Honda HRN216 Series Manual Download Page 141

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10-18

CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER

HRN216

7. OIL FILLER CAP / EXTENSION REMOVAL/INSTALLATION

O-RING

OIL FILLER CAP/DIPSTICK

OIL FILLER EXTENSION

OIL FILLER PACKING

6 x 14 mm SPECIAL BOLT (2)

12 N•m (9 ft-lb)

INSTALLATION:

Be sure that no dust or
foreign material enters
when installing the O-ring.
Be careful not to pinch the
O-ring.

Summary of Contents for HRN216 Series

Page 1: ...ing safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair pa...

Page 2: ...practical or possible to warn you about all the hazards associated with servicing these mowers You must use your own good judgment You will find important safety information in a variety of forms incl...

Page 3: ...n the U S A Quick Identifier TYPE FRAME SERIAL NO ENGINE SERIAL NO FEATURES PKA A PKC A PKU A MANA 1000001 thru subsequent GJATK 1000001 thru subsequent GJAUA 1000001 thru subsequent Push mower not se...

Page 4: ...1 1 1 SPECIFICATIONS 1 SPECIFICATIONS 1 2 3 WIRING DIAGRAM VLA TYPE 1 5 2 DIMENSIONAL DRAWINGS 1 3...

Page 5: ...oke overhead valve single cylinder Displacement 166 cc 10 1 cu in Bore x stroke 60 x 59 mm 2 36 x 2 32 in Compression ratio 8 0 1 Maximum governed speed 3 100 0 150 rpm Ignition system Transistorized...

Page 6: ...1 3 HRN216 SPECIFICATIONS 2 DIMENSIONAL DRAWINGS PKA TYPE Cutting height set to 27 mm 1 in Handle in high position 676 mm 26 6 in 575 mm 22 6 in 530 mm 20 9 in 1 025 mm 40 4 in 1 550 mm 61 0 in...

Page 7: ...1 4 SPECIFICATIONS HRN216 VKA VLA VYA TYPES Cutting height set to 27 mm 1 in Handle in high position 676 mm 26 6 in 575 mm 22 6 in 530 mm 20 9 in 1 037 mm 40 8 in 1 550 mm 61 0 in VKA type shown...

Page 8: ...NI BLADE HOLDER FUSE BATTERY BOX BATTERY FUSE 30A SLO BLO START SWITCH 4P250 2P250 2P250 3A B R B B B B B B B B B R B R B R R R R R R Y R Y R Y W Y W SPARK PLUG N O N C COM CHG IGN COIL COIL W Y W R Y...

Page 9: ...1 6 SPECIFICATIONS HRN216 NOTES...

Page 10: ...NUAL As you read this manual you may find the following symbols with the instructions 1 SERVICE RULES 2 1 7 TROUBLESHOOTING 2 7 2 SYMBOLS USED IN THIS MANUAL 2 1 8 TROUBLESHOOTING TECHNIQUES 2 13 3 SE...

Page 11: ...r of the mower deck behind the engine The engine serial number is located on the crankcase below the fuel valve on the left hand side of the engine Refer to the frame serial number or engine serial nu...

Page 12: ...0 5100 Piston rings Ring width Top 0 935 0 950 0 0368 0 0374 0 890 0 0350 Second 0 975 0 990 0 0384 0 0390 0 930 0 0366 Oil 2 380 2 460 0 0937 0 9685 2 370 0 0933 Ring side clearance Top 0 055 0 089 0...

Page 13: ...x 1 0 Nylock 4 9 0 5 3 6 Flywheel nut PKA VKA VLA types M14 x 1 5 55 5 6 41 VYA type 75 7 5 55 Fuel cock screw PKA VKA VLA types Tapping screw 2 5 0 3 1 8 VYA type M5 x 10 pan head screw Governor hold...

Page 14: ...mm 40 4 1 30 12 mm 59 5 9 44 CT Cutting threads flange bolt Retightening 5 mm 5 5 0 6 4 1 6 mm 12 1 2 9 Flange bolt and weld nut 6 mm 10 1 0 7 8 mm 25 2 5 18 ITEM TOOL NAME TOOL NUMBER APPLICATION 1 C...

Page 15: ...EEPV503 Cylinder compression test 3 Strap wrench STV S 17 Flywheel removal 4 Flywheel puller OTC 1035 Flywheel removal 5 Cleaning brush Cleaning combustion chamber 6 Digital multimeter FLU 88 Electri...

Page 16: ...Good spark No or weak spark Install a compression gauge in the spark plug hole P 2 13 and briskly crank the engine repeatedly until a stabilized reading is obtained Install the spark plug in the plug...

Page 17: ...RT position and check the voltage from the red wire at the starter magnetic switch to engine ground P 9 13 Magnetic switch is not functioning Check for voltage at the yellow wire on the solenoid and t...

Page 18: ...Check the cranking voltage at the starter motor P 11 28 Be sure the two starter motor wires are installed on the correct terminals before testing Pinion OK 9 0 V or more starter engaged Replace the st...

Page 19: ...rger Allow to rest for 1 hour and retest Check battery connections P 11 27 With the engine running check the charge coil output current P 2 16 Start the engine and verify the speed is 2950 3100 rpm P...

Page 20: ...ed too high OK Adjust Smart Drive TRANSMISSION PROPELS THE MOWER BUT SLIPS OR SLOWS DOWN UNDER LOAD on page 2 18 Transmission slips or slows down under load Mower self propels with Smart Drive release...

Page 21: ...9 11 Check the flywheel brake cable for binding Check the flywheel brake spring P 9 11 Check flywheel brake pad P 3 12 Replace engine stop switch P 9 11 Blade engine does not stop turning or takes lon...

Page 22: ...s an immediate problem that requires repair SPARK PLUG TEST An assistant is required during this test 1 Turn the fuel valve lever to the OFF position and then drain the gasoline from the carburetor 2...

Page 23: ...ll keyway as shown NOTICE When checking the crankshaft runout do not allow the dial indicator tip to drop into any of the keyways or the dial indicator tip can be damaged 7 Zero the dial indicator 8 P...

Page 24: ...rol see below Replace the carburetor P 8 2 Start the engine and check to see if the choke opens within 3 minutes Opens too slowly or does not open Allow the engine to cool Push the choke valve open an...

Page 25: ...the flywheel brake lever is released from the handlebar 3 Remove the fan cover P 7 3 4 Disconnect the engine stop switch black wire connector from the ignition coil primary terminal 5 With the multim...

Page 26: ...PROVED MANNER Directions Step 1 Add water to the water line Step 2 Add gasoline to the gasoline line Step 3 Replace cap and shake vigorously Step 4 Stand vial vertically with cap upright Let stand for...

Page 27: ...DOWN UNDER LOAD a Adjust the Smart Drive cable P 3 10 b Inspect the belt and both pulleys for damage With the Smart Drive control engaged confirm that the transmission pulley is tight and not slippin...

Page 28: ...remove all the slack from the belt Inspect the clearance between the outside of the belt and the belt guides e If the clearance is out of specification adjust or replace the belt and belt guide s Belt...

Page 29: ...a Remove and clean the transmission P 13 1 and check to identify the source of the leak Replace the leaking seal s or O ring as shown on page 13 10 Fill the transmission to the proper level with SAE 1...

Page 30: ...he wire holder and then tighten the wire holder around the cable Position the two cable ties in the locations shown using the pivot bolt as a starting point for your measurements Tighten the two cable...

Page 31: ...ies in the locations shown using the pivot bolt as a starting point for your measurements Tighten the two cable ties Trim off any remaining tail from each cable tie and then rotate the cable ties so t...

Page 32: ...ies in the locations shown using the pivot bolt as a starting point for your measurements Tighten the two cable ties Trim off any remaining tail from each cable tie and then rotate the cable ties so t...

Page 33: ...the handlebar throttle cable and Smart Drive cable Loosely install the lower cable tie only around the throttle cable and Smart Drive cable Right side handlebar Loosely install the two upper cable ti...

Page 34: ...crankcase cover until the paint mark on the tube aligns with the edge of the brake assy BREATHER TUBE FUEL TUBE Attach the clip at 5 0 3 0 mm 0 20 0 11 in from the tube edge with the clip lever facing...

Page 35: ...2 26 SERVICE INFORMATION HRN216 STOP SWITCH CORD PKA VKA types IGNITION COIL HIGH TENSION CORD STOP SWITCH CORD PKA VKA VLA types HIGH TENSION CORD STOP SWITCH CORD PKA VKA types...

Page 36: ...P SWITCH CORD HIGH TENSION CORD IGNITION COIL ENGINE STOP SWITCH STOP SWITCH CORD IGNITION COIL HIGH TENSION CORD PKA VKA types VLA type also see page 2 30 STOP SWITCH CORD HIGH TENSION CORD IGNITION...

Page 37: ...e assy BREATHER TUBE FUEL TUBE Attach the clip at 3 0 1 0 mm 0 11 0 04 in from the tube edge with the clip lever facing down Attach the clip at 4 0 1 0 mm 0 16 0 04 in from the tube edge with the cent...

Page 38: ...2 29 HRN216 SERVICE INFORMATION STOP SWITCH CORD IGNITION COIL HIGH TENSION CORD STOP SWITCH CORD HIGH TENSION CORD...

Page 39: ...battery box STARTER MOTOR POSITIVE TERMINAL WHITE WIRE ENGINE STOP SWITCH WIRE CONNECTOR YELLOW WIRE WHITE WIRE TO STARTER MOTOR POSITIVE TERMINAL BATTERY WIRE FROM STARTER SWITCH RED WIRE STOP SWITCH...

Page 40: ...TIONS 3 3 13 FUEL TANK AND STRAINER 3 11 4 REAR SHIELD 3 3 14 BLADE CONTROL OPERATION CHECK 3 12 5 BLADES 3 4 15 FLYWHEEL BRAKE 3 12 6 ENGINE OIL 3 6 16 ROTO STOP 3 13 7 AIR FILTER CLEANING 3 7 17 THR...

Page 41: ...f use or every two years See page Rear shield Check O 3 3 Blades Inspect O 3 4 Blade mounting bolts Inspect O 3 4 Engine oil Check O 3 6 Change O O 1 O O 3 6 Air filter Check O 3 7 Clean O 2 O 2 O 2 R...

Page 42: ...8 0 031 in Spark arrester optional part Brush carbon deposits from screen no breaks or tears 3 9 Valve clearance cold Intake 0 10 0 02 mm Exhaust 0 10 0 02 mm 3 15 Governor Adjust so shaft is rotated...

Page 43: ...to hold the blades with your hand to prevent the blades from turning when removing the bolt 3 Clean dirt and grass from around the blade mounting area 4 Install the blades using the two blade bolts an...

Page 44: ...o develop in the blades during mower operation Maintain the original bevel angle 30 40 while sharpening Do not alter the angle Remove equal amounts of material from both cutting edges to preserve symm...

Page 45: ...in the trash or pour it on the ground or down a drain 4 Refill with the recommended oil to the upper limit mark on the dipstick Do not overfill Check oil level with the mower on a level surface and t...

Page 46: ...als and performs as designed 1 Press the latch tabs on the top of the air cleaner and remove the air cleaner cover 2 Remove the paper filter from the air cleaner housing 3 Inspect the filter and repla...

Page 47: ...park plug can cause engine damage Use the recommended spark plug or an exact equivalent 1 Visually inspect the spark plug Discard the plug if the insulator is cracked or chipped 2 Measure the plug gap...

Page 48: ...id damaging the spark arrester screen Inspect the screen for holes or tears and replace if necessary 8 Install the spark arrester into the muffler 9 Install the muffler shield on the engine and tighte...

Page 49: ...rive lever LOOSEN the cable adjuster five 5 complete revolutions using the adjuster mark as a reference Lawn mower does not propel forward without engaging the Smart Drive lever Slowly tighten the cab...

Page 50: ...fuel strainer into the fuel tank fitting 8 Connect the fuel tube to the fuel tank fitting 9 Position the fuel tube clip over the fuel tank fitting After assembly check for fuel leaks FUEL TUBE INSPECT...

Page 51: ...handlebar and the blades should stop quickly when you release the lever 15 FLYWHEEL BRAKE INSPECTION To inspect the flywheel brake lining thickness 1 Remove the fan cover fuel tank P 8 15 2 Measure th...

Page 52: ...the adjuster counterclockwise distance increases c Tighten the lock nut and recheck the clearance INSPECTION Before inspecting brake or clutch wear it is important to make sure the blade control lever...

Page 53: ...l move if you continue pulling hard enough 5 Tighten the locking clamp screw 6 Start the engine and let it warm up 7 Engage the Roto Stop and then check the engine speed with the throttle set to the F...

Page 54: ...r gauge between the valve adjusting screw and valve stem to measure the valve clearance If adjustment is necessary proceed as follows ADJUSTMENT 1 Hold the valve adjusting screw using the special tool...

Page 55: ...axle and ratchet holder 5 Remove the ratchet holder from the axle shaft and then carefully remove the spring from the ratchet holder 6 Remove the inner washer but do not remove the inner circlip 7 Ins...

Page 56: ...r onto the axle shaft and up against the inner circlip 2 Rotate the axle so that the keyway is facing up and then fill the axle shaft keyway with grease 3 Install the ratchet holder onto the axle shaf...

Page 57: ...alling There are markings on the ratchet holder that indicate which direction the spring should be installed for each side NOTICE Failure to install the spring in the correct direction will result in...

Page 58: ...to the teeth of the pinion gear 11 Rotate the spring so that its end tab is pointing at the wheel mounting bolt PINION GEAR The pinion gear has an L left marking on one side and an R right marking on...

Page 59: ...the slot and that all four plastic tabs on the dust shield are clipped onto the axle plate securely 13 Apply grease to the wheel shaft and then install the rear wheel and tighten the flange nut Rotate...

Page 60: ...operating temperature 6 Have an assistant hold the flywheel brake lever while you perform the maximum engine speed adjustment 7 Check the maximum engine speed 8 If adjustment is necessary bend the gov...

Page 61: ...e 7 Engage the Roto Stop lever and check the maximum engine speed 8 If adjustment is necessary bend the governor spring tab on the fuel valve plate very slightly Moving the tab to the left decreases g...

Page 62: ...4 1 4 BLADE HOLDER ROTO STOP 1 BLADE HOLDER DRIVE PULLEY 4 2 2 ROTO STOP DRIVE PULLEY 4 6...

Page 63: ...x 25 mm SPECIAL BOLT LOWER BLADE UPPER BLADE SPECIAL WASHER Install the washer in the direction shown TORQUE 54 N m 40 ft lb Align the slot in the blade holder with the Woodruff key in the crankshaft...

Page 64: ...of the crankshaft 5 Remove the Woodruff key from the slot in the crankshaft INSTALLATION Install in the reverse order of removal Be sure the Woodruff key is installed in the slot closest to the end o...

Page 65: ...lot in the blade holder with the Woodruff key in the crankshaft WOODRUFF KEY Install the Woodruff key into the slot closest to the end of the crankshaft 3 8 24 x 1 in SPECIAL BOLT DRIVE PULLEY N code...

Page 66: ...ove the two 6 x 14 mm flange bolts and the belt guide 7 Slide the drive pulley away from the engine and remove the V belt from the drive pulley INSTALLATION Install in the reverse order of removal Adj...

Page 67: ...ng WOODRUFF KEY Install in lower keyway slot CLUTCH SPRING UP mark towards engine INSPECT P 4 10 BEARING Replace if it doesn t rotate smoothly BRAKE PLATE SPECIAL BLADE HOLDER BOLT SPRING INSPECT P 4...

Page 68: ...with tape to prevent damaging the clutch spring Use needle nose pliers to lift the clutch return spring hook off the upper anchor point and then remove the spring During removal avoid damaging the spr...

Page 69: ...te the crankshaft so that the crankshaft keyway is up 8 Remove the drive disk but do not remove the key from the crankshaft 9 Slide the brake assembly off the crankshaft and leave the transmission dri...

Page 70: ...he driven disk is washed with parts cleaner the driven disk will require replacement 3 Disassemble the brake assembly a Push the spring hook plate down b Rotate the spring hook plate clockwise c Relea...

Page 71: ...g Rotate and check for smooth operation Replace any damaged bearings When installing the bearings be sure to only press on the outer bearing race during installation 7 Check the clutch spring for abno...

Page 72: ...ok plate counterclockwise to lock all three hooks in place Make sure all three spring hooks are secured e Rotate the brake plate and confirm that it moves smoothly and springs back 9 Inspect the Roto...

Page 73: ...older with the metal surface facing the clutch spring Note The driven disk will have a code mark starting with an R shown in the 5 digit code Rxxxx and identifies the disk will fit an HRN216VYA model...

Page 74: ...pper anchor point using the needle nose pliers Do not clamp or contact the spring coils during installation Be careful not to damage or bend the spring 8 Adjust the blade control lever free play P 3 1...

Page 75: ...4 14 BLADE HOLDER ROTO STOP HRN216 NOTES...

Page 76: ...5 1 5 ENGINE REMOVAL INSTALLATION 1 PKA VKA TYPES 5 2 3 VYA TYPE 5 6 2 VLA TYPE 5 4...

Page 77: ...or is facing up 5 Remove the blades and blade holder as an assembly Use a pair of thick leather gloves to hold the blades with your hand to prevent the blades from turning and then remove the center 3...

Page 78: ...h the top side of the brake lever VKA type Adjust the belt guide P 2 19 Be sure the belt is properly routed through the shutter assembly P 12 4 Be sure the blade holder Woodruff key is properly instal...

Page 79: ...des and blade holder as an assembly Use a pair of thick leather gloves to hold the blades with your hand to prevent the blades from turning and then remove the center 3 8 24 x 1 inch special bolt 5 Re...

Page 80: ...the reverse order of removal Be sure to install the flywheel brake cable Z fitting cable end through the top side of the brake lever Adjust the belt guide P 2 19 Be sure the belt is properly routed t...

Page 81: ...the oil dipstick Continue to keep the mower tilted on its right side so the carburetor is facing up 5 Remove the blades P 4 2 Use a pair of thick leather gloves to hold the blades with your hand to p...

Page 82: ...op cover shutter from the mower deck See page 12 1 for detailed removal instructions 12 Support the engine and remove the four 5 16 24 x 1 inch engine mounting bolts 13 Remove the engine INSTALLATION...

Page 83: ...5 8 ENGINE REMOVAL INSTALLATION HRN216 NOTES...

Page 84: ...6 1 6 MUFFLER 1 REMOVAL INSTALLATION 6 2...

Page 85: ...R 6 x 79 mm BOLT CT bolt 2 4 x 6 mm SCREW optional part Use a plastic hammer to loosen carbon deposits from the muffler and then remove carbon deposits from muffler If the seal flange is dented or dam...

Page 86: ...OVAL INSTALLATION 7 1 4 RECOIL STARTER INSPECTION 7 4 2 RECOIL REMOVAL INSTALLATION 7 2 5 RECOIL STARTER ROPE REPLACEMENT 7 4 3 FAN COVER REMOVAL INSTALLATION 7 3 6 REEL UNWOUND 7 6 TOP COVER FUEL TAN...

Page 87: ...7 2 RECOIL STARTER HRN216 2 RECOIL REMOVAL INSTALLATION Remove the top cover P 7 1 6 x 14 mm BOLT 3 8 5 N m 6 3 ft lb RECOIL STARTER...

Page 88: ...over P 7 1 and then reinstall the fuel tank cap to prevent dirt or debris from entering the fuel tank The recoil starter assembly does not need to be removed to remove the fan cover Reassembly is the...

Page 89: ...ion of the ratchets by pulling the starter rope out several times 3 Check the tabs on the flywheel for damage 5 RECOIL STARTER ROPE REPLACEMENT 1 Remove the recoil starter P 7 2 2 Pull the starter rop...

Page 90: ...ip and make a slip knot at the end of the rope 6 Pass the other end of the starter rope through the rope hole in the starter case and through the rope hole in the starter reel and make a slip knot at...

Page 91: ...p knot at the end of the rope 4 Pass the other end of the starter rope through the rope hole in the starter case then through the rope hole in the starter reel and make a slip knot at the end of the r...

Page 92: ...8 1 8 FUEL SYSTEM 1 AIR CLEANER CARBURETOR 8 2 3 FUEL TANK 8 15 2 CONTROL BASE GOVERNOR ARM 8 12 4 FUEL TUBE 8 16...

Page 93: ...LATOR GASKET CARBURETOR GASKET FUEL TUBE INSTALLATION Insert into the breather hole in the top crankcase cover Be sure it is properly seated in the hole If not connected properly dirt ingestion and en...

Page 94: ...screw to clean the pilot air jet ASSEMBLY Before installing clean thoroughly with low pressure compressed air max 30 psi MAIN JET NUMBER 68 SET GASKET FLOAT PIN 5 x 6 mm ACCESS SCREW MAIN NOZZLE ASSEM...

Page 95: ...must be installed NOTICE Tampering is a violation of federal and California law 1 When the limiter cap has been broken off remove the broken pilot screw 2 Place the spring on the replacement pilot scr...

Page 96: ...ody throttle and choke levers and pilot screw including limiter cap for damage If any damage exists carburetor replacement may be necessary 2 Remove the set bolt float chamber float pin float valve an...

Page 97: ...or a jet needle that is too large may damage the carburetor Never force a needle and never use a needle with a bent or damaged tip Inspect the center and side holes for damage or contamination by hol...

Page 98: ...he pilot jet thoroughly by using the appropriate size jet cleaning tool carburetor cleaner and compressed air The passage is small and easily obstructed so repeat several times It is not necessary to...

Page 99: ...ons Spray carburetor cleaner through the slow speed air passage From the opposite end confirm that a steady stream of carburetor cleaner sprays out from around the pilot screw tip and transition ports...

Page 100: ...and float chamber Make sure the float valve is properly attached to the float Ensure the float chamber is installed correctly making a good seal with the gasket 17 Reinstall the carburetor on the eng...

Page 101: ...pin extends b Screw a No 6 sheet metal or drywall screw into the thermowax body and then carefully pry the thermowax out b Use the side of the cylinder as a prying surface as shown Do not pry against...

Page 102: ...to ensure the gasket aligns with the port 4 Carburetor 5 Air cleaner gasket Be sure the vent hole in the air cleaner gasket aligns with the hole in the carburetor 7 Install the crankcase breather tub...

Page 103: ...RM NUT 12 N m 9 ft lb FUEL VALVE B12 TUBE CLIP B8 TUBE CLIP 6 x 14 mm BOLT CT bolt 2 GOVERNOR ARM INSTALLATION Install the governor rod through the throttle return spring as shown Connect each to the...

Page 104: ...T FUEL VALVE B12 TUBE CLIP B8 TUBE CLIP BOLT CT bolt 6 x 14 mm CONTROL BASE FUEL TUBE GOVERNOR ARM INSTALLATION Install the governor rod through the throttle return spring as shown Connect each to the...

Page 105: ...SASSEMBLY REASSEMBLY SCREW 4 x 12 mm WASHER 4 mm ENGINE STOP SWITCH CABLE HOLDER SCREW 5 x 16 mm LEVER SPRING CONTROL LEVER RETURN SPRING CONTROL BASE WIDE TERMINAL to stop switch wire NARROW TERMINAL...

Page 106: ...an be burned or seriously injured when handling fuel Stop the engine and let it cool Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately TANK MOUNT RUBBER A FUEL TANK...

Page 107: ...Connect the fuel tube to the fuel valve 5 Position the fuel tube clip over the fuel valve fitting 6 Remove the fuel tube clamp and return the fuel valve to the ON position 7 Check for fuel leaks and r...

Page 108: ...9 1 9 IGNITION COIL FLYWHEEL 1 IGNITION COIL 9 2 2 FLYWHEEL 9 8 3 FLYWHEEL BRAKE LEVER ENGINE STOP SWITCH 9 11 4 ELECTRIC STARTER VLA TYPE 9 12 5 SIDE PLATE VYA TYPE 9 16...

Page 109: ...WHEEL HRN216 1 IGNITION COIL REMOVAL INSTALLATION PKA VKA TYPES Remove the fan cover P 7 1 After installation adjust the ignition coil air gap P 9 6 IGNITION COIL SPARK PLUG CAP STOP SWITCH CORD CONNE...

Page 110: ...E Remove the fan cover P 7 3 Disconnect the stop switch cord and charge coil connectors After installation adjust the ignition coil air gap P 9 6 IGNITION COIL SPARK PLUG CAP STOP SWITCH CORD CONNECTO...

Page 111: ...9 4 IGNITION COIL FLYWHEEL HRN216 VYA TYPE Remove the fan cover P 7 3 After installation adjust the ignition coil air gap P 9 6 IGNITION COIL SPARK PLUG CAP STOP SWITCH CORD CONNECTOR 6 x 23 mm BOLT 2...

Page 112: ...rank the engine by pulling the recoil starter and check whether sparks jump across the electrode INSPECTION IGNITION COIL Remove the ignition coil P 9 2 Primary Side Resistance Measure the resistance...

Page 113: ...ompletely There should be no continuity when the plunger is released Replace the engine stop switch if the correct continuity test results are not obtained IGNITION COIL AIR GAP ADJUSTMENT Adjustment...

Page 114: ...structions for testing diodes Some meters show current flow from negative to positive while others show current flow from positive to negative The polarity of the meter does not matter when testing di...

Page 115: ...emove the ignition coil P 9 2 3 Remove the electric starter VLA type only P 9 12 PKA VKA VLA types 55 N m 41 ft lb VYA type 75 N m 55 ft lb FLYWHEEL NUT 14 mm INSTALLATION When installing the flywheel...

Page 116: ...APB Z28A101 NOTICE Inserting a rod or screwdriver in the fan blades can damage the blades or the aluminum casting projections 5 Position a commercially available 6 inch flywheel puller on the flywheel...

Page 117: ...holder special tool or a commercially available strap wrench tighten the 14 mm special nut to the specified torque TOOLS FLYWHEEL HOLDER 07APB Z28A101 TORQUE PKA VKA VYA types 55 N m 41 ft lb VYA typ...

Page 118: ...g the brake assembly P 9 8 STOP SWITCH CORD WASHER 6 x 22 mm BOLT ENGINE STOP SWITCH 1 8 N m 1 3 ft lb 4 x 12 mm SCREW BRAKE LEVER SPRING BRAKE ASSY 6 x 14 mm BOLT INSTALLATION Connect to the narrow t...

Page 119: ...e 1 time and verify that the cranking voltage does not drop below 9 0 VDC if the engine is turning over If the pinion does not raise and engage the flywheel the voltage at the starter must be over 10...

Page 120: ...d bullet connector black wire side Once power is supplied you should hear an audible click from the starter magnetic switch 6 Measure continuity between the two large terminals There should be continu...

Page 121: ...heck the pinion gear for smooth operation while rotating it on the shaft 2 Check the gear teeth for wear Replace the starter motor if the gear teeth are worn or damaged 3 Inspect the flywheel ring gea...

Page 122: ...seal for damage Replace the starter if the rubber damper is damaged or will not seat properly around the drive plate 5 Firmly push the pinion rubber damper down over the drive plate Make sure the damp...

Page 123: ...TION COIL FLYWHEEL HRN216 5 SIDE PLATE VYA TYPE REMOVAL INSTALLATION 1 Remove the flywheel P 9 8 BOLT 6 x 14 mm 2 SIDE PLATE STOP SWITCH CORD INSTALLATION Connect to the wide terminal of the engine st...

Page 124: ...VAL INSTALLATION 10 3 8 PISTON CONNECTING ROD DISASSEMBLY ASSEMBLY 10 20 3 CYLINDER REMOVAL INSTALLATION 10 4 9 CYLINDER COMPRESSION CHECK 10 21 4 CYLINDER HEAD DISASSEMBLY ASSEMBLY 10 7 10 CRANKSHAFT...

Page 125: ...r equivalent tool into the recesses as shown and remove the crankcase cover REMOVAL Carefully remove with a screwdriver at the pry points INSTALLATION Thoroughly clean both surfaces and then apply a b...

Page 126: ...10 3 HRN216 CAMSHAFT CRANKSHAFT PISTON CYLINDER 2 BREATHER COVER REMOVAL INSTALLATION Remove the crankcase cover P 10 2 6 x 14 mm BOLT BREATHER COVER 5 x 8 mm SCREW BREATHER VALVE...

Page 127: ...Crankcase cover P 10 2 Carburetor P 8 2 Muffler P 6 2 Rocker arms and push rods P 10 7 REMOVAL Insert a screwdriver or equivalent tool into the recesses 1 as shown and carefully pry to remove the cyl...

Page 128: ...aft and lifters before installing the cylinder P 10 8 During reassembly recheck the valve clearance page 3 15 6 x 14 mm BOLT 4 CYLINDER HEAD COVER 24 N m 18 ft lb 8 x 40 mm BOLT 2 24 N m 18 ft lb 8 x...

Page 129: ...ly 30 minutes after assembly and before filling with oil and starting the engine CYLINDER HEAD COVER INSTALLATION Do not reuse the original cover if it is bent or damaged Clean the mating surfaces of...

Page 130: ...drop into the cylinder 8 N m 5 9 ft lb VALVE ADJUSTING LOCK NUT 2 VALVE STEM SEAL Intake valve only VALVE SPRING 2 INTAKE VALVE EXHAUST VALVE ROCKER ARM 2 ROCKER ARM SHAFT 2 VALVE ADJUSTING SCREW 2 PU...

Page 131: ...WASHER PISTON INSPECTION Install the piston through the crankcase so that the FW mark points toward the flywheel side 10 N m 7 ft lb VALVE LIFTER 2 VALVE LIFTER BOLT 2 CRANKCASE INSTALLATION P 10 8 In...

Page 132: ...ery part MAIN COMPONENTS TOP COVER FAN COVER FLYWHEEL CRANKCASE COVER with ignition coil brake starter assemblies CRANKSHAFT TIMING GEAR THRUST WASHER BLADE HOLDER or ROTO STOP WOODRUFF KEY UPPER BLAD...

Page 133: ...and then remove the top cover P 7 1 Pull outward on the four tabs from underneath them to release the top cover from the fan cover 6 Remove the five 6 x 23 mm bolts and the fan cover P 7 3 Note The re...

Page 134: ...coil removal my be required when using a strap wrench and or puller Position a commercially available 2 jaw flywheel puller on the flywheel with one of the puller jaws under the magnets at the PULLER...

Page 135: ...the bolt is accessible Use a flat screwdriver and pry at the two pry points shown to lift the crankcase cover off the crankcase Disconnect the breather tube from the cover 11 Disconnect the connecting...

Page 136: ...slot in the crankshaft 4 Rotate the camshaft so that the two dot marking is aimed at the center of the crankshaft boss P 10 8 5 Insert the crankshaft with timing gear into the crankshaft boss so that...

Page 137: ...cover P 8 2 9 PKA VKA VLA types only Reconnect the flywheel brake cable and Z fitting to the brake assembly and then pull the flywheel brake lever and secure the lever to the handlebar with a strap o...

Page 138: ...bearing if the crankshaft is being replaced due to impact damage Install the Roto Stop assembly following the instructions starting on P 4 11 13 Install the fan cover and tighten the five 6 x 23 mm b...

Page 139: ...r bolt failure that can cause the blade holder to come off VYA type only Install a new set of blades and then tighten the two blade bolts to the specified torque P 4 6 Wear a pair of thick leather glo...

Page 140: ...against the groove in the shaft LOCK PIN GOVERNOR HOLDER SHAFT Before installing check for wear and damage of the gear Check that the weights move freely Be sure to install the governor weight before...

Page 141: ...EXTENSION REMOVAL INSTALLATION O RING OIL FILLER CAP DIPSTICK OIL FILLER EXTENSION OIL FILLER PACKING 6 x 14 mm SPECIAL BOLT 2 12 N m 9 ft lb INSTALLATION Be sure that no dust or foreign material ent...

Page 142: ...d CAM TIMING INSPECTION Remove the spark plug and crankcase cover P 10 2 Rotate the crankshaft until the two dots on the timing gear and the two dots on the camshaft align with each other If the dots...

Page 143: ...h long nosed pliers and rotating the clip in PISTON PIN CLIP 2 ASSEMBLY Chrome plated Do not interchange with the SECOND RING TOP RING OIL RING COMBINATION RING SECOND RING MANUFACTURERS MARK Install...

Page 144: ...a spark plug wrench Pull the recoil starter several times to expel unburned gasoline Thread a commercially available compression gauge into the spark plug hole PKA VKA VLA types Have an assistant pul...

Page 145: ...ace the crankshaft 11 CAMSHAFT CYLINDER PISTON VALVE INSPECTION CAM LOBE HEIGHT Measure the cam lobe height If the measurement is less than the service limit replace the camshaft CAMSHAFT BORE I D Mea...

Page 146: ...ght It is normal for the decompressor to lock up when pushing on the pin and not the weight Repeat several times If the weight fails to completely return on its own at any time by spring force replace...

Page 147: ...bottom of the skirt and 90 degrees to the piston pin bore If the measurement is less than the service limit replace the piston PISTON TO CYLINDER CLEARANCE Subtract the piston skirt O D from the cylin...

Page 148: ...cylinder and then use the piston crown to push the ring down This will make the piston ring horizontal so ring end gap can be measured Measure each piston ring 1 end gap using a feeler gauge If any o...

Page 149: ...to obtain the piston pin to piston pin bore clearance If the calculated clearance is more than the service limit replace the piston pin and recheck the clearance If the clearance is still more than th...

Page 150: ...cap CRANKSHAFT MAIN JOURNAL O D Measure the crankshaft main journal O D PTO side Flywheel side If the measurement is less than the service limit replace the crankshaft CRANKPIN O D Measure the crankp...

Page 151: ...g rod bolt 1 threads and seating surface Tighten the connecting rod bolts to the specified torque Do not rotate the crankshaft while the Plastigauge is in place Remove the connecting rod cap and measu...

Page 152: ...washer timing gear crankshaft crankcase and crankcase cover for wear or damage VALVE SPRING FREE LENGTH PERPENDICULARITY Measure the valve spring free length If the measured length is less than the se...

Page 153: ...ore than the service limit replace the cylinder GUIDE TO STEM CLEARANCE Subtract each valve stem O D from the corresponding guide I D to obtain the guide to stem clearance If the calculated clearance...

Page 154: ...seat is too high or too low recondition the valve seat P 10 31 VALVE SEAT RECONDITIONING Thoroughly clean the combustion chamber and valve seats to remove carbon deposits P 3 9 Apply a light coat of P...

Page 155: ...cylinder Insert the thick paper into the cylinder to protect the cylinder wall during valve seat reconditioning Valve seat cutters grinder or equivalent valve seat re facing equipment is recommended...

Page 156: ...lable valve lapper and lapping compound After lapping wash all residual compound off the cylinder head and valve Do not push the valve against the seat with force during lapping Apply a light pass wit...

Page 157: ...oil seal Drive a new oil seal 1 in the position as shown using the special tools INSTALLATION HEIGHT 1 0 1 5 mm 0 04 0 06 in TOOLS Bearing driver attachment 62 x 64 mm 2 07947 6340400 Driver handle 3...

Page 158: ...ROLS 1 HANDLEBAR 11 2 6 ROTO STOP CABLE 11 22 2 SMART DRIVE CONTROL 11 13 7 THROTTLE CABLE 11 26 3 SMART DRIVE CABLE 11 16 8 THROTTLE LEVER ASSEMBLY 11 26 4 FLYWHEEL BRAKE CABLE 11 17 9 BATTERY BOX 11...

Page 159: ...pulling inward on the left hand side of the lever until the end slides out of the handlebar The right hand side of the lever has a hooked end Rotate the lever over the right hand side of the handlebar...

Page 160: ...sition 6 Remove both handle locking knobs P 11 10 7 Have an assistant hold and support the handlebar and then remove the two special bolts and the handlebar from the handle stays 8 Install the handleb...

Page 161: ...sen the 6 x 45 mm flange bolt to remove the flywheel brake cable assembly from the handlebar assembly Note Be sure to turn the 6 x 45 mm flange bolt and not the nylon nut 6 Remove the flywheel brake l...

Page 162: ...r the mower into the storage position 9 Remove both handle locking knobs P 11 10 10 Have an assistant hold and support the handlebar and then remove the two special bolts and the handlebar from the ha...

Page 163: ...Loosen the Smart Drive cable adjuster completely 4 Remove the Smart Drive control P 11 13 5 Remove the Smart Drive cable from the handlebar by pulling it down through the hole in the pipe 6 Hold the 6...

Page 164: ...cking nut frame washer and rope guide from the handlebar 9 Unlock both handle locking knobs and fold the handlebar over the mower into the storage position 10 Remove both handle locking knobs P 11 10...

Page 165: ...lywheel brake cable Smart Drive cable and Roto Stop cable to the handlebar 5 Remove the Roto Stop and throttle assemblies from the handlebar P 11 18 The Roto Stop and throttle cables may be left conne...

Page 166: ...e storage position 8 Remove both handle locking knobs P 11 10 9 Have an assistant hold and support the handlebar and then remove the two special bolts and the handlebar from the handle stays 10 Instal...

Page 167: ...so that the pin and pin clip protrude from the handle locking knob 3 Use a pick tool needle nose pliers or side cutters to pry the pin clip from the 8 mm pin shaft The clip will get bent or damaged du...

Page 168: ...from the handle locking knob 6 Install a new pin clip into the groove on the end of the 8 mm pin The pin clip must be installed in the direction shown with the concave side of the clip facing away fro...

Page 169: ...side handlebar and then loosely install the 6 mm locking nut onto the threaded end of the rope guide 2 Rotate the rope guide so that the bend in the guide rests parallel to the handlebar 3 Fully tigh...

Page 170: ...p and remove the upper and lower bracket covers 5 Remove the 5 x 37 mm roller pin the four 4 mm self tapping screws and the upper and lower grip brackets SMART DRIVE CABLE REMOVAL INSTALLATION P 11 16...

Page 171: ...the upper and lower grip brackets together around the handlebar slot and secure with the four 4 mm self tapping screws The grip brackets will seat together when properly assembled 4 Insert the 5 x 37...

Page 172: ...ng in the track of the lower clutch grip and place the assembly over the inner bracket cover 8 Place the upper clutch grip over the adjuster assembly and secure to the lower clutch grip with the four...

Page 173: ...rear housing 3 Install the Smart Drive cable end snap fitting into the cable holder in rear housing 4 Route the upper end of the Smart Drive cable through the hole in the handlebar left side until it...

Page 174: ...e blade control lever 4 Pinch the flywheel brake cable lock with needle nose pliers and remove the cable lock from the flywheel brake cable bracket 5 Slide the inner cable through the cable holder slo...

Page 175: ...y 4 Remove the 6 x 65 mm flange bolt and Roto Stop control assembly BLADE CONTROL LEVER ROTO STOP CONTROL ASSEMBLY REPLACEMENT P 11 18 6 x 65 mm FLANGE BOLT BLADE CONTROL LEVER RETURN SPRING ROTO STOP...

Page 176: ...ENT P 3 13 ROTO STOP RIGHT CASE ROTO STOP RETURN SPRING SELF TAPPING SCREW 4 ROTO STOP LEFT CASE PUSH KNOB ROTO STOP ARM ASSEMBLY DISASSEMBLY REASSEMBLY PLAIN WASHER ROTO STOP ARM LOCK RETURN SPRING L...

Page 177: ...e the Roto Stop arm assembly is rotated to the back of the Roto Stop left case as shown 4 Position the yellow push knob in the Roto Stop right case Install the lever return spring between the push kno...

Page 178: ...and to the ball plate 8 Install the Roto Stop cable ball end in the ball plate Secure the Roto Stop cable locking tabs in the return spring hook 9 Install new cable ties securing the Roto Stop cable...

Page 179: ...wn and remove it from the Roto Stop control assembly 4 Remove the 6 x 65 mm flange bolt 6 mm lock nut 6 mm plain washer and the Roto Stop control assembly from the handle pipe 5 Remove the spacer from...

Page 180: ...e vent into the air cleaner and onto the Roto Stop assembly when the mower is set back on its wheels 12 Remove the shutter assembly P 12 1 13 Remove the Roto Stop cable ball end from the ball plate 14...

Page 181: ...left case Make sure the Roto Stop arm assembly is rotated all the way to the back as shown 4 Position the yellow push knob in the Roto Stop right case Install the lever return spring between the push...

Page 182: ...locking tabs in the return spring hook 9 Install the Roto Stop cover and shutter P 12 3 Make sure to route the Roto Stop cable on the correct side of the rib as shown so it does not contact the drive...

Page 183: ...INSTALLATION 1 Insert the throttle cable barrel into the throttle lever 2 Insert the cable fitting into the left throttle case slot 3 Insert the collar and the spring over the throttle lever 4 Instal...

Page 184: ...ector on the handle below the recoil starter rope grip 2 Locate the battery charger adapter harness and connect the adapter harness into the charge port connector that is closest to the battery 3 Inse...

Page 185: ...of 0 3 amps 2 Disconnect the charger and let the battery rest for 4 hours 3 Battery voltage should be greater than 12 9 V Battery Load Test 1 Confirm that there is at least 12 9 V at the battery 2 Di...

Page 186: ...spring and green lower shutter lock away from the metal shutter lever arm 3 Turn the fuel valve to the OFF position and tilt the mower on its right side so that the air filter is pointing up 4 PKA VK...

Page 187: ...t side closest to the front of the mower away from the mower deck and then work the right hand side of the shutter assembly out of the two alignment tabs on the rear component housing Note The fitment...

Page 188: ...e mower deck by removing the two screws INSTALLATION 1 Install the Clip Director cover onto the mower deck and tighten the two screws 2 Align the shutter with the Roto Stop cover until the four tabs a...

Page 189: ...o alignment tabs go into the retaining slots in the rear housing d Push the left hand side closest to the front of the mower into place until it seats completely against the mower deck e VKA VLA VYA t...

Page 190: ...k leather gloves and hold the blades with your hand while tightening the bolts Be sure the concave side of the special washers face the lower blade TORQUE 54 N m 40 ft lb 7 Install the Clip Director k...

Page 191: ...from underneath for clarity AXLE NUT FRONT WHEEL AXLE SPACER The larger lip side should face toward the wheel Apply grease to the inside of both axle spacers FRONT AXLE ASSEMBLY CUTTING HEIGHT ADJUSTM...

Page 192: ...emove the two shoulder bolts inside the front of the metal mower deck 3 Remove the four 6 mm flange bolts underneath the front of the metal mower deck 4 Remove the front cover assembly from the metal...

Page 193: ...aining lip side of the sleeves face the wheels 2 Place the front axle assembly into the front cover ensuring the plastic sleeves fit in between the covers walls and not in the axle holders Ensure the...

Page 194: ...oulder bolts and be sure the shoulder portion of the bolts fit through the metal mower deck 6 Confirm that the front cover sits flush on the metal mower deck Once all six bolts have been installed ful...

Page 195: ...er housing P 12 12 4 Remove the rear housing assembly from the cutter housing P 12 13 Installation is the reverse order of removal MOWER DECK SHUTTER CLIP DIRECTOR KNOB ASSEMBLY REMOVAL P 12 1 INSTALL...

Page 196: ...ing strap etc Only replace one handlebar stay at a time 2 Unlock the handlebar adjustment knob and then remove the special bolt and the handlebar assembly from the handlebar stay 3 Remove the three 8...

Page 197: ...HIELD SHAFT AXLE BRACKETS 2 TRANSMISSION AXLE SHAFT ASSEMBLY VKA VLA VYA type shown 6 x 12 mm FLANGE BOLT 2 6 x 12 mm FLANGE BOLT 2 SMART DRIVE CABLE HOLDER VKA VLA VYA types TRANSMISSION RETURN SPRIN...

Page 198: ...er P 4 13 c Hold the flywheel nut with a 19 mm socket while removing the Roto Stop special blade holder bolt If the flywheel nut loosens be sure to tighten to the proper torque during reassembly P 9 8...

Page 199: ...the transmission VYA type Remove flywheel brake cable from the engine P 5 4 the lower end of the Smart Drive cable from the transmission and disconnect the battery charge connector and cable ties from...

Page 200: ...assembly from the rear housing by removing the four 6 mm flange bolts P 12 12 Pay attention to the direction of the two axle brackets The two triangular points on the axle brackets should face inward...

Page 201: ...ct side of the rib guide as shown The 10 bolts that fasten the rear housing to the mower deck and handle stays MUST be tightened in the following sequence shown below a The threaded nut inserts that a...

Page 202: ...on the right hand side so that the air cleaner is facing up 3 Remove the Phillips head screw and plain washer from the rear housing 4 Use a pick tool to pull the rear shield shaft out of the slot in t...

Page 203: ...ugh the rear shield and then into the right hand side of rear housing 2 Insert the bent end of the shaft into the slot in the left hand side of the rear housing until it is full seated 3 Install the P...

Page 204: ...handlebar and tip the mower up and rest the upper handlebar on a table top 5 Remove the blades and blade holder 6 Remove the belt guide 7 Slide the drive pulley away from the engine and remove the bel...

Page 205: ...ssembly onto the rear housing and then remove the transmission from the rear housing 11 If drive belt replacement is required hold the end of the transmission input shaft with an adjustable wrench and...

Page 206: ...Woodruff key is properly inserted in the end of the crankshaft and that it does not fall out when installing the blade holder Make sure the axle holders are installed in the correct direction with th...

Page 207: ...g cap P 3 8 3 Fully loosen the Smart Drive cable adjuster 4 Remove the blades Use a pair of thick leather gloves to hold the blades with your hand to prevent the blades from turning and then remove th...

Page 208: ...lder bolt If the flywheel nut come loose while removing the blade holder bolt it must be tightened to the proper torque P 9 8 7 Pull the Roto Stop brake assembly off the crankshaft as a complete assem...

Page 209: ...ousing and then remove the transmission assembly and drive belt together 11 If drive belt removal is required hold the input shaft end with an adjustable wrench and then remove the 10 mm flange nut Se...

Page 210: ...e crankshaft and does not fall out when installing the Roto Stop brake assy Make sure the axle holders are installed in the correct direction with the triangle tabs facing inward Readjust the Smart Dr...

Page 211: ...r each side The ratchet holder pinion and spring must be installed in the appropriate direction for the left and right wheel pinion assemblies WASHER FLANGE NUT WASHER AXLE REAR WHEEL PINION GEAR 13 T...

Page 212: ...ADJUSTER PLATE REAR AXLE SHAFT DRIVESHAFT BUSHING DRIVESHAFT BUSHING CIRCLIP CIRCLIP REMOVAL P 13 1 DISASSEMBLY P 13 10 INSTALLATION P 13 3 AXLE BEARING 2 INSPECTION Remove the bearing from the bushi...

Page 213: ...c 1 5 oz 10 mm FLANGE NUT 27 N m 20 ft lb 12 7 x 22 2 x 6 4 mm OIL SEAL 2 PINION SHAFT DOWEL PINS 2 10 x 24 mm HARDENED WASHER DRIVEN PULLEY HALVES REMOVAL Hold the pinion shaft with a wrench and then...

Page 214: ...bly Reassembly 9 16 Flywheel Disassembly Reassembly 9 16 Front Cover Disassembly Reassembly 12 6 Installation 12 8 Removal 12 7 Fuel Tube Removal Installation 8 16 Fuel tube Inspection 3 11 G Grass Ba...

Page 215: ...ment 3 13 3 14 Tools Commercially Available 2 6 Special 2 5 Torque Values 2 4 Transmission Disassembly reassembly 13 8 Oil leak 2 20 Troubleshooting 2 7 2 13 Drive system 2 20 V Valve Clearance Adjust...

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Honda HRN216 Series, Manual

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