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Honda HRR216VKA K10, Manual, Page: 169 / 183

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Honda HRR216VKA K10 Manual Download Page 169

13-8

TRANSMISSION

HRR216VKA

11. Remove the pinion gear collars and wheel covers from 

each side.

12.Remove the remaining thrust collars and circlips from 

each side.

13.Remove the 22 mm circlip from each side, and slide them 

and the washers inward towards the transmission.

14.Remove the adjuster assembly from each side, taking 

care not to damage the seals.

WHEEL 
COVER

PINION 
GEAR 
COLLAR

13 mm 
WASHER

THRUST 
COLLAR

13 mm 
CIRCLIP

WASHER

CIRCLIP

ADJUSTER 
ASSEMBLY

Summary of Contents for HRR216VKA K10

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: ...ety information throughout this manual Of course it is not practical or possible to warn you about all the hazards associated with servicing these mowers You must use your own good judgment You will f...

Page 3: ...e model prefix changed from GJAEA to GJAPA Fluorinated fuel tube applied to meet 2009 CARB EPA regulation Wheel color changed from white to gray running change after first 4 000 units K7 MZCG 8200001...

Page 4: ...ter element no steel mesh Nylon crankshaft timing gear New breather tube and air cleaner case Laser etched serial number New ignition coil New fan cover studs collars removed New camshaft decompressor...

Page 5: ...INTRODUCTION HRR216VKA iv NOTES...

Page 6: ...83 1 lbs Grass bag capacity 66 L 1 8 bushels 2 3 cu ft 15 US gal Fuel tank capacity 0 93 L 0 25 US gal Engine oil capacity 0 50 L 17 oz Refill amount 0 35 0 40 L 12 0 13 5 oz Ground speed 0 5 8 kph 0...

Page 7: ...3 6 mph 0 6 5 km h 0 1 8 m s 0 4 0 mph Clutch type Slipping friction cone type V belt slip Drive mechanism V belt Lubrication type SAE 10W 30 engine oil SJ or later Lubrication amount 150 cc 5 1 oz 6...

Page 8: ...SIONAL DRAWINGS K5 thru K7 K5 K6 966 mm 38 0 in K7 961 mm 37 8 in K5 K6 630 m m 24 8 in K7 620 m m 24 4 in K5 K6 1 600 mm 63 0 in K7 1 620 mm 63 8 in Dimensions measured with the cutting height set in...

Page 9: ...TIONS HRR216VKA K8 and K9 Dimensions measured with the cutting height set in the lowest position and the handlebar height set in the highest position 1 534mm 60 4 in 582 mm 22 9 in 1 014 mm 39 9 in 62...

Page 10: ...A SPECIFICATIONS K10 K11 Dimensions measured with the cutting height set in the lowest position and the handlebar height set in the highest position 1 532 mm 60 3 in 582 mm 22 9 in 1 024 mm 40 3 in 62...

Page 11: ...1 6 SPECIFICATIONS HRR216VKA 3 WIRING DIAGRAM SPARK PLUG IGNITION COIL ENGINE STOP SWITCH NORMALLY CLOSED...

Page 12: ...and operation 2 SYMBOLS USED IN THIS MANUAL As you read this manual you may find the following symbols with the instructions 1 SERVICE RULES 2 1 2 SYMBOLS USED IN THIS MANUAL 2 1 3 SERIAL NUMBER LOCAT...

Page 13: ...K11 K5 K8 K5 K8 K9 K11 Carburetor BB65E A Main jet Float height Pilot screw opening 70 9 2 mm 0 36 in N A K5 Carburetor BB75E A Main jet Float height Pilot screw opening 68 7 2 mm 0 28 in N A K5 Carbu...

Page 14: ...K9 K11 64 000 64 015 mm 2 5197 2 5203 in 64 105 mm 2 5238 in 64 110 mm 2 5240 in Connecting rod Small end I D Big end I D Big end oil clearance Big and axial clearance 13 005 mm 0 5120 in 26 02 mm 1...

Page 15: ...0 ST 12 1 2 8 7 Engine stop switch assembly M4 x 0 7 1 6 0 16 1 18 Fan cover stud bolt M6 x 1 0 12 1 2 8 7 Flywheel nut M14 x 1 5 52 5 3 38 Fuel valve bracket screw M5 x 0 6 4 5 0 45 2 2 Governor arm...

Page 16: ...TION 1 Carburetor float level gauge 07401 0010000 Carburetor float level inspection 2 Valve adjustment wrench 3 mm 07908 KE90200 Valve clearance adjustment 3 Flywheel holder 07APB Z28A100 Flywheel rem...

Page 17: ...ession test 3 Flywheel puller OTC 1035 Flywheel removal 4 Combustion chamber cleaning brush and drill extension Procured locally Clean combustion chamber 5 Spring scale SAMIN25MRP Roll back force chec...

Page 18: ...backwards but stops propelling when the Smart Drive is released 2 10 Only one wheel propels or one wheel intermittently stops rotating under load clicking sound can be heard 2 11 Transmission leaks o...

Page 19: ...transmission replacement is necessary 3 Position the mower on a smooth concrete surface 4 Start the engine and firmly engage the Smart Drive control while holding the lawn mower from moving forward Th...

Page 20: ...If the spring is broken missing or damaged replace it 4 Place the mower on its wheels and roll it backwards If it rolls easily then adjust the Smart Drive cable page 3 10 If the mower is difficult to...

Page 21: ...s 49 N 11 lb continue as follows Remove the rear adjuster arms and clean and inspect the bushings and axle shaft Replace any excessively worn bushings Apply Honda Marine extreme pressure NLGI 2 GC LB...

Page 22: ...ply general purpose grease to the ratchet key spring and axle on the left and right sides 3 Be sure the correct pinion gears are installed 8 inch wheels use 12 tooth pinion gears FLAT WASHER 3 mm SPAC...

Page 23: ...NG SHIFT SHAFT OIL SEAL INPUT SHAFT OIL SEAL TRANSMISSION CASE INSTALLATION Use SAE 10W 30 engine oil and fill to the capacity shown below The correct oil level should be 8 12 mm 0 3 0 5 in from the t...

Page 24: ...smission pulley is tight and not slipping on the input shaft 3 Position the mower on a smooth concrete surface 4 Start the engine and firmly engage the Smart Drive control while holding the lawn mower...

Page 25: ...replace it 4 Push the control arm up to remove all the slack from the belt Inspect the clearance between the outside of the belt and the belt guides Belt Guide Clearance Driven Pulley Belt Guide Clea...

Page 26: ...o step 4 4 Remove the rear adjuster arms and clean and inspect the bushings and axle shaft Replace any excessively worn bushings Clean the axle shaft using a 5 Thoroughly apply a coat of Honda Marine...

Page 27: ...Only use an extreme pressure NLGI 2 GC LB wheel bearing grease Proper application of the correct grease is critical to ensure proper operation DO NOT USE anti seize white lithium silicone WD 40 or an...

Page 28: ...elow Fill the transmission to the proper level with SAE 10W 30 oil 2 Reinstall the transmission and proceed to the Smart Drive Cable Adjustment procedure P 3 10 CASE O RING TRANSMISSION CASE INSTALLAT...

Page 29: ...ompression is too high Install a compression gauge in the spark plug hole P 2 21 and crank the engine several times Install the spark plug in the plug cap and perform the spark test P 2 20 Remove P 8...

Page 30: ...APPROVED 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 f...

Page 31: ...ignition coil primary terminal 3 With the multimeter set to measure Ohms connect one lead to the engine stop switch connector and the other lead to ground There should be continuity when the flywheel...

Page 32: ...engine must be completely cool before proceeding 1 If there is gasoline in the fuel tank drain it into an approved container 2 Remove the recoil starter and fan cover P 7 1 Do not tilt the fan cover w...

Page 33: ...valve clearance measurement is less than or equal to 0 24 mm 0 0094 in 1 Rotate the flywheel until the cam pulley decompressor weight slot faces out 2 Carefully inspect the weight position and confir...

Page 34: ...remove the exhaust rocker pin and rocker arm 3 Closely inspect the rocker arm for cracks and damage Inspect the rocker pin for excessive wear or grooves If the rocker arm is damaged and or the pin app...

Page 35: ...haust rocker arm above the pivot pin in location A shown in step 7 9 Push and hold the tappet screw against the exhaust valve 10 While holding the tappet screw against the valve maintain zero valve la...

Page 36: ...l 13 Apply Hondabond HT P N 08718 0004 or Loctite 5900 to a new cylinder head cover in the areas shown Assemble within 10 minutes after applying the liquid gasket Tighten the head cover bolts evenly i...

Page 37: ...lly Replace the choke control assembly See if the choke valve opens after 5 8 minutes opening time will vary based on load and ambient temperature Choke opens fully System operates normally Does not o...

Page 38: ...TROL LINKAGE Abnormal Replace the carburetor P 8 1 Allow the engine to cool Push the choke valve open and release it The choke should open smoothly and snap closed when released Replace the carburetor...

Page 39: ...end of the bolt against the auto choke plunger and slowly push it until the flange nut seats and then slowly release the bolt Do this slowly several times and make sure the choke control operates smoo...

Page 40: ...brake pad P 9 1 Check the flywheel brake cable for binding Check the flywheel brake spring P 3 12 Check flywheel brake pad P 3 12 Replace engine stop switch P 9 1 Blade engine does not stop turning wh...

Page 41: ...dicator NOTICE When checking the crankshaft runout do not allow the dial indicator tip to drop into the keyway or the dial indicator tip can be damaged 7 Use the blade holder bolt and a wrench to rota...

Page 42: ...D 3 4 5 BLADES 3 4 6 ENGINE OIL 3 7 7 AIR FILTER CLEANING 3 8 8 GRASS BAG 3 8 9 SPARK PLUG INSPECTION 3 9 10 SPARK ARRESTER CLEANING OPTIONAL PART 3 9 11 SMART DRIVE CABLE 3 10 12 FUEL TANK AND FILTER...

Page 43: ...ours of use or every two years See page Rear shield Check O 3 4 Blades Inspect O 3 4 Blade mounting bolts Inspect O 3 6 Engine oil Check O 3 7 Change O O 1 O O 3 7 Air filter Check O 3 8 Clean O 2 O 2...

Page 44: ...rotated fully clockwise at full throttle Check the engine rpm after adjusting 3 17 Flywheel brake cable No adjustment Inspect for proper operation only 3 13 Flywheel brake mechanism Brake shoe thickn...

Page 45: ...valve to the OFF position This will reduce the possibility of fuel leakage when the mower is tilted 2 Disconnect the spark plug cap 3 Tilt the mower on its right side so the carburetor is up 4 Inspect...

Page 46: ...Grind or file the upper surface of the blades only The cutting edge must be even with the lower surface of the blades Taper the blade profile removing material from the blade tip never the inner end o...

Page 47: ...any signs of damage If they are damaged they must be replaced 2 Install the blades using the two blade bolts and special washers as shown Install the special washers with the concave side toward the b...

Page 48: ...or down a drain 3 Refill with the recommended oil to the upper limit mark on the dipstick Check the oil level with the mower on a level surface and the dipstick fully inserted but not screwed in Oil i...

Page 49: ...ter Tap the filter several times on a hard surface to remove dirt or blow with compressed air not exceeding 207 kPa 30 psi through the filter from the inside Never try to brush off dirt brushing will...

Page 50: ...can overheat and damage the engine Overtightening can damage the threads in the cylinder head 10 SPARK ARRESTER CLEANING OPTIONAL PART The spark arrester must be serviced every 100 hours to keep it f...

Page 51: ...approximately the 5 00 o clock position 3 If they don t perform the cable adjustment procedure below CABLE ADJUSTMENT 1 With the engine off loosen the adjuster jam nut 2 Without pushing the Smart Dri...

Page 52: ...ged 6 Remove the fuel filter from the fuel tube 7 Inspect the fuel filter for sediment and other foreign material Inspect for tears or other damage 8 Wash with solvent to clean and dry thoroughly befo...

Page 53: ...t with a regular fuel tube Two styles of fuel tube clamps have been used If you replace the clamps use the same style that is currently on the mower 13 FLYWHEEL BRAKE INSPECTION 1 Remove the recoil st...

Page 54: ...he engine cold 1 Remove the spark plug cap from the spark plug 2 Remove the fan cover fuel tank P 8 24 3 Remove the four flange bolts from the cylinder head cover 4 Remove the cylinder head cover by p...

Page 55: ...N m 5 8 ft lb d Recheck valve clearance after tightening the lock nut 9 Thoroughly clean the old sealant from the cylinder head surface using an abrasive cloth and brake cleaner 10 Apply liquid gasket...

Page 56: ...atchet spring IMPORTANT Only use an extreme pressure NLGI 2 GC LB wheel bearing grease Proper application of the correct grease is critical to ensure proper operation DO NOT USE anti seize white lithi...

Page 57: ...ghly apply a coat of Honda Marine extreme pressure NLGI 2 GC LB grease or equivalent INSIDE the adjuster arms and on the axle surfaces IMPORTANT Only use an extreme pressure NLGI 2 GC LB wheel bearing...

Page 58: ...eel brake lever while you perform the maximum engine speed adjustment 7 Check the maximum engine speed 8 If adjustment is necessary bend the governor spring tab on the fuel valve plate very slightly L...

Page 59: ...U K8 1 With the engine running at normal operating temperature push the governor arm toward the carburetor and hold it in this position 2 Adjust the throttle stop screw to obtain the specified idle sp...

Page 60: ...bolt and remove the blade holder 6 Install in the reverse order of removal Pay attention to the following Note that the keyway for the blade holder Woodruff key is on the opposite side of the cranksh...

Page 61: ...ge screwdriver between the belt tension arm and transmission cover Rotate the transmission to loosen and remove the drive belt from the driven pulley 6 Remove the belt from the drive pulley 7 Remove t...

Page 62: ...spring 2 Using a large flat blade screwdriver hook the belt tension spring on the belt tension arm 3 Place a large screwdriver between the belt tension arm and transmission cover Rotate the transmiss...

Page 63: ...en the belt tension arm and transmission cover Rotate the transmission to loosen and remove the drive belt from the driven pulley 6 Remove the belt from the drive pulley 7 Remove the belt tension spri...

Page 64: ...de screwdriver hook the belt tension spring on the belt tension arm 3 Place a large screwdriver between the belt tension arm and transmission cover Rotate the transmission as shown and install the dri...

Page 65: ...th an adjustable wrench and then remove the 10 mm flange nut 9 Remove the driven pulley 10 x 24 mm washer and the drive belt from the transmission INSTALLATION 1 Install in the reverse order of remova...

Page 66: ...7 Remove the three 6 x 10 mm flange bolts 1 two 6 x 8 mm shoulder bolts 2 and one shoulder screw 3 and then remove the rear scroll 8 Serial numbers MZCG 9506882 9999999 and MZCG 1000001 1999999 Remove...

Page 67: ...Woodruff key is installed It is easy for the key to fall out during installation If it is not installed the blade holder bolt will eventually break allowing the blade and blade holder to fall off duri...

Page 68: ...olt and remove the blade holder and Woodruff key 8 K9 through K11 models serial numbers MZCG 9506882 9999999 and MZCG 1000001 1999999 Remove the belt guide 9 Slide the drive pulley off the crankshaft...

Page 69: ...l the belt guide 4 Install the Woodruff key and attach the blade holder using the 3 8 24 x 1 flange bolt Be sure the Woodruff key remains in place when installing the blade holder TORQUE 49 59 N m 36...

Page 70: ...er has been removed SPARK ARRESTER optional part INSTALLATION Install after removing the carbon from the screen with a wire brush MUFFLER INSTALLATION Use a plastic hammer to loosen carbon deposits fr...

Page 71: ...6 2 MUFFLER HRR216VKA NOTES...

Page 72: ...starter rope is frayed or worn out replace the starter rope P 7 2 Do not disassemble the recoil starter assembly 1 REMOVAL INSTALLATION 7 1 2 STARTER ROPE REPLACEMENT 7 2 RECOIL STARTER ASSEMBLY 6 mm...

Page 73: ...r reel side and remove the starter rope 4 Pass the new starter rope through the starter grip and make a knot at the end of the rope 5 Pass the other end of the starter rope through the rope hole in th...

Page 74: ...ake a knot at the end of the rope 3 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 the end of th...

Page 75: ...7 4 RECOIL STARTER HRR216VKA NOTES...

Page 76: ...3 mm stud Install and hand tighten the stud 5 While pushing the air cleaner case toward the engine remove the other 6 x 83 mm flange bolt and temporarily install another 6 x 83 mm stud 6 Pull the brea...

Page 77: ...21 PAPER ELEMENT CLEANING P 3 8 AIR CLEANER COVER CRANKCASE BREATHER TUBE INSTALLATION P 8 20 6 x 83 mm STUD 2 PART NUMBER 90013 ZG9 T00 Temporarily install to make carburetor installation easier GOV...

Page 78: ...ce AIR CLEANER GASKET Replace AIR CLEANER COVER 6 x 83 mm STUD 2 PART NUMBER 90013 ZG9 T00 Temporarily install to make carburetor installation easier AIR GUIDE GASKET Replace GOVERNOR SPRING INSTALLAT...

Page 79: ...LY Replace AIR CLEANER GASKET Replace AIR GUIDE GASKET Replace GOVERNOR SPRING INSTALLATION P 8 21 SPACER K8 ONLY AIR CLEANER CASE K8 6 x 12 mm FLANGE BOLT 6 x 28 mm FLANGE BOLT FUEL VALVE ASSEMBLY TH...

Page 80: ...llation FLOAT VALVE REPLACE OK FLOAT CHAMBER SEALING WASHER 5 x 6 mm ACCESS SCREW INSPECTION Remove access screw to clean the slow speed jet REASSEMBLY Clean thoroughly with compressed air 30 psi max...

Page 81: ...ificant amount of water contamination or deteriorated gasoline is inside the float chamber inspect and clean the inside of the fuel tank and fuel filter screen Carefully inspect all the gaskets for da...

Page 82: ...ecessary See image on the previous page 3 Remove the main jet and the main nozzle With the main jet removed push down on the top of the main nozzle with a screwdriver If the nozzle does not come out s...

Page 83: ...8 8 FUEL SYSTEM HRR216VKA 5 Remove the 5 x 6 mm screw covering the pilot jet 6 Clean the float valve seat using carburetor cleaner and compressed air FLOAT VALVE SEAT...

Page 84: ...o not use a welding tip cleaning needle NOTICE Using a welding tip cleaning needle or a jet needle that is too large may damage the carburetor Never force a needle and never use a needle with a bent o...

Page 85: ...a welding tip cleaning needle 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 Carefully inspect the main jet for dam...

Page 86: ...using the appropriate size jet cleaning tool carburetor cleaner and compressed air The passage is small and easily obstructed so repeat several times 12 Clean the high speed air passage with carburet...

Page 87: ...t hole with carburetor cleaner and compressed air 14 Clean the slow speed air passage Spray carburetor cleaner and compressed air through the slow speed air passage The passage is small so repeat seve...

Page 88: ...peed air channel for obstructions 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 transi...

Page 89: ...rew and spring if applicable Tighten the screw just far enough so the throttle plate begins to open 18 Reinstall the main nozzle and main jet making sure the nozzle long end extends into the venturi A...

Page 90: ...it to warm up for several minutes Then adjust the idle speed P 3 18 and check the maximum no load engine speed P 3 18 FLOAT LEVEL HEIGHT INSPECTION Place the carburetor in the position as shown and m...

Page 91: ...ke assembly heat sink as shown Do not apply too much only a small amount is needed 3 Verify that the carburetor choke lever is in the fully closed position 4 Install the carburetor and choke assembly...

Page 92: ...mowax assembly into the cylinder barrel 3 Verify that the carburetor choke lever is in the fully closed position 4 Install the carburetor and choke assembly P 8 3 5 After installation verify that ther...

Page 93: ...mbly If the length is less than 21 5 mm and or wax is visible around the plunger replace the thermowax assembly 1 Position a pair of pliers on the thermowax assembly as shown Do not apply force yet 2...

Page 94: ...e a pair of pliers to carefully pull the thermowax assembly out of the cylinder barrel Pull the thermowax straight out Be careful not to damage any points used for prying 4 Use a knife or small scrape...

Page 95: ...acted during assembly 4 Verify that the carburetor choke lever is in the fully closed position 5 Install the carburetor and choke assembly page 8 4 6 After installation verify that there is clearance...

Page 96: ...IDENTIFICATION P 8 23 GOVERNOR SPRING REASSEMBLY Install with the short end side toward the governor arm CONTROL BASE 6 x 45 mm FLANGE BOLT GOVERNOR ARM THROTTLE RETURN SPRING INSTALLATION Install th...

Page 97: ...ugh the throttle return spring as shown Connect each to the governor arm and carburetor throttle arm as shown LONG END THROTTLE THROTTLE ARM GOVERNOR ROD GOVERNOR ARM THROTTLE RETURN SPRING LONG END G...

Page 98: ...nted on them If you replace a low permeation fuel tube you must replace it with a low permeation fuel tube that has the emissions compliance identification number printed on it If you replace a regula...

Page 99: ...ng fuel Stop the engine and let it cool Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately FAN COVER INSTALLATION Check that the high tension cord and the stop switch...

Page 100: ...ured when handling fuel Stop the engine and let it cool Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately FAN COVER INSTALLATION Check that the high tension cord is...

Page 101: ...OTICE If the fuel tube is pried off the fuel valve with a tool the fuel valve may be damaged 5 Remove the other end of the fuel tube from the fuel tank using the same procedure The filter will come ou...

Page 102: ...ambient temperature or consumption of gasoline the air drawn through the canister releases the stored gasoline vapor from the charcoal The released gasoline vapor returns to the fuel tank FUEL TUBES...

Page 103: ...8 28 FUEL SYSTEM HRR216VKA NOTES...

Page 104: ...t lb CLIP A STOP SWITCH WIRE 6 x 14 FLANGE BOLT FLYWHEEL BRAKE INSPECTION P 3 12 ENGINE STOP SWITCH INSPECTION P 2 20 4 mm WASHER 4 x 12 mm SCREW WASHER 1 8 N m 1 3 ft lb 6 x 23 FLANGE BOLT BRAKE LEVE...

Page 105: ...ring disassembly and reassembly to prevent damage FAN COVER STUD BOLT 3 12 N m 8 9 ft lb 6 x 20 mm FLANGE BOLT IGNITION COIL INSPECTION P 9 6 ADJUSTMENT P 9 6 25 x 18 mm SPECIAL WOODRUFF KEY REASSEMBL...

Page 106: ...it there with a strap or equivalent material This allows the flywheel and crankshaft to turn 4 Hold the flywheel with the special tool and a breaker bar and remove the 14 mm special nut with a wrench...

Page 107: ...under the magnets at the PULLER mark Set a shop towel or equivalent cloth between the flywheel and the puller 7 Tighten the flywheel puller and then tap the end of the puller with a brass hammer to r...

Page 108: ...TALLATION 1 Ensure the spark plug cap is disconnected before proceeding 2 Make sure the flywheel taper is free of dirt oil grease and other foreign material before installation 3 Make sure there is no...

Page 109: ...tests is out of specification AIR GAP ADJUSTMENT Adjustment is required only when the ignition charge coil or the flywheel has been removed 1 Loosen the ignition charge coil bolts 2 Insert a long fee...

Page 110: ...E ROCKER ARM INSPECTION P 10 15 VALVE ADJUSTING LOCK NUT 2 7 8 N m 5 8 ft lb CAM PULLEY DECOMPRESSOR WEIGHT INSPECTION P 10 2 INSTALLATION P 10 2 Take care not to drop the cam pulley EXHAUST ROCKER AR...

Page 111: ...ankshaft key groove PTO side faces up as shown The two woodruff key grooves will face down 2 Install the cam pulley on the timing belt so that the cam pulley alignment marks are in line with the cylin...

Page 112: ...cleaning agent and a clean shop towel 2 Apply liquid gasket Hondabond HT or Loctite 5900 to a new cylinder head cover specifically to the inner wall of the groove and bolt hole in the cylinder head c...

Page 113: ...Apply grease to the lips 28 x 41 25 x 6 mm OIL SEAL INSTALLATION Be careful not to damage the lip of the oil seal when installing the oil pan with the oil seal TIMING BELT INSTALLATION Check that the...

Page 114: ...side of the connecting rod big end are at the right side The crankshaft must be at the top dead center of the compression stroke The model mark on the piston must be positioned toward the oil pan NOTI...

Page 115: ...er block 5 Apply a bead 1 5 2 0 mm 0 06 0 08 in of liquid gasket ThreeBond 1216 Hondabond HT or Loctite 5900 to the cylinder block 6 Install the oil pan on the cylinder block Assemble within 10 minute...

Page 116: ...pward as shown Do not interchange the top ring and the second ring After assembly check for smooth movement of the piston ring Stagger the piston ring end gaps 120 apart Do not align with the piston p...

Page 117: ...down 3 Set the connecting rod in the piston so that the model mark ZL8 Z8B or Z2A by the piston pin hole and the longer side of the connecting rod large face to the right hand side 4 Apply oil to the...

Page 118: ...P 10 20 INTAKE VALVE REASSEMBLY Do not interchange with the exhaust valve VALVE HEAD DIAMETER IN 25 mm 0 98 in EX 24 mm 0 94 in INSPECTION P 10 20 VALVE SPRING 2 INSPECTION P 10 20 VALVE SPRING RETAI...

Page 119: ...during cleaning of the combustion chamber Do not press the cleaning brush with force against the combustion chamber VALVE SEAT RECONDITIONING Valve Seat Inspection 1 Thoroughly clean the combustion ch...

Page 120: ...r to protect the cylinder wall during valve seat reconditioning 60 45 31 VALVE SEAT CUTTER SOLID PILOT BAR 5 50 mm NWY PM 100055SH SOLID PILOT BAR 5 51 mm NWY PM 100552S VALVE SEAT CUTTER 115 31 NWY C...

Page 121: ...remove any possible burrs at the edge of the seat VALVE SEAT WIDTH 1 After resurfacing the seats inspect for even valve seating Apply Prussian Blue or erasable felt tipped marker ink to the valve fac...

Page 122: ...BLY Before installing check for wear and damage of the gear Check that the weights move freely Be sure to install the governor weight before installing the crankshaft 8 mm LOCK PIN REASSEMBLY Install...

Page 123: ...INSPECTION Inspect the decompressor return spring for proper strength Check the decompressor arm and pin for proper movement and wear CAM PULLEY SHAFT O D INSPECTION Standard Service limit 37 394 mm...

Page 124: ...e service limit it must be replaced Do not hone the cylinder 2 Measure and record the Piston O D at a point 10 mm 0 4 in from the bottom of the skirt and 90 to the piston pin bore 3 Subtract the Pisto...

Page 125: ...tandard Service limit Top ring 0 93 0 95 mm 0 036 0 037 in 0 91 mm 0 035 in Second ring 0 97 0 99 mm 0 038 0 039 in 0 95 mm 0 037 in Standard Service limit Top ring 0 055 0 089 mm 0 002 0 004 in 0 150...

Page 126: ...ANKSHAFT MAIN JOURNAL O D INSPECTION Standard Service limit 13 002 mm 0 5119 in 13 048 mm 0 5137 in Standard Service limit 13 005 mm 0 5120 in 13 07 mm 0 515 in Standard Service limit 26 02 mm 1 024 i...

Page 127: ...ND AXIAL CLEARANCE INSPECTION Measure the clearances with a feeler gauge CONNECTING ROD BIG END OIL CLEARANCE INSPECTION 1 Wipe oil off the crank pin and connecting rod bearing mating surface 2 Place...

Page 128: ...ment OIL PAN MAIN JOURNAL I D INSPECTION Inspect the bearing surface for scoring or damage If the bearing surface is worn or damaged the oil pan and crankshaft will require replacement CRANKSHAFT AXIA...

Page 129: ...VE GUIDE I D INSPECTION Measure and record each valve guide I D Replace the cylinder block if they are over the service limit VALVE SEAT WIDTH INSPECTION 1 Measure the valve seat width 2 Recondition t...

Page 130: ...rip brackets 8 Remove the Smart Drive cable from the lower grip bracket and then from the handle pipe assembly 9 Remove the two special bolts nylon washers and the handle assembly from the handle stay...

Page 131: ...of its removal 13 Readjust the Smart Drive cable P 3 10 NYLON WASHER 2 SPECIAL BOLT 2 HEIGHT ADJUSTING COLLAR 2 8 mm PIN 2 HEIGHT ADJUSTING SPRING 2 HANDLE LOCKING KNOB 2 INSTALLATION P 11 10 2 x 12...

Page 132: ...ard return springs are under tension and can fly out and injure someone 3 To replace the grass bag plate remove the three grass bag plate bolts 4 Release the handlebar locking knobs and allow the hand...

Page 133: ...is the reverse of removal The left and right discharge guard return springs are different Position the springs so the hooks lead to the underside of the spring Apply pressure to hold the springs in p...

Page 134: ...careful when removing the discharge guard shaft The guard return springs are under tension and can fly out and injure someone 3 To replace the grass bag plate remove the three grass bag plate bolts Re...

Page 135: ...e 13 mm circlip pinion gear collar 12 tooth pinion gear ratchet key and ratchet return spring from each side 9 Remove the pinion gear collars and wheel covers from each side FLAT WASHER WHEEL WASHER W...

Page 136: ...to damage the seals 13 If removing the left hand side handle stay disconnect the Smart Drive cable from the transmission and then disconnect the upper end of the belt tension spring Be sure to fully...

Page 137: ...e bracket 15 Installation is the reverse of removal Refer to step 4 through step 22 on page 13 18 for reassembly NOTE The left and right discharge guard return springs are different Position the sprin...

Page 138: ...rope guide P 11 1 2 Remove the handle pipe from the handle stays P 11 1 3 Remove the old grip s 4 Lubricate the inside of the handle grip with soapy water 5 Slide the grip onto the handle pipe The gr...

Page 139: ...d push it through until you can see the hole in the pin on the other side 4 Install the handle locking knob onto the top of the pin and line up the holes on the pin and the knob 5 Insert the 1 16 drif...

Page 140: ...er and lower clutch grips Carefully remove the multi position adjuster and spring 6 Remove the upper and lower bracket covers 7 Remove the four 4 mm self tapping screws and the upper and lower grip br...

Page 141: ...e the Smart Drive cable down through the hole in the cutter housing 2 Attach the Smart Drive cable end on the transmission control arm 3 Align the Smart Drive cable wire with the cable holder slot and...

Page 142: ...slot and secure with the four 4 mm self tapping screws The grip brackets will seat together when properly assembled 11 Insert the 5 x 37 mm roller pin through the Smart Drive cable end and center the...

Page 143: ...he adjuster assembly and secure to the lower clutch grip with the four 4 mm self tapping screws 16 Rotate the Smart Drive control and confirm that the lower end of the Smart Drive cable moves the tran...

Page 144: ...r clutch grips Carefully remove the multi position adjuster and spring 6 Remove the upper and lower bracket covers 7 Remove the four 4 mm self tapping screws and the upper and lower grip brackets 8 Re...

Page 145: ...e the Smart Drive cable down through the hole in the cutter housing 2 Attach the Smart Drive cable end on the transmission control arm 3 Align the Smart Drive cable wire with the cable holder slot and...

Page 146: ...slot and secure with the four 4 mm self tapping screws The grip brackets will seat together when properly assembled 11 Insert the 5 x 37 mm roller pin through the Smart Drive cable end and center the...

Page 147: ...e the adjuster slots are located toward the rear of the mower 14 Grease both sides of the clutch grip guides Insert the multi position adjuster and spring in the track of the lower clutch grip and pla...

Page 148: ...e belt cover P 4 5 18 Install new cable ties securing the Smart Drive cable to the handle stay and handle pipe 19 Readjust the Smart Drive cable P 3 10 20 Start and test the Smart Drive operation K8 K...

Page 149: ...and remove the Smart Drive cable from the control arm 13 Using pliers pinch the Smart Drive cable locks pull on the cable and remove it from the cable holder 14 Remove the Smart Drive cable from the l...

Page 150: ...grip brackets will seat together when properly assembled 4 Insert the 5 x 37 mm roller pin through the Smart Drive cable end and center the pin in the upper and lower grip bracket slots LOWER GRIP BRA...

Page 151: ...the multi position adjuster and spring 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...

Page 152: ...to the handle stay and handle pipe 15 Readjust the Smart Drive cable P 3 10 16 Start and test the Smart Drive operation 6 SMART DRIVE DISASSEMBLY AND INSPECTION 1 Confirm the rubber grips do not conta...

Page 153: ...the roller pin with the bracket cover grooves 8 Grease both sides of the clutch grip guides 9 Insert the multi position adjuster and spring in the track of the lower clutch grip 10 Place the assembly...

Page 154: ...handle is spring loaded and tends to pop apart when removed 7 Remove the Clip Director door through the back of the deck 8 Installation is done in the reverse order of removal Pay attention to the fol...

Page 155: ...LD SHAFT REAR SHIELD PUSH NUT 5 16 24 x 1 FLANGE BOLT 4 BELT COVER FRONT SCROLL MULCHING PLUG SCROLL PLATE GUIDE PLATE 8 mm FLANGE NUT 2 8 mm FLAT WASHER 2 COVER SPRING 2 HINGE PLATE 2 REAR DOOR DOOR...

Page 156: ...ront scroll 1 22 Nylon locknut 8 mm 1 6 Rear scroll 1 23 Plain washer 5 16 2 7 Rear shield shaft 1 24 Flange nut 8 mm 2 8 Scroll plate 1 25 Flange bolt 6 x 10 7 9 Guide plate 1 26 Push nut 3 96 mm 1 1...

Page 157: ...eld shaft 405 mm 1 25 Grass bag plate bolt 3 8 Roto Stop cover 1 26 Flange bolt 5 16 24X1 4 9 Cable grommet 1 27 Flat round push nut 3 96 mm 1 11 Plug grommet 1 28 Push nut 7 94 mm 1 12 Shutter cover...

Page 158: ...MOWER DECK WHEELS 3 WHEELS FRONT WHEEL GRIP ADJUSTER BOLT WHEEL BOLT ADJUSTER PLATE COLLAR ADJUSTER PANEL ADJUSTER ARM 8mm FLANGE NUT 5 16 in WASHER WHEEL WASHER REASSEMBLY Install the washer as shown...

Page 159: ...shown WHEEL SIDE WHEEL BOLT 25 mm CIRCLIP PINION GEAR COLLAR RETURN SPRING CIRCLIP KEY 13 mm THRUST WASHER BEARING 2 COVER ADJUSTER ARM SEAL GRIP ADJUSTER PLATE 13 x 27 x 1 mm THRUST WASHER CIRCLIP 26...

Page 160: ...CLIP KEY 13 mm THRUST WASHER BEARING 2 COVER ADJUSTER ARM SEAL GRIP ADJUSTER PLATE 13 x 27 x 1 mm THRUST WASHER CIRCLIP 26 x 44 mm FLAT WASHER Right Side Shown PINION GEAR 12 tooth Install with the pu...

Page 161: ...12 8 CLIP DIRECTOR MOWER DECK WHEELS HRR216VKA NOTES...

Page 162: ...elt cover belt tension spring and drive belt P 4 2 7 Rotate the transmission out slightly not too far or you ll kink the cable 8 Use needle nose pliers to remove the snap fitting from the clutch cable...

Page 163: ...and ratchet key from each side 11 Remove the wheel cover and pinion gear collar from each side 12 Remove the remaining collar circlip and washer from each side as shown RATCHET KEY RATCHET RETURN SPRI...

Page 164: ...nsmission 14 Remove the adjuster assembly from each side taking care not to damage the seals 15 Slide the transmission axle to the right side and then rotate it until the left side can be removed from...

Page 165: ...TRANSMISSION CASE INSTALLATION Use SAE 10W 30 engine oil and fill to the capacity shown The correct oil level should be 8 12 mm 0 3 0 5 in from the top of the transmission case when it is upside down...

Page 166: ...L ARM 6 x 12 mm FLANGE BOLT 4 8 8 11 8 N m 6 5 8 7 ft lb CASE O RING 10 x 19 x 7 mm OIL SEAL RETURN SPRING 12 7 x 28 6 x 6 4 mm OIL SEAL WIRE HOLDER 6 x 14 mm FLANGE BOLT 2 BELT TENSION SPRING TENSION...

Page 167: ...inion gears ratchet springs and ratchet keys Use Honda Marine extreme pressure NLGI 2 GC LB grease or equivalent IMPORTANT Only use an extreme pressure NLGI 2 GC LB wheel bearing grease Proper applica...

Page 168: ...ension spring and drive belt P 4 4 7 Rotate the transmission out slightly not too far or you ll kink the cable 8 Use needle nose pliers to remove the snap fitting from the clutch cable holder and disc...

Page 169: ...llars and circlips from each side 13 Remove the 22 mm circlip from each side and slide them and the washers inward towards the transmission 14 Remove the adjuster assembly from each side taking care n...

Page 170: ...nd the left side adjuster panel 16 Slide the transmission axle to the right side then rotate it until the left side can be removed from the mower deck Remove the transmission from the mower deck 22 mm...

Page 171: ...ges of the pulley 6 mm FLANGE NUT 6 x 14 mm FLANGE BOLT 2 BELT TENSION ARM TRANSMISSION CONTROL ARM 6 x 12 mm FLANGE BOLT 4 8 8 11 8 N m 6 5 8 7 ft lb CASE O RING 10 x 19 x 7 mm OIL SEAL RETURN SPRING...

Page 172: ...e axle surfaces IMPORTANT Only use an extreme pressure NLGI 2 GC LB wheel bearing grease Proper application of the correct grease is critical to ensure proper operation DO NOT USE anti seize white lit...

Page 173: ...any other spray lubricant 12 Install a ratchet return spring and ratchet key 13 Install a pinion gear pinion gear collar and 13 mm circlip Make sure the pinion gear is installed correctly for each si...

Page 174: ...upper handle pipe and tip the mower up and secure the upper handle pipe in a bench vise 6 Remove the rear scroll P 4 7 7 Remove the blades and blade holder P 4 1 8 Serial numbers MZCG 9506882 9999999...

Page 175: ...13 mm circlip pinion gear collar pinion gear ratchet key and ratchet return spring from each side 14 Remove the pinion gear collars and wheel covers from each side FLAT WASHER WHEEL WASHER WHEEL BOLT...

Page 176: ...from each side taking care not to damage the seals 18 K8 and K9 models only Remove the two 8 mm flange nuts and the left side adjuster panel 19 Slide the transmission axle to the right side and then r...

Page 177: ...OLT 4 8 8 11 8 N m 6 5 8 7 ft lb CASE O RING 12 7 x 28 6 x 6 4 mm OIL SEAL RETURN SPRING BELT GUIDE INSPECTION P 2 14 6 x 12 mm FLANGE BOLT 2 TRANSMISSION CASE INSTALLATION Use SAE 10W 30 engine oil a...

Page 178: ...ty shown The correct oil level should be 18 20mm 0 71 0 79 in from the top of the transmission case when it is upside down CAPACITY 65 cc 2 2 oz TOP OF CASE 18 20 mm 0 71 0 79 in 10 mm FLANGE NUT 39 N...

Page 179: ...uster arms and on the axle surfaces IMPORTANT Only use an extreme pressure NLGI 2 GC LB wheel bearing grease Proper application of the correct grease is critical to ensure proper operation DO NOT USE...

Page 180: ...ricant 13 Install a ratchet return spring and ratchet key 14 Install a pinion gear pinion collar and 13 mm circlip Make sure the pinion gear is installed correctly for each side as shown 15 Install a...

Page 181: ...ve pulley on the crankshaft 20 Serial numbers MZCG 9506882 9999999 and MZCG 1000001 1999999 Install the belt guide 21 Install the rear scroll P 4 7 22 Install the blade holder and blades P 4 1 23 Reco...

Page 182: ...h 2 20 9 5 Troubleshooting 2 18 Evaporative emission control system 8 27 F Fan cover removal installation K5 K8 8 24 K9 K11 8 25 Filter air 3 8 Flywheel Disassembly reassembly K5 K8 9 1 Disassembly re...

Page 183: ...1 11 Cable removal K7 11 15 Cable removal K8 K11 11 19 Disassembly inspection 11 23 Spark arrester 3 9 Spark plug Inspection cleaning 3 9 Test 2 20 Special tools 2 5 Specifications Dimensions weight c...

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