32 mm 2 HRD536 K1 K2 14 STARTER MOTOR DISASSEMBLY REASSEMBLY ch 9 2b INSPECTION ch 9 2c 15 SCREW 6 x 32 mm 2 16 COLLAR 2 17 SCREW...

Page 62: ...h for wear or damage replace if necessary Also check the flywheel ring gear teeth if the pinion gear teeth damaged 4 1 OFF SET WRENCH 4 2 STOPPER 5 DRIVE SIDE HOUSING 6 GASKET 7 PINION GEAR SHAFT 8 ST...

Page 63: ...ng gear teeth if the pinion gear teeth damaged 3 1 OFF SET WRENCH 3 2 STOPPER 4 DRIVE SIDE HOUSING 5 GASKET 6 BRUSH REASSEMBLY Push in the brushes so they do not interfere with the commutator 7 SET SC...

Page 64: ...are clogged or mica depth is less than the service limit recut the grooves using a hacksaw blade or small file OVER RUNNING CLUTCH 1 Check the over running clutch for smooth axial movement Apply oil g...

Page 65: ...ternin 2 3 steps TIGHTNING TORQUE 24 N m 3 HEAD COVER GASKET 4 SCREW 6 x 14 mm 4 5 CYLINDER HEAD COVER 6 SPARK PLUG INSPECTION ch 3 2 Recommended spark plug HRA536 HRD536 K1 K2 BPR5ES NGK W16EPR U NIP...

Page 66: ...n and slid the retainer to the side so the valve stem slips through the hole at the side of the retainer CAUTION Do not remove the valve spring retainer while the cylinder head is installed or the val...

Page 67: ...PAGE Remove the carbon deposits from the combustion chamber Clean off any gasket material from the cylinder head surface Check the spark plug hole and valve areas for cracks Check the cylinder head fo...

Page 68: ...The intake valve guide cannot be disassembled on model HRD535 E N 8189912 Recondition the valve seats whenever the valve guides are replaced 10 4 Valve guide replacement 1 Chill the replacement valve...

Page 69: ...from the valve guide 4 Thoroughly clean the cylinder head while removing it from the valve guide 5 Check the valve guide bore it should be straight round and centered in the valve guide Insert the va...

Page 70: ...that the width of the finished valve seat is within specification Standard valve seat width 0 8 mm 5 Make a light pass with 45 cutter to remove any possible burs at the edges of the seat 6 After resu...

Page 71: ...9 OIL SEAL 6 x 11 x 4 mm REASSEMBLY Apply grease to the inside of the oil seal lip 10 LOCK PIN REASSEMBLY Install by aligning the straight section with the groove of the governor arm shaft After inst...

Page 72: ...ment 1 DRIVER HANDLE 07749 0010000 2 HRD535 K1 K2 ATTACHMENT 37 x 40 mm 07746 0010200 HRA536 HRD536 K1 K2 ATTACHMENT 42 x 47 mm 07746 0010300 c Inspection CAMSHAFT HOLDER I D Measure the camshaft hold...

Page 73: ...for gear wear or damage 8 PLAIN WASHER 9 LOCK PIN 10 LUG 11 1 OIL RETURN PIPE HRD535 K1 K2 11 2 OIL RETURN RUBBER HRA536 HRD536 K1 K2 only 12 OIL SEAL 12 x 20 x 6 mm Apply to the lip of the oil seal 1...

Page 74: ...6 K1 K2 6205 REPLACEMENT ch 12 1 7 OIL SEAL HRD535 K1 K2 22 x 35 x 6 mm HRA536 HRD536 K1 K2 25 x 38 x 7 mm REASSEMBLY ch 12 1 8 CONNECTING ROD REASSEMBLY Make sure that the longer end mark A facing si...

Page 75: ...1 TOP RING CHROME PLATED 2 SECOND RING 3 SIDE RAILS 4 SPACER 5 OIL RING 6 MARKING VALVE TIMING ADJUSTMENT After installing the crankshaft install the camshaft by aligning the timing marks on the timin...

Page 76: ...OT 22 mm 07746 0041000 HRA536 HRD536 K1 K2 3 PILOT 25 mm 07746 0040600 OIL SEAL REASSEMBLY Apply grease to the oil seal lip and drive it in squarely with the driver and attachment 4 DRIVER HANDLE 0774...

Page 77: ...limit Top Second 0 15 mm Oil HRA536 HRD536 K1 K2 only 0 15 mm PISTON RING WIDTH Measure the piston ring thickness Service limit Top Second 1 37 mm Oil HRA536 HRD536 K1 K2 only 2 37 mm PISTON RING END...

Page 78: ...imit HRD535 K1 K2 HRA536 HRD536 K1 K2 13 048 mm 18 048 mm PISTON PIN O D Measure and record the piston pin O D Service limit HRD535 K1 K2 HRA536 HRD536 K1 K2 12 954 mm 17 954 mm CYLINDER I D Measure a...

Page 79: ...9 92 mm CONNECTING ROD BIG END OIL CLEARANCE 1 Clean all oil from the crank pin and the connecting rod bearing surfaces 2 Place a piece of plastigauge on the crank pin install the connecting rod and t...

Page 80: ...grind the crank pin and use an undersize connecting rod CAMSHAFT INSPECTION Make sure that there is no wear or damage on the decompression spring Measure the cam height Service limit IN 27 45 mm EX 27...

Page 81: ...HRD535 K1 except Q type HRD536 K1 K2 1 ADJUSTER CENTER SCREW 8 mm 2 2 COLLAR 2 3 ADJUSTER GRIP 2 4 FRONT ADJUSTER LEVER 2 5 FLANGE NUT 8 mm 2 TIGHTNING TORQUE 25 N m 6 FRONT WHEEL ASSEMBLY 2 7 WHEEL B...

Page 82: ...2 TIGHTNING TORQUE 24 N m 12 WHEEL WASHER 2 REASSEMBLY Install the washer as shown 12 1 WHEEL SIDE 13 FRONT ADJUSTER ARM 14 42 x 8 5 mm WASHER 15 FRONT AXLE HRA536 16 ADJUSTER GRIP 2 17 FRONT ADJUSTER...

Page 83: ...HER 13 mm 2 9 SNAP RING 4 10 RATCHET RETURN SPRING 2 11 PINION GEAR COLLAR 12 PINION GEAR 2 REASSEMBLY Install with punch mark facing LEFT inside RIGHT outside 12 1 PUNCH MARK 13 RATCHET KEY 2 14 REAR...

Page 84: ...l to correctly identify and install them Check operation after assembly 12 1 LEFT WHEEL 12 2 RIGHT WHEEL 12 3 DRIVE DIRECTION 12 4 DRIVE DIRECTION 13 ROLL PIN 5 x 23 8 mm 2 14 DUST SEAL 2 REASSEMBLY G...

Page 85: ...pulley aligns with the hole in the transmission bracket Insert a screw driver or rod into the holes and pivot the transmission to remove the drive belt from the pulley 5 Tilt the mower so the carbure...

Page 86: ...e from the cable stay on the transmission bracket 13 Unhook the tension spring from the transmission bracket and remove the transmission 1 REAR ADJUSTER ARM 2 AXLE SHAFT GROOVE 3 TENSION SPRING 4 RIGH...

Page 87: ...STOPPER RUBBER 7 SCREW 8 x 16 mm 2 TIGHTNING TORQUE 24 N m H type 8 SELF LOCKING NUT 10 mm TIGHTNING TORQUE 30 N m maximum 9 DRIVEN PULLEY REASSEMBLY Install the pulley with the smaller boss toward t...

Page 88: ...olders and tighten the 6 x 12 screws securely 6 Connect the tension spring to the transmission Turn the transmission pulley transmission side so the hole in the pulley aligns with the hole in the tran...

Page 89: ...r 4 Press on the pulley to pivot the transmission forwards in order to release the belt from the pulley 5 Disconnect the Rotostop cable Rotostop side 6 Disassemble the return spring 7 Unscrew and remo...

Page 90: ...elt by removing the driving pulley from the engine s output shaft 8 Remove the rear wheels and the cutting height adjustment mechanism ch 13 2 9 Remove the clutch cable 10 Release the cable from the a...

Page 91: ...y Reassembly the transmission by performing the above operations in reverse order NOTE Pulley Center the pin 5 on the input shaft use the pin driver to measure V Belt 1 Replace the belt tension spring...

Page 92: ...T PIN 3 Loosen the lock nuts and slacken the shift cable 5 LOCK NUTS 4 Remove the rear wheels ch 13 2a and extract the hydrostatic drive disengage the end piece of the control arm shift cable 5 Reasse...

Page 93: ...11 N m 4 PUMP CASE 5 NEEDLE BEARING PLATE 6 BEARING PLATE 7 PUMP PISTON 7 8 PISTON SPRING 7 9 PUMP CYLINDER PLATE REASSEMBLY Position the hole and groove of the pump cylinder plate as shown Be careful...

Page 94: ...pumpcontrolyokeinthedirection of the arrow 5 1 PUMP CONTROL YOKE 5 2 CONTROL YOKE BUSH A 6 BEARING SNAP RING REASSEMBLY Be careful not to damage the pump shaft with the snap ring ends 7 OIL SEAL 10 x...

Page 95: ...callipers as shown 1 DEPTH SLIDE CALLIPERS 2 PUMP CONTROL YOKE 3 Measure the height A from the pump case surface and record 3 PUMP CASE 4 Install the relief valve needle and measure the height from th...

Page 96: ...engine and make sure the engine speed is 3 100 rpm 1 Place the mower on level surface and start the engine Set the shift lever on the minimum position and engage the drive clutch lever 2 Move the mowe...

Page 97: ...TON SPRING 7 6 MOTOR CYLINDER PLATE REASSEMBLY Position the hole and groove of the motor cylinder plate as shown Be careful not to reassemble inside out Make sure holes of the motor cylinder plate agr...

Page 98: ...inal shaft can be rotated by hand after reassembly 6 ROLL PIN 6 x 22 4 mm 7 DRIVEN GEAR 66 T 8 SCREW 6 x 12 mm SH 9 MAGNET PLATE FIXING 10 TRANSMISSION CASE Oil capacity 0 35 l Specified oil Honda HST...

Page 99: ...hat the shafts have rotated are as follows Oil pump shaft 5 10 turns Final shaft 2 3 turns 4 Apply the hydrostatic transmission oil to a new O ring Install a new O ring and a new plug screw and tighte...

Page 100: ...l starter cover and fuel tank 1 TAPPING SCREW 5 x 12 mm 6 2 RIGHT SIDE COVER 3 FLANGE NUT 8 mm 2 4 RIGHT SIDE COVER BRACKET 5 SELF LOCKING NUT 8 mm 6 COLLAR 7 ADJUSTER PANEL 8 FLANGE NUT 6 mm 9 REAR B...

Page 101: ...ER 3 AXLE SHAFT REASSEMBLY Check for runout replace if necessary 4 THRUST WASHER 5 RADIAL BALL BEARING 6004 2 6 EFT ROLLER 7 SNAP RING 15 mm 8 TRANSMISSION ASSEMBLY DISASSEMBLY REASSEMBLY ch 14 1 102...

Page 102: ...SEMBLY Seat the clip securely after installing the joint pin 5 DRIVE SHAFT JOINT ASSEMBLY 6 DOWEL PIN 8 x 14 mm 2 7 THRUST WASHER 10 x 21 mm 8 BEVEL PINION 9 BEVEL GEAR REASSEMBLY Check the dogs and t...

Page 103: ...Check the claws for wear 27 ROLLER BEARING 15 x 21 x 16 mm 2 28 DUST SEAL 15 x 21 x 3 mm 2 29 PAN SCREW 5 x 20 mm 30 CLUTCH ARM REASSEMBLY Align the punch mark on the arm with the aligning mark on the...

Page 104: ...BLY Hooktothedriveclutchleverfrominsideasshowntoavoidinter fering with the Rotostop lever 15 DRIVE CLUTCH CABLE ADJUSTMENT ch 3 5 16 HROTTLE CABLE ADJUSTMENT ch 3 4 17 HANDLE JOINT KNOB 2 18 SHIFT CAB...

Page 105: ...NG 14 ROTOSTOP CABLE 15 DRIVE CLUTCH CABLE 16 THROTTLE CABLE 17 HANDLE HOLDER SCREW 18 HANDLE JOINT KNOB 2 19 UPPER HANDLE 20 CLUTCH SPRING REASSEMBLY Hook to the drive clutch lever from inside as sho...

Page 106: ...ENT ch 3 4 16 HANDLE JOINT KNOB 2 17 THROTTLE CABLE 18 SHIFT CABLE 19 ROTOSTOP CABLE 20 HANDLE HOLDER SCREW 2 21 SHIFT CABLE ADJUSTMENT ch 3 7 22 UPPER HANDLE 23 CLUTCH SPRING REASSEMBLY Hook to the d...

Page 107: ...ANDLE JOINT KNOB 2 HRD535 F N 8021986 HRD536 F N 8010818 HRD535K1 K2 6 LEFT HANDLE SUPPORT 7 SELF LOCKING NUT 8 mm 2 8 HANDLE SUPPORT COLLAR 9 SCREW 8 x 55 mm 2 10 SCREW 8 x 25 mm 2 11 LOWER HANDLE CO...

Page 108: ...WASHER 10 mm 13 SHIFT LEVER SPRING 14 PLAIN WASHER 6 mm 15 FLANGE NUT 6 mm Q type 16 THROTTLE LEVER PLATE REASSEMBLY Align the cut out in the throttle shaft as shown 16 1 THROTTLE LEVER SIDE 17 THROTT...

Page 109: ...N WASHER 6 mm 18 LOCK PIN 6 mm 19 CENTER LEVER PIN TME type 20 THROTTLE LEVER 21 SPRING 15 mm 22 SPRING SEAT 23 THROTTLE CABLE 24 COLLAR 10 6 5 x 11 mm 25 WASHER SPRING 17 5 11 5 mm 26 CASE 27 SHIFT L...

Page 110: ...lwiresbetweentheoilfillertubeandcrankcase 8 HANDLE JOINT KNOB 9 WIRE BAND Clamp wire harness and all control cables to handle 10 CABLE CLAMP Clamp shift cable S type only and wire harness 11 RECOIL ST...

Page 111: ...ire harness through cut out TME type cable route Secure two cable clamps 18 to maintain the cable harness as shown NOTE Clamps should always be hand tightened so as not to damage the wiring harness HR...

Page 112: ...ype 14 SHIFT CABLE 15 THROTTLE CABLE 16 ROTOSTOP CABLE Q type 15 THROTTLE CABLE 16 ROTOSTOP CABLE 17 DRIVE CLUTCH CABLE 18 CLUTCH SPRING Hooktothedriveclutchleverfrominsideasshowntoavoidinterferingwit...

Page 113: ...VAL Disconnect the negative terminal first then positive INSTALLATION Connectthepositiveterminalfirst thennegativewithcarenottoshort the battery terminals INSPECTION ch 16 3 8 CONTROL BOX 9 SCREW 6 x...

Page 114: ...mes and cigarettes away Provide adequate ventilation when charging The battery contains sulphuric acid electrolyte Contact with skin or eyes may cause severe burns If electrolyte gets on your skin flu...

Page 115: ...connector to battery coupler With battery removal 1 Remove the battery ch 16 1 2 Connect the charger positive terminal to the battery positive terminal and negative terminal to the battery negative t...

Page 116: ...voltage or low voltage check following Open circuit in white and black line Charging coil Regulator rectifier Fuse REGULATOR RECTIFIER Measure the resistance between the each terminals according to th...

Page 117: ...ARGE GUARD GRASS BAG 17 1 Discharge guard a Disassembly Reassembly 1 STOPPER WASHER 2 2 DISCHARGE GUARD SHAFT 3 GUARD RETURN SPRING 4 DISCHARGE GUARD 118 HRA536 HRD535 HRD536 1 2 3 4 DISCHARGE GUARD G...

Page 118: ...e and the plastic edge of the grass bag Fix the two caps to each end of the shaft using a mallet NOTE Be sure to replace the cap nuts with a new one when disassembling or replacing the grass bag as an...

Page 119: ...ions directions and specifications included in this publication are based on the latest product information available at the time of approval for printing Honda France Manufacturing S A S reserves the...

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