Honda HRS216PKA Manual Download

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INDEX

Air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Air gap adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Blades

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Torque spec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3,3-5

Breather tube installation . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Cam pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2,9-14
Carburetor

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . . . . 7-3
Float level height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Choke control assembly. . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Choke control system . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Combustion chamber cleaning . . . . . . . . . . . . . . . . . . . 9-10
Commercially available tools . . . . . . . . . . . . . . . . . . . . . . 2-6
Compression test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Connecting rod

Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Oil clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

Decompressor weight . . . . . . . . . . . . . . . . . . . . . . .9-2,9-14
Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Drive belt removal/installation . . . . . . . . . . . . . . . . . . . . 12-2

Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Emission control system . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Engine

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23,8-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Evaporative emission control system. . . . . . . . . . . . . . . 7-19

Fan cover removal/installation . . . . . . . . . . . . . . . . . . . . 7-17
Filter, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Flywheel

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Flywheel brake

Brake shoe inspection . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Brake spring installation . . . . . . . . . . . . . . . . . . . . . . . 3-11
Cable inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Operation check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Fuel cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Fuel strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Fuel tank and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Fuel tank removal/installation . . . . . . . . . . . . . . . . . . . . 7-17
Fuel tube

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Fuel valve disassembly/reassembly . . . . . . . . . . . . . . . 7-16

Governor

Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . . . 9-13
Max speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Governor arm disassembly/reassembly . . . . . . . . . . . . 7-16

Handle grip removal/installation. . . . . . . . . . . . . . . . . . 10-12
Handle locking knob . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Handle pipe replacement. . . . . . . . . . . . . . . . . . . . . . . . 10-2

Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Ignition coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Inspection

K version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

Maintenance

Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Model type identification . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Models and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Oil

Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Oil leak, transmission (VKA) . . . . . . . . . . . . . . . . . . . . . 2-15

Summary of Contents for HRS216PKA

Page 1: ...othing and using 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 parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields anytime you hammer drill grind or work arou...

Page 2: ...vided safety messages and other safety 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 find important safety information in a variety of forms including Safety Labels on the mower Safety Messages preceded by a safety alert symbol and one of three signal...

Page 3: ... s name changed from SDA to SKA Auto choke applied New tapered style fan cover Fixed throttle no throttle lever Many engine changes including Round intake port aluminum carburetor new flywheel brake and stop switch design new breather tube and a c case laser etched serial number and new camshaft decompressor components HRS216K6 PKA VKA Frame MZBZ 6550001 thru 6570000 Engine GJARA 4840001 thru 8000...

Page 4: ... AND FEATURES Standard equipment Optional equipment Model HRS216K5 HRS216K6 Type PKA SKA PKA VKA Push model Self propelled 1 speed Self propelled variable speed Single blade Twin blades Side discharge door chute ...

Page 5: ...iv HRS216PKA HRS216SKA HRS216VKA NOTES ...

Page 6: ... Refill capacity 0 35 0 40 L 12 0 13 5 oz Engine model GCV160LA0 Engine type 4 stroke overhead cam single cylinder Displacement 160 cc 9 8 cu in Bore x stroke 64 x 50 mm 2 52 x 1 97 in Compression ratio 8 5 1 Maximum governed speed 2 950 3 050 rpm Ignition system Transistorized magneto ignition Ignition timing 20 B T D C Fuel supply system Gravity feed with a manual shut off valve Lubrication syst...

Page 7: ...216VKA 1 2 2 DIMENSIONAL DRAWINGS K5 MODELS K5 model wheel height adjusters are set to the 25 mm 1 in position 485 mm 19 1 8 in 948 mm 37 3 8 in 605 mm 23 7 8 in SKA 1 621 mm 63 7 8 in PKA 1 554 mm 61 1 8 in 585 mm 23 in K5 SKA model shown ...

Page 8: ...S 1 3 K6 MODELS K6 model wheel height adjusters are set to the 28 mm 1 1 8 in position 492 mm 19 3 8 in PKA 1 013 mm 39 7 8 in VKA 1 024 mm 40 1 4 in 610 mm 24 in VKA 1 532 mm 60 3 8 in PKA 1 512 mm 59 1 2 in 582 mm 22 7 8 in K6 VKA model shown ...

Page 9: ...SPECIFICATIONS HRS216PKA HRS216SKA HRS216VKA 1 4 3 WIRING DIAGRAM UNIT Black SPARK PLUG IGNITION COIL ENGINE STOP SWITCH NORMALLY CLOSED ENGINE SWITCH CONTACT RUN OPEN STOP CLOSE ...

Page 10: ... parts installation 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 LOCATIONS 2 2 4 SERVICE SPECIFICATIONS 2 3 5 TORQUE VALUES 2 4 6 TOOLS 2 5 7 TROUBLESHOOTING 2 7 8 SMART DRIVE SYSTEM TROUBLESHOOTING VKA TYPE 2 10 9 TROUBLESHOOTING TECHNIQUES 2 16 A s...

Page 11: ...ock above the oil cap dipstick The frame serial number is located at the left rear corner of the deck For additional serial number information see LAWN MOWER K VERSION IDENTIFICATION on page ii Refer to the engine and frame serial numbers when ordering parts and when making technical inquiries ENGINE SERIAL NUMBER FRAME SERIAL NUMBER ...

Page 12: ... in 0 91 mm 0 035 in 0 95 mm 0 037 in 2 37 mm 0 093 in 0 150 mm 0 006 in 0 150 mm 0 006 in 0 150 mm 0 006 in 1 00 mm 0 040 in 1 00 mm 0 040 in 1 00 mm 0 040 in Cylinder Sleeve I D 64 000 64 015 mm 2 5197 2 5203 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 1 024 in 0 040 0 063 mm 0 0016 0 0025 in 0 1 0 4 m...

Page 13: ... bolt M6 x 1 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 bolt M6 x 0 6 4 5 0 45 2 2 Governor arm nut M6 x 1 0 10 1 0 7 4 Governor holder bolt M6 x 1 0 12 1 2 8 7 Muffler bolt M6 x 1 0 12 1 2 8 7 Oil pan bolt M6 x 1 0 ST 12 1 2 8 7 Recoil starter nut M6 x 1 0 8 5 0 85 6 1 Spark plug M1...

Page 14: ...ER APPLICATION 1 Carburetor float level gauge 07401 0010000 Carburetor float level inspection 2 Valve adjustment wrench 3 mm 07908 KE90200 Valve clearance adjustment 3 Multi use flywheel holder 07APB Z28A100 Flywheel removal 4 Alcohol tester 07AAJ E85A100 Check percent of ethanol in fuel 2 1 3 4 ...

Page 15: ...n gauge EEPV503 Compression test 3 Flywheel puller OTC 1035 Flywheel removal 4 Tachometer KE 1 5 Measuring engine speed 5 Digital multimeter FLU 88 Electrical component testing 6A Valve seat cutter 31 NWY CU 115 Valve seat reconditioning 6B Valve seat cutter 45 NWY CU 122 6C Valve seat cutter 60 NWY CU 111 6D Solid pilot bar 5 50 mm NWY PM 10055SH 6E Solid pilot bar 5 51 mm NWY PM 100552S 6F T wre...

Page 16: ... spark NORMAL COMPRESSION Compression is high 80 psi Install a compression gauge in the spark plug hole P 2 16 and crank the engine several times Install the spark plug in the plug cap and perform the spark test P 2 21 Remove P 7 1 disassemble P 7 3 and clean the carburetor P 7 4 Check the choke butterfly with the engine cold Choke closed Confirm the fuel quality If gasoline is more than 30 days o...

Page 17: ...ark No or weak spark NORMAL COMPRESSION Compression is high 80 psi Install a compression gauge in the spark plug hole P 2 16 and crank the engine several times Install the spark plug in the plug cap and perform the spark test P 2 21 Remove P 7 1 disassemble P 7 3 and clean the carburetor P 7 4 Check the choke butterfly with the engine cold Choke closed Confirm the fuel quality If gasoline is more ...

Page 18: ...t P 2 21 Mechanical damage such as a bent crankshaft Grass and debris lodged under mower deck No Yes No No No Yes Yes Yes Yes Repair or replace the cable Correct as required P 8 2 Replace flywheel brake pad P 8 2 Check the flywheel brake spring P 8 2 Check flywheel brake pad P 3 10 Replace engine stop switch P 8 2 Blade engine does not stop turning within 3 seconds when the flywheel brake lever is...

Page 19: ...ve control If the control arm does not move go to SMART DRIVE DISASSEMBLY AND INSPECTION VKA TYPE on page 10 17 If the control arm moves go to SMART DRIVE CABLE VKA TYPE on page 3 9 HRS216VKA Lawn mower will not self propel when the Smart Drive is engaged 2 10 Transmission propels the mower but slips or slows down under load 2 11 Lawn mower continues to self propel when the Smart Drive is released...

Page 20: ...le holding the lawn mower from moving forward The rear wheels should spin slip on the concrete surface If the wheels intermittently stop and or a clicking sound can be heard inspect the pinion gears and ratchets see P 2 14 If both wheels stop but no ratcheting or clicking sound can be heard the drive belt may be worn and replacement is necessary LAWN MOWER CONTINUES TO SELF PROPEL WHEN THE SMART D...

Page 21: ... 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 Clearance 2 3 mm Drive Pulley Belt Guide Clearance 3 4 mm 5 If the clearance is out of specification adjust or replace the belt and belt guide s DRIVEN PULLEY BELT GUIDE CLEARANCE 2 3 mm 0 079 0 118 in BELT GUIDE DRIVEN PULLEY BELT DRIVE ...

Page 22: ...e the rear adjuster arms and clean and inspect the bushings and axle shaft Replace any excessively worn bushings 5 Thoroughly clean the bushing contact areas on the axle using a Scotch Brite pad 6 Thoroughly 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 bear...

Page 23: ...MPORTANT 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 any other spray lubricant 3 Be sure the correct pinion gears are installed 8 inch wheels use 12 tooth pinion gears FLAT WASHER PINION GEAR COLLAR 13 mm CIRCLIP WHEEL BOLT REAR WHEEL RATCHET SPRI...

Page 24: ...ing as shown below 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 9 AXLE SHAFT OIL SEAL CASE O RING INPUT SHAFT OIL SEAL AXLE SHAFT OIL SEAL TRANSMISSION CASE INSTALLATION Use SAE 10W 30 engine oil and fill to the capacity shown The correct oil level should be 18 20 mm 0 71 0 79 in from the to...

Page 25: ...the compression first and proceed if the compression measures greater than 80 psi The engine must be completely cool before proceeding 1 Remove the recoil starter P 6 1 2 If there is gasoline in the fuel tank drain it into an approved container 3 Remove the fan cover P 7 17 Do not tilt the fan cover with fuel in the tank this will saturate the charcoal in the fuel cap and prevent it from venting p...

Page 26: ...asures more than 80 psi and the exhaust 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 confirm that it is fully retracted If it is not fully retracted replace the cam pulley P 9 2 3 If the weight is fully retracted operate the decompressor by very slowly...

Page 27: ...troke cam pulley lobe facing out 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 appears significantly worn replace both parts before proceeding 4 Fabricate a plate with the indicated dimensions using 1 4 inch or thicker steel 5 Attach the fabricated ...

Page 28: ...inst the exhaust 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 lash move the rocker back and forth at the pivot point and measure the rocker arm pivot point free play with the dial indicator Repeat the measurement with the dial indicator at location B Ma...

Page 29: ... Loctite 5900 or equivalent 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 in several steps to the specified torque Wait for at least 20 minutes after assembly before filling with oil and starting the engine TORQUE 12 N m 9 ft lb 14 Reinstall the muffler heat shield fan cover and recoil starter 15 Reco...

Page 30: ...e holder and drive pulley P 3 4 4 Attach the dial indicator magnetic base to the lower deck surface 5 Position the tip of the dial indicator perpendicular and 5 10 mm 0 20 0 39 in from the end of the crankshaft 6 Zero the dial indicator 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 Hold the flywheel...

Page 31: ... engine to cool Push the choke valve open and release it The choke should open smoothly and snap closed when released Replace the carburetor assembly P 7 1 and the spark plug P 3 8 Opens too slowly or does not open Hard to move Closed Start the engine If the choke doesn t open after 1 2 minutes push the choke control linkage by hand and confirm it moves freely and springs back If it does the therm...

Page 32: ...nition 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 brake lever is released There should be no continuity when the flywheel brake lever is held against the handlebar IGNITION PRIMARY TERMINAL ENGINE STOP SWITCH CONNECTOR ...

Page 33: ... SAMPLE IN 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 for 10 minutes Step 5 If bubbles remain lightly tap vial to disperse bubbles for better accuracy Step 6 Locate the gasoline water separation line and read scale The separation line will indi...

Page 34: ... REAR WHEEL ADJUSTER BUSHING 3 15 16 PINION GEAR 3 17 Item Action Before each use 5 hours of use or first month First 25 hours of use 50 hours of use or every 6 months 100 hours of use or every year 150 hours of use or every two years See page Rear shield Check O 3 3 Blade Inspect O 3 3 Blade mounting bolts Inspect O 3 5 Engine oil Check O 3 6 Change O O 1 O O 3 6 Air filter Check O 3 7 Clean O 2 ...

Page 35: ...ust 0 20 0 04 mm 3 12 Governor arm Adjust so shaft is rotated fully clockwise at full throttle Check engine rpm after adjusting 3 13 Flywheel brake cable No adjustment Inspect for damage and proper operation only 3 11 Flywheel brake mechanism Brake shoe thickness service limit 3 0 mm 0 12 in 3 10 Blade and blade bolt Sharpen or replace as necessary Blade bolt torque 49 59 N m 36 43 ft lb 3 3 Rear ...

Page 36: ...FF 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 the blade for damage cracks and excessive wear rust or corrosion 5 Verify the blade bolts are tight TORQUE 49 59 N m 36 43 ft lb 6 If the blade is bent or severely damaged check the crankshaft runout P 2 21 7 A du...

Page 37: ...otect your hands Grind or file the upper surface of the blade only The cutting edge must be even with the lower surface of the blade Taper the blade profile removing material from the blade tip never the inner end of the cutting surface Grinding or filing a step in the blade can create a weak point causing cracks to develop in the blade during mower operation Maintain the original bevel angle 30 4...

Page 38: ...ect the blade bolts for any signs of damage If they are damaged they must be replaced 2 Install the blade using the two blade bolts and special washers as shown Install the special washers with the concave side toward the blade and the convex side toward the head of the bolts The blade bolts are specially designed for this application and must not be replaced with other bolts 3 Tighten the blade b...

Page 39: ...on the ground 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 is a major factor affecting performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used w...

Page 40: ... engine causing rapid engine wear This type of damage is not covered by the Distributor s Limited Warranty 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 replace it if it is damaged 4 Clean the filter Tap the filter several times on a hard surface to remove dirt or blow with compr...

Page 41: ...OTICE A loose spark plug can overheat and damage the engine Overtightening can damage the threads in the cylinder head 9 SPARK ARRESTER CLEANING OPTIONAL PART The spark arrester must be serviced every 100 hours to keep it functioning as designed Allow the engine to cool before proceeding 1 Remove the three flange bolts from the muffler protector 2 Remove the 4 x 6 mm self tapping screw from the sp...

Page 42: ...heels rotate 3 If the wheels rotate backwards mark the adjuster and TIGHTEN the adjuster one turn at a time until the wheels lock up when pulling rearward 4 Turn the adjuster in the LOOSEN direction 8 complete revolutions 5 Tighten the jam nut to lock the adjuster in place 11 FUEL TANK AND FILTER FUEL TANK DRAINING AND CLEANING 1 Turn the fuel valve to the OFF position 2 Loosen the carburetor bowl...

Page 43: ...Position the fuel tube clip over the fuel tank fitting 13 After assembly check for fuel leaks FUEL TUBE INSPECTION 1 Check the fuel tubes for deterioration cracks or signs of leakage Replace the fuel tubes if necessary 2 To replace the fuel tubes drain the fuel into a suitable container 3 Replace the fuel tubes with the correct low permeation fuel tubes The fuel tubes must show the emissions compl...

Page 44: ...LYWHEEL BRAKE SPRING INSTALLATION Flywheel removal is required to install a new spring P 8 3 Install the flywheel brake spring as shown Make sure the hook on the long end of the spring is attached down through the hole in the flywheel brake arm FLYWHEEL BRAKE CABLE INSPECTION The flywheel brake cable cannot be adjusted Inspect the flywheel brake cable for damage and proper operation only Service l...

Page 45: ...Remove the fan cover fuel tank P 7 17 3 Remove the four flange bolts from the cylinder head cover 4 Remove the cylinder head cover by prying slowly at each corner Discard the head cover and replace it with a new one after completing this procedure P 9 3 5 Rotate the engine until the cam lobe is pointing directly forward away from the flywheel 6 x 12 mm FLANGE BOLT 4 CYLINDER HEAD COVER Replace CAM...

Page 46: ...ut TORQUE 8 N m 5 8 ft lb d Recheck valve clearance after tightening the lock nut 8 Thoroughly clean the old sealant from the cylinder head surface using an abrasive cloth and brake cleaner 9 Apply liquid gasket Hondabond HT ThreeBond 1216 Loctite 5900 or equivalent to a new cylinder head cover sealing surface and install the cylinder head cover P 9 3 Standard valve clearance cold IN 0 15 0 04 mm ...

Page 47: ...ure 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 governor spring tab on the fuel valve plate very slightly Left increases spring tension and engine speed Right decreases spring tension and engine speed DANGER The blade is rotating during this procedure The rotating blad...

Page 48: ...uantity per wheel Wheel shaft bolt 1 Circlip 1 Wheel bearing 1 Thrust washer 13 mm 1 Wheel 1 Collar 1 Wheel bearing 1 Cover 1 Wheel washer 1 Bushing 1 Flat washer 1 Adjuster arm 1 Circlip 1 Seal 1 Collar pinion gear 1 Adjuster plate 1 Pinion gear 12T 1 Grip 1 Key ratchet 1 Flat washer 26 x 36 mm 1 Spring 1 Circlip 25 mm 1 Collar pinion gear 1 WHEEL WASHER REASSEMBLY Install the washer as shown WHE...

Page 49: ...NSIDE the adjuster 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 anti seize white lithium silicon WD 40 or any other spray lubricant 9 Reinstall the adjuster assembly and secure with the washer and circlip 10 Reassemble the rear wheel in the reverse or...

Page 50: ... the pinion gear 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 lithium silicone WD 40 or any other spray lubricant 6 Reassemble in the reverse order of disassembly FLAT WASHER 13 mm CIRCLIP WHEEL BOLT REAR WHEEL RATCHET SPRING AXLE PINION GEAR COLLAR PINION GEAR CO...

Page 51: ...MAINTENANCE HRS216PKA HRS216SKA HRS216VKA 3 18 NOTES ...

Page 52: ... 1 blade holder flange bolt and then remove the blade holder and Woodruff key from the crankshaft VKA type Remove the belt guide P 12 5 SKA and VKA types only Remove the drive belt from the crankshaft pulley SKA P 12 2 VKA P 12 3 and then remove the crankshaft pulley 8 Support the engine remove the four 5 16 24 x 1 engine mounting flange bolts and remove the engine 1 REMOVAL 4 1 2 INSTALLATION 4 2...

Page 53: ...he crankshaft and position the blade holder on the crankshaft Be sure the Woodruff key remains in place when installing 5 Attach the blade holder using the 3 8 24 x 1 flange bolt TORQUE 49 59 N m 36 43 ft lb 6 Attach the blade using the two special bolts and washers TORQUE 49 59 N m 36 43 ft lb 7 Connect the flywheel brake cable to the engine 8 Attach the recoil starter rope to the handlebar rope ...

Page 54: ...gasket anytime the muffler 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 from the muffler and then remove carbon deposits from muffler Do not tap on the muffler seal flange to avoid damaging this part If the seal flange is dented or damaged replace th...

Page 55: ...MUFFLER HRS216PKA HRS216SKA HRS216VKA 5 2 NOTES ...

Page 56: ...ION If the starter rope is frayed or worn out replace the starter rope P 6 2 Do not disassemble the recoil starter assembly 1 REMOVAL INSTALLATION 6 1 2 STARTER ROPE REPLACEMENT 6 2 RECOIL STARTER ASSEMBLY 6 mm FLANGE NUT 3 8 3 N m 6 1 ft lb ...

Page 57: ... the starter 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 the starter case and through the rope hole in the starter reel and make a slipknot at the end of the rope 6 Remove the band holding the starter reel and carefully allow the starter reel to re...

Page 58: ... grip and make 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 slipknot at the end of the rope 4 Remove the band holding the starter reel and carefully allow the starter reel to rewind 5 Check the operation of the ratchets by pulling the starter rope several times STARTER REEL ...

Page 59: ...RECOIL STARTER HRS216PKA HRS216SKA HRS216VKA 6 4 NOTES ...

Page 60: ...and tighten the stud 5 While pushing the air cleaner case toward the engine remove the other 6 x 85 mm flange bolt and temporarily install another 6 x 83 mm stud 6 Pull the breather tube from the engine and then remove the air cleaner case from the studs 7 Hold the carburetor assembly together and remove it from the studs 1 AIR CLEANER CARBURETOR REMOVAL INSTALLATION 7 1 2 CARBURETOR DISASSEMBLY R...

Page 61: ...rnor rod from the carburetor THROTTLE RETURN SPRING INSTALLATION P 7 16 GOVERNOR ROD INSTALLATION P 7 16 INSULATOR GASKET Replace CHOKE CONTROL ASSEMBLY TROUBLESHOOTING P 2 22 INSTALLATION P 2 22 AIR CLEANER GASKET AIR GUIDE GASKET Replace GOVERNOR SPRING INSTALLATION P 7 16 AIR CLEANER CASE 6 x 14 mm FLANGE BOLT 6 x 14 mm FLANGE BOLT FUEL VALVE ASSEMBLY THERMOWAX ASSEMBLY CRANKCASE BREATHER TUBE ...

Page 62: ...n jet size 60 REASSEMBLY Clean thoroughly with compressed air 30 psi max before installation FLOAT PIN FLOAT VALVE REASSEMBLY Check for worn float valve seat and float valve before installation 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 PILOT JET is n...

Page 63: ...CLEANING If a significant 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 damage and replace as necessary Be sure the work surface is clean Use compressed air pressure of 207 kPa 30 psi maximum CLEANING PROCEDURE 1 Thoroughly clean the outside of the carbure...

Page 64: ...nd replace if necessary See image on page 7 4 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 spray carburetor cleaner around the nozzle to loosen it and tap the carburetor on the workbench 4 Remove the throttle stop screw and spring if applicable SCREWDRIVER ...

Page 65: ...FUEL SYSTEM HRS216PKA HRS216SKA HRS216VKA 7 6 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 66: ...essed air Do 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 or damaged tip Inspect the center and side holes for damage or contamination by holding the main nozzle up to a light to verify they are clean ...

Page 67: ...OTICE 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 or damaged tip Carefully inspect the main jet for damage or contamination 9 Clean the main jet and nozzle bore thoroughly using carburetor cleaner and compressed air 10 Inspect the inside of the bore for contamination JET CLEANER 07JPZ 001010...

Page 68: ...oroughly by 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 carburetor cleaner and compressed air PILOT JET HIGH SPEED AIR PASSAGE ...

Page 69: ...chamber vent 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 several times FLOAT CHAMBER VENT HOLE SLOW SPEED AIR PASSAGE ...

Page 70: ... the slow speed 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 transition ports Steady stream around the transition ports CHOKE SIDE THROTTLE SIDE SLOW SPEED AIR PASSAGE ...

Page 71: ...tle stop screw 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 Adjust so throttle plate just begins to open Nozzle extension ...

Page 72: ...Start the engine and allow it to warm up for several minutes Then check the maximum no load engine speed P 3 17 FLOAT LEVEL HEIGHT INSPECTION Place the carburetor in the position as shown and measure the distance between the float top and the carburetor body when the float contacts the seat TOOL Float level gauge 07401 0010000 FLOAT HEIGHT 10 2 mm 0 40 in If the height is out of specification repl...

Page 73: ...cavity Thermowax Installation The thermowax plunger MUST be fully retracted and the overall length of the thermowax must be 21 5 23 0 mm before installation Do not use the thermowax if the length is not within proper specifications If the thermowax plunger is not fully retracted proceed with the steps below to fully retract the plunger prior to reassembly 1 Position a pair of pliers on the thermow...

Page 74: ...23 5 Verify that the carburetor choke lever is in the fully closed position 6 Install the carburetor and choke assembly page 7 2 6 After installation verify that there is clearance between choke lever A and the carburetor choke lever Push on choke lever A and confirm it moves freely and springs back when released BREATHER TUBE Installation Connect the end with the white mark to the breather cover ...

Page 75: ...ION Install the governor rod through 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 GOVERNOR ARM B8 TUBE CLIPS GOVERNOR SPRING REASSEMBLY Install with the short end side toward the governor arm 4 5 x 110 mm FUEL TUBE REASSEMBLY Inspect for cracks or de...

Page 76: ... seriously injured when handling fuel Stop the engine and let it cool before handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately FAN COVER INSTALLATION Check that the high tension cord is securely set in the groove in the fan cover as shown HIGH TENSION CORD FUEL TANK INSTALLATION Wash with solvent to remove the sediment and dry thoroughly before inst...

Page 77: ...screwdriver or other tool when removing the fuel tube NOTICE If the fuel tube is pried off the fuel valve with a tool the fuel valve may be damaged 4 Connect the fuel tube to the fuel valve Use the correct low permeation fuel tube for replacement The fuel tube must contain the emissions compliant identification number 5 Position the fuel tube clip over the fuel valve fitting 6 Remove the fuel tube...

Page 78: ... When the pressure in the fuel tank decreases because of low 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 Use only low permeation fuel tubes These fuel tubes have the emissions compliance identification number printed on the tube as shown in this...

Page 79: ...FUEL SYSTEM HRS216PKA HRS216SKA HRS216VKA 7 20 NOTES ...

Page 80: ...8 1 8 FLYWHEEL IGNITION COIL 1 DISASSEMBLY REASSEMBLY 8 2 2 FLYWHEEL REMOVAL INSTALLATION 8 3 3 IGNITION COIL 8 5 ...

Page 81: ... mm FLANGE BOLT 12 N m 8 9 ft lb 14 x 1 5 mm SPECIAL NUT REMOVAL AND INSTALLATION P 8 3 TORQUE 52 N m 38 ft lb FLYWHEEL INSTALLATION P 8 4 Use caution during disassembly and reassembly to prevent damaging the flywheel FAN COVER STUD BOLT 3 12 N m 8 9 ft lb 6 x 20 mm FLANGE BOLT IGNITION COIL INSPECTION P 8 5 ADJUSTMENT P 8 5 25 x 18 mm SPECIAL WOODRUFF KEY REASSEMBLY When installing the flywheel c...

Page 82: ... and remove the 14 mm special nut with a wrench NOTICE Inserting a rod or screwdriver in the fan blades can damage the blades or the aluminum casting projections 4 Remove the plastic cooling fan 5 Position a commercially available 6 inch flywheel puller on the flywheel with one of the puller jaws under the magnets at the PULLER mark Set a shop towel or equivalent cloth between the flywheel and the...

Page 83: ...reign material on the magnets 3 Be sure the woodruff key is set in the keyway properly 4 Install the flywheel 5 Hold the flywheel with the special tool and tighten the 14 mm special nut with a torque wrench TORQUE 52 N m 38 ft lb 6 Remove the strap or equivalent material from the flywheel brake lever 7 Install and adjust the ignition coil P 8 5 8 Install the fan cover fuel tank P 7 17 9 Reconnect ...

Page 84: ...core 3 Replace the ignition charge coil if either of the above tests is out of specification AIR GAP ADJUSTMENT Adjustment is required only when the ignition coil or the flywheel has been removed 1 Loosen the ignition coil bolts 2 Insert a long feeler gauge of the proper thickness between the legs of the coil assembly and the flywheel Specified clearance 0 2 0 5 mm 0 008 0 020 in 3 Avoid the magne...

Page 85: ...FLYWHEEL IGNITION COIL HRS216PKA HRS216SKA HRS216VKA 8 6 NOTES ...

Page 86: ...x 1 9 mm Replace INTAKE ROCKER ARM INSPECTION P 9 15 VALVE ADJUSTING LOCK NUT 2 7 8 N m 5 8 ft lb CAM PULLEY DECOMPRESSOR WEIGHT INSPECTION P 9 2 INSTALLATION P 9 2 Take care not to drop the cam pulley EXHAUST ROCKER ARM INSPECTION P 9 15 CYLINDER HEAD COVER Replace INSTALLATION P 9 3 FLANGE BOLT 6 x 12 mm 4 12 N m 8 7 ft lb VALVE ADJUSTING SCREW 2 ADJUSTMENT P 3 13 ROCKER ARM SHAFT 2 INSPECTION P...

Page 87: ...ng Repeat several times If the weight fails to completely return on its own at any time by spring force replace the cam pulley see CAM PULLEY INSTALLATION below CAM PULLEY INSTALLATION 1 Turn the crankshaft so that the long crankshaft key groove PTO side faces up as shown Top Dead Center The two woodruff key grooves will face down 2 Install the cam pulley on the timing belt so that the cam pulley ...

Page 88: ...he opposite side of the cam pulley as shown CYLINDER HEAD COVER INSTALLATION 1 Clean the mating surface of the cylinder block using a de greasing cleaning agent and a clean shop towel 2 Apply liquid gasket Hondabond HT ThreeBond 1216 Loctite 5900 or equivalent to a new cylinder head cover specifically to the inner wall of the groove and bolt hole in the cylinder head cover Assemble within 10 minut...

Page 89: ...NECTING ROD CAP INSTALLATION P 9 10 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 belt is not worn or cracked and do not bend or twist the belt PISTON ASSEMBLY DISASSEMBLY REASSEMBLY P 9 7 INSPECTION P 9 15 INSTALLATION P 9 5 CRANKSHAFT INSPECTIO...

Page 90: ...e longer 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 NOTICE Take care not to break the piston ring when installing the piston assembly into the cylinder 3 Apply clean engine oil to the cylinder block crankshaft bearing area and install the cranksha...

Page 91: ...he cylinder block 5 Apply a bead 1 5 2 0 mm 0 06 0 08 in of liquid gasket Hondabond HT ThreeBond 1216 Loctite 5900 or equivalent to the cylinder block 6 Install the oil pan on the cylinder block Assemble within 10 minutes after applying the liquid gasket If it is hard to install the oil pan securely assemble by turning the crankshaft a little 7 Loosely tighten each 6 x 25 mm flange bolt and then t...

Page 92: ...upward 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 pin SECOND RING OIL RING TOP RING chrome plated PISTON PIN CLIP 2 REASSEMBLY Install by setting one end of the clip in the piston groove holding the other end with long nosed pliers and rotating the c...

Page 93: ...iston points 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 piston pin and install it in the piston 5 Install new piston pin clips 6 Install the piston connecting rod assembly in the cylinder block P 9 10 PISTON MODEL MARK ZL8 Z8B Z2A FW MARK PIST...

Page 94: ...osits and inspect the valve INSPECTION P 9 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 9 20 VALVE SPRING 2 INSPECTION P 9 19 VALVE SPRING RETAINER 2 DISASSEMBLY Push down and slide the retainer to the side so the valve stem slips through the hole at the side of the retainer Do not remove the valve spring re...

Page 95: ...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 chamber and valve seats to remove carbon deposits using the procedure shown above 2 Apply a light coat of Prussian Blue compound or erasable felt tipped marker ink to the valve faces 3 Insert the valves...

Page 96: ...e thick paper into the cylinder 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 CU 115 VALVE SEAT CUTTER 122 45 NWY CU 122 VALVE SEAT CUTTER 111 60 NWY CU 111 T WRENCH 505 NWY TW 503 1 T WRENCH ADAPTER NWY TW 503 1 ACCESSORY PACKAGE NWY TW 246 T WRENC...

Page 97: ... 45 cutter to 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 faces Insert the valves into the cylinder block then lift and snap them closed against their seats several times Be sure the valves do not rotate in their seats The seating surface as shown ...

Page 98: ...LY REASSEMBLY 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 the lock pin immediately after installing the governor arm shaft and move the shaft over against the governor slider The lock pin must be installed with the straight side of the pin against ...

Page 99: ...PRESSOR INSPECTION Inspect the decompressor return spring for proper strength Check the decompressor arm and pin for proper movement and wear P 2 17 CAM PULLEY SHAFT O D INSPECTION Standard Service limit 37 394 mm 1 4722 in 37 369 mm 1 4712 in Standard Service limit 10 027 mm 0 3948 in 10 075 mm 0 3967 in Standard Service limit 9 987 mm 0 3932 in 9 920 mm 0 3906 in SPRING ARM PIN ...

Page 100: ...D is worn beyond the 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 Piston O D from the Cylinder I D to determine the Piston to Cylinder clearance PISTON RING WIDTH INSPECTION Standard Service limit 5 990 mm 0 2358 in 5 953 mm 0 2344 in Standard Service ...

Page 101: ...PECTION PISTON PIN BORE I D INSPECTION Standard Service limit Top ring 0 055 0 089 mm 0 002 0 004 in 0 150 mm 0 006 in Second ring 0 015 0 049 mm 0 0006 0 0019 in 0 150 mm 0 006 in Standard Service limit Top ring 0 20 0 35 mm 0 008 0 014 in 1 00 mm 0 040 in Second ring 0 35 0 50 mm 0 014 0 020 in 1 00 mm 0 040 in Oil ring 0 20 0 70 mm 0 008 0 030 in 1 00 mm 0 040 in Standard Service limit 13 000 m...

Page 102: ...gear for excess wear damage or cracks and replace if necessary Always replace the timing belt when replacing the gear Make sure the timing gear boss fits completely into the slot in the crankshaft Standard Service limit 13 005 mm 0 5120 in 13 07 mm 0 515 in Standard Service limit 26 02 mm 1 024 in 26 066 mm 1 0262 in Standard Service limit PTO Side 27 993 mm 1 1021 in 27 933 mm 1 0997 in Flywheel ...

Page 103: ...axially Tighten the two bolts equally while holding the crankshaft to keep it from turning TORQUE 12 N m 9 ft lb 3 Remove the connecting rod cap and measure the Plastigage with the scale on the Plastigage package to determine the oil clearance 4 If the clearance exceeds the service limit measure the connecting rod I D and crankpin O D and replace the worn parts as necessary Recheck the big end oil...

Page 104: ...eplacement CRANKSHAFT AXIAL CLEARANCE INSPECTION Measure the crankshaft axial play before removing the oil pan crankshaft and piston If the axial clearance is too great inspect the oil pan and timing gear thrust washer for wear and replace as necessary VALVE SPRING FREE LENGTH INSPECTION Measure the free length of the valve springs Replace the springs if they are shorter than the service limit Sta...

Page 105: ...nd 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 the valve seat page 9 10 if any of the following are true Valve seat width is under or over the standard Valve seat is too high or low Valve seat is pitted or damaged Standard Service limit IN 5 48 mm 0 216 in 5 318 mm 0 2094 in EX 5 ...

Page 106: ...ANDLE PIPE REPLACEMENT 10 2 2 HANDLE STAY REMOVAL 10 6 3 HANDLE GRIP REMOVAL INSTALLATION VKA TYPE 10 12 4 HANDLE LOCKING KNOB K6 TYPES 10 12 5 SMART DRIVE CABLE VKA TYPE 10 13 6 SMART DRIVE DISASSEMBLY AND INSPECTION VKA TYPE 10 17 ...

Page 107: ... from the handle pipe then from the lever stop 4 Remove the lever stop from the handle pipe 5 Remove the two handle knobs and the handle pipe from the handle stays 6 Remove the 6 mm nylon nut and the rope guide 7 Install the handle pipe in the reverse order of its removal FLYWHEEL BRAKE LEVER 6 mm NYLON NUT DRIVE CLUTCH CABLE SKA HANDLE STAY 2 LEVER STOP FLYWHEEL BRAKE CONTROL CABLE 6 x 60 mm HEX ...

Page 108: ...d then remove the 6 mm locking nut and the rope guide 6 Remove the two special bolts nylon washers and the handle assembly from the handle stays 7 Drive out the two 2 x 12 mm roll pins and remove the handle lock assemblies 8 Install the handle pipe in the reverse order of its removal FLYWHEEL BRAKE LEVER 6 mm LOCKING NUT 6 mm PLAIN WASHER LOCK PIN NYLON WASHER 2 SPECIAL BOLT 2 HANDLE STAY 2 REMOVA...

Page 109: ...mm self tapping screws and the upper and lower clutch grips Carefully remove the multi position adjuster and spring 6 Unsnap and remove the upper and lower bracket covers 7 Remove the 5 x 37 mm roller pin the four 4 mm self tapping screws and the upper and lower grip brackets HANDLE GRIP 2 REMOVAL INSTALLATION P 10 12 FLYWHEEL BRAKE LEVER 6 mm LOCKING NUT 6 mm PLAIN WASHER LOCK PIN SMART DRIVE CAB...

Page 110: ...m the handle stays 11 Drive out the two 2 x 12 mm roll pins and remove the handle lock assemblies 12 Install the handle pipe in the reverse order of its removal Reassemble the Smart Drive control before attaching the lower end of the Smart Drive cable to the transmission 13 Readjust the Smart Drive cable P 3 9 NYLON WASHER 2 SPECIAL BOLT 2 HEIGHT ADJUSTING COLLAR 2 8 mm PIN 2 HEIGHT ADJUSTING SPRI...

Page 111: ...assembly from the handle stays 3 Remove the rear scroll P 11 2 4 Move the rear adjusting lever all the way forward 5 Remove the three 8 mm flange nuts and the left handle stay 6 Remove the three 8 mm flange nuts and the right handle stay Installation is the reverse of removal HANDLE LOCKING KNOB 2 HANDLE STAY left side shown SPECIAL BOLT 2 NYLON WASHER 2 HANDLE PIPE ASSEMBLY 8 mm FLANGE NUT 3 LEFT...

Page 112: ... mower in the storage transportation position 2 Remove the two special bolts and nylon washers release the handle pipe assembly from the handle stays 3 Remove the rear scroll by loosing the four 8 mm flange nuts P 11 2 4 Remove the wheel bolt wheel wheel washer and flat washer from each side 5 Remove the 25 mm circlip and the 26 x 36 mm washers from each side HANDLE LOCKING KNOB 2 HANDLE STAY left...

Page 113: ...6PKA HRS216SKA HRS216VKA 10 8 6 Remove the one remaining 8 mm flange bolt and 8 mm flange nut holding each handle stay to the mower deck Installation is the reverse of removal 8 mm FLANGE NUT RIGHT HANDLE STAY 8 mm FLANGE BOLT ...

Page 114: ...transportation position 2 Remove the two special bolts and nylon washers release the handle pipe assembly from the handle stays 3 Remove the rear scroll P 11 2 4 Remove the wheel bolt wheel wheel washer and flat washer from each side 5 Remove the 13 mm circlip pinion gear collar pinion gear ratchet key and ratchet return spring from each side HANDLE LOCKING KNOB 2 HANDLE STAY left side shown SPECI...

Page 115: ...13 mm washers and circlips from each side 8 Remove the 25 mm circlip from each side and slide them and the 26 x 36 mm washers inward toward the transmission 9 Remove the adjuster assembly from each side taking care not to damage the seals WHEEL COVER PINION GEAR COLLAR 13 mm CIRCLIP THRUST COLLAR 13 mm WASHER 26 x 36 mm WASHER 25 mm CIRCLIP ADJUSTER ASSEMBLY ...

Page 116: ...e the one remaining 8 mm flange bolt and 8 mm nut holding each handle stay to the mower deck Installation is the reverse of removal Refer to step 3 through step 20 on page 12 13 for detailed reassembly information 8 mm FLANGE BOLT RIGHT HANDLE STAY 8 mm FLANGE NUT ...

Page 117: ...4 HANDLE LOCKING KNOB K6 TYPES REMOVAL 1 Drive the 2 x 12 mm roll pin out with a 1 16 drift punch 2 Separate the parts as shown INSTALLATION 1 Insert the height adjusting collar into the lower mounting hole in the handle so that the flat part is resting against the handle 2 Slide the spring over the 8 mm pin 3 Insert the pin into the collar and push it through until you can see the hole in the pin...

Page 118: ...l pin and gently tap it in until it is flush with the knob 5 SMART DRIVE CABLE VKA TYPE REMOVAL 1 Drain the fuel tank 2 Drain the engine oil 3 Fully loosen the Smart Drive cable adjuster 4 Cut the cable tie securing the flywheel brake control cable to the Smart Drive cable 2 x 12 mm ROLL PIN 1 16 DRIFT PUNCH HANDLE LOCKING KNOB TIGHTEN LOOSEN ADJUSTER MARK JAM NUT CABLE TIE ...

Page 119: ...er handle pipe Tip the mower up and secure the upper handle pipe in a bench vise 11 Remove the belt cover and rear scroll P 11 2 12 Push the transmission as shown 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 lawn mower UPPER CLUTCH GRIP UPPER BRA...

Page 120: ...er and lower grip brackets together around the handle pipe 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 mm roller pin through the Smart Drive cable end and center the pin in the upper and lower grip bracket slots CABLE END SMART DRIVE CABLE HANDLE PIPE SLOT LOWER GRIP BRACKET SMART DRIVE CABLE 4 mm SELF TAPP...

Page 121: ...sert 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 the lower clutch grip with the four 4 mm self tapping screws LOWER BRACKET COVER GRIP BRACKET 2 INSIDE PIN GROOVES 5 x 37 mm ROLLER PIN UPPER BRACKET COVER MULTI POSITION ADJUSTER SPRING BOTH SID...

Page 122: ... cable to the handle pipe 15 Readjust the Smart Drive cable P 3 9 16 Start and test the Smart Drive operation 6 SMART DRIVE DISASSEMBLY AND INSPECTION VKA TYPE 1 Confirm the rubber grips do not contact the Smart Drive handle Any contact will likely prevent the control from releasing properly 2 Loosen the Smart Drive cable adjuster completely P 3 9 3 Remove the 4 mm screws and separate the upper an...

Page 123: ...to align 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 over the inner bracket cover 11 Place the upper grip over the cover assembly and secure to the lower clutch grip with the four 4 mm self tapping screws Rotate the Smart Drive grip and confirm...

Page 124: ...11 1 11 MOWER DECK WHEELS 1 MOWER DECK 11 2 2 WHEELS 11 3 ...

Page 125: ... Rear shield 1 Push nut 1 Cable grommet SKA 1 Grommet plug K5 PKA 1 Cable grommet VKA 1 Grommet plug K6 PKA 1 Plug PKA 1 Flange Bolt 6 x 10 mm SKA VKA 2 Spring 1 Hinge 1 Shaft 1 Side discharge chute 1 Discharge guard 1 Flange nut 6 mm 2 Front scroll 1 Flange bolt 5 16 24 x 1 4 Belt cover SKA VKA 1 Rear scroll 1 ...

Page 126: ... TYPE Reference Description Quantity per wheel Wheel bolt 1 Wheel bearing 1 Wheel 1 Wheel bearing 1 Wheel washer 1 Collar 1 Adjuster arm 1 Adjuster plate 1 Grip 1 Flat washer 26 x 36 mm 1 Circlip 1 WHEEL WASHER REASSEMBLY Install the washer as shown WHEEL SIDE right side shown ...

Page 127: ... Wheel bearing 1 Cover 1 Wheel washer 1 Bushing 1 Flat washer 1 Adjuster arm 1 Circlip 1 Seal 1 Collar pinion gear 1 Adjuster plate 1 Pinion gear 12T 1 Grip 1 Key ratchet 1 Flat washer 26 x 36 mm 1 Spring 1 Circlip 25 mm 1 Collar pinion gear 1 WHEEL WASHER REASSEMBLY Install the washer as shown WHEEL SIDE PINION GEAR 12T Install with the punch mark facing Left inside Right outside Apply grease ins...

Page 128: ...r 1 Seal 1 Thrust washer 13 x 27 mm 1 Adjuster plate 1 Circlip 2 Grip 1 Collar pinion gear 2 Flat washer 26 x 36 mm 1 Pinion gear 12T 1 Circlip 25 mm 1 Key ratchet 1 Spring 1 Thrust washer 13 mm 1 Thrust collar 1 WHEEL WASHER REASSEMBLY Install the washer as shown WHEEL SIDE PINION GEAR 12T Install with the punch mark facing Left inside Right outside Apply grease inside bushing right side shown Ap...

Page 129: ...uantity Front wheel shaft bolt 1 Wheel washer 1 Front wheel 1 Adjuster arm bolt 1 Front adjuster plate 1 Adjuster grip 1 Right left front adjuster arm 1 Front adjusting collar 1 Front adjuster panel 1 Washer 8 mm 1 Flange nut 8 mm 1 WHEEL WASHER REASSEMBLY Install the washer as shown WHEEL SIDE right side shown ...

Page 130: ...nt wheel shaft bolt 1 Wheel washer 1 Front wheel 1 Adjuster arm bolt Torx T35 1 Front adjuster plate 1 Adjuster grip 1 Right left front adjuster arm 1 Front adjusting collar 1 Front adjuster panel 1 Washer 8 mm 1 Flange nut 8 mm 1 WHEEL WASHER REASSEMBLY Install the washer as shown WHEEL SIDE right side shown ...

Page 131: ...MOWER DECK WHEELS HRS216PKA HRS216SKA HRS216VKA 11 8 NOTES ...

Page 132: ...12 1 12 TRANSMISSION DRIVE BELT 1 DRIVE BELT 12 2 2 TRANSMISSION REMOVAL 12 6 3 TRANSMISSION INSTALLATION 12 12 4 TRANSMISSION DISASSEMBLY REASSEMBLY 12 16 ...

Page 133: ...he two 6 x 10 mm flange bolts from the belt cover and then remove the cover 5 Put a 10 mm wrench on the self locking belt tensioner nut and then loosen don t remove the tensioner bolt Stop when the nut is almost off the bolt 6 Turn the transmission enough to remove the belt from the input pulley Installation is the reverse of removal Be sure the self locking belt tensioner nut fully seats against ...

Page 134: ... 8 24 x 1 blade holder flange bolt and then remove the one piece blade holder drive pulley and the Woodruff key from the crankshaft 7 Separate drive belt from the blade holder drive pulley 8 Loosen the two 8 mm flange bolts and then remove the belt cover 9 Rotate the left rear wheel and adjuster fully clockwise and the right rear wheel and adjuster fully counterclockwise until the two front handle...

Page 135: ...e the belt tension spring from the cable holder and the transmission control arm 13 Hold the end of the transmission input shaft with an adjustable wrench and then remove the 10 mm flange nut 14 Remove the driven pulley 10 mm washer and the V belt from the transmission 8 mm FLANGE BOLT 4 8 mm FLANGE NUT 2 REAR SCROLL SMART DRIVE CABLE END Push on the transmission control arm in the direction shown...

Page 136: ... pulley Be sure the blade holder Woodruff key is installed and does not fall out when installing the blade holder 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 during operation Adjust the drive pulley belt guide clearance Readjust the Smart Drive cable P 3 9 TRANSMISSION DRIV...

Page 137: ...ther wrench or socket to loosen and remove the belt tensioner bolt Pay attention to the order of the parts self locking nut washer spring washer and bolt as they are removed 6 Remove the two blade bolts and special washers from the blade holder Use a wooden block to prevent the blades from turning when removing the bolts P 3 5 7 Remove the belt from the transmission pulley 8 Remove the wheel bolt ...

Page 138: ...p pinion collar pinion gear and wheel cover from each side 10 Remove the ratchet key and spring from each side 11 Remove the remaining collars circlip and washer from each side as shown WHEEL COVER PINION GEAR PINION COLLAR 13 mm CIRCLIP RATCHET KEY SPRING WASHER CIRCLIP COLLAR COLLAR ...

Page 139: ...ed It is not necessary to remove the left side adjuster parts 13 Pivot the transmission and disconnect the plastic clutch cable clip from the transmission bracket with needle nose pliers Take care not to damage or force the clip 14 Slide the transmission axle to the right side until it clears the left side adjuster Rotate the transmission slightly and then lift it out of the mower deck FLAT WASHER...

Page 140: ...and blade holder P 3 3 7 Remove the belt cover and rear scroll P 11 2 8 Remove the belt guide 9 Remove the drive pulley and separate the belt from the drive pulley P 3 4 Leave the belt attached to the transmission 10 Push down on the transmission control arm as shown and disconnect the Smart Drive cable from the transmission control arm 11 Remove the belt tension spring from the cable holder and t...

Page 141: ...chet return spring from each side 14 Remove the pinion gear collars and wheel covers from each side 15 Remove the remaining thrust collars 13 mm washers and circlips from each side RATCHET KEY RATCHET RETURN SPRING 12 TOOTH PINION GEAR PINION GEAR COLLAR 13 mm CIRCLIP WHEEL COVER PINION GEAR COLLAR 13 mm CIRCLIP THRUST COLLAR 13 mm WASHER ...

Page 142: ...not to damage the seals 18 Remove the transmission from the mower deck a Slide the transmission assembly to the right side until the axle shaft is clear of the left handle stay and mower deck hole b Tilt the left side of transmission assembly away from the mower deck and then pull the right side of the transmission axle shaft out of the right side handle stay hole 26 x 36 mm WASHER 25 mm CIRCLIP A...

Page 143: ...B grease or equivalent INSIDE the adjuster arms and on the axle surfaces P 3 15 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 lithium silicon WD 40 or any other spray lubricant 4 Make sure the punch mark on the pinion gear faces in toward the mower deck on the left...

Page 144: ...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 grease Proper application of the correct grease is critical to ensure proper operation DO NOT USE anti seize white lithium silicon WD 40 or any other spray lubricant 6 Slide the adjuster plate onto the right side adjusti...

Page 145: ...m silicon WD 40 or any other spray lubricant 12 Install a ratchet return spring and ratchet key 13 Install a pinion gear pinion collar and 13 mm circlip Make sure the pinion gear is installed correctly for each side as shown 14 Install a wheel washer flat washer wheel and wheel bolt 15 Repeat steps 4 14 for the left side WHEEL COVER PINION GEAR COLLAR RATCHET KEY RATCHET RETURN SPRING 12 TOOTH PIN...

Page 146: ...st the belt guide clearance 20 Install the belt cover and rear scroll P 11 2 21 Install the blade holder and blade P 4 2 22 Add fuel and engine oil P 3 6 23 Reconnect the spark plug cap 24 Start the engine and adjust the Smart Drive cable P 3 9 TRANSMISSION CONTROL ARM BELT TENSION SPRING DRIVE PULLEY BELT GUIDE SMART DRIVE CABLE CABLE HOLDER DRIVE BELT Blade holder belt cover and scroll shown rem...

Page 147: ...DRIVE BELT HRS216PKA HRS216SKA HRS216VKA 12 16 4 TRANSMISSION DISASSEMBLY REASSEMBLY K5 SKA MODEL The single speed transmission is not serviceable It must be replaced as a complete assembly SPRING PIN DRIVEN PULLEY ...

Page 148: ...y 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 m 29 ft lb 12 7 x 22 2 x 6 4 mm OIL SEAL 2 PINION SHAFT SMART DRIVE CABLE PINS CABLE HOLDER 10 x 24 mm HARDENED WASHER DRIVEN PULLEY HALVES REMOVAL Hold the pinion shaft with a wrench and then remove ...

Page 149: ...TRANSMISSION DRIVE BELT HRS216PKA HRS216SKA HRS216VKA 12 18 NOTES ...

Page 150: ... 7 17 Filter air 3 7 Flywheel Installation 8 4 Removal 8 3 Flywheel brake Brake shoe inspection 3 11 Brake spring installation 3 11 Cable inspection 3 11 Operation check 3 10 Fuel cap 7 19 Fuel strainer 7 17 Fuel tank and filter 3 9 Fuel tank removal installation 7 17 Fuel tube Inspection 3 10 Removal installation 7 18 Fuel valve disassembly reassembly 7 16 G Governor Disassembly reassembly 9 13 M...

Page 151: ... plug Inspection cleaning 3 8 Test 2 21 Special tools 2 5 Specifications Dimensions weight capacities 1 1 Engine 1 1 Maintenance 3 2 Service 2 3 Transmission SKA and VKA 1 1 Tune up 3 2 Stop switch 8 4 Stop switch inspection 2 23 Symbols 2 1 T Thermowax installation 7 14 Throttle return spring 7 16 Thrust washer 9 6 Tools Commercially available 2 6 Special 2 5 Torque values 2 4 Transmission Disass...

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