Honda - Stepwgn - Workshop Manual - 2021 - 2021

A Few Words About Safety SERVICE INFORMATION The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage this Honda product or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not recommended by Honda must determine the risks to his or her personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer’s Safety Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight while servicing this product can result in faulty operation, damage to the product, or injury to others. Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (Hot parts-wear gloves, for example). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing 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 around pressurized air, pressurized liquids, springs or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. • Protect yourself and others whenever you have engine-power equipment up in the air. Anytime you lift this product with a hoist, make sure that the hoist hook is securely attached to the product. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. • Burns from hot parts. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gasses from battery are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. • Use only a nonflammable solvent, not gasoline, to clean parts. • Never store gasoline in an open container. • Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts. HRR216VKA CONTENTS INTRODUCTION This manual covers service and repair procedures for the Honda HRR216VKA K5 through K11 model rotary mowers. SPECIFICATIONS 1 All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. SERVICE INFORMATION 2 MAINTENANCE 3 BLADE HOLDER/DRIVE BELT 4 ENGINE REMOVAL/ INSTALLATION 5 MUFFLER 6 RECOIL STARTER 7 FUEL SYSTEM 8 FLYWHEEL/IGNITION COIL 9 No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and tables. As you read this manual, you will find information that is preceded by a NOTICE symbol. The purpose of this message is to help prevent damage to the mower, other property, or the environment. SAFETY MESSAGES Your safety and the safety of others are very important. To help you make informed decisions, we have provided 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 words: DANGER, WARNING, or CAUTION. These signal words mean:  DANGER You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.  WARNING You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.  CAUTION You CAN be HURT if you don’t follow instructions. CAM PULLEY/CRANKSHAFT/ PISTON/ CYLINDER BLOCK 10 HANDLE PIPE/CABLES/SMART DRIVE 11 CLIP DIRECTOR/MOWER DECK/ WHEELS 12 TRANSMISSION 13 INDEX • Instructions – how to service these mowers correctly and safely. American Honda Motor Co., Inc. Service Communications Department PSV61VG3600VKAE5.2019.06 i INTRODUCTION HRR216VKA LAWN MOWER K VERSION IDENTIFICATION Throughout this manual, the K version is listed when the repair procedure varies by version. The K version number is the seventh digit in the model number as shown here. K VERSION NUMBER MEETS CPSC BLADE SAFETY REQUIREMENTS. CONFORMS TO ANSI B 71.1 SAFETY STANDARD HRR2169VKA MZCG –– XXXXXXX XX AMERICAN CO., INC. AmericanHONDA Honda MOTOR Motor Co., Inc. ALPHARETTA, GA 30005-8847 Alpharetta, GA 30005-8847 Use the information in the following table to identify the version you are repairing. (K9 label shown) VERSION FRAME SERIAL NUMBERS ENGINE SERIAL NUMBERS K5 MZCG – 7800001 thru 7999999 GJAEA – 1000001 and later IDENTIFIERS/FEATURES/CHANGES • • K6 MZCG – 8000001 thru 8199999 GJAPA – 1000001 thru 9999999 • • • K7 MZCG – 8200001 thru 8399999 GJAPA – 1000001 thru 9999999 • • • K8 MZCG – 8400001 thru 8669999 GJAPA – 1000001 thru 9999999 • • • • • • ii HRR216VKA model introduced with adjustable Smart Drive, fixed throttle, Automatic Choke System (ACS), and quick-release handle adjustment Running change at s/n 7819953— transmission pulley changed from steel to plastic and additional internal transmission improvements implemented Engine 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) Maximum cutting height increased from 3.25 to 4 inches New front adjuster arms and rear adjuster panels Smart Drive™ transmission changed to a smaller design New square Auto Choke System™ thermowax Slip belt Smart Drive transmission Grass bag frame and mount redesigned Grass bag mount changed to plastic Deep rear discharge door implemented to allow rear discharge to the ground Mulching plug redesigned to work with new deep rear discharge door HRR216VKA INTRODUCTION VERSION FRAME SERIAL NUMBERS ENGINE SERIAL NUMBERS K9 IDENTIFIERS/FEATURES/CHANGES MZCG – 8670001 ~ 9999999 GJARA – 1000001 ~ 4840000 • also: MZCG – 1000001 ~ 1140000 • • • • • • K10 MZCG – 1140001 ~ 1450000 GJARA – 4840001 ~ 8000000 • • • • • • K11 MZCG-1660001 ~ 1999999 GJATA – 1000001 ~ up • • . . Engine model prefix changed from GJAPA to GJARA 3-in-1 Clip Director®—no mulching plug New MicroCut® blades Rear scroll and belt cover changed from steel to plastic Plastic ramp added to the inside of the cutting housing to improve mulching performance New style fan cover Engine changes including: – New aluminum carburetor – Round intake port – New flywheel brake and stop switch design – New flywheel with separate cooling fan – New orange air filter 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 components Textured mower deck paint Color changed from Rose Champagne to Emboss Bright Gray Metallic (NH-B67M) Tire tread changed to improve traction Wheel hub color changed to Vintage Gray (NH-462R) One piece rear handle stay and height adjuster panels New front mower deck decal Engine serial number prefix changed from GJARA to GJATA Otherwise identical to K10 model iii INTRODUCTION HRR216VKA NOTES iv 1. SPECIFICATIONS 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 1-1 3. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 1-6 2. DIMENSIONAL DRAWINGS . . . . . . . . . . . 1-3 1. SPECIFICATIONS DIMENSIONS, WEIGHTS, AND CAPACITIES VERSION K5/K6 K7 Height 966 mm (38.0 in) 961 mm (37.8 in) 1,014 mm (39.9 in) 1,024 mm (40.3 in) Length 1,600 mm (63.0 in) 1620 mm (63.8 in) 1,534 mm (60.4 in) 1,532 mm (60.3 in) Mower deck width Wheel base (cut height set to 28 mm [1-1/4 in]) K8 K9 K10/K11 582 mm (22.9 in) 630 mm (24.8 in) 620 mm (24.4 in) Cutting width 530 mm (21.0 in) Cutting height (6 positions) 19, 28, 41.5, 54, 67, 79 mm (3/4, 1-1/8, 1-3/4, 2-1/4, 2-3/4, 3-1/4 in) Dry mass 37.6 kg (82.9 lbs) 37.2 kg (82.0 lbs) 36.5 kg (80.5 lbs) 36.7 kg (80.9 lbs) Wet mass 38.8 kg (85.8 lbs) 38.4 kg (84.7 lbs) 37.5 kg (82.7 lbs) 37.7 kg (83.1 lbs) 28, 44, 60, 75, 90, 102 mm (1-1/8, 1-3/4, 2-1/2, 3, 3-1/2, 4 in) 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 ~ 3.6 mph) 0 ~ 6.5 kph (0 ~ 4.0 mph) ENGINE Engine model Engine type GCV160LA0 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 Maximum governed speed (no load) 8.5 : 1 K5 ~ K8: 2,950 ~ 3,100 rpm K9 ~ K11: 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 system Splash type Cooling system Forced air Starting system Recoil starter Stopping system Ignition primary circuit ground and a flywheel brake Carburetor Horizontal-type, butterfly valve Air cleaner Dry (paper) type Governor Centrifugal mechanical governor Fuel used Unleaded gasoline with a pump octane number 86 or higher 1-1 SPECIFICATIONS HRR216VKA DRIVE TRAIN VERSION K5/K6 Type Ground speed Clutch type K7 Variable Speed Slip Belt 0 ~ 5.8 km/h, 0 ~ 1.6 m/s (0 ~ 3.6 mph) 0 ~ 6.5 km/h, 0 ~ 1.8 m/s (0 ~ 4.0 mph) Slipping friction cone type V-belt slip Drive mechanism Lubrication type Lubrication amount K8/K9/K10/K11 V-belt SAE 10W-30 engine oil SJ or later 150 cc (5.1 oz) 65 cc (2.2 oz) FEATURES VERSION K5/K6/K7 K8 K9/K10/K11 Smart Drive System    Quadracut twin blades    MicroCut® twin blades Grass bag   Mulching plug   ACS (Auto Choke System)   Clip Director®  = standard equipment 1-2    HRR216VKA SPECIFICATIONS 2. DIMENSIONAL DRAWINGS K5 thru K7 *K5/K6: 966 mm (38.0 in) *K7: 961 mm (37.8 in) in) .0 (63 n) m 8i 0 m (63. 0 6 1, mm 6: /K ,620 5 *K 7: 1 *K 58 2 m m (2 2. 9 in ) in 4.8 ) 2 ( m .4 in 0 m (24 3 6 m 6: /K 20 m 5 K :6 K7 * Dimensions measured with the cutting height set in the lowest position. 1-3 SPECIFICATIONS HRR216VKA K8 and K9 *1,014 mm (39.9 in) *1,534mm (60.4 in) 620 mm (24.4 in) 582 mm (22.9 in) * Dimensions measured with the cutting height set in the lowest position and the handlebar height set in the highest position. 1-4 HRR216VKA SPECIFICATIONS K10/K11 *1,024 mm (40.3 in) *1,532 mm (60.3 in) 620 mm (24.4 in) 582 mm (22.9 in) * Dimensions measured with the cutting height set in the lowest position and the handlebar height set in the highest position. 1-5 SPECIFICATIONS HRR216VKA 3. WIRING DIAGRAM SPARK PLUG 1-6 IGNITION COIL ENGINE STOP SWITCH (NORMALLY CLOSED) 2. SERVICE INFORMATION 1. 2. 3. 4. 5. 6. SERVICE RULES . . . . . . . . . . . . . . . . . . . . SYMBOLS USED IN THIS MANUAL. . . . . SERIAL NUMBER LOCATIONS . . . . . . . . SERVICE SPECIFICATIONS . . . . . . . . . . . TORQUE VALUES . . . . . . . . . . . . . . . . . . . TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 7. DRIVE SYSTEM TROUBLESHOOTING . . 2-7 2-1 8. ENGINE TROUBLESHOOTING. . . . . . . . 2-18 2-2 9. FLYWHEEL BRAKE TROUBLESHOOTING . . . . . . . . . . . . . . . 2-29 2-2 2-4 10. TROUBLESHOOTING VIBRATION PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . 2-30 2-5 1. SERVICE RULES • Use Honda Genuine parts or their exact equivalent. Lower quality parts can damage the mower or reduce its performance. • Install new gaskets, O-rings, and seals during reassembly. • This mower uses metric fasteners and SAE (non-metric) fasteners. Metric bolts, nuts, and screws are not interchangeable with non-metric fasteners. The use of incorrect tools and fasteners may damage the mower. • When tightening nuts and bolts, begin with the larger-diameter or inner bolts, and tighten diagonally to the specified torque values, unless a particular tightening sequence is specified. • When tightening self-tapping screws, be especially careful to avoid cross-threading or overtightening. • Clean parts in nonflammable solvent after disassembly. • Lubricate sliding surfaces before reassembly. • After reassembly, check parts installation and operation. 2. SYMBOLS USED IN THIS MANUAL As you read this manual, you may find the following symbols with the instructions.  (commercially available)   A special tool is required to perform the procedure. Commercially available tools are distinguished by the words (commercially available). They are not available through the American Honda Parts Department. Most commercially available tools shown in this shop manual can be ordered through the Tool and Equipment program by calling (888) 424-6857. Refer to the Tool and Equipment program catalogue for a complete tool listing. Apply grease (extreme pressure NLGI #2 GC-LB grease or equivalent) Apply oil OxO(O) Indicates the diameter, length, and quantity of metric flange bolts used. P. O-O Indicates the reference page. 2-1 SERVICE INFORMATION HRR216VKA 3. SERIAL NUMBER LOCATIONS The engine serial number is located on the cylinder block near the muffler. Refer to the engine serial number when ordering parts and when making technical inquiries. The frame serial number is located at the center rear of the deck. FRAME SERIAL NUMBER MEETS CPSC BLADE SAFETY REQUIREMENTS. CONFORMS TO ANSI B 71.1 SAFETY STANDARD HRR2169VKA MZCG –– XXXXXXX XX H O N D A AMERICAN CO., INC. AmericanHONDA Honda MOTOR Motor Co, Inc. ALPHARETTA, GA 30005-8847 Alpharetta, GA 30005-8847 ENGINE SERIAL NUMBER A D N O H 4. SERVICE SPECIFICATIONS PART ITEM Maximum governed speed Engine Carburetor BB65E A Carburetor BB75E A Carburetor BB75E B Carburetor BB75E C Carburetor BB76A A 2-2 Idle speed Cylinder compression Main jet Float height Pilot screw opening Main jet Float height Pilot screw opening Main jet Float height Pilot screw opening Main jet Float height Pilot screw opening Main jet Float height Pilot screw opening STANDARD VERSIONS 2,950 ~ 3,100 rpm 2,950 ~ 3,050 rpm 1,700 ± 150 rpm 490 kPa (5.0 kg/cm2, 71 psi) at 600 rpm 420 kPa (4.3 kg/cm2, 61 psi) at 600 rpm #70 9.2 mm (0.36 in) N/A #68 7.2 mm (0.28 in) N/A #68 7.2 mm (0.28 in) N/A #68 7.2 mm (0.28 in) N/A #60 10.2 mm (0.40 in) N/A K5 ~ K8 K9 ~ K11 K5 ~ K8 K5 ~ K8 K9 ~ K11 K5 K5 K6, K7 K8 K9, K10, K11 HRR216VKA PART Spark plug SERVICE INFORMATION ITEM Gap Valve clearance (cold) IN EX Stem O.D. IN Valves EX Guide I.D. IN/EX Seat width IN/EX Spring free length IN/EX Skirt O.D. K5~K8 K9~K11 Piston-to-cylinder clearance Piston K5~K8 K9~K11 Piston pin bore I.D. Pin O.D. Ring width Top Second Oil Ring side clearance Top Piston rings Second Oil Ring end gap Top Second Oil Sleeve I.D. K5~K8 Cylinder K9~K11 Small end I.D. Big end I.D. Connecting rod Big end oil clearance Big and axial clearance Main journal O.D. PTO side Crankshaft Flywheel side Crank pin O.D. Main journal I.D. Cylinder block Crankshaft axial clearance Oil pan Main journal I.D. Cam height Cam pulley Cam Pulley I.D. (Bearing) Cam pulley shaft O.D. Rocker arm I.D. Rocker arm Rocker arm shaft O.D. Rocker arm shaft bearing I.D. Resistance Primary coil Ignition coil (K5 thru K8) Secondary coil Air gap (at flywheel) Resistance Primary coil Ignition coil (K9) Secondary coil Air gap (at flywheel) Resistance Primary coil Ignition coil (K10/K11) Secondary coil Air gap (at flywheel) Flywheel brake Brake shoe thickness STANDARD SERVICE LIMIT 0.7 - 0.8 mm (0.028 ~ 0.031 in) 0.15 ± 0.04 mm 0.20 ± 0.04 mm 5.48 mm (0.216 in) 5.44 mm (0.214 in) 5.50 mm (0.217 in) 0.7 mm (0.028 in) 30.5 mm (1.20 in) 63.961 ~ 63.985 mm (2.5181 ~ 2.5190 in) 63.966 ~ 63.990 mm (2.5183 ~ 2.5193 in) ---------------------------------------------------------------------------------------------5.318 mm (0.2094 in) 5.275 mm (0.2077 in) 5.572 mm (0.2194 in) 1.8 mm (0.07 in) 29.0 mm (1.14 in) 63.880 mm (2.5129 in) 63.880 mm (2.5129 in) 0.015 ~ 0.054 mm (0.0005 ~ 0.0021 in) 0.010 ~ 0.049 mm (0.0004 ~ 0.0019 in) 13.002 mm (0.5119 in) 13.000 mm (0.5118 in) 0.93 ~ 0.95 mm (0.036 ~ 0.037 in) 0.97 ~ 0.99 mm (0.038 ~ 0.039 in) 2.5 mm (0.10 in) 0.055 ~ 0.089 mm (0.002 ~ 0.004 in) 0.015 ~ 0.049 mm (0.0006~0.0019 in) 0.015 ~ 0.045 mm (0.0006~0.0018 in) 0.20 ~ 0.35 mm (0.008 ~ 0.014 in) 0.35 ~ 0.50 mm (0.014 ~ 0.020 in) 0.20 ~ 0.70 mm (0.008 ~ 0.030 in) 0.12 mm (0.005 in) 0.12 mm (0.005 in) 13.048 mm (0.5137 in) 12.954 mm (0.5100 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) 64.105 mm (2.5238 in) 64.000 ~ 64.015 mm (2.5197 ~ 2.5203 in) 64.110 mm (2.5240 in) 13.07 mm (0.515 in) 13.005 mm (0.5120 in) 26.066 mm (1.0262 in) 26.02 mm (1.024 in) 0.12 mm (0.005 in) 0.040 ~ 0.063 mm (0.0016 ~ 0.0025 in) 0.8 mm (0.031 in) 0.1 ~ 0.4 mm (0.004 ~ 0.016 in) 27.933 mm (1.0997 in) 27.993 mm (1.1021 in) 25.333 mm (0.9974 in) 25.393 mm (0.9997 in) 25.92 mm (1.020 in) 25.98 mm (1.023 in) 25.466 mm (1.0026 in) 25.420 mm (1.0008 in) 0.15 ~ 0.75 mm (0.006 ~ 0.030 in) 1.0 mm (0.04 in) 28.020 mm (1.1031 in) 28.066 mm (1.1050 in) 37.394 mm (1.4722 in) 37.369 mm (1.4712 in) 10.027 mm (0.3948 in) 10.075 mm (0.3967 in) 9.987 mm (0.3932 in) 9.920 mm (0.3906 in) 6.000 mm (0.2362 in) 6.043 mm (0.2379 in) 5.990 mm (0.2358 in) 5.953 mm (0.2344 in) 6.000 mm (0.2362 in) 6.043 mm (0.2379 in) 1.0 ~ 1.4 Ω ----------------------------------10.6 ~ 12.8 kΩ ----------------------------------0.2 ~ 0.4 mm (0.008 ~ 0.016 in) ----------------------------------1.0 ~ 1.2 Ω ----------------------------------10 ~ 40 kΩ ----------------------------------0.2 ~ 0.5 mm (0.008 ~ 0.020 in) --------------------------------------------------------------------See page 9-6 ----------------------------------See page 9-6 0.2 ~ 0.5 mm (0.008 ~ 0.020 in) --------------------------------------------------------------------------------------------3.0 mm (0.12 in) 2-3 SERVICE INFORMATION HRR216VKA 5. TORQUE VALUES SPECIAL FASTENERS ITEM THREAD DIAMETER x PITCH TORQUE N•m kgf•m ft-lb M6 x 1.0 (ST) M6 x 1.0 10 10 1.0 1.0 7.4 7.4 special 49 ~ 59 5.0 ~ 6.0 36 ~ 43 3/8-24 x 1” special 49 ~ 59 5.0 ~ 6.0 36 ~ 43 Breather cover bolt M6 x 1.0 12 1.2 8.7 Connecting rod bolt M7 x 1.0 special 12 1.2 8.7 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 screw M5 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 (ST) 12 1.2 8.7 Oil pan bolt M6 x 1.0 (ST) 12 1.2 8.7 M6 x 1.0 8.5 0.85 6.1 M14 x 1.25 20 2.0 14 M5 x 0.5 special 8 0.8 5.8 Air cleaner case bolt Blade bolt Blade holder bolt Cylinder head cover bolt Recoil starter nut Spark plug Valve adjusting lock nut Use standard torque values for fasteners that are not listed above. (ST) Indicates a self-tapping bolt. STANDARD FASTENERS STANDARD FASTENERS Screw Bolt and nut Flange bolt and nut 2-4 THREAD DIAMETER TORQUE N•m kg-m ft-lb 5 mm 3.9 0.4 2.9 6 mm 8.8 0.9 6.5 5 mm 4.9 0.5 3.6 6 mm 9.8 1.0 7.2 8 mm 21 2.1 15 10 mm 34 3.5 25 12 mm 54 5.5 40 6 mm 12 1.2 8.7 8 mm 26 2.7 20 10 mm 39 4.0 29 HRR216VKA SERVICE INFORMATION 6. TOOLS SPECIAL ITEM TOOL NAME TOOL NUMBER APPLICATION 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 removal 4 Alcohol tester 07AAJ-E85A100 Check the percent of ethanol in the fuel 1 2 3 4 2-5 SERVICE INFORMATION HRR216VKA COMMERCIALLY AVAILABLE ITEM TOOL NAME TOOL NUMBER 1A Dial indicator and magnetic base FPL-72-520-300 1B Dial indicator magnetic base FFL-72-585-010 Crankshaft runout check and crankshaft axial clearance check 2 Compression gauge SUN-EEP-V303A Compression 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 check 6 Digital multimeter FLU-88 Electrical component testing 7A Valve seat cutter, 31° NWY CU 115 7B Valve seat cutter, 45° NWY CU 122 7C Valve seat cutter, 60° NWY CU 111 7D Solid pilot bar, 5.50 mm NWY PM 10055SH 7E Solid pilot bar, 5.51 mm NWY PM 100552S 7F T-wrench, #505 NWY TW 505 7G T-wrench adaptor, #503-1 NWY TW 503-1 7H T-wrench extension, 6 in NWY TW 503-6H 7I Accessory package #246 NWY KACC 246 8 Tachometer KE-1-5 1A 2 APPLICATION Valve seat reconditioning Engine rpm 3 5 4 5 1B AUTOMOTIVE METER F ZERO MIN MAX RANGE RPM SMOOTH 6 Hz mV C HOLD H %DUTY ALERT ms-PULSE + TRIGGER - 7 : V mA A RPM ~V mA A ~ OFF A mA 10A MAX FUSED COM 400mA MAX FUSED ! : V RPM 1000V MAX B A I 60° 8 45° TACHOMETER 31° D E rpm G 21:42 H Commercially available tools are distinguished by the words (commercially available). They are not available through the American Honda Parts Department. Most commercially available tools shown in this shop manual can be ordered through the Honda Power Equipment (P/E) Tool and Equipment program by calling (888) 424-6857. Refer to the Tool and Equipment program catalog for a complete tool listing. 2-6 HRR216VKA SERVICE INFORMATION 7. DRIVE SYSTEM TROUBLESHOOTING Version K5 thru K7 K8 thru K11 Symptom See page Lawn mower will not self-propel when the Smart Drive is engaged 2-7 Transmission propels the mower, but slips or slows down under load 2-8 Lawn mower continues to self-propel when the Smart Drive is released 2-9 Lawn mower is difficult to roll backwards, but stops propelling when the Smart Drive is released Only one wheel propels or one wheel intermittently stops rotating under load (clicking sound can be heard) Transmission leaks oil 2-10 2-11 2-12 Lawn mower will not self-propel when the Smart Drive is engaged 2-13 Transmission propels the mower, but slips or slows down under load 2-13 Lawn mower continues to self-propel when the Smart Drive is released 2-14 Lawn mower is difficult to roll backwards, but stops propelling when the Smart Drive is released Only one wheel propels or one wheel intermittently stops rotating under load (clicking sound can be heard) Transmission leaks oil K5 thru K7 2-15 2-16 2-17 SERVICE BULLETIN #94 => LAWN MOWER WILL NOT SELF-PROPEL WHEN THE SMART DRIVE IS ENGAGED 1. Inspect the drive belt, transmission input shaft, Smart Drive cable, and pulley condition. 2. Inspect the transmission control arm. Replace the control arm if it is damaged. Inspect the drive belt, pulley, and input shaft. Inspect the transmission control arm for damage. 2-7 SERVICE INFORMATION HRR216VKA 3. Verify the transmission control arm moves when rotating the Smart Drive control. • If the control arm does not move, see “SMART DRIVE DISASSEMBLY AND INSPECTION” on page 11-23. • If the control arm moves, adjust the Smart Drive cable (see “CABLE ADJUSTMENT” on page 3-10.) Confirm the transmission control arm moves when rotating the Smart Drive control. . (K5 ~ K7) TRANSMISSION PROPELS THE MOWER, BUT SLIPS OR SLOWS DOWN UNDER LOAD 1. Adjust the Smart Drive cable (P. 3-10). CONTROL ARM 2. Have an assistant engage the Smart Drive control while you inspect the transmission control arm position. If the control arm contacts the transmission case as shown, the clutch is worn and transmission replacement is necessary. No contact between the control arm and transmission case with the Smart Drive control engaged. . 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. 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 (page 2-11). If both wheels stop, but no ratcheting or clicking sound can be heard, the clutch may be worn and transmission replacement is necessary. 2-8 Hold the mower from moving forward and engage the Smart Drive control on a smooth concrete surface. HRR216VKA SERVICE INFORMATION (K5 ~ K7) LAWN MOWER CONTINUES TO SELF-PROPEL WHEN THE SMART DRIVE IS RELEASED 1. Loosen the Smart Drive cable adjuster completely. ADJUSTER LOCK NUT LOOSEN . 2. Confirm there is no tension in the Smart Drive cable at the transmission control arm. If tension exists, proceed to “SMART DRIVE DISASSEMBLY AND INSPECTION” on page 11-23. 3. Inspect the transmission control arm return spring. 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 roll backwards, refer to “(K5 ~ K7) THE LAWN MOWER IS DIFFICULT TO ROLL BACKWARDS, BUT DOES STOP PROPELLING WHEN THE SMART DRIVE IS RELEASED” on page 2-10. Confirm there is no tension in the Smart Drive cable. Inspect the control arm return spring. • If the Smart Drive is still engaged (stuck) and will not roll backwards and propels when running, replace the transmission. 2-9 SERVICE INFORMATION HRR216VKA (K5 ~ K7) THE LAWN MOWER IS DIFFICULT TO ROLL BACKWARDS, BUT DOES STOP PROPELLING WHEN THE SMART DRIVE IS RELEASED 1. Raise the mower to the highest cutting height to prevent the rear shield from creating extra roll-back drag. 2. With the engine off and the Smart Drive control released, place a commercially available spring scale on the handlebar. Slowly and steadily pull the mower backwards and measure the continuous roll-back force. Slowly pull the mower backwards and measure the roll-back force. Maximum continuous force is 49 N (11 lb). • Continuous roll-back force should be less than 49 N (11 lb). SPRING SCALE, SAMIN25MRP (Commercially available) • If the roll-back force exceeds 49 N (11 lb), refer to steps 1 thru 3 on page 2-9. . 3. Check the roll-back force once again. If the force exceeds 49 N (11 lb), continue as follows: ADJUSTER ARM AND AXLE Clean and inspect the rear adjuster bushings and axle. 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 grease or equivalent to the inside of the bushings. 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. 4. Go to the Smart Drive Cable Adjustment procedure (P. 3-10). 2-10 26 x 44 mm WASHER 25 mm CIRCLIP  Apply extreme pressure NLGI #2 GC-LB grease. ADJUSTER PLATE HRR216VKA SERVICE INFORMATION (K5 ~ K7) ONLY ONE WHEEL PROPELS OR ONE WHEEL INTERMITTENTLY STOPS ROTATING UNDER LOAD (CLICKING SOUND CAN BE HEARD) 1. Clean and inspect the pinion gears, wheel gears, and ratchet keys. 2. Apply 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.   RATCHET SPRING PINION GEAR (12-tooth) Install with the punch mark facing: Left - inside Right - outside RATCHET KEY AXLE 3 mm SPACER 13 mm CIRCLIP FLAT WASHER WHEEL WASHER REASSEMBLY: Install the washer as shown. WHEEL SIDE REAR WHEEL WHEEL BOLT 2-11 SERVICE INFORMATION HRR216VKA (K5 ~ K7) TRANSMISSION LEAKS OIL 1. Remove the transmission (P. 13-1), clean it, and identify the source of the leak. Note: Dark oil or a slight metallic residue in the oil is normal and usually does not indicate a problem. 2. Replace the leaking seal(s) or O-ring as shown below. 3. Fill the transmission to the proper level with SAE 10W-30 oil. 4. Reinstall the transmission, and proceed to the Smart Drive Cable Adjustment procedure (P. 3-10) K5/K6 AXLE SHAFT OIL SEAL 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 top of the transmission case when it is upside down. AXLE SHAFT OIL SEAL CAPACITY: 150 cc (5.1 oz) TOP OF 8 ~ 12 mm CASE (0.3 ~ 0.5 in) CASE O-RING K7 10 x 19 x 7 mm OIL SEAL 12.7 x 28.6 x 6.4 mm OIL SEAL 12.7 x 22.2 x 6.4 mm OIL SEAL (2) TRANSMISSION CASE INSTALLATION: Use SAE 10W-30 engine oil and fill to the capacity shown. The correct oil level should be 10 ~ 12 mm (0.4 ~ 0.5 in) from the top of the transmission case when it is upside down. CAPACITY: 150 cc (5.1 oz) TOP OF 10 ~ 12 mm CASE (0.4 ~ 0.5 in) 2-12 CASE O-RING HRR216VKA K8 thru K11 SERVICE INFORMATION SERVICE BULLETIN #98 => SERVICE BULLETIN #104 => MOWER WILL NOT SELF-PROPEL WHEN THE SMART DRIVE IS ENGAGED 1. Inspect the drive belt, transmission input shaft, Smart Drive cable, and pulley condition. Inspect the transmission control arm, Smart Drive cable, and return spring for damage. 2. Inspect the transmission control arm, Smart Drive cable, and return spring. Replace as necessary. 3. Verify the transmission pivots and the control arm moves when rotating the Smart Drive control. • If the control arm does not move, go to “SMART DRIVE DISASSEMBLY AND INSPECTION” on page 11-23. • If the control arm moves, go to “CABLE ADJUSTMENT” on page 3-10. Inspect the drive belt, pulley, and input shaft. . (K8 ~ K11) TRANSMISSION PROPELS THE MOWER, BUT SLIPS OR SLOWS DOWN UNDER LOAD 1. Adjust the Smart Drive cable (P. 3-10). 2. Inspect the belt and both pulleys for damage. Confirm that the transmission pulley is tight and not slipping on the input shaft. 3. Position the mower on a smooth concrete surface. Hold the mower from moving forward and engage the Smart Drive control on a smooth concrete surface. 4. Start the engine and firmly engage the Smart Drive control while 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 “(K8 ~ K11) ONLY ONE WHEEL PROPELS OR ONE WHEEL INTERMITTENTLY STOPS ROTATING UNDER LOAD (CLICKING SOUND CAN BE HEARD)” on page 2-16). If both wheels stop but no ratcheting or clicking sound can be heard, the clutch may be worn and transmission replacement is necessary. 2-13 SERVICE INFORMATION HRR216VKA (K8 ~ K11) LAWN MOWER CONTINUES TO SELF-PROPEL WHEN THE SMART DRIVE IS RELEASED JAM NUT ADJUSTER MARK 1. Loosen the Smart Drive cable adjuster completely. TIGHTEN LOOSEN . . 2. Confirm there is no tension in the Smart Drive cable at the transmission control arm. Confirm there is no tension in the Smart Drive cable. If tension exists, proceed to the SMART DRIVE DISASSEMBLY AND INSPECTION procedure on page 11-23. 3. Inspect the transmission control arm return spring. If the spring is broken, missing, or damaged, replace it. Inspect the control arm return spring. 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 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). DRIVE PULLEY BELT GUIDE CLEARANCE DRIVEN PULLEY BELT GUIDE CLEARANCE 3 ~ 4 mm (0.118 ~ 0.157 in) 2 ~ 3 mm (0.079 ~ 0.118 in) BELT DRIVE PULLEY DRIVEN PULLEY BELT BELT GUIDE 2-14 BELT GUIDE HRR216VKA SERVICE INFORMATION (K8 ~ K11) LAWN MOWER IS DIFFICULT TO ROLL BACKWARDS, BUT STOPS PROPELLING WHEN THE SMART DRIVE IS RELEASED 1. Raise the mower to the highest cutting height to prevent the rear shield from creating extra roll-back drag. SERVICE BULLETIN #107 => 2. With the engine off and the Smart Drive control released, place a commercially available spring scale on the handlebar. Slowly and steadily pull the mower backwards and measure the continuous roll-back force. Slowly pull the mower backwards and measure the roll-back force. Maximum continuous force is 58 N (13 lb). • Continuous roll-back force should be less than 58 N (13 lb). SPRING SCALE, SAMIN25MRP (Commercially available) • If the roll-back force exceeds 58 N (13 lb), refer to steps 1 thru 3 under “(K8 ~ K11) LAWN MOWER CONTINUES TO SELF-PROPEL WHEN THE SMART DRIVE IS RELEASED” on page 2-14. 3. Check the roll-back force once again. If the force exceeds 58 N (13 lb), continue to 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 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, silicone, WD-40, or any other spray lubricant. 6. Proceed to the Smart Drive Cable Adjustment procedure (P. 3-10). ADJUSTER ARM AND AXLE Clean and inspect the rear adjuster bushings and axle. 26 x 44 mm WASHER 25 mm CIRCLIP  Apply grease. ADJUSTER PLATE Clean bushing contact areas with a Scotch-Brite™ pad. . 2-15 SERVICE INFORMATION HRR216VKA (K8 ~ K11) ONLY ONE WHEEL PROPELS OR ONE WHEEL INTERMITTENTLY STOPS ROTATING UNDER LOAD (CLICKING SOUND CAN BE HEARD) 1. Clean and inspect the pinion gears, wheel gears, and ratchet keys. 2. Apply Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent to the ratchet key, spring, and axle on the left and right sides. 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. 3. Be sure the correct pinion gears are installed: 8-inch wheels use 12-tooth pinion gears.    RATCHET SPRING Install with the punch mark facing: Left - inside Right - outside RATCHET KEY AXLE PINION GEAR COLLAR 13 mm CIRCLIP FLAT WASHER WHEEL WASHER REASSEMBLY: Install the washer as shown. WHEEL SIDE 2-16 PINION GEAR (12 tooth) REAR WHEEL WHEEL BOLT HRR216VKA SERVICE INFORMATION (K8 ~ K11) TRANSMISSION LEAKS OIL 1. Remove and clean the transmission (P. 13-1), and check to identify the source of the leak. Note: Dark oil or a slight metallic residue in the oil is normal and usually does not indicate a problem. • Replace the leaking seal(s) or O-ring 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. 3-10). 12.7 x 22.2 x 6.4 mm AXLE SHAFT OIL SEAL (2) 12.7 x 28.6 x 6.4 mm 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 top of the transmission case when it is upside down. CASE O-RING CAPACITY: 65 cc (2.2 oz) TOP OF 18 ~ 20 mm CASE (0.71 ~ 0.79 in) 2-17 SERVICE INFORMATION HRR216VKA 8. ENGINE TROUBLESHOOTING SERVICE BULLETIN #94 => HARD STARTING OR POOR PERFORMANCE SERVICE REMINDER #3 => Make sure the fuel valve is ON. Check the fuel level. Sufficient fuel in tank Confirm the fuel quality. If gasoline is more than 30 days old, the engine may be hard to start (P. 2-19). Fresh fuel Check the air filter. SERVICE BULLETIN #106 => SERVICE BULLETIN #98 => No fuel in tank Refuel. Stale fuel Drain the fuel system, and refill with fresh gasoline. Clogged Clean or replace the air filter. Clean Check the choke butterfly with the engine cold. Choke partially open Choke closed Check the fuel filter. See “CHOKE CONTROL SYSTEM (ACS) (K8 ~ K11)” ON page 2-27. Clogged Clean or replace the fuel filter. Clogged Clean or replace the spark arrester. Clean Check the spark arrester (if equipped). Clean Remove the spark plug and inspect (P. 3-9). Dry Install the spark plug in the plug cap and perform the spark test (P. 2-20). Wet No or weak spark • Install a new spark plug, then restart the engine. • Check the carburetor for flooding. • Check the ignition coil air gap (P. 9-6). • Check the engine stop switch (P. 2-20. Good spark Install a compression gauge in the spark plug hole (P. 2-21) and crank the engine several times. Compression normal Remove (P. 8-1), disassemble (P. 8-5), and clean the carburetor (P. 8-6). Install the spark plug and restart the engine. 2-18 Compression is too high Compression is too low Check the valve clearance (P. 3-13), and then perform the cylinder compression test. If the cylinder compression is too high, go to “STARTING DECOMPRESSION SYSTEM INSPECTION” on page 2-21. Check the valve clearance (P. 3-13), and then perform the cylinder compression test. If the cylinder compression is still too low, perform a leak down test. If the air leak down test shows air leakage, check the following as determined by the test: - Valve sticking open (P. 3-13) - Valve seat width (P. 10-20) - Valve face irregularly worn (P. 10-10) - Piston ring side clearance (P. 10-16) - Piston ring width (P. 10-16) - Piston ring end gap (P. 10-16) - Piston skirt O.D. (P. 10-15) - Cylinder sleeve I.D. (P. 10-15) HRR216VKA SERVICE INFORMATION FUEL/ETHANOL TEST This test will determine the percent of ethanol in gasoline. Honda engines are approved to run on a content of 10% ethanol or less. Follow the directions on the tester shown below.  GAS/ALCOHOL TESTER Directions: 90% 75% 70% 65% 60% 55% 50% 45% 40% 35% 30% 25% 20% 15% 10% 5% Add water to the water line. Step 2 DO NOT SMOKE OR USE NEAR FLAME DISCARD GASOLINE SAMPLE IN APPROVED MANNER 80% Step 1 Add gasoline to this line 85% Add water to this line PN 07AAJ-E85A100 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 seperation line and read scale. The seperation line will indicate the per centage of alcohol, if present. 2-19 SERVICE INFORMATION HRR216VKA SPARK TEST 1. Remove the spark plug, attach it to the spark plug cap, and ground the side electrode against the cylinder head cover.  WARNING Gasoline is highly flammable and explosive. If ignited, gasoline can burn you severely. Before testing the spark plug: • • Be sure there is no spilled fuel near the engine. Place the spark plug away from the spark plug hole. 2. Hold the flywheel brake lever against the handlebar. 3. Pull the recoil starter and check to see if sparks jump across the electrodes. ENGINE STOP SWITCH INSPECTION 1. Remove the fan cover. 2. Disconnect the engine stop switch connector from the 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 brake lever is released. ENGINE STOP SWITCH CONNECTOR (K9 model shown) There should be no continuity when the flywheel brake lever is held against the handlebar. IGNITION PRIMARY TERMINAL 2-20 HRR216VKA SERVICE INFORMATION COMPRESSION TEST 1. Remove the spark plug and install a compression gauge in the spark plug hole. COMPRESSION GAUGE (commercially available) 2. Hold the flywheel brake lever against the handlebar. 3. Crank the engine several times with the recoil starter and measure compression. Compression* K5 ~ K8: 490 kPa (71 psi) at 600 rpm K9 ~ K11: 420 kPa (61 psi) at 600 rpm *Decompression mechanism engaged. A compression test reading above 550 kPa (80 psi) indicates the decompression system may not be working correctly. See STARTING DECOMPRESSION SYSTEM INSPECTION below. STARTING DECOMPRESSION SYSTEM INSPECTION The 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 with fuel in the tank; this will saturate the charcoal in the fuel cap and prevent it from venting properly. 3. Remove the four 6 mm flange bolts and remove the cylinder head cover. 4. Disconnect the spark plug cap. 5. Rotate the flywheel until the engine is at TDC (top dead center) of the compression stroke. The cam pulley lobe will face directly out, away from the block as shown. TOP DEAD CENTER 2-21 SERVICE INFORMATION 6. Measure the exhaust valve clearance using a feeler gauge. Exhaust Valve Clearance Specification: 0.16 ~ 0.24 mm (0.0063 ~ 0.0094 in). HRR216VKA VALVE ADJUSTING LOCK NUT ROCKER ARM If the clearance is less than or equal to 0.24 mm (0.0094 in), the cam pulley decompressor is likely binding. Go to Cam Pulley Decompressor Inspection below. If the valve clearance is greater than 0.24 mm (0.0094 in) go to Exhaust Rocker Arm Pivot Free-Play Inspection (P. 2-23). Exhaust Valve Stem Exhaust Valve Maximum Clearance Specification 0.24 mm (0.0094 in) Cam Pulley Decompressor Inspection Perform this procedure if the 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. 10-1). 3. If the weight is fully retracted, operate the decompressor by very slowly moving it to the opposite end of the slot and gently releasing. Repeat several times. If the weight fails to completely return on its own at any time (by spring force), replace the cam pulley (P. 10-1). DECOMPRESSOR WEIGHT 2-22 HRR216VKA SERVICE INFORMATION Exhaust Rocker Arm Pivot Free-Play Inspection Perform this procedure if the exhaust valve clearance measurement was greater than 0.24 mm. 1. Loosen the three 6 mm flange bolts and remove the muffler heat shield.    2. With the engine positioned at TDC of the compression stroke (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. Inspect rocker arm for cracks. Inspect rocker pin for wear grooves. 9/16 in (15 mm) ∅ 5/16 in 2 in 7 in 5. Attach the fabricated steel plate to the muffler shield boss using a 6 x 20 mm flange bolt. 2-23 SERVICE INFORMATION HRR216VKA 6. Attach a dial indicator with a magnetic base to the steel plate as shown. 7. Use the dial indicator to measure the rocker arm pivot free-play at locations A and B following the procedure in step 8. A B FREE-PLAY MEASUREMENT POINTS 8. Position the dial indicator against 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. Maximum Allowable Rocker Arm Free-Play = 0.16 mm (0.0063 in) 2-24 HRR216VKA SERVICE INFORMATION 11. If the free-play measurement is within specification, readjust the valve clearance. If the free-play exceeds 0.16 mm (0.0063 in), install a new rocker arm and pin, adjust the valve clearance, and repeat the free-play measurement. If the free-play is still excessive, the rocker tower bore is worn and the cylinder barrel or engine will require replacement. Excessive free-play with a new rocker arm and pin installed indicates worn rocker tower holes. 12. Clean the cylinder barrel mating surface with a degreasing agent and a shop towel. Clean the cylinder barrel mating surface. 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 in several steps to the specified torque. Wait for approximately 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. Start the engine and check operation. Apply liquid gasket to the back side of the new cylinder head cover. . 2-25 SERVICE INFORMATION HRR216VKA CHOKE CONTROL SYSTEM (ACS) (K5 ~ K7) With the engine cold, remove the paper element and check the choke valve. Partially or totally open Closed Remove the carburetor. Turn and hold the choke arm in the choke CLOSED position. Push the choke valve open, and let it go. Check that the choke valve snaps back to the choke CLOSED position. SERVICE REMINDER #3 => Not normal Replace the carburetor. Normal Replace the choke control assembly. Start the engine and check to see if the choke flutters and opens as the engine warms up. Does not flutter Check the choke valve for freedom of movement. Hard to move Moves freely System operates normally. Flutters See if the choke valve opens after 5-8 minutes (opening time will vary based on load and ambient temperature). Choke opens fully Replace the carburetor assembly. Does not open or opens slowly Does not open: Check that the ACS control is installed correctly. The choke lever tab may be on the wrong side of the carburetor choke lever post, which will cause the choke to remain closed. If the ACS is installed correctly, replace the carburetor assembly (P. 8-1). Replace the choke control assembly. CHOKE LEVER TAB System operates normally. CARBURETOR CHOKE LEVER POST Opens slowly: • (K5 only) Apply Hondabond HT to heat sink and push heat sink against cylinder barrel to ensure good heat transfer (P. 8-16). • (K6~K7) Replace the thermowax (P. 8-17). • Be sure a BPR5ES spark plug is installed and not the cooler BPR6ES plug. The BPR5ES is less susceptible to fouling on ACS equipped engines. 2-26 SERVICE BULLETIN #106 => HRR216VKA SERVICE BULLETIN #100 => CHOKE CONTROL SYSTEM (ACS) (K8 ~ K11) With the engine cold, remove the paper element and check the choke valve. Partially or totally open Closed SERVICE INFORMATION SERVICE REMINDER #3 => Remove the carburetor. Turn and hold the choke arm in the choke CLOSED position. Push the choke valve open, and let it go. Check that the choke valve snaps back to the choke CLOSED position. Normal SERVICE BULLETIN #98 => Inspect the choke control assembly linkage for smooth operation (P. 2-28). If it operates properly, replace the thermowax (P. 8-18). CHOKE CONTROL ASSEMBLY CHOKE CONTROL LINKAGE THERMOWAX ASSEMBLY Abnormal Replace the carburetor (P. 8-1) Start the engine and check to see if the choke opens within 3 minutes. Opens too slowly or does not open Allow the engine to cool. Push the choke valve open and release it. The choke should open smoothly and snap closed when released. Hard to move Replace the carburetor assembly (P. 8-1) and the spark plug (P. 3-9). Normal Check that the choke control assembly is installed correctly. The choke lever tab may be on the wrong side of the choke lever post, which will prevent the choke from opening. This problem can occur if the carburetor is installed when the engine is still warm. CHOKE LEVER TAB Remove the carburetor and inspect the choke control assembly linkage for smooth operation (P. 2-28). If it operates properly, replace the thermowax assembly (P. 8-18). Normal CHOKE CONTROL ASSEMBLY CHOKE CONTROL LINKAGE THERMOWAX ASSEMBLY CARBURETOR CHOKE LEVER POST 2-27 SERVICE INFORMATION HRR216VKA SERVICE BULLETIN #100 => CHOKE CONTROL INSPECTION (K8 ~ K11) 1. Thread a flange nut onto an 8 x 20 mm or longer flange bolt until only 12 mm of threads are exposed beyond the nut. 12 mm 2. Position the 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 smoothly and springs back when released. If the auto-choke assembly does not return smoothly, it must be replaced. Push the bolt against the plunger. Make sure choke does not bind. 2-28 HRR216VKA SERVICE INFORMATION 9. FLYWHEEL BRAKE TROUBLESHOOTING Blade (engine) does not stop turning when the flywheel brake lever is released. Check the flywheel brake cable for binding. Abnormal Repair or replace the cable. Abnormal Correct as required (P. 9-1). Abnormal Replace engine stop switch (P. 9-1). Abnormal Replace flywheel brake pad (P. 9-1). OK Check the flywheel brake spring (P. 3-12). OK Check the engine stop switch (go to step 1 on page 2-20). OK Check flywheel brake pad (P. 3-12). 2-29 SERVICE INFORMATION HRR216VKA 10. TROUBLESHOOTING VIBRATION PROBLEMS Grass and debris lodged under mower deck. Yes Clean out mower deck. Yes Tighten blade bolts (P. 3-4). No Blades bolts loose. No Blades bent, damaged, or unbalanced by improper sharpening. Yes • Inspect blades (P. 3-4). • Replace blades (P. 3-4). • Check crankshaft runout. (P. 2-30). No Yes Engine speed excessive Check/adjust the engine rpm. No Engine mounting bolts loose. Yes Tighten the bolts (P. 5-2). No Mechanical damage, such as a bent crankshaft. Yes Check crankshaft runout (P. 2-30). CRANKSHAFT RUNOUT INSPECTION If the mower has excessive vibration, or if blade replacement is required because of damage caused by an object hitting the blade, inspect the crankshaft runout. 1. Turn the fuel valve to the OFF position, and tilt the mower on its side so the carburetor is up. 2. Disconnect the spark plug cap, and remove the spark plug (P. 3-9). 3. Remove the blades, blade holder, and drive pulley (P. 4-1). 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. DIAL INDICATOR (Commercially available) 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. BLADE HOLDER BOLT 7. Use the blade holder bolt and a wrench to rotate the crankshaft. Record the runout. Crankshaft Service limit 0.20 mm (0.008 in) 8. Replace the crankshaft if runout exceeds the service limit. 2-30 90° 90° 5-10 mm (0.20-0.39 in) 3. MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. MAINTENANCE SCHEDULE . . . . . . . . . . MAINTENANCE SPECIFICATIONS . . . . . ENGINE TUNE-UP SPECIFICATIONS . . . REAR SHIELD . . . . . . . . . . . . . . . . . . . . . . BLADES . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CLEANING. . . . . . . . . . . . . . . GRASS BAG . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG INSPECTION . . . . . . . . . . . 3-2 3-3 3-3 3-4 3-4 3-7 3-8 3-8 3-9 10. SPARK ARRESTER CLEANING (OPTIONAL PART) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 11. SMART DRIVE CABLE . . . . . . . . . . . . . . 3-10 12. FUEL TANK AND FILTER . . . . . . . . . . . . .3-11 13. FLYWHEEL BRAKE. . . . . . . . . . . . . . . . . 3-12 14. VALVE CLEARANCE. . . . . . . . . . . . . . . . 3-13 15. PINION GEAR . . . . . . . . . . . . . . . . . . . . . 3-15 16. REAR WHEEL ADJUSTER BUSHING . . 3-16 17. GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . 3-17 3-1 MAINTENANCE HRR216VKA 1. MAINTENANCE SCHEDULE 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 3-4 Blades Inspect O 3-4 Blade mounting bolts Inspect O 3-6 Check O 3-7 Engine oil Check Air filter O Change O (1) O O (2) O (2) O (2) Blade control operation Check Spark plug 3-8 O Replace Check 3-7 O Clean Grass bag O O 3-8 O O 3-12 O Check O Replace O 3-9 Spark arrester (optional part) Clean Smart Drive cable Adjust Fuel tank/filter Clean O 3-11 Flywheel brake pad Check O 3-12 Valve clearance Checkadjust O Pinion gears Grease O Rear wheel adjuster bushings Inspectgrease Fuel lines Check O O O O 3-9 O 3-13 3-15 O Check every 2 years and replace if necessary (1) Change engine oil every 25 hours when used under heavy load or in high outside air temperatures. (2) Service more frequently when used in dusty areas. Failure to follow this maintenance schedule could result in non-warrantable failures. 3-2 3-10 3-16 3-12 HRR216VKA MAINTENANCE 2. MAINTENANCE SPECIFICATIONS Item Specification See page Engine oil Capacity: 0.50 L (17 oz) * Refill amount: 0.35 ~ 0.40 L (12.0 ~ 13.5 oz) Use SAE 10W - 30 for general use. 3-7 Air cleaner Clean with compressed air, not exceeding 207 kPa (30 psi). 3-8 Spark plug NGK-BPR5ES Gap: 0.70 ~ 0.80 mm (0.028 ~ 0.031 in) 3-9 Spark Arrester (optional) Brush carbon deposits from screen. 3-9 Fuel tank Back flush with nonflammable solvent. 3-11 Fuel filter Remove the fuel filter from the fuel line and clean. 3-11 Fuel line Replace if damaged or deteriorated. 3-12 Valve clearance (cold) Intake:. . . . . . . . . . . . . . . . . . . . . . . . .0.15 ± 0.04 mm Exhaust: . . . . . . . . . . . . . . . . . . . . . . .0.20 ± 0.04 mm 3-13 Governor arm Adjust so shaft is 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 thickness service limit: 3.0 mm (0.12 in) 3-12 Pinion gear Lubricate with Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent. 3-15 Blades and blade bolts Sharpen or replace as necessary. Blade bolt torque: 49 ~ 59 N•m (36 ~ 43 ft-lb) 3-4 Grass bag Clean with a garden hose. Replace if worn or damaged. 3-8 Rear wheel adjuster bushing Inspect for corrosion or wear, and then apply Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent. 3-16 3. ENGINE TUNE-UP SPECIFICATIONS Item Specification See page Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 3-9 Engine idle speed (K5 thru K8 only) 1,700 ± 150 rpm 3-18 Valve clearance (cold) Intake: . . . . . . . . . . . . . . . . . . . . . . . . 0.15 ± 0.04 mm Exhaust: . . . . . . . . . . . . . . . . . . . . . . 0.20 ± 0.04 mm 3-13 Other specifications No other adjustments needed. 3-3 MAINTENANCE HRR216VKA 4. REAR SHIELD During normal use, the rear shield is subject to deterioration and wear. Remove the grass bag and raise the discharge guard. Check the rear shield for cracks or tears. If the rear shield is worn, replace it. To remove the shield, pry the push nut off the shaft using a flat blade screwdriver. If the shaft is crimped at the end, cut the shaft with a small hacksaw and replace the shaft. DISCHARGE GUARD REAR SHIELD 5. BLADES INSPECTION (K9~K11 Blades Shown) 1. Turn the fuel valve to the OFF position. This will reduce the possibility of fuel leakage when the mower is tilted. K9 MODEL SHOWN 2. Disconnect the spark plug cap. 3. Tilt the mower on its right side, so the carburetor is up. 4. Inspect the blades for damage, cracks, and excessive wear, rust, or corrosion. 5. Verify the blade bolts are tight. Blade bolt torque BLADE BOLTS BLADES 49 ~ 59 N•m (36 ~ 43 lbf-ft) 6. If the blades are bent or severely damaged, check the crankshaft runout (P. 2-30). 7. Dull blades can be sharpened, but blades that are worn out, bent, cracked, or otherwise damaged must be replaced. Normal Trailing edge EXCESSIVELY WORN Trailing edge NORMAL 3-4 WORN BENT CRACKED HRR216VKA MAINTENANCE REMOVAL 1. Turn the fuel valve to the OFF position, disconnect the spark plug, and tilt the mower on its right side. 2. Remove the two blade bolts and special washers from the blade control assembly. Use a wooden block to prevent the blades from turning when removing the bolts (page 3-6). UPPER BLADE LOWER BLADE SPECIAL WASHER (2) 3. Clean dirt and grass from around the blade mounting area. BLADE BOLT (2) SHARPENING CORRECT SHARPENING NOTICE Do not sharpen a blade that is damaged or excessively worn or corroded. 1. Grind or file the blades no more than necessary to remove nicks and restore straight, sharp cutting edges. • Always wear eye protection when operating a grinder. TAPER • Wear heavy gloves to protect your hands. • 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 of the cutting surface. Grinding or filing a step in the blades can create a weak point, causing cracks to develop in the blades during mower operation. 30° ~ 40° • Maintain the original bevel angle (30° ~ 40°) while sharpening. Do not alter the angle. • Remove equal amounts of material from both cutting edges to preserve symmetry and balance. 2. After sharpening, dress the cutting edges with a file so they will not be razor-sharp. Razor-sharp edges will easily chip and will quickly become dull. 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) The blades should be 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) thick at the cutting edges. 3-5 MAINTENANCE HRR216VKA 3. Check blade balance by placing the clean, sharpened blade on a dowel or screwdriver, as shown. A balanced blade will stay horizontal. If one end of the blade dips, grind or file the heavy end until good balance is achieved. NOTICE An unbalanced blade will cause abnormal vibration that may eventually damage the mower. INSTALLATION 1. Inspect the blade bolts for any signs of damage. If they are damaged, they must be replaced. K9 BLADES SHOWN 2. Install the blades using the two blade bolts and special washers, as shown. UPPER BLADE Install the special washers with the concave side toward the blades 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. LOWER BLADE BLADE BOLT [2] AND WASHER [2] SPECIAL WASHER DIRECTION 3. Tighten the blade bolts to the torque specification below. TORQUE: WOODEN BLOCK 49 ~ 59 N•m (36 ~ 43 ft-lb) TORQUE WRENCH TORQUE: 36 ~ 43 ft-lb 3-6 HRR216VKA MAINTENANCE 6. ENGINE OIL OIL LEVEL CHECK 1. Run the engine for a few minutes prior to draining to allow complete and rapid draining. 2. To check the oil level, remove the oil filler cap and wipe the dipstick clean. 3. Insert the dipstick in the oil filler neck, but don’t screw it in. Remove the dipstick and check the oil level. FILLER CAP/ DIPSTICK 4. Add the recommended oil to the upper limit mark on the dipstick. Do not overfill. LOWER LIMIT UPPER LIMIT 5. Tighten the oil filler cap securely. OIL CHANGE 1. Check that the fuel tank cap is tightened securely. 2. Remove the oil filler cap. Tilt the engine toward the oil filler cap side and drain the used oil into a suitable container. Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash or pour it on the ground or down a drain.  CAUTION Used engine oil contains substances that have been identified as carcinogenic. If repeatedly left in contact with the skin for prolonged periods, it may cause skin cancer. Wash your hands thoroughly with soap and water as soon as possible after contact with used engine oil. 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. Engine oil capacity 0.50 L (17 oz) Refill amount: 0.35 ~ 0.40 L (12.0 ~ 13.5 oz) 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 when the average temperature in your area is within the recommended range. The SAE oil viscosity and service classification are given in the API label on the oil container. Honda recommends that you use API service category SJ or later oil. 30 5W-30 • 10W-30 0 20 40 60 80 100°F -20 -10 0 10 20 30 40°C OUTSIDE AIR TEMPERATURE 3-7 MAINTENANCE HRR216VKA 7. AIR FILTER CLEANING A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If the engine is operated in dusty areas, clean the air filter more often than specified in the MAINTENANCE SCHEDULE. We recommend the use of a Honda Genuine air filter to ensure it seals and performs as designed. Using a nonHonda air filter can result in dirt bypassing the filter, causing damage to the engine or fuel system. NOTICE Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered by the Distributor’s Limited Warranty. 1. With the engine stopped, 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. A D N O 4. Clean the filter. 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 force dirt into the fibers. AIR CLEANER HOUSING COVER TABS FILTER COVER 5. Wipe dirt from the inside of the air cleaner housing and cover using a moist rag. Be careful to prevent dirt from entering the air duct leading to the carburetor. 6. Reinstall the filter and air cleaner cover. 8. GRASS BAG INSPECTION The grass bag is subject to wear during normal use. Inspect the bag for excessive wear or holes or tearing, and replace if necessary. CLEANING Wash a dirty grass bag with a garden hose, and allow it to dry completely before use. A wet bag will clog quickly. REPLACEMENT Replace a worn or damaged bag with a Honda Genuine replacement bag or its equivalent. BAG FRAME GRASS BAG HANDLE 1. Unclip the plastic edges of the bag from the frame. 2. Remove the bag from the frame. 3. Insert the frame into the replacement bag, as shown. 4. Clip the plastic edges of the bag onto the frame, as shown. 3-8 PLASTIC CLIP GRASS BAG HRR216VKA MAINTENANCE 9. SPARK PLUG INSPECTION Recommended spark plug NGK BPR5ES Using an incorrect spark plug can cause engine damage. Use the recommended spark plug or an exact equivalent. SPARK PLUG 1. Remove the spark plug with a 13/16 in (21 mm) spark plug wrench. 2. Visually inspect the spark plug. Discard the plug if the insulator is cracked or chipped. SPARK PLUG CAP 3. Measure the plug gap with a wire-type gauge. If necessary, adjust the gap by bending the side electrode. Spark plug gap 0.028 ~ 0.031 in (0.7 ~ 0.8 mm) 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 4. Make sure the sealing washer is in good condition and replace if necessary. SEALING WASHER 5. Install the plug finger-tight to seat the washer, then tighten with a plug wrench to compress the sealing washer: Tighten a new plug 1/2 turn after the plug seats. Tighten a reused plug 1/8 ~ 1/4 turn after the plug seats. Spark plug torque 20 N•m (14 lbf-ft) NOTICE A loose spark plug can overheat and damage the engine. Overtightening can damage the threads in the cylinder head. 10. SPARK ARRESTER CLEANING (OPTIONAL PART) SETSCREW D A The spark arrester must be serviced every 100 hours to keep it functioning as designed. 2. Remove the 4 x 6 mm self-tapping screw from the spark arrester, and remove the spark arrester from the muffler. Be careful not to damage the spark arrester screen. 3. Check for carbon deposits around the exhaust FLANGE BOLT (3) port and spark arrester. Clean with a wire brush, if necessary. Replace the spark arrester if there are any breaks or tears. H O N 1. Remove the three flange bolts from the muffler protector. SPARK ARRESTER HEAT SHIELD 4. Install the spark arrester and muffler protector in the reverse order of disassembly. 3-9 MAINTENANCE HRR216VKA 11. SMART DRIVE CABLE CABLE CHECK 1. With the engine off, use the multi-position adjuster to set the Smart Drive control in its lowest position. 2. Gradually push the Smart Drive control down while pulling the lawn mower backwards. The rear wheels should lock up before the Smart Drive paddles are straight down. Ideally, they should lock up at 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. ADJUSTER MARK JAM NUT 2. Without pushing the Smart Drive control, pull the lawn mower backwards to check wheel resistance. 3. If no wheel resistance exists, 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. 3-10 TIGHTEN LOOSEN HRR216VKA MAINTENANCE 12. FUEL TANK AND FILTER FUEL TANK DRAINING AND CLEANING  FUEL TANK WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and let it cool. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. 1. Turn the fuel valve to the OFF position. 2. Loosen the carburetor bowl set bolt and drain the fuel bowl into an approved container. 3. Turn the fuel valve to the ON position and allow the remaining fuel in the tank to fully drain. FUEL TUBE TUBE CLIP FUEL FILTER 4. Slide the tube clip back on the fuel tube. 5. Rotate the fuel tube to help release the tube from the fuel tank, and then pull the tube from the tank fitting. NOTICE Do not pry against the fuel tank with a screwdriver or other tool, or the fuel tank may become damaged. 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 before installation. Replace if necessary. 9. If the fuel filter is dirty, remove and clean the fuel tank (P. 8-23). 10. Insert the fuel filter into the fuel tank fitting. 11. Connect the fuel tube to the fuel tank fitting. 12. Position the fuel tube clip over the fuel tank fitting. 13. After assembly, check for fuel leaks. 3-11 MAINTENANCE HRR216VKA 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. Honda Power Equipment manufactured in 2009 and later uses low-permeation fuel tubes that have the CARB Executive Order (C-U-05-003, for example) printed on them. If you replace a low-permeation fuel tube, you must replace it with a low-permeation fuel tube that has the emissionscompliance identification number printed on it. If you replace a regular fuel tube, you can replace it 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. FUEL TUBE FUEL VALVE “D” STYLE CLAMP 13. FLYWHEEL BRAKE K5 thru K8 EMISSIONS-COMPLIANCE IDENTIFICATION NUMBER WIRE STYLE CLAMP 3.0 mm (0.12 in) INSPECTION 1. Remove the recoil starter (P. 7-1). 2. Remove the fan cover. 3. Measure the thickness of the brake shoe. Service limit 3.0 mm (0.12 in) FLYWHEEL BRAKE SHOE 4. If brake shoe thickness is less than the service limit, replace the flywheel brake shoe. K9~K11 Flywheel Brake Spring Installation Flywheel removal is required to install a new spring (P. 9-1). 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. 3-12 K9~K11 HRR216VKA MAINTENANCE FLYWHEEL BRAKE CABLE INSPECTION FLYWHEEL BRAKE LEVER 1. Start the engine outdoors. 2. Release the flywheel brake lever. The engine should stop in less than 3 seconds. If the flywheel brake does not operate properly, recheck the flywheel brake shoe. If the flywheel brake shoe is within the recommended service limit, check the engine stop switch circuit and check the flywheel brake cable for binding. Replace if necessary (P. 11-1). 14. VALVE CLEARANCE INSPECTION AND ADJUSTMENT Valve clearance inspection and adjustment must be performed with the engine cold. 1. Remove the spark plug cap from the spark plug. 6 x 12 mm FLANGE BOLT (4) 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 prying slowly at each corner. Discard the head cover and replace it with a new one. 5. To position the piston at top dead center of the compression stroke (both valves are fully closed), rotate the engine until the cam lobe is pointing away from the flywheel. CYLINDER HEAD COVER (Replace) FAN COVER/FUEL TANK MOUNTING STUD 6. Align the flywheel arrow alignment mark with the right rear fan cover/fuel tank mounting stud (K5 thru K8 only). ARROW ALIGNMENT MARK (K5 thru K8 ONLY) CAM LOBE POINTING STRAIGHT OUT 3-13 MAINTENANCE HRR216VKA 7. Insert a feeler gauge between the valve stem and the adjusting screw on the rocker arm. Standard valve clearance (cold) IN 0.15 ± 0.04 mm EX 0.20 ± 0.04 mm FEELER GAUGE TOOL: Valve adjustment wrench, 3 mm 07908-KE90200 VALVE ADJUSTMENT LOCK NUT 8. If adjustment is necessary: a. Hold the adjustment screw using the special tool, and loosen the lock nut.  VALVE b. Turn the adjustment screw to obtain the specified intake and exhaust valve clearance. ADJUSTMENT WRENCH, 3 mm 07908-KE90200 c. Hold the adjusting screw using the special tool, and tighten the lock nut. TORQUE:8 N•m (5.8 ft-lb) d. Recheck valve clearance after tightening the lock nut. VALVE ADJUSTMENT SCREW VALVE ADJUSTMENT LOCK NUT 8 N•m (5.8 ft-lb) 9. Thoroughly clean the old sealant from the cylinder head surface using an abrasive cloth and brake cleaner. 10. Apply liquid gasket (Hondabond HT, Three Bond 1216, Loctite 5900 or equivalent) to a new cylinder head cover sealing surface, and install the cylinder head cover (P. 10-3). 3-14 VALVE STEM To increase valve clearance, screw out. To decrease valve clearance, screw in. HRR216VKA MAINTENANCE 15. PINION GEAR LUBRICATION  1. Remove the 8 x 12 mm wheel bolt and the rear wheel. 2. Remove the wheel washer and the flat washer. RATCHET KEY 3. Remove the 13 mm circlip, pinion gear collar, and the pinion gear. 4. Inspect the pinion gear and ratchet key for wear or damage. Replace as necessary. 5. Apply Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent to the pinion gear, axle, and ratchet spring. PINION GEAR (12 tooth) PINION GEAR COLLAR   RATCHET SPRING  PINION GEAR COLLAR AXLE 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. Install with the punch mark facing: Left - inside Right - outside 13 mm CIRCLIP FLAT WASHER 6. Reassemble in the reverse order of disassembly. WHEEL BOLT REAR WHEEL WHEEL WASHER REASSEMBLY: Install the washer as shown. Install the curved wheel washer in the direction shown. 3-15 MAINTENANCE HRR216VKA 16. REAR WHEEL ADJUSTER BUSHING LUBRICATION 1. Drain the fuel and engine oil. 2. Put a protective pad around the upper handle pipe. Turn the lawn mower over. Tip it UP and secure the upper handle pipe in a vise. 3. Remove the rear wheel, pinion gear, ratchet key and spring, wheel cover, and all collars and circlips from the transmission axle. 4. (K5 thru K8 only): Remove the rear scroll and drive belt (P. 4-2), and then disconnect the tension spring.   PINION GEAR  RATCHET KEY THRUST COLLAR RATCHET SPRING FLAT WASHER  Install with the punch mark facing: Left - inside Right - outside 3 mm PINION GEAR COLLAR (2) AXLE 13 mm CIRCLIP (2) WHEEL COVER WHEEL WASHER REASSEMBLY: FLAT WASHER Install the washer as shown. WHEEL BOLT REAR WHEEL Install the curved wheel washer in the direction shown. 5. Remove the 22 mm circlip, and then slide the circlip and the washer inward toward the transmission. ADJUSTER ASSEMBLY 6. Remove the adjuster assembly, taking care not to damage the seal. 7. Inspect the bushing and seals for wear and replace as necessary. WASHER 8. Thoroughly clean the bushing contact areas on the axle using a Scotch-Brite™ pad. CIRCLIP 9. 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 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. 10. Reinstall the adjuster assembly and secure with the washer and circlip. 11. Reassemble the rear wheel in the reverse order of removal, applying grease as shown. 12. Perform this procedure for the other side. 3-16  Clean bushing contact areas with a Scotch-Brite™ pad. HRR216VKA MAINTENANCE 17. GOVERNOR SERVICE BULLETIN #106 => MAXIMUM SPEED ADJUSTMENT 1. Loosen the governor arm nut on the governor arm. GOVERNOR ARM 2. Push the governor arm away from the carburetor to open the carburetor throttle valve fully. 3. Hold the carburetor throttle valve fully open, and turn the governor arm shaft clockwise fully. Tighten the governor arm nut to the specified torque. FUEL VALVE PLATE GOVERNOR ARM SHAFT TORQUE:10 N•m (7 ft-lb) 4. Verify that the governor arm and the carburetor throttle valve arm operate smoothly. GOVERNOR SPRING TAB GOVERNOR SPRING 5. Start the engine and warm it up to the normal operating temperature. 6. Have an assistant hold the flywheel brake lever while you perform the maximum engine speed adjustment.  DANGER BEND INCREASE SPEED BEND DECREASE SPEED GOVERNOR ARM NUT The blades are rotating during this procedure. The rotating blades will cause amputation if you come in contact with the blades. Do not allow your hands or feet to come into contact with the rotating blades while performing this procedure. 7. Check the maximum engine speed. Maximum speed (no load) K5 ~ K8 2,950 ~ 3,100 rpm K9 ~ K11 2,950 ~ 3,050 rpm 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. 3-17 MAINTENANCE HRR216VKA IDLE SPEED ADJUSTMENT (K5 THRU 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 speed. Engine idle speed 3-18 1,700 ± 150 rpm THROTTLE STOP SCREW 4. BLADE HOLDER/DRIVE BELT 1. BLADE HOLDER . . . . . . . . . . . . . . . . . . . . 4-1 2. DRIVE BELT (K5, K6) . . . . . . . . . . . . . . . . 4-2 3. DRIVE BELT (K7). . . . . . . . . . . . . . . . . . . . 4-4 4. DRIVE BELT (K8). . . . . . . . . . . . . . . . . . . . 4-6 5. DRIVE BELT (K9/K10/K11) . . . . . . . . . . . . 4-7 1. BLADE HOLDER REMOVAL/INSTALLATION 1. Turn the fuel 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. Remove the two blade bolts and special washers, and then remove the blades (page 3-5). 5. Remove the 3/8-24 x 1” flange 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 crankshaft from the slot for the drive pulley key. K9~K11 BLADES SHOWN UPPER BLADE WOODRUFF KEY BLADE HOLDER LOWER BLADE SPECIAL WASHER (2) 3/8-24 X 1” FLANGE BOLT DRIVE PULLEY BLADE BOLT (2) • Use a torque wrench to tighten the blade bolts and blade holder bolt. TORQUE:49 ~ 59 N•m (36 ~ 43 ft-lbs) 4-1 BLADE HOLDER/DRIVE BELT HRR216VKA 2. DRIVE BELT (K5, K6) REMOVAL 1. Disconnect the spark plug cap. 2. Drain the fuel tank and engine oil. 3. Put a protective pad around the upper handle pipe. Tip the mower upside down and secure the upper handle pipe in a bench vise. 4. Remove the 4 flange bolts and the belt cover. 5. Place a large screwdriver between the belt tension arm and transmission cover. Rotate the transmission to loosen and remove the drive belt from the driven pulley. BELT COVER FLANGE BOLT (4) SCREWDRIVER BELT TENSION ARM 6. Remove the belt from the drive pulley. DRIVEN PULLEY DRIVE BELT DRIVE PULLEY 7. Remove the belt tension spring from the tension arm by using a large flat blade screwdriver and lifting the spring hook off the tension arm as shown. SCREWDRIVER BELT TENSION ARM 8. Remove the belt from the lawn mower. BELT TENSION SPRING 4-2 HRR216VKA BLADE HOLDER/DRIVE BELT INSTALLATION BELT TENSION ARM 1. Install the drive belt around the drive pulley. Be sure the drive belt is positioned between the driven pulley on the transmission and the belt tension spring. 2. Using a large flat blade screwdriver, hook the belt tension spring on the belt tension arm. DRIVEN PULLEY DRIVE BELT 3. Place a large screwdriver between the belt tension arm and transmission cover. Rotate the transmission as shown, and install the drive belt around the driven pulley. BELT TENSION SPRING BELT COVER 4. Install the belt cover. BELT TENSION ARM DRIVE PULLEY DRIVE BELT 4-3 BLADE HOLDER/DRIVE BELT HRR216VKA 3. DRIVE BELT (K7) REMOVAL 1. Disconnect the spark plug cap. 2. Drain the fuel tank and engine oil. 3. Put a protective pad around the upper handle pipe. Tip the mower up and secure the upper handle pipe in a bench vise. 4. Remove the 4 flange bolts and the belt cover. BELT COVER FLANGE BOLT (4) SCREWDRIVER 5. Place a large screwdriver between the belt tension arm and transmission cover. Rotate the transmission to loosen and remove the drive belt from the driven pulley. BELT TENSION ARM 6. Remove the belt from the drive pulley. DRIVE BELT DRIVEN PULLEY DRIVE PULLEY 7. Remove the belt tension spring from the tension arm by using a large flat blade screwdriver and lifting the spring hook off the tension arm as shown. BELT TENSION ARM 8. Remove the belt from the lawn mower. DRIVE BELT SCREWDRIVER BELT TENSION ARM 4-4 BELT TENSION SPRING HRR216VKA BLADE HOLDER/DRIVE BELT INSTALLATION 1. Install the drive belt around the drive pulley. Be sure the drive belt is positioned between the driven pulley on the transmission and the belt tension spring. 2. Using a large flat blade screwdriver, hook the belt tension spring on the belt tension arm. BELT TENSION ARM DRIVEN PULLEY SCREWDRIVER DRIVE BELT BELT TENSION SPRING DRIVE BELT 3. Place a large screwdriver between the belt tension arm and transmission cover. Rotate the transmission as shown, and install the drive belt around the driven pulley. 4. Install the belt cover. BELT COVER FLANGE BOLT (4) SCREWDRIVER BELT TENSION ARM DRIVEN PULLEY DRIVE BELT DRIVE PULLEY 4-5 BLADE HOLDER/DRIVE BELT 4. DRIVE BELT (K8) HRR216VKA SERVICE BULLETIN #104 => REMOVAL 1. Turn the fuel valve OFF and disconnect the spark plug cap. 2. Completely loosen the Smart Drive cable (page 11-19). 3. Tilt the mower on its right side with the fuel filler cap up. 4. Remove the blades and the blade holder (page 3-4). 5. Remove the rear scroll and belt cover assembly (page 4-4). 6. Remove the drive pulley and the drive belt from the crankshaft. Do not remove the belt guide. 7. Disconnect the drive cable and the return spring from the transmission. 8. Hold the input shaft end with 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. SMART DRIVE CABLE INPUT SHAFT RETURN SPRING 10 mm FLANGE NUT 40 N•m (30 ft-lb) DRIVE BELT 10 x 24 mm WASHER BELT GUIDE DRIVE PULLEY DRIVEN PULLEY INSTALLATION 1. Install in the reverse order of removal. Be sure to do the following items: • Be sure to install the 10 x 24 mm washer on the transmission input shaft before assembling the pulley. • Align the holes in the transmission pulley halves when reassembling the pulley. • Be sure to tighten the blade holder and blade bolts using a torque wrench. 2. Adjust the Smart Drive cable (page 3-10). 3. Start the engine and test the drive system. 4-6 HRR216VKA BLADE HOLDER/DRIVE BELT 5. DRIVE BELT (K9/K10/K11) REMOVAL/INSTALLATION 1. Turn the fuel valve OFF. SERVICE BULLETIN #104 => 2. Disconnect the spark plug cap. 3. Move the Clip Director® to the fully open (BAG) position. 4. Fully loosen the Smart Drive cable adjuster (page 11-19). 5. Turn the mower on its right side with the gas filler cap up. 6. Remove the blades and blade holder (page 3-4). 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. [1] [2] [3] [2] [1] [1] 8. Serial numbers MZCG-9506882 ~ 9999999 and MZCG-1000001 ~ 1999999: Remove the belt guide. 9. Remove the Woodruff key, slide the drive pulley away from the engine, and remove the V-belt from the drive pulley. Do not remove the belt guide for mowers with a frame serial number before MZCG-9506882. V-BELT DRIVE PULLEY BELT GUIDE 10. Rotate the transmission and remove the Smart Drive cable and the return spring. 4-7 BLADE HOLDER/DRIVE BELT HRR216VKA 11. Hold the end of the transmission input shaft with an adjustable wrench and remove the 10 mm flange nut. 12. Remove the driven pulley, 10 mm washer, and the V-belt from the transmission. INPUT SHAFT 13. Install in the reverse order of removal. Pay attention to the following: • Be sure to install the 10 mm washer on the transmission input shaft before assembling the driven pulley. FLANGE NUT 10 mm • Align the holes in the driven pulley halves when reassembling the pulley. • Be sure the blade holder 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 during operation. • Serial numbers MZCG-9506882 ~ 9999999 and MZCG-1000001 ~ 1999999: Adjust the belt guide clearance (P. 2-14). • Be sure the Clip Director® is fully open (BAG) when installing the rear scroll. SPECIAL NUT • Align the lower Clip Director® hinge pin with the hole in the scroll. • Use a long flat blade screwdriver and a piece of tape to hold the upper special nut in place while installing the shoulder screw in the center of the rear scroll. • Readjust the Smart Drive cable (P. 3-10). 4-8 5. ENGINE REMOVAL/INSTALLATION 1. REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1. REMOVAL 2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 5-2 SERVICE BULLETIN #98 => 1. Disconnect the spark plug cap. K9~K11 BLADES SHOWN 2. Drain the gasoline from the fuel tank into an approved container. 3. Drain the engine oil (page 3-7). 4. Release the recoil starter rope from the handlebar rope guide. 5. Disconnect the flywheel brake cable from the engine. UPPER BLADE LOWER BLADE BELT GUIDE ENGINE MOUNTING BOLT (4) WOODRUFF KEY BLADE HOLDER SPECIAL WASHER (2) 6. Remove the blades. 7. Remove the 3/8-24 x 1" flange bolt 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. BLADE BOLT (2) DRIVE PULLEY 3/8-24 x 1" FLANGE BOLT 9. Slide the drive pulley off the crankshaft and remove the V-belt. 10. Support the engine, remove the four 5/16-24 x 1" engine mounting flange bolts, and remove the engine. 5-1 ENGINE REMOVAL/INSTALLATION HRR216VKA 2. INSTALLATION 1. Set the engine on the mower deck and install the four 5/16-24 x 1” engine mounting flange bolts. TORQUE: 22 N•m (16 ft-lbs) 2. Slide the V-belt over the drive pulley, and then slide the pulley on the crankshaft. 3. K9 through K11 models: serial numbers MZCG-9506882~9999999 and MZCG-1000001 ~ 1999999: Reinstall 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 ~ 43 ft-lbs) CRANKSHAFT WOODRUFF KEY 5. Attach the blades using the two special bolts and washers. TORQUE: 49 ~ 59 N•m (36 ~ 43 ft-lbs) BLADE HOLDER UPPER BLADE WASHER LOWER BLADE SPECIAL BLADE BOLT 6. Connect the flywheel brake cable to the engine. 7. Attach the recoil starter rope to the handlebar rope guide. 8. Add oil (page 3-7) and gasoline before starting the engine. 5-2 6. MUFFLER 1. REMOVAL/INSTALLATION . . . . . . . . . . . . 6-1 1. REMOVAL/INSTALLATION  CAUTION The engine and muffler become very hot during operation, and they remain hot for a while after operation. Be sure that the engine is cold before muffler removal/installation. 4 x 6 mm SELF-TAPPING SCREW (optional part) SPARK ARRESTER (optional part) INSTALLATION: Install after removing the carbon from the screen with a wire brush. SPARK ARRESTER IDENTIFICATION PLATE (optional part) 6 x 12 mm SCREW, (3) MUFFLER GASKET (optional part) Install a gasket anytime the muffler has been removed. MUFFLER MUFFLER PROTECTOR 6 x 79 mm FLANGE BOLT (2) 12 N•m (9 ft-lb) INSTALLATION: • Use a plastic hammer to loosen carbon deposits from the muffler, and then remove the 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 the muffler. • Check the cylinder exhaust port for damage, and install the muffler. MUFFLER SEAL FLANGE EXHAUST PORT 6-1 MUFFLER HRR216VKA NOTES 6-2 7. RECOIL STARTER 1. REMOVAL/INSTALLATION . . . . . . . . . . . . 7-1 1. REMOVAL/INSTALLATION 2. STARTER ROPE REPLACEMENT . . . . . . 7-2 SERVICE REMINDER #4 => • If the starter rope is frayed or worn out, replace the starter rope (P. 7-2). • Do not disassemble the recoil starter assembly . RECOIL STARTER ASSEMBLY 6 mm FLANGE NUT (3) 8.3 N•m (6.1 ft-lb) 7-1 RECOIL STARTER HRR216VKA 2. STARTER ROPE REPLACEMENT Starter Rope and Reel Intact 1. Pull starter grip until the starter rope is pulled out fully. 2. To prevent the starter reel from rewinding, hold the starter reel and starter case with a band or equivalent material as shown. 3. Untie the knots of the starter rope at the starter grip side and 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 rewind. 7. Check the operation of the ratchets by pulling the starter rope several times. BAND STARTER CASE STARTER REEL STARTER REEL STARTER ROPE STARTER GRIP RATCHETS 7-2 HRR216VKA Starter Rope Broken Or Reel Unwound 1. Turn the starter reel in the direction of the arrow six turns. Align the rope hole in the starter case with the rope hole in the starter reel. RECOIL STARTER ALIGN HOLES STARTER REEL 2. Pass the starter rope through the starter 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 slip knot at the end of the rope. 4. Remove the band holding the starter reel and carefully allow the starter reel to rewind. STARTER CASE 5. Check the operation of the ratchets by pulling the starter rope several times. STARTER REEL STARTER ROPE STARTER GRIP RATCHETS 7-3 RECOIL STARTER HRR216VKA NOTES 7-4 8. FUEL SYSTEM 1. AIR CLEANER/CARBURETOR REMOVAL/INSTALLATION . . . . . . . . . . . . 8-1 2. CARBURETOR DISASSEMBLY/REASSEMBLY. . . . . . . . . 8-5 3. FUEL VALVE/GOVERNOR ARM. . . . . . . 8-21 4. FAN COVER/FUEL TANK . . . . . . . . . . . . 8-24 5. EVAPORATIVE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 1. AIR CLEANER/CARBURETOR REMOVAL/INSTALLATION NOTICE If the carburetor is removed before the engine has completely cooled, the thermowax plunger may still be extended. The plunger will not retract when the thermowax assembly is allowed to cool after removal without a continuous force applied (see page 8-18). Before removing the carburetor, allow the engine to cool long enough for the choke to completely close. This typically requires about 20 minutes.  WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and let it cool. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. 1. Turn the fuel valve to the OFF position. 2. Completely drain the carburetor (page 3-11). 3. Remove the air cleaner cover and air filter. 4. Remove one 6 x 86 mm flange bolt securing the air cleaner case, and temporarily replace it with a 6 x 83 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. FUEL VALVE 6 x 86 mm FLANGE BOLT (2) AIR CLEANER CASE AIR CLEANER COVER 6 x 83 mm STUD (2) Temporarily installed. P/N 90013-ZG9-T00 AIR FILTER 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. 8-1 FUEL SYSTEM HRR216VKA 8. Remove the throttle return spring from the carburetor throttle lever. 9. Rotate the carburetor in the direction shown, and remove the governor rod from the carburetor throttle lever. 10. The insulator, air guide, and gaskets do not need to be removed unless the gaskets are damaged and need to be replaced. Reinstall in the reverse order from removal. K5 VERSION GOVERNOR ROD/THROTTLE RETURN SPRING THROTTLE RETURN SPRING GOVERNOR ROD INSTALLATION: P. 8-21 INSTALLATION: P. 8-21 REMOVAL: Remove the throttle return spring, and then rotate the carburetor in the direction shown and remove the governor rod from the carburetor. GOVERNOR SPRING INSTALLATION: P. 8-21 CARBURETOR DISASSEMBLY/REASSEMBLY: P. 8-5 CLEANING: P. 8-6 INSPECTION: P. 8-15 CONTROL BASE DISASSEMBLY/REASSEMBLY: P. 8-21 INSULATOR GASKET Replace. SERVICE BULLETIN #66 => CHOKE CONTROL ASSEMBLY TROUBLESHOOTING: P. 2-26 INSTALLATION: P. 8-16 AIR GUIDE 6 x 45 mm FLANGE BOLT CARBURETOR GASKET Replace. TUBE CLIP (4) IDENTIFICATION: P. 8-23 CRANKCASE BREATHER TUBE INSTALLATION: P. 8-20 6 x 83 mm FLANGE BOLT (2) 9.8 N•m (7.2 ft-lb) PAPER ELEMENT CLEANING: P. 3-8 AIR CLEANER GASKET 6 x 83 mm STUD (2) PART NUMBER: 90013-ZG9-T00 Temporarily install to make carburetor installation easier. 8-2 AIR CLEANER COVER HRR216VKA FUEL SYSTEM K6 ~ K7 VERSION SERVICE BULLETIN #98 => GOVERNOR ROD/THROTTLE RETURN SPRING REMOVAL: Remove the throttle return spring, and then rotate the carburetor in the direction shown and remove the governor rod from the carburetor. THROTTLE RETURN SPRING GOVERNOR ROD INSTALLATION: P. 8-22 INSTALLATION: P. 8-22 GOVERNOR SPRING INSTALLATION: P. 8-22 FUEL VALVE ASSEMBLY DISASSEMBLY/REASSEMBLY: P. 8-22 B12 TUBE CLIP (2) IDENTIFICATION: P. 8-23 6 x 28 mm FLANGE BOLT 6 x 12 mm FLANGE BOLT THERMOWAX ASSEMBLY B8 TUBE CLIP (2) INSULATOR GASKET CARBURETOR GASKET Replace. IDENTIFICATION: P. 8-23 Replace. CHOKE CONTROL ASSEMBLY (without heat sink) TROUBLESHOOTING: P. 2-26 INSTALLATION: P. 8-17 SPACER AIR GUIDE GASKET AIR CLEANER GASKET Replace. Replace. CARBURETOR DISASSEMBLY/REASSEMBLY: P. 8-5 CLEANING: P. 8-6 INSPECTION: P. 8-15 PAPER ELEMENT AIR CLEANER CASE CRANKCASE BREATHER TUBE INSTALLATION: P. 8-20 CLEANING: P. 3-8 6 x 83 mm STUD (2) PART NUMBER: 90013-ZG9-T00 Temporarily install to make carburetor installation easier. 6 x 86 mm FLANGE BOLT (2) 10 N•m (7 ft-lb) AIR CLEANER COVER 8-3 FUEL SYSTEM HRR216VKA K8 ~ K11 VERSION SERVICE BULLETIN #98 => K8 MODEL SHOWN GOVERNOR ROD/THROTTLE RETURN SPRING REMOVAL: Remove the throttle return spring, and then rotate the carburetor in the direction shown and remove the governor rod from the carburetor. THROTTLE RETURN SPRING INSTALLATION: P. 8-21 GOVERNOR ROD INSTALLATION: P. 8-21 GOVERNOR SPRING INSTALLATION: P. 8-21 THERMOWAX ASSEMBLY FUEL VALVE ASSEMBLY INSPECTION: P. 8-18 Apply a small amount of Hondabond HT to the bottom and lower third of the new thermowax, as shown. Do not apply too much. B12 TUBE CLIP (2) 6 x 28 mm FLANGE BOLT 6 x 12 mm FLANGE BOLT B8 TUBE CLIP (2) K9 MODEL HAS A ROUND INTAKE PORT K8 INSULATOR GASKET K9/K10/K11 Replace. CARBURETOR GASKET (K8 ONLY) Replace. SPACER (K8 ONLY) CHOKE CONTROL ASSEMBLY TROUBLESHOOTING: P. 2-27 INSTALLATION: P. 2-27 AIR GUIDE GASKET Replace. CARBURETOR DISASSEMBLY/REASSEMBLY: P. 8-5 CLEANING: P. 8-6 INSPECTION: P. 8-15 CRANKCASE BREATHER TUBE INSTALLATION: P. 8-20 8-4 AIR CLEANER GASKET Replace. AIR CLEANER CASE (K8) AIR CLEANER CASE (K9/K10/K11) HRR216VKA FUEL SYSTEM 2. CARBURETOR DISASSEMBLY/REASSEMBLY Clean the outside of the carburetor before disassembly.  WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and let it cool. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. STANDARD VERSIONS Carburetor BB65E A PART Main jet Float height ITEM #70 9.2 mm (0.36 in) K5 Carburetor BB75E A Main jet Float height #68 7.2 mm (0.28 in) K5 Carburetor BB75E B Main jet Float height #68 7.2 mm (0.28 in) K6, K7 Carburetor BB75E C Main jet Float height #68 7.2 mm (0.28 in) K8 Carburetor BB76A A Main jet Float height #60 10.2 mm (0.40 in) K9, K10, K11 NOTICE Tampering is a violation of federal and California law. 5 x 6 mm ACCESS SCREW INSPECTION: Remove access screw PILOT JET (non-removable) to clean the slow speed jet. REASSEMBLY: Clean thoroughly with compressed air (30 psi max). THROTTLE STOP SCREW (K5 ~ K8) CARBURETOR BODY FLOAT VALVE CLEANING: P. 8-6 REASSEMBLY: Clean internal passages and orifices with compressed air (30 psi max) before installation. REASSEMBLY: Check for worn float valve seat and float valve before installation. MAIN NOZZLE REASSEMBLY: Clean thoroughly with compressed air (30 psi max) before installation. FLOAT VALVE MAIN JET OK REPLACE Standard main jet size: P. 2-2 REASSEMBLY: Clean thoroughly with compressed air (30 psi max) before installation. FLOAT PIN SET GASKET FLOAT REASSEMBLY: Check for smooth movement after installation. FLOAT CHAMBER INSPECTION: P. 8-15 SET BOLT SEALING WASHER REASSEMBLY: After assembly, check for any signs of fuel leakage. 8-5 FUEL SYSTEM HRR216VKA CLEANING Use the jet cleaner set special tool (P/N 07JPZ-001010B) and Honda Carburetor Cleaner (P/N 08732-CC000) with its plastic spray nozzle to clean the carburetor ports. Some commercially available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as O-rings, floats, choke valves, and float valve seats. Check the container for instructions. If you are in doubt, do not use these products to clean Honda carburetors. NOTICE High air pressure may damage the carburetor. Use low pressure settings when cleaning passages. BEFORE 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.  CAUTION Always wear a face shield or safety glasses when using carburetor cleaner or compressed air. Applying pressure into small passages can cause fluid and air to shoot back into your face. CLEANING PROCEDURE 1. Thoroughly clean the outside of the carburetor body using carburetor cleaner and compressed air. Inspect the carburetor body, throttle and choke levers, and pilot screw (if equipped) (including limiter cap) for damage. If any damage exists, carburetor replacement may be necessary. 8-6 HRR216VKA FUEL SYSTEM 2. Remove the set bolt, float chamber, float pin, float valve, and float. Clean and then inspect the float valve tip for damage and replace if necessary. 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, spray carburetor cleaner around the nozzle to loosen it and tap the carburetor on the workbench. SCREWDRIVER 4. Remove the throttle stop screw and spring (if applicable). 8-7 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 8-8 HRR216VKA FUEL SYSTEM 7. Clean the main nozzle thoroughly using carburetor cleaner, appropriate size jet cleaning tool, and compressed 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. 8-9 FUEL SYSTEM HRR216VKA 8. Clean the main jet by spraying carburetor cleaner through the jet and using the appropriate size jet cleaning tool and compressed 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. Carefully inspect the main jet for damage or contamination. JET CLEANER 07JPZ-001010B 9. Clean the main jet and nozzle bore thoroughly using carburetor cleaner and compressed air. 10. Inspect the inside of the bore for contamination. 8-10 MAIN JET AND NOZZLE BORE HRR216VKA FUEL SYSTEM 11. Clean the pilot jet thoroughly by using the appropriate size jet cleaning tool, carburetor cleaner, and compressed air. The passage is small and easily obstructed, so repeat several times. PILOT JET 12. Clean the high speed air passage with carburetor cleaner and compressed air. HIGH SPEED AIR PASSAGE 8-11 FUEL SYSTEM HRR216VKA 13. Clean the float chamber vent hole with carburetor cleaner and compressed air. FLOAT CHAMBER VENT HOLE 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. 8-12 SLOW SPEED AIR PASSAGE HRR216VKA FUEL SYSTEM 15. Reinstall the 5 x 6 mm screw covering the pilot jet. 16. Check 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. SLOW SPEED AIR PASSAGE CHOKE SIDE THROTTLE SIDE Steady stream around the transition ports. 8-13 FUEL SYSTEM HRR216VKA 17. Reinstall the throttle stop screw and spring (if applicable) Tighten the screw just far enough so the throttle plate begins to open. Adjust so throttle plate just begins to open. 18. Reinstall the main nozzle and main jet, making sure the nozzle long end extends into the venturi. Nozzle extension 8-14 HRR216VKA FUEL SYSTEM 19. Install the float valve, float, and float chamber. Make sure the float chamber is installed correctly, making a good seal with the gasket. 20. Reinstall the carburetor on the engine, turn the fuel valve on, and check for fuel leaks. 21. Start the engine and allow 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 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: See page 2-2 If the height is out of specification, replace the float and/or the float valve. Recheck the float height.  FLOAT LEVEL GAUGE 8-15 FUEL SYSTEM CHOKE CONTROL ASSEMBLY (K5) HRR216VKA HEAT SINK Apply a 3 ~ 5 mm thick bead of Hondabond HT to the bottom surface of the heat sink as shown. INSTALLATION 1. Install the choke assembly when the cylinder head temperature is less than 40 °C (104 °F). 2. Apply a small amount (3 ~ 5 mm thick bead) of Hondabond HT Silicone (P/N 08718-0004) to the bottom of the auto-choke 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 (P. 8-2). 5. After installation, verify that there is clearance between choke lever A and the carburetor choke lever. CHOKE LEVER A CLEARANCE EXISTS 8-16 CARBURETOR CHOKE LEVER HRR216VKA FUEL SYSTEM CHOKE CONTROL ASSEMBLY (K6 THRU K7) INSTALLATION THERMOWAX ASSEMBLY 1. Install the choke assembly when the cylinder head temperature is less than 40 °C (104 °F). 2. Install the thermowax 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 there is clearance between choke lever A and the carburetor choke lever. INSULATOR GASKET Replace. CHOKE ASSEMBLY CHOKE LEVER A CLEARANCE EXISTS CARBURETOR CHOKE LEVER 8-17 FUEL SYSTEM HRR216VKA CHOKE CONTROL ASSEMBLY (K8 thru K11) Thermowax Installation The thermowax plunger MUST be fully retracted and the overall length of the thermowax must be 21.5 to 23.0 mm before installation. If the thermowax plunger is not fully retracted, proceed with the steps below to fully retract the plunger prior to reassembly. 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. Place the thermowax under warm tap water (not exceeding 40 °C or 104 °F) and gently squeeze pliers until the plunger is fully retracted. Be careful not to apply too much force or bend the thermo plunger. Only 15 N (3.4 lbs) of force is required to push the plunger in. Measure the thermowax and confirm the length is 21.5 to 23.0 mm. 8-18 21.5~23.0 mm HRR216VKA FUEL SYSTEM Thermowax removal Follow the steps below if you need to remove the thermowax assembly. NOTICE Removing the thermowax assembly will ruin it. A new assembly will be required for replacement. 1. Use a small pair of pliers to pull the plunger out of the assembly. 2. Screw a one-inch or longer #6 screw into the thermowax where the plunger was removed. 3. Use 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 scraper to remove the old sealant from the cylinder barrel. Carburetor cleaner or brake cleaner and a small wire brush can help remove the sealant. Use compressed air to blow residue from the cylinder barrel. Removing the sealant, particularly in the rear of the socket, is important; the new thermowax assembly must be pushed completely into the socket to operate the choke properly. 8-19 FUEL SYSTEM HRR216VKA Choke Assembly Installation 1. Install the choke assembly when the cylinder head temperature is less than 40 °C (104 °F). 2. Apply a small amount of Hondabond HT or Loctite 5900 to the bottom and lower third of the new thermowax. Do not apply too much. 3. Install the thermowax assembly into the cylinder barrel. The plunger must remain fully retracted during assembly. 4. Verify that the carburetor choke lever is in the fully closed position. THERMOWAX ASSEMBLY 5. Install the carburetor and choke assembly (page 8-4). CHOKE ASSEMBLY HONDABOND HT 6. After installation, verify that there is clearance between choke lever A and the carburetor choke lever. INSULATOR GASKET Replace. CHOKE LEVER A CLEARANCE EXISTS CARBURETOR CHOKE LEVER BREATHER TUBE Installation Connect the end with the white mark to the breather cover hole as shown. Connect the other end to the air cleaner case. WHITE MARK BREATHER TUBE 8-20 BREATHER COVER HRR216VKA FUEL SYSTEM 3. FUEL VALVE/GOVERNOR ARM SERVICE BULLETIN #106 => DISASSEMBLY/REASSEMBLY (K5) GOVERNOR ARM/THROTTLE RETURN SPRING INSTALLATION: Install the governor rod through the throttle return spring as shown. Connect each to the governor arm and carburetor throttle arm as shown. THROTTLE ARM GOVERNOR ARM GOVERNOR ROD LONG END LONG END THROTTLE RETURN SPRING GOVERNOR ARM ADJUSTMENT: P. 3-17 GOVERNOR SPRING REASSEMBLY: Install with the short end side toward the governor arm. GOVERNOR ARM BOLT GOVERNOR ARM NUT 9.8 N•m (7.2 ft-lb) FUEL TUBE IDENTIFICATION: P. 8-23 CONTROL BASE 5 x 10 mm SCREW-WASHER 6 x 45 mm FLANGE BOLT 2.9 N•m (2.2 ft-lb) COLLAR FUEL VALVE TUBE CLIP (4) IDENTIFICATION: P. 8-23 5.5 x 150 mm FUEL HOSE IDENTIFICATION: P. 8-23 8-21 FUEL SYSTEM HRR216VKA DISASSEMBLY/REASSEMBLY (K6 thru K11) GOVERNOR ARM/THROTTLE RETURN SPRING INSTALLATION: Install the governor rod through the throttle return spring as shown. Connect each to the governor arm and carburetor throttle arm as shown. THROTTLE ARM GOVERNOR ARM GOVERNOR ROD LONG END LONG END THROTTLE RETURN SPRING LOW PERMEATION FUEL TUBE WITH EMISSIONS COMPLIANCE ID NUMBER 4.5 x 110 mm FUEL TUBE REASSEMBLY: Inspect for cracks or deterioration before installation, and replace if necessary. Only use the correct low permeation fuel tube when replacing. The fuel tube must contain the emissions-compliance identification number. GOVERNOR ARM GOVERNOR SPRING REASSEMBLY: Install with the short end side toward the governor arm. FUEL VALVE BRACKET TUBE CLIP (2) 2.3 ~ 2.8 N•m (20 ~ 24 in•lb) 7.3 x 160 mm FUEL TUBE FUEL VALVE REASSEMBLY: Inspect for cracks or deterioration before installation, and replace if necessary with low permeation fuel tube. TUBE CLIP (2) 6 x 28 mm FLANGE BOLT 8-22 10 N•m (7 ft-lb) GOVERNOR ARM BOLT 6 x 12 mm SELF-TAPPING SCREW Use the same style clips originally equipped on the unit. 6 x 12 mm FLANGE BOLT GOVERNOR ARM NUT HRR216VKA FUEL SYSTEM FUEL TUBE AND CLAMP CHANGES Honda Power Equipment manufactured after January 1, 2009, uses low-permeation fuel tubes that have the CARB Executive Order (C-U-05-003, for example) printed 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 regular fuel tube, you can replace it with a regular fuel tube. “D” STYLE CLAMP WIRE STYLE CLAMP Two styles of fuel tube clamps are used. If you replace the clamps, use the same style that is currently on the mower. 8-23 FUEL SYSTEM HRR216VKA 4. FAN COVER/FUEL TANK REMOVAL/INSTALLATION (K5 thru K8) 1. 2. 3. 4. 5. 6. 7. 8. Before removal, drain the gasoline into an approved container. Remove the recoil starter and the fan cover. Remove the fuel tube from the fuel tank. Remove the fuel tank cap from the fuel tank. Unscrew the tether from the fuel filler threads. Unscrew the tank mount nut from the fuel filler threads, and remove the fuel filler neck seal. Using a screwdriver, pry the tank mount clip locking leg from the right tank mount. Slide fuel tank mount rubber B from the right tank mount, and then remove the fuel tank from the fan cover. Fuel tank installation is the reverse of its removal.  WARNING FUEL TANK CAP Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and let it cool. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. TETHER RIGHT TANK MOUNT LEFT TANK MOUNT FUEL FILLER NECK SEAL TANK SIDE OPERATION: (P. 8-27) TANK MOUNT NUT Gently tighten the new tank mount nut, using tongue and groove pliers, until the alignment mark is in the position as shown. TANK MOUNT NUT ALIGNMENT MARK ALIGNMENT POSITION MARK RANGE FUEL LEVEL GAUGE TANK MOUNT RUBBER B FAN COVER 13.5 mm (0.5 in) INSTALLATION: Check that the high-tension cord and the stop switch wire are securely set in the groove in the fan cover as shown. STOP SWITCH WIRE FUEL TANK INSTALLATION: Wash with solvent to remove the sediment, and dry thoroughly before installation. INSPECTION (K8): P. 8-27 FUEL FILTER TANK MOUNT CLIP FUEL TANK MOUNT TANK MOUNT RUBBER B TANK MOUNT CLIP 8-24 HIGH-TENSION CORD TUBE CLIP (2) FUEL TUBE REMOVAL/INSTALLATION: P. 8-26 INSPECTION: Inspect for cracks or deterioration before installation, and replace if necessary. TANK MOUNT RUBBER A 8.0 mm (0.31 in) HRR216VKA FUEL SYSTEM REMOVAL/INSTALLATION (K9 thru K11) 1. 2. 3. 4. 5. 6. Before removal, drain the gasoline into an approved container. Remove the recoil starter and the fan cover. Remove the fuel tube from the fuel tank. Remove the fuel tank cap from the fuel tank. Unscrew the tether from the fuel filler threads. Unscrew the tank mount nut from the fuel filler threads and turn the fan cover over. Press the latch on the tank mount clip as shown below and remove the clip, and then remove the fuel tank from the fan cover. 7. Fuel tank installation is the reverse of its removal.  WARNING FUEL TANK CAP Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and let it cool. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. TETHER FUEL FILLER NECK SEAL TANK SIDE TANK MOUNT CLIP PRESS HERE TO RELEASE OPERATION: (P. 8-27) TANK MOUNT NUT Gently tighten the new tank mount nut, using tongue and groove pliers, until the TANK alignment MOUNT NUT mark is in ALIGNMENT MARK the position shown. ALIGNMENT POSITION MARK RANGE FAN COVER INSTALLATION: Check that the high-tension cord is securely set in the groove in the fan cover as shown. TANK MOUNT RUBBER B 13.5 mm (0.5 in) HIGH-TENSION CORD FUEL TANK TANK MOUNT RUBBER A INSTALLATION: Wash with solvent to remove the sediment, and dry thoroughly before installation. INSPECTION: P. 8-27 FUEL STRAINER 8.5 mm (0.33 in) TUBE CLIP (2) FUEL TUBE REMOVAL/INSTALLATION: P. 8-26 INSPECTION: Inspect for cracks or deterioration before installation, and replace if necessary. 8-25 FUEL SYSTEM HRR216VKA FUEL TUBE REMOVAL 1. Drain the fuel from the fuel tank and carburetor. 2. Use pliers to open the fuel clip, and slide the fuel clip up the tube. 3. Rotate the fuel tube to help release the tube from the fuel valve fitting. FUEL VALVE FUEL CLIP 4. Gently pull the fuel tube from the fuel valve. Do not pry against the fuel valve with a 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. 5. Remove the other end of the fuel tube from the fuel tank using the same procedure. The filter will come out of the tank along with the fuel tube. FUEL FILTER FUEL TUBE INSTALLATION 1. Attach the ends of the fuel tube to the fuel valve and fuel tank. Be sure the filter is inserted into the tank outlet prior to installing the fuel tube. 2. Position the fuel tube clips over the fuel valve and fuel tank fitting. 3. Fill with fuel and check for fuel leaks and repair as necessary. 8-26 HRR216VKA FUEL SYSTEM 5. EVAPORATIVE EMISSION CONTROL SYSTEM FUEL TANK CAP This engine has an EVAPORATIVE EMISSION CONTROL CANISTER built into the fuel tank cap to prevent the escape of gasoline vapors into the atmosphere. The cap also contains a ratchet mechanism to provide the operator with feedback to indicate that the cap is sealed. Charging Gasoline vapor produced in the fuel tank at high ambient temperature is absorbed and stored by the charcoal in the canister, which is built into the fuel tank cap. Purging 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 If the mower has low-permeation fuel tubes you must use only low-permeation fuel tubes as replacements. These fuel tubes have the emissions-compliance identification number printed on the tube as shown in this example. FUEL TANK Low-permeation fuel tanks have a light colored (grayish) inner liner. If the fuel tank is scratched deeply enough that the light gray inner liner can be seen from outside the tank, the fuel tank must be replaced. OUTER LAYER INNER LAYER DEEP SCRATCH If the outer layer is scratched deeply enough for the light gray inner layer to show, replace the fuel tank. 8-27 FUEL SYSTEM HRR216VKA NOTES 8-28 9. FLYWHEEL/IGNITION COIL 1. DISASSEMBLY/REASSEMBLY . . . . . . . . . 9-1 2. FLYWHEEL REMOVAL/INSTALLATION . . 9-3 3. IGNITION COIL . . . . . . . . . . . . . . . . . . . . . 9-6 1. DISASSEMBLY/REASSEMBLY (K5 thru K8) 1. 2. 3. 4. Remove the recoil starter (P. 7-1) and fan cover (P. 8-24). Remove the fan cover stud, the 6 x 20 mm flange bolt, and the ignition coil. Remove the 14 mm special nut and the flywheel (page 9-3). Remove the wire from the brake assembly; then remove the 6 x 23 mm and 6 x 14 mm flange bolts and the brake assembly. 14 mm SPECIAL NUT 4 x 12 mm SCREW WASHER REMOVAL/INSTALLATION: P. 9-3 TORQUE: 52 N•m (38 ft-lb) 1.8 N•m (1.3 ft-lb) 6 x 23 FLANGE BOLT FLYWHEEL REMOVAL: P. 9-3 When disassembling and reassembling, take care not to damage the fan blades. 4 mm WASHER BRAKE LEVER SPRING ENGINE STOP SWITCH 6 x 20 FLANGE BOLT FAN COVER STUD BOLT (3) 12 N•m (9 ft-lb) INSPECTION: P. 2-20 IGNITION COIL FLYWHEEL BRAKE INSPECTION: P. 9-6 ADJUSTMENT: P. 9-6 INSPECTION: P. 3-12 6 x 14 FLANGE BOLT HIGH-TENSION CORD STOP SWITCH WIRE REASSEMBLY: Check for cracked or damaged insulation; replace if necessary. CLIP A BREATHER COVER 25 x 18 mm SPECIAL WOODRUFF KEY REASSEMBLY: When installing the flywheel, check to be sure that the woodruff key remains in its slot on the crankshaft. BREATHER VALVE 6 x 14 FLANGE BOLT BREATHER COVER GASKET 12 N•m (9 ft-lb) Do not reuse. 9-1 FLYWHEEL/IGNITION COIL HRR216VKA (K9 thru K11) 14 x 1.5 mm SPECIAL NUT REMOVAL AND INSTALLATION: P. 9-3 TORQUE: 52 N•m (38 ft-lb) FLYWHEEL INSTALLATION: P. 9-5 14 x 45 WASHER Use caution during disassembly and reassembly to prevent damage. COOLING FAN 6 x 20 mm FLANGE BOLT WIRE CLAMP ENGINE STOP SWITCH 5 x 16 mm SPECIAL BOLT (2) INSPECTION: P. 2-20 FAN COVER STUD BOLT (3) 5 mm PLAIN WASHER 12 N•m (8.9 ft-lb) IGNITION COIL BRAKE CABLE BRACKET TENSIONER SPRING INSPECTION: P. 9-6 ADJUSTMENT: P. 9-6 SPECIAL BOLT HIGH-TENSION CORD REASSEMBLY: SPECIAL WASHER Check for cracked or damaged insulation; replace the coil if necessary. 25 x 18 mm SPECIAL WOODRUFF KEY STOP SWITCH WIRE (see P. 9-5 for routing) BREATHER VALVE 6 x 14 mm FLANGE BOLT FLYWHEEL BRAKE ARM INSPECTION: P. 3-12 BRAKE LEVER SPRING INSPECTION: P. 3-12 REASSEMBLY: When installing the flywheel, check to be sure that the woodruff key remains in its slot on the crankshaft. 9-2 CRANKCASE BREATHER COVER AND GASKET Replace as an assembly 6 x 14 mm FLANGE BOLT 12 N•m (8.9 ft-lb) HRR216VKA FLYWHEEL/IGNITION COIL 2. FLYWHEEL REMOVAL/INSTALLATION REMOVAL 1. Remove the fan cover/fuel tank (P. 7-1). 2. Disconnect the spark plug cap. 3. Hold the flywheel brake lever against the handlebar and secure it there with a strap or equivalent material. This allows the flywheel and crankshaft to turn. K9 ~ K11 MODEL SHOWN  FLYWHEEL HOLDER 07APB-Z28A100 4. Hold the flywheel with the special tool and a breaker bar, 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. 5. Remove the plastic cooling fan (K9, K10, K11 models). 9-3 FLYWHEEL/IGNITION COIL 6. Position a commercially available 6-inch flywheel puller on the flywheel with one of the puller jaws under the magnets (at the PULLER mark). HRR216VKA K5 thru K8 VERSION FLYWHEEL PULLER, OTC-1035 (commercially available) 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 remove the flywheel. SHOP TOWEL PULLER MARK K9 / K10 / K11 VERSION PULLER MARK 9-4 HRR216VKA FLYWHEEL/IGNITION COIL STOP SWITCH WIRE ROUTING (K9 thru K11 VERSIONS) Be sure the stop switch wire is routed between the engine stop switch and the ignition primary coil as shown before installing the flywheel. 1. Route the stop wire under the cord clamper. 2 1 3 2. Push the stop switch wire between the spring tensioner and the barrel. Do not pinch, cut, or damage the wire. 3. Run the stop switch wire under the spring tensioner, then up and over the cord rest on the spring tensioner. 4 ENGINE STOP SWITCH 4. Run the stop switch wire under the ignition coil between the coil mounting bosses. INSTALLATION 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. K9 MODEL SHOWN  FLYWHEEL HOLDER TORQUE WRENCH 52 N•m (38 ft-lb) 07APB-Z28A100 3. Make sure there is no foreign material on the magnets. 4. Be sure the woodruff key is set in the keyway properly. 5. Install the flywheel. 6. Apply oil to the threads. 7. 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) 8. Remove the strap or equivalent material from the flywheel brake lever. 9. Install and adjust the ignition coil (P. 9-6). 10. Install the fan cover/fuel tank (P. 7-1). 11. Check the operation of the flywheel brake (P. 3-12). 9-5 FLYWHEEL/IGNITION COIL HRR216VKA 3. IGNITION COIL IGNITION COIL TEST 1. Measure the resistance of the primary ignition coil by touching one ohmmeter lead to the ignition coil’s flat terminal while touching the other lead to the iron core. PRIMARY COIL K5 ~ K8 Models Primary coil resistance 1.0 ~ 1.4 Ω IRON CORE SPARK PLUG CAP (SECONDARY COIL) K9 ~ K11 Models There are two versions of the ignition coil. Before measuring the primary coil resistance, you must identify the ignition coil’s potting color, and then use the table below to determine the correct specification range. Primary coil resistance Red Potting Black Potting 1.0 ~ 1.4 Ω 1.0 ~ 1.2 Ω 2. Measure the resistance of the secondary ignition coil by touching one ohmmeter lead to the spark plug cap while touching the other lead to the iron core. Secondary coil resistance K5 ~ K8 10.6 ~ 12.8 kΩ K9 ~ K11 10 ~ 40 kΩ K9 ~ K11 only BLACK POTTING RED POTTING 3. Replace the ignition/charge coil if either of the above tests is out of specification. AIR GAP ADJUSTMENT IGNITION COIL 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 feeler gauge of the proper thickness between the legs of the coil assembly and the flywheel. K5 ~ K8 0.2 ~ 0.4 mm (0.008 ~ 0.016 in) K9 ~ K11 0.2 ~ 0.5 mm (0.008 ~ 0.020 in) Specified clearance K5~K8: 0.2 ~ 0.4 mm (0.008 ~ 0.016 in) K9~K11: 0.2 ~ 0.5 mm (0.008 ~ 0.020 in) FLYWHEEL 3. Avoid the magnetic part of the flywheel. 4. All gaps must be adjusted simultaneously. 5. Push the coil assembly firmly toward the flywheel and tighten the bolts. 6. Remove the feeler gauge. 9-6 10. CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 1. CAM PULLEY/ROCKER ARM. . . . . . . . . 10-1 2. OIL PAN/CRANKSHAFT/ CYLINDER BLOCK . . . . . . . . . . . . . . . . . 10-4 3. PISTON. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 4. VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 5. GOVERNOR . . . . . . . . . . . . . . . . . . . . . . 10-13 6. COMPONENT INSPECTION . . . . . . . . . 10-14 1. CAM PULLEY/ROCKER ARM REMOVAL/INSTALLATION CYLINDER HEAD COVER (Replace) INSTALLATION: P. 10-3 FLANGE BOLT, 6 x 12 mm (4) 12 N•m (8.7 ft-lb) VALVE ADJUSTING SCREW (2) ADJUSTMENT: P. 3-14 EXHAUST ROCKER ARM  INSPECTION: P. 10-15 VALVE ADJUSTING LOCK NUT (2)  7.8 N•m (5.8 ft-lb)   ROCKER ARM SHAFT (2) CAM PULLEY DECOMPRESSOR WEIGHT INSPECTION: P. 10-15 INSTALLATION: P. 10-3 INSPECTION: P. 10-2 INSTALLATION: P. 10-2 Take care not to drop the cam pulley.  INTAKE ROCKER ARM INSPECTION: P. 10-15 CAM PULLEY SHAFT INSPECTION: P. 10-2 K9~K11 VERSIONS HAVE A ROUND INTAKE PORT O-RING, 6.8 x 1.9 mm Replace. TIMING BELT  10-1 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA CAM PULLEY DECOMPRESSOR INSPECTION 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. 10-1). 3. If the weight is fully retracted, operate the decompressor by very slowly moving it to the opposite end of the slot and gently releasing. Repeat several times. If the weight fails to completely return on its own at any time (by spring force), replace the cam pulley (P. 10-1). DECOMPRESSOR WEIGHT CAM PULLEY INSTALLATION 1. Turn the crankshaft so that the long crankshaft 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 cylinder head cover mating surface. ALIGNMENT MARKS CAM PULLEY CYLINDER HEAD COVER MATING SURFACE Install the cam pulley on the timing belt with care not to turn the crankshaft. LONG KEY GROOVE WOODRUFF KEY GROOVE (2) VIEW FROM PTO SIDE 3. Apply oil to a new O-ring and install it on the cam pulley shaft. CAM PULLEY 4. Install the cam pulley shaft in the cylinder block. 5. Hold the cam pulley alignment marks in line with the cylinder head cover mating surface. Check again that the crankshaft key groove is facing up. 6. If the key groove is not facing up, repeat the procedure from step 1. 10-2 CAM PULLEY SHAFT  O-RING, 6.8 x 1.9 mm TIMING BELT HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK ROCKER ARM SHAFT INSTALLATION Install the rocker arm shaft from the opposite side of the cam pulley as shown. ROCKER ARM SHAFT CAM PULLEY CYLINDER HEAD COVER INSTALLATION 1. Clean the mating surface of the cylinder block using a de-greasing cleaning agent and a clean shop towel. CYLINDER HEAD COVER VIEWED FROM BACK SIDE (New) 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 cover. Assemble within 10 minutes after applying the liquid gasket. LIQUID GASKET APPLICATION AREA 3. Wait for approximately 20 minutes after assembly before filling with oil and starting the engine. 10-3 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA 2. OIL PAN/CRANKSHAFT/CYLINDER BLOCK REMOVAL/INSTALLATION Remove the cam pulley and rocker arm.  (Apply grease to the lips.) 6 x 25 FLANGE BOLT (8) 12 N•m (9 ft-lb) 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. OIL PAN ASSEMBLY INSPECTION: P. 10-19 REMOVAL: P. 10-5 ASSEMBLY: P. 10-6 8 x 20 mm DOWEL PIN (2) TIMING BELT INSTALLATION: Check that the belt is not worn or cracked and do not bend or twist the belt. THRUST WASHER PISTON ASSEMBLY INSTALLATION: P. 10-6 DISASSEMBLY/REASSEMBLY: P. 10-7 INSPECTION: P. 10-15 INSTALLATION: P. 10-5 CRANKSHAFT INSPECTION: P. 10-17 INSTALLATION: Be careful not to damage the oil seal. After installation, clean the crankshaft tapered surface.  CYLINDER BLOCK INSPECTION: P. 10-19 ASSEMBLY: P. 10-4  K9~K11 models have a round intake port.  CONNECTING ROD BOLT (2) 12 N•m (9 ft-lb) CONNECTING ROD CAP INSTALLATION: P. 10-10 10-4  K9~K11 models have a removable plastic timing gear. See page 10-18.  (Apply grease to the lips.) 25.4 x 62 x 6 mm OIL SEAL HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK OIL PAN REMOVAL RECESS 1. Set piston at TDC of compression stroke. 2. Remove the 6 x 25 mm flange bolts 3. Insert a screwdriver or equivalent tool into the recess as shown, and remove the oil pan from the cylinder block. Be careful not to damage the sealing surfaces. Use a tool that fits tightly into the recesses. Twist the tool to break the sealant loose. Do not drive the tool into the sealing surfaces with a hammer. PISTON ASSEMBLY/CONNECTING ROD CAP INSTALLATION 1. Apply oil to the inner wall of the cylinder and to the outer surface of the piston. MODEL MARK 2. Install the piston assembly in the cylinder so that the model mark (ZL8, Z8B, or Z2A) by the piston pin hole and the 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. CONNECTING ROD WITH THE LONG END NOTICE Take care not to break the piston ring when installing the piston assembly in the cylinder. 3. Apply clean engine oil to the cylinder block crankshaft bearing area, and install the crankshaft in the cylinder block. 4. Apply oil to the connecting rod big end bearing and the crank pin; then connect the connecting rod to the crank pin. 5. Apply oil to the connecting rod cap bearing. 6. Install so that the projection by the oil dipper and the projection of the connecting rod face in the same direction. Note that the oil dipper must be on the right- hand side at this time. 7. Tighten the connecting rod bolts to the specified torque. TORQUE: 12 N•m (9 ft-lb) OIL DIPPER PROJECTIONS 10-5 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK THRUST WASHER INSTALLATION 1. Install the timing belt on the timing belt pulley. HRR216VKA THRUST WASHER 2. Install the thrust washer; note the installation direction. TIMING BELT CYLINDER BLOCK/OIL PAN ASSEMBLY 1. Align the mark on the cylinder block with the mark on the crankshaft. CRANKSHAFT 2. Install the cam pulley (P. 10-2). MARK CYLINDER BLOCK 3. Clean the mating surfaces of the cylinder block and the oil pan using a degreasing cleaning agent or a clean shop towel. 4. Install the two 8 x 20 mm dowel pins in the cylinder block. MARK LIQUID GASKET APPLICATION AREA CYLINDER 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 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 tighten to the specified torque in the numbered sequence. TORQUE: 12 N•m (9 ft-lb) 8. Wait for approximately 20 minutes after assembly before filling it with oil and starting the engine. 10-6 8 x 20 mm DOWEL PIN 8 x 20 mm DOWEL PIN HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 3. PISTON DISASSEMBLY/REASSEMBLY TOP RING PISTON RINGS REASSEMBLY: Chrome plated. Do not interchange with SECOND RING. INSPECTION: P. 10-16 REASSEMBLY: Install with the maker mark facing 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. TOP RING (chrome plated) MAKER MARK 120° 120° 120° SECOND RING SECOND RING 10 mm (0.4 in) EXPANDER RING REASSEMBLY: Install the expander in the piston oil ring groove first. OIL RING 10 mm (0.4 in) OIL CONTROL RING (2) REASSEMBLY: Space the side rail end gaps at least 20 mm (0.8 in) apart. PISTON INSPECTION: P. 10-15 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 clip in. Do not align the end gap of the clip with the cutout in the piston pin bore. MODEL MARK (ZL8, Z8B, or Z2A)  PISTON PIN INSPECTION: P. 10-16  CLIP CUTOUT CONNECTING ROD INSPECTION: P. 10-17 REASSEMBLY: P. 10-8 10-7 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK PISTON CONNECTING ROD REASSEMBLY 1. Apply oil to the piston pin, piston pin hole and the connecting rod small end. PISTON HRR216VKA PISTON PIN 2. Set the piston so that the 'FW' mark stamped at the back of the piston points down. PISTON PIN CLIP (2) 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. FW MARK 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. 10-10). MODEL MARK (ZL8, Z8B, or Z2A) CONNECTING ROD WTH THE LONG END 10-8 HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 4. VALVES DISASSEMBLY/REASSEMBLY 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.  VALVE SPRING (2) INSPECTION: P. 10-20 VALVE STEM SEAL (INTAKE ONLY) Do not remove the valve spring retainer while the piston is installed, or the valves will drop into the cylinder. SPARK PLUG INSPECTION: P. 3-9 Standard spark plug: BPR5ES (NGK) K9~K11 VERSIONS HAVE A ROUND INTAKE PORT VALVE GUIDE INSPECTION: P. 10-20 CYLINDER BLOCK CLEANING: P. 10-10 EXHAUST VALVE REASSEMBLY: Before installation, remove carbon deposits and inspect the valve. INSPECTION: 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 10-9 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA COMBUSTION CHAMBER CLEANING 1. Prepare a cylinder of thick paper or equivalent material, with a diameter large enough to fit against the inner wall of the cylinder, and insert it into the cylinder for protection. 2. Attach a combustion chamber cleaning brush (commercially available) to an electric drill and clean the combustion chamber. Be sure to insert thick paper into the cylinder to protect the inner wall of the cylinder during cleaning of the combustion chamber. Do not press the cleaning brush with force against the combustion chamber. THICK PAPER OR EQUIVALENT ELECTRIC DRILL VALVE SEAT RECONDITIONING Valve Seat Inspection 1. Thoroughly clean the combustion chambers and valve seats to remove carbon deposits (page 10-10). 2. Apply a light coat of Prussian Blue compound or erasable felt-tipped marker ink to the valve faces. 3. Insert the valves, and then lift them and snap them closed against their seats several times. Be sure the valve does not rotate on the seat. The transferred marking compound will show any area of the seat that is not concentric and may require valve seat reconditioning. 10-10 VALVE FACE HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK Valve seat reconditioning tools (commercially available) 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 ADAPTOR (NWY TW 503-1) T-WRENCH EXTENSION, 6 in (NWY TW 503-6H) ACCESSORY PACKAGE (NWY TW #246) T-WRENCH VALVE SEAT CUTTER 31° 45° ACCESSORY PACKAGE 60° 45° 60° 31° SOLID PILOT BARS T-WRENCH ADAPTOR T-WRENCH EXTENSION, 6 in Reconditioning Procedure 1. Prepare a thick paper cylinder or equivalent material with a large enough diameter to fit against the cylinder wall of the cylinder block. 2. Insert the thick paper into the cylinder to protect the cylinder wall during valve seat reconditioning. THICK PAPER OR EQUIVALENT 10-11 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 3. Use the 31° and 60° cutters to narrow and adjust the valve seat so that it contacts the middle of the valve face. The 31° cutter removes material from the top edge. The 60° cutter removes material from the bottom edge. Be sure that the width of the finished valve seat is within specification. HRR216VKA CONTACT TOO HIGH 31° CONTACT TOO LOW 60° Always turn the cutter clockwise, never counterclockwise. Continue to turn the cutter as you remove it from the valve seat. Always follow the valve seat cutter manufacturer’s instructions. VALVE SEAT CUTTER (commercially available) NOTICE Avoid removing excess material from the valve seats. Remove only enough material to clean up the seats, and avoid going over the valve seat width service limit. 4. Make a light pass with the 45° cutter to remove any possible burrs at the edge of the seat. VALVE SEAT WIDTH Standard 0.7 mm (0.028 in) Service limit 1.8 mm (0.07 in) 1. After resurfacing the seats, inspect for even valve seating. Apply Prussian Blue or erasable felt-tipped marker ink to the valve faces. 0.7 mm (0.28 in) Insert the valves into the cylinder block, and 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 by the transferred marking compound, should have a good contact all the way around the valve face. 2. Lap the valves into their seats using a 4 mm tube and some commercially available lapping compound. NOTICE To avoid severe engine damage, be sure to remove all lapping compound from the cylinder block before assembly. 3. Check the valve clearance after reassembly (P. 3-13). 10-12 4 mm TUBE (commercially available) HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 5. GOVERNOR DISASSEMBLY/REASSEMBLY GOVERNOR HOLDER CLIP GOVERNOR WEIGHT HOLDER ASSEMBLY REASSEMBLY: Insert firmly into the shaft groove. 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. GOVERNOR HOLDER SHAFT 6 mm THRUST WASHER GROOVE OIL FILLER CAP /DIPSTICK GOVERNOR SLIDER REASSEMBLY: Spread the governor weights to install the slider; then check to be sure the slider moves smoothly. LOCK WASHER  REASSEMBLY: Install the notch over the rib on the oil pan. GASKET 6 x 14 FLANGE BOLT (2) 12 N•m (9 lb-ft) OIL FILLER EXTENSION REASSEMBLY: Hand tighten until the O-ring is compressed, then bend up the two lock washer edges to secure gasketthe oil filler extension. 6 mm WASHER REASSEMBLY: Install inside the case. GOVERNOR ARM SHAFT O-RING RIB 8 mm LOCK PIN OIL PAN INSPECTION: P. 10-19 REASSEMBLY: GOVERNOR ARM SHAFT 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 the groove in the shaft. GROOVE LOCK PIN 10-13 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA 6. COMPONENT INSPECTION CAM PULLEY HEIGHT INSPECTION Standard 37.394 mm (1.4722 in) Service limit 37.369 mm (1.4712 in) CAM PULLEY I.D. (BEARING) INSPECTION Standard Service limit 10.027 mm (0.3948 in) 10.075 mm (0.3967 in) CAM PULLEY DECOMPRESSOR INSPECTION ARM Inspect the decompressor return spring for proper strength. Check the decompressor arm and pin for proper movement and wear. SPRING CAM PULLEY SHAFT O.D. INSPECTION Standard 9.987 mm (0.3932 in) 10-14 Service limit 9.920 mm (0.3906 in) PIN HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK ROCKER ARM INSPECTION 1. To check the rocker arms for excessive free-play, follow the steps in “Exhaust Rocker Arm Pivot Free-Play Inspection” on page 2-23. Repeat the steps for the intake valve. 2. Measure the Rocker Arm Shaft O.D. Standard 5.990 mm (0.2358 in) Service limit 5.953 mm (0.2344 in) PISTON-TO-CYLINDER CLEARANCE INSPECTION 1. Measure and record the Cylinder I.D. at three levels in both the “X” axis (perpendicular to crankshaft) and the “Y” axis. Take the maximum reading to determine cylinder wear and taper. Standard 64.000 ~ 64.015 mm (2.5197 ~ 2.5203 in) Service limit 64.105 mm (2.5238 in) (K5~K8) 64.110 mm (2.7209 in) (K9~K11) If the cylinder I.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. Standard K5~K8: 63.961 ~ 63.985 mm (2.5181 ~ 2.5190 in) K9/K11: 63.966 ~ 63.990 mm (2.5183 ~ 2.5193 in) Service limit 63.880 mm (2.5149 in) 3. Subtract the Piston O.D. from the Cylinder I.D. to determine the Piston-to-Cylinder clearance. Standard K5~K8: 0.015 ~ 0.054 mm (0.0006 ~ 0.0021 in) K9~K11: 0.010 ~ 0.049 mm (0.0004 ~ 0.0019 in) Service limit 0.12 mm (0.005 in) Do not hone the aluminum cylinder when replacing rings. 10-15 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK PISTON RING WIDTH INSPECTION Top ring Second ring Standard 0.93 ~ 0.95 mm (0.036 ~ 0.037 in) 0.97 ~ 0.99 mm 0.038 ~ 0.039 in) Service limit 0.91 mm (0.035 in) 0.95 mm (0.037 in) PISTON RING SIDE CLEARANCE INSPECTION Top ring Second ring Standard 0.055 ~ 0.089 mm (0.002 ~ 0.004 in) 0.015 ~ 0.049 mm (0.0006 ~ 0.0019 in) Service limit 0.150 mm (0.006 in) 0.150 mm (0.006 in) PISTON RING END GAP INSPECTION Use the top of the piston to position the ring horizontally in the cylinder. Top ring Second ring Oil ring Standard 0.20 ~ 0.35 mm (0.008 ~ 0.014 in) 0.35 ~ 0.50 mm (0.014 ~ 0.020 in) 0.20 ~ 0.70 mm (0.008 ~ 0.030 in) Service limit 1.00 mm (0.040 in) 1.00 mm (0.040 in) 1.00 mm (0.040 in) NOTICE Do not hone the cylinder when replacing the piston rings. PISTON PIN O.D. INSPECTION Standard Service limit 13.000 mm (0.5118 in) 12.954 mm (0.5100 in) 10-16 HRR216VKA HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK PISTON PIN BORE I.D. INSPECTION Standard 13.002 mm (0.5119 in) Service limit 13.048 mm (0.5137 in) CONNECTING ROD SMALL END I.D. INSPECTION Standard 13.005 mm (0.5120 in) Service limit 13.07 mm (0.515 in) CONNECTING ROD BIG END I.D. INSPECTION Standard 26.02 mm (1.024 in) Service limit 26.066 mm (1.0262 in) CRANKSHAFT MAIN JOURNAL O.D. INSPECTION PTO Side Flywheel side Standard 27.993 mm (1.1021 in) 25.393 mm (0.9997 in) Service limit 27.933 mm (1.0997 in) 25.333 mm (0.9974 in) FLYWHEEL SIDE PTO SIDE 10-17 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK TIMING GEAR INSPECTION (K9~K11) HRR216VKA TIMING GEAR SLOT The plastic timing gear is separate from the crankshaft in the K9, K10, and K11 versions. BOSS Inspect the timing 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. TIMING GEAR CRANK PIN O.D. INSPECTION Standard 25.98 mm (1.023 in) Service limit 25.92 mm (1.020 in) CONNECTING ROD BIG END AXIAL CLEARANCE INSPECTION Measure the clearances with a feeler gauge. Standard 0.1 ~ 0.4 mm (0.004 ~ 0.016 in) Service limit 0.8 mm (0.031 in) CONNECTING ROD BIG END OIL CLEARANCE INSPECTION 1. Wipe oil off the crank pin and connecting rod bearing mating surface. 2. Place the Plastigage® on the crank pin. Set the connecting rod and cap, and tighten the connecting rod bolts to the specified torque. TORQUE: 12 N•m (9 ft-lb) Place the Plastigage axially. Tighten the two bolts equally while holding the crankshaft to keep it from turning. 10-18 CONNECTING ROD BIG END HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 3. Remove the connecting rod cap and measure the Plastigage® with the scale on the Plastigage package to determine the oil clearance. Standard oil clearance 0.040 ~ 0.063 mm (0.0016 ~ 0.0025 in) PLASTIGAGE SCALE Service limit 0.12 mm (0.005 in) 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 clearance. PLASTIGAGE CYLINDER BLOCK MAIN JOURNAL I.D. INSPECTION Standard 25.420 mm (1.0008 in) Service limit 25.466 mm (1.0026 in) Inspect the bearing surface for scoring or damage. If the bearing surface is worn or damaged, the cylinder block and crankshaft will require replacement. OIL PAN MAIN JOURNAL I.D. INSPECTION Standard 28.020 mm (1.1031 in) Service limit 28.066 mm (1.1050 in) 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 AXIAL CLEARANCE INSPECTION Measure the crankshaft axial play before removing the oil pan, crankshaft, and piston. Standard 0.15 ~ 0.75 mm (0.006 ~ 0.030 in) Service limit 1.0 mm (0.04 in) If the axle clearance is too great, inspect the oil pan, cylinder block, and timing gear thrust washer for wear and replace as necessary. 10-19 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK VALVE SPRING FREE LENGTH INSPECTION Measure the free length of the valve springs. Standard 30.5 mm (1.20 in) Service limit 29.0 mm (1.14 in) Replace the springs if they are shorter than the service limit. VALVE FACE/STEM O.D. INSPECTION Inspect each valve face for pitting or wear irregularities. Inspect each valve stem for bending or abnormal stem wear. Replace the valve if necessary. Measure and record each valve stem. IN EX Standard 5.48 mm (0.216 in) 5.44 mm (0.214 in) Service limit 5.318 mm (0.2094 in) 5.275 mm (0.2077 in) VALVE FACE Replace the valves if their O.D. is smaller than the service limit. VALVE GUIDE I.D. INSPECTION Measure and record each valve guide I.D. Standard 5.50 mm (0.217 in) Service limit 5.572 mm (0.2194 in) Replace the cylinder block if they are over the service limit. VALVE SEAT WIDTH INSPECTION 1. Measure the valve seat width. Standard 0.70 mm (0.028 in) Service limit 1.8 mm (0.07 in) 2. Recondition the valve seat (page 10-10) if any of the following are true: VALVE SEAT TOO LOW • Valve seat width is under or over the standard • Valve seat is too high or low • Valve seat is pitted or damaged 10-20 VALVE SEAT TOO HIGH HRR216VKA 11. HANDLE PIPE/CABLES/SMART DRIVE 1. HANDLE PIPE REPLACEMENT . . . . . . . .11-1 2. HANDLE STAY/DISCHARGE GUARD . . .11-3 3. HANDLE GRIP REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . .11-9 4. HANDLE LOCKING KNOB . . . . . . . . . . .11-10 5. SMART DRIVE CABLE . . . . . . . . . . . . . . 11-11 6. SMART DRIVE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . .11-23 1. HANDLE PIPE REPLACEMENT 1. Cut the three cable ties securing the brake cable and Smart Drive cable to the handle pipe. Fully loosen the Smart Drive cable adjuster (P. 3-10). 2. Remove the 6 mm locking nut, 6 x 45 mm flange bolt, 6 mm plain washer, and the flywheel brake cable assembly from the handle pipe assembly. 3. Remove the flywheel brake lever from the handle pipe, then from the lever stop. 4. Remove the lock pin; then remove the lever stop from the handle pipe. 5. Remove the four 4 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. UPPER BRACKET COVER HANDLE GRIP (2) REMOVAL/INSTALLATION: P. 11-9 UPPER CLUTCH GRIP UPPER GRIP BRACKET MULTI-POSITION ADJUSTER LOWER GRIP BRACKET LOWER BRACKET COVER SPRING 5 x 37 mm ROLLER PIN LOWER CLUTCH GRIP SMART DRIVE CABLE REMOVAL/ INSTALLATION: (P. 11-11) 4 mm SELF-TAPPING SCREW (8) LEVER STOP LOCK PIN FLYWHEEL BRAKE LEVER ROPE GUIDE HANDLE PIPE CABLE TIE (3) FLYWHEEL BRAKE CONTROL CABLE 6 x 45 mm FLANGE BOLT 6 mm PLAIN WASHER 6 mm LOCKING NUT 8. 9. 10. 11. Remove the Smart Drive cable from the lower grip bracket and then from the handle pipe assembly. Remove the two special bolts, nylon washers, and the handle assembly from the handle stays. Drive out the two 2 x 12 mm roll pins and remove the handle lock assemblies. Remove the 6 mm locking nut and the rope guide. 11-1 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA ROPE GUIDE 6 mm LOCKING NUT HANDLE STAY (2) (K5~K9 style shown) HEIGHT ADJUSTING SPRING (2) REPLACEMENT: P. 11-3 8 mm PIN (2) NYLON WASHER (2) SPECIAL BOLT (2) 2 x 12 mm ROLL PIN (2) HEIGHT ADJUSTING COLLAR (2) 12. Install the handle pipe in the reverse order of its removal. 13. Readjust the Smart Drive cable (P. 3-10). 11-2 HANDLE LOCKING KNOB (2) INSTALLATION: (P. 11-10) HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 2. HANDLE STAY/DISCHARGE GUARD REMOVAL/INSTALLATION K5 ~ K9 Models GUARD RETURN SPRING (2) 1. Pry the push nut off the discharge guard shaft. DISCHARGE GUARD 2. Remove the discharge guard shaft, the left and right guard return springs, and the discharge guard. PUSH NUT Be 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. GRASS BAG PLATE BOLT (3) . 4. Release the handlebar locking knobs and allow the handle pipe assembly to rest on the floor. 5. Remove the two special bolts and nylon washers, and remove the handle pipe assembly from the handle stays. NYLON WASHER (2) HANDLE PIPE ASSEMBLY SPECIAL BOLT (2) HANDLE STAY (left side shown) HANDLE LOCKING KNOB (2) 11-3 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 6. Remove the rear scroll (P. 4-7). 7. Move the rear adjusting lever all the way forward. 8. Remove the three 8 mm flange nuts and the left handle stay. REAR ADJUSTING LEVER 8 mm FLANGE NUT (3) LEFT HANDLE STAY . 9. Remove the three 8 mm flange nuts and the right handle stay. 8 mm FLANGE NUT (3) RIGHT HANDLE STAY . 10. Installation 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 place when installing the discharge guard shaft. . 11. After installation, raise the discharge guard and confirm it moves freely and closes by spring force. 11-4 LEFT SPRING RIGHT SPRING HRR216VKA K10/K11 Models This procedure is explains the removal and installation for both left and right handle stays. If only replacing one handle stay, follow the instructions for only that side. HANDLE PIPE/CABLES/SMART DRIVE GUARD RETURN SPRING (2) DISCHARGE GUARD 1. Remove the push nut from the discharge guard shaft by prying it off with a thin flat tipped screwdriver. PUSH NUT 2. Remove the discharge guard shaft, left and right guard return springs, and the discharge guard. Pull the discharge guard shaft out from the right-hand side of the mower. Be 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. Removal of the grass bag plate is not required for handle stay removal. GRASS BAG PLATE BOLT (3) 4. Release the handlebar locking knobs and fold the handle pipe assembly over the lawn mower, as done during storage or transporting. NYLON WASHER (2) HANDLE PIPE ASSEMBLY 5. Remove the two special bolts and nylon washers to detach the handle pipe assembly from the handle stays. 6. Remove the rear scroll (P. 12-1). SPECIAL BOLT (2) HANDLE STAY (left side shown) HANDLE LOCKING KNOB (2) 11-5 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 7. Remove the wheel bolt, wheel, wheel washer, and flat washer on each side. FLAT WASHER WHEEL BOLT WHEEL WASHER 8. Remove the 13 mm circlip, pinion gear collar, 12 tooth pinion gear, ratchet key, and ratchet return spring from each side. RATCHET KEY RATCHET RETURN SPRING PINION GEAR (12 TOOTH) PINION GEAR COLLAR 9. Remove the pinion gear collars and wheel covers from each side. 11-6 13 mm CIRCLIP PINION GEAR COLLAR WHEEL COVER HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 10. Remove the remaining circlips, thrust collars, and 13 mm washers from each side. THRUST COLLAR 13 mm CIRCLIP 13 mm WASHER 11. Remove the 25 mm circlip from each side, and slide them and the 25 mm washers inward towards the transmission. 12. Remove the adjuster assembly from each side, taking care not to damage the seals. ADJUSTER ASSEMBLY 25 mm WASHER 25 mm CIRCLIP 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. SMART DRIVE CABLE BELT TENSION SPRING UPPER END Be sure to fully loosen the Smart Drive cable adjuster before attempting to remove the cable from the transmission. . Push in on the transmission to help disconnect the Smart Drive cable. 11-7 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 14. Remove the handle stay(s) by loosening the four 8 mm flange nuts. HANDLE STAY If removing the left-hand side handle stay, do not remove the forward-most nut that attaches the Smart Drive cable bracket onto the mower deck. Only the rearward nut needs to be removed from the Smart Drive cable 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 springs so the hooks lead to the underside of the spring. . Apply pressure to hold the springs in place while installing the discharge guard shaft, working from right to left. After installation, raise the discharge guard and confirm it moves freely and closes by spring force. . 11-8 8 mm FLANGE BOLT (4) LEFT SPRING RIGHT SPRING HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 3. HANDLE GRIP REMOVAL/INSTALLATION 1. Remove the following, depending on the grip that needs replacement: • Smart Drive cable (P. 11-11) HANDLE GRIP (2) 45 ~ 50 mm (1.75 ~ 2.0 in) SMART DRIVE CONTROL • Flywheel brake cable (P. 11-1) • 6 mm locking pin and 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 grip should be 45 ~ 50 mm from the Smart Drive control as shown. ™ CONTROL MULTI-POSITION ADJUSTER 6. Reassemble the handle pipe and install the handle pipe to the handle stays. 11-9 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 4. HANDLE LOCKING KNOB REMOVAL 1/16” DRIFT PUNCH 1. Drive the 2 x 12 mm roll pin out with a 1/16” drift punch. 2. Separate the parts as shown. HANDLE LOCKING KNOB 2 x 12 mm ROLL PIN 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 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. 8 mm PIN LOWER MOUNTING HOLE HANDLE LOCKING KNOB HEIGHT ADJUSTING SPRING HEIGHT ADJUSTING COLLAR 2 x 12 mm ROLL PIN 5. Insert the 1/16” drift punch from the bottom to keep the two holes aligned. 6. From the top side, start the 2 x 12 mm roll pin and gently tap it in until it is flush with the knob. 1/16” DRIFT PUNCH 2 x 12 mm ROLL PIN HANDLE LOCKING KNOB 11-10 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 5. SMART DRIVE CABLE K5, K6 REMOVAL 1. 2. 3. 4. Drain the fuel tank. Drain the engine oil. Fully loosen the Smart Drive cable adjuster. Cut the cable tie securing the flywheel brake control cable to the Smart Drive cable. LOCK NUT LOOSEN TIGHTEN ADJUSTER 5. Remove the four 4 mm self-tapping screws and the upper 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 brackets. 8. Remove the 5 x 37 mm roller pin. 9. Remove the cable from the lower grip bracket. UPPER CLUTCH GRIP UPPER BRACKET COVER UPPER GRIP BRACKET SPRING 5 x 37 mm ROLLER PIN MULTI-POSITION ADJUSTER 4 mm SELF-TAPPING SCREW (8) LOWER CLUTCH GRIP LOWER BRACKET COVER LOWER GRIP BRACKET 11-11 HANDLE PIPE/CABLES/SMART DRIVE 10. Put a protective pad around the upper handle pipe. Tip the mower up and secure the upper handle pipe in a bench vise. 11. Remove the belt cover and drive belt (P. 4-2). 12. Rotate the transmission 180° as shown. 13. Using pliers, pinch the Smart Drive cable locks, pull on the cable, and remove it from the cable holder. 14. Lift the Smart Drive cable wire through the slot in the cable holder and remove the cable end from the transmission control arm. 15. Remove the Smart Drive cable from the lawn mower. INSTALLATION 1. Route 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 install the snap fitting into the cable bracket. 4. Reinstall the belt tensioner spring and drive belt (P. 4-3). HRR216VKA CABLE LOCKS CABLE HOLDER CABLE HOLDER SLOT SNAP FITTING CUTTER HOUSING HOLE SMART DRIVE CABLE WIRE SMART DRIVE CABLE END TRANSMISSION CONTROL ARM 5. If installing a new Smart Drive cable, fully loosen the cable adjuster before installing the new Smart Drive cable. 6. Route the upper end of the Smart Drive cable through the hole in the handle pipe until it's visible in the slot in the top of the handle pipe. HANDLE PIPE SLOT CABLE END SMART DRIVE CABLE 11-12 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 7. Install a screwdriver between the mower deck and the transmission control arm. 8. Remove the mower from the vise and set in its normal operating position. SCREWDRIVER TRANSMISSION CONTROL ARM 9. Connect the upper end of the Smart Drive cable to the lower grip bracket. SMART DRIVE CABLE 10. Fit the upper 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. LOWER GRIP BRACKET LOWER GRIP BRACKET 4 mm SELF-TAPPING SCREW (4) HANDLE PIPE SLOT Viewed from above the handle pipe. 11. 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. UPPER GRIP BRACKET SMART DRIVE CABLE END Viewed from under the handle pipe. UPPER GRIP BRACKET 5 x 37 mm ROLLER PIN LOWER GRIP BRACKET 11-13 HANDLE PIPE/CABLES/SMART DRIVE 12. Grease the inside pin grooves of the upper and lower bracket covers. 13. Snap the upper and lower bracket covers together with the roller pin located in the pin groove. Make sure the adjuster slots are located toward the rear of the mower. HRR216VKA UPPER BRACKET COVER GRIP BRACKET (2) 5 x 37 mm ROLLER PIN  INSIDE PIN GROOVES LOWER BRACKET COVER 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 place the assembly over the inner bracket cover.  LOWER CLUTCH GRIP BOTH SIDES OF GUIDES ADJUSTER SLOTS SPRING MULTI-POSITION ADJUSTER 15. Place the upper clutch grip over the 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 transmission control arm. 17. Install the belt cover (P. 4-3). 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. UPPER CLUTCH GRIP LOWER CLUTCH GRIP 4 mm SELF-TAPPING SCREW (4) . 11-14 Viewed from under the handle pipe. HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE K7 LOCK NUT REMOVAL 1. 2. 3. 4. Drain the fuel tank. Drain the engine oil. Fully loosen the Smart Drive cable adjuster. Cut the cable tie securing the flywheel brake control cable to the Smart Drive cable. LOOSEN TIGHTEN ADJUSTER 5. Remove the four 4 mm self-tapping screws and the upper 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 brackets. 8. Remove the 5 x 37 mm roller pin. 9. Remove the cable from the lower grip bracket. UPPER CLUTCH GRIP UPPER BRACKET COVER UPPER GRIP BRACKET SPRING 5 x 37 mm ROLLER PIN MULTI-POSITION ADJUSTER 4 mm SELF-TAPPING SCREW (8) LOWER CLUTCH GRIP LOWER BRACKET COVER LOWER GRIP BRACKET . 11-15 HANDLE PIPE/CABLES/SMART DRIVE 10. Put a protective pad around the upper handle pipe. Tip the mower up and secure the upper handle pipe in a bench vise. 11. Remove the belt cover and drive belt (P. 4-4). 12. Rotate the transmission 180° as shown. 13. Using pliers, pinch the Smart Drive cable locks, pull on the cable, and remove it from the cable holder. 14. Lift the Smart Drive cable wire through the slot in the cable holder and remove the cable end from the transmission control arm. 15. Remove the Smart Drive cable from the lawn mower. INSTALLATION 1. Route 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 install the snap fitting into the cable bracket. 4. Reinstall the belt tensioner spring and drive belt (P. 4-5). HRR216VKA CABLE HOLDER CABLE LOCKS CABLE HOLDER SLOT SNAP FITTING SMART DRIVE CABLE WIRE SMART DRIVE CABLE END CUTTER HOUSING HOLE 5. If installing a new Smart Drive cable, fully loosen the cable adjuster before installing the new Smart Drive cable. 6. Route the upper end of the Smart Drive cable through the hole in the handle pipe until it's visible in the slot in the top of the handle pipe. HANDLE PIPE SLOT CABLE END SMART DRIVE CABLE 11-16 TRANSMISSION CONTROL ARM HRR216VKA 7. Install a screwdriver between the mower deck and the transmission control arm. 8. Remove the mower from the vise and set in its normal operating position. HANDLE PIPE/CABLES/SMART DRIVE SCREWDRIVER TRANSMISSION CONTROL ARM 9. Connect the upper end of the Smart Drive cable to the lower grip bracket. SMART DRIVE CABLE 10. Fit the upper 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. LOWER GRIP BRACKET LOWER GRIP BRACKET 4 mm SELF-TAPPING SCREW (4) HANDLE PIPE SLOT Viewed from above the handle pipe. 11. 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. UPPER GRIP BRACKET SMART DRIVE CABLE END Viewed from under the handle pipe. UPPER GRIP BRACKET 5 x 37 mm ROLLER PIN LOWER GRIP BRACKET 11-17 HANDLE PIPE/CABLES/SMART DRIVE 12. Grease the inside pin grooves of the upper and lower bracket covers. HRR216VKA UPPER BRACKET COVER GRIP BRACKET (2) 5 x 37 mm ROLLER PIN 13. Snap the upper and lower bracket covers together with the roller pin located in the pin groove. Make sure the adjuster slots are located toward the rear of the mower.  INSIDE PIN GROOVES LOWER BRACKET COVER 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 place the assembly over the inner bracket cover.  LOWER CLUTCH GRIP BOTH SIDES OF GUIDES ADJUSTER SLOTS SPRING MULTI-POSITION ADJUSTER . 11-18 HRR216VKA 15. Place the upper clutch grip over the adjuster assembly and secure to the lower clutch grip with the four 4 mm self-tapping screws. HANDLE PIPE/CABLES/SMART DRIVE UPPER CLUTCH GRIP 16. Rotate the Smart Drive control and confirm that the lower end of the Smart Drive cable moves the transmission control arm. 17. Install the 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). LOWER CLUTCH GRIP 20. Start and test the Smart Drive operation. 4 mm SELF-TAPPING SCREW (4) Viewed from under the handle pipe. K8 ~ K11 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. LOCK NUT LOOSEN TIGHTEN ADJUSTER 11-19 HANDLE PIPE/CABLES/SMART DRIVE 5. Remove the four 4 mm self-tapping screws and the upper 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 brackets. HRR216VKA UPPER CLUTCH GRIP UPPER BRACKET COVER UPPER GRIP BRACKET SPRING 5 x 37 mm ROLLER PIN MULTI-POSITION ADJUSTER 8. Remove the 5 x 37 mm roller pin. 9. Remove the cable from the lower grip bracket. 4 mm SELFTAPPING SCREW (8) LOWER CLUTCH GRIP 10. Put a protective pad around the upper handle pipe. Tip the mower up and secure the upper handle pipe in a bench vise. CONTROL ARM LOWER BRACKET COVER LOWER GRIP BRACKET DRIVE CLUTCH CABLE 11. Remove the rear scroll (P. 4-7). CABLE HOLDER 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. CABLE LOCKS 14. Remove the Smart Drive cable from the lawn mower. INSTALLATION If installing a new Smart Drive cable, fully loosen the cable adjuster before installing the new Smart Drive cable. 1. Route the upper end of the Smart Drive cable through the hole in the handle pipe until it's visible in the slot in the top of the handle pipe. HANDLE PIPE SLOT CABLE END SMART DRIVE CABLE 11-20 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 2. Connect the upper end of the Smart Drive cable to the lower grip bracket. SMART DRIVE CABLE 3. Fit the upper 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. LOWER GRIP BRACKET LOWER GRIP BRACKET 4 mm SELF-TAPPING SCREW (4) HANDLE PIPE SLOT Viewed from above the handle pipe. 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. UPPER GRIP BRACKET SMART DRIVE CABLE END Viewed from under the handle pipe. UPPER GRIP BRACKET 5 x 37 mm ROLLER PIN LOWER GRIP BRACKET 11-21 HANDLE PIPE/CABLES/SMART DRIVE 5. Grease the inside pin grooves of the upper and lower bracket covers. HRR216VKA UPPER BRACKET COVER GRIP BRACKET (2) 5 x 37 mm ROLLER PIN 6. Snap the upper and lower bracket covers together with the roller pin located in the pin groove. Make sure the adjuster slots are located toward the rear of the mower.  INSIDE PIN GROOVES LOWER BRACKET COVER 7. Grease both sides of the clutch grip guides. Insert the multi-position adjuster and spring in the track of the lower clutch grip and place the assembly over the inner bracket cover.  LOWER CLUTCH GRIP BOTH SIDES OF GUIDES ADJUSTER SLOTS SPRING MULTI-POSITION ADJUSTER 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. UPPER CLUTCH GRIP LOWER CLUTCH GRIP 4 mm SELF-TAPPING SCREW (4) 11-22 Viewed from under the handle pipe. HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 9. Route the Smart Drive cable down through the hole in the cutter housing. SMART DRIVE CABLE END CONTROL ARM SNAP FITTING 10. Attach the Smart Drive cable end on the control arm. 11. Push the transmission as shown, align the Smart Drive cable wire with the cable holder slot, and install the snap fitting into the cable bracket. 12. Rotate the Smart Drive control and confirm that the lower end of the Smart Drive cable moves the transmission control arm. 13. Install the belt cover (K8 P. 4-6) or rear scroll (K9/K10/ K11 P. 4-7). 14. Install new cable ties securing the Smart Drive cable to the handle stay and handle pipe. 15. Readjust the Smart Drive cable (P. 3-10). SMART DRIVE CABLE WIRE CABLE HOLDER SLOT 16. Start and test the Smart Drive operation. 6. SMART DRIVE DISASSEMBLY AND INSPECTION 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. 3-10). 45 ~ 50 mm (1.75 ~ 2.0 in) 45 ~ 50 mm (1.75 ~ 2.0 in) ™ CONTROL HANDLE GRIP (2) SMART DRIVE HANDLE RUBBER GRIP (2) 3. Remove the 4 mm screws and separate the upper and lower grips and multi-position adjuster and spring. UPPER CLUTCH GRIP Viewed from under the handle pipe. LOWER CLUTCH GRIP 4 mm SELF-TAPPING SCREW (4) Multi-position adjuster and spring . 11-23 HANDLE PIPE/CABLES/SMART DRIVE 4. Separate the upper and lower bracket covers. Thoroughly clean the inside of the bracket covers and inner bracket. 5. Slide the roller pin back and forth to confirm the pin and cable move smoothly. If the cable binds, replace it. 6. Have an assistant rotate the transmission up in the direction that tensions the drive belt. The transmission should rotate clockwise, when viewed from the left-hand side of the mower. The assistant should hold the transmission in place while you perform the next step. 7. Apply grease to the inside of the bracket covers and reinstall. Be sure 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. HRR216VKA UPPER BRACKET COVER 5 x 37 mm ROLLER PIN Verify the pin and cable move smoothly.  INSIDE PIN GROOVES LOWER BRACKET COVER  LOWER CLUTCH GRIP BOTH SIDES OF GUIDES 10. Place the assembly over the inner bracket cover. ADJUSTER SLOTS Multi-position adjuster and spring 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 that it rotates smoothly and the cable moves at the transmission. UPPER CLUTCH GRIP Viewed from under the handle pipe. 12. Go to the Smart Drive Cable Adjustment procedure (P. 3-10). LOWER CLUTCH GRIP 4 mm SELF-TAPPING SCREW (4) 11-24 12. CLIP DIRECTOR/MOWER DECK/WHEELS 1. CLIP DIRECTOR (K9~K11 ONLY) . . . . . 12-1 2. MOWER DECK . . . . . . . . . . . . . . . . . . . . 12-2 3. WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 1. CLIP DIRECTOR (K9~K11 ONLY) REMOVAL/INSTALLATION 1. Move the Clip Director lever to the BAG position. [1] [2] 2. Turn the fuel valve OFF and tilt the mower on its right side with the gas filler cap up. [3] [2] 3. 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. [1] Shown with blades removed for clarity. [1] 4. Remove the 5 x 16 mm self-tapping screw. 5. Remove the two 6 mm cap nuts and special bolts. 6. Lift the Clip Director lever and shutter cover assembly away from the mower deck. If you remove the handle from the cover, be careful. The handle is spring loaded and tends to pop apart when removed. 5 x 16 mm SELF-TAPPING SCREW 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 following: • Be sure the Clip Director is fully open (BAG position) when installing the rear scroll. • Align the lower Clip Director hinge pin with the hole in the scroll. 6 mm CAP NUTS • Use a long flat blade screwdriver and a piece of tape to hold the upper special nut in place while installing the shoulder screw [3] in the center of the rear scroll. • Make sure the Clip Director shutter door pivot point aligns with the hole in the rear scroll when assembling. 12-1 CLIP DIRECTOR/MOWER DECK/WHEELS HRR216VKA 2. MOWER DECK SERVICE BULLETIN #67 => K5 thru K7 SCROLL PLATE MULCHING PLUG GUIDE PLATE SPRING (2) HINGE PLATE (2) GROMMETS REAR DOOR PUSH NUT SHIELD SHAFT DOOR SHAFT 6 mm NYLON LOCK NUT REAR SHIELD COVER 8 mm FLAT WASHER (2) FRONT SCROLL 5/16-24 x 1" FLANGE BOLT (4) 8 mm FLANGE NUT (2) PUSH NUT BELT COVER 6 x 10 mm FLANGE BOLT (5) REAR SCROLL 12-2 HRR216VKA CLIP DIRECTOR/MOWER DECK/WHEELS K8 VERSION Reference # Description Quantity Reference # Description Quantity 2 Belt cover 1 17 Left guard return spring 1 3 Cutter housing 1 19 Flange bolt (5/16-24X1") 4 4 Rear shield 1 21 Push nut (7.94 mm) 1 5 Front 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 10 Roto-Stop® cover 1 28 Pan bolt (6 x 12) 1 12 Plug grommet 2 29 Mulching plug stopper 1 13 Mulching plug 1 30 Grass bag plate 1 14 Discharge guard 1 31 Grass bag plate bolt 3 15 Discharge guard shaft 1 32 Flange nut (6 mm) 3 16 Right guard return spring 1 12-3 CLIP DIRECTOR/MOWER DECK/WHEELS HRR216VKA K9~K11 VERSIONS Reference # 2 Description Special nut (6 x 7) Quantity Reference # 4 20 Description Quantity Scroll ramp 1 3 Cutter housing 1 21 Left guard return spring 1 4 Rear shield 1 22 Grass bag plate 1 5 Front scroll 1 23 Scroll bolt 2 6 Rear scroll 1 24 Special bolt (6 x 12.5) 3 7 Rear shield 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 1 29 Flange cap nut (6 mm) 2 13 Shutter 1 30 Nylon lock nut (6 mm) 1 14 Shutter lever 2 31 Plain washer (5/16) 2 15 Lock lever 1 32 Tapping screw (5 x 16 mm) 1 16 Lever spring 1 33 Flange nut (6 mm) 2 17 Discharge guard 1 34 Flange nut (8 mm) 2 18 Discharge guard shaft 1 35 Plain washer (6 mm) 1 19 Right guard return spring 1 36 Flange bolt (6 x 10) 3 12-4 HRR216VKA CLIP DIRECTOR/MOWER DECK/WHEELS 3. WHEELS FRONT WHEEL Right Side Shown  ADJUSTER BOLT GRIP ADJUSTER PLATE ADJUSTER ARM  WHEEL BOLT 5/16 in WASHER WHEEL WASHER REASSEMBLY: Install the washer as shown. COLLAR WHEEL SIDE ADJUSTER PANEL 8mm FLANGE NUT 12-5 CLIP DIRECTOR/MOWER DECK/WHEELS HRR216VKA REAR WHEEL For additional information on how to remove or install the rear wheel assembly, refer to the appropriate section in Chapter 13 for your model. K5 ~ K9 Models Right Side Shown WHEEL WASHER REASSEMBLY: Install the washer as shown. BEARING (2) GRIP WHEEL SIDE ADJUSTER PLATE  13 x 27 x 1 mm THRUST WASHER WHEEL BOLT CIRCLIP BUSHING Apply extreme pressure NLGI #2 GC-LB grease inside bushing  ADJUSTER PANEL 8 mm FLANGE NUT KEY PINION GEAR COLLAR  COVER PINION GEAR (12 tooth) SEAL  RETURN SPRING Install with the punch mark facing: Left – inside Right – outside THRUST COLLAR COLLAR 13 mm THRUST WASHER ADJUSTER ARM SERVICE BULLETIN #107 => 25 mm CIRCLIP CIRCLIP 26 x 44 mm FLAT WASHER 12-6 HRR216VKA CLIP DIRECTOR/MOWER DECK/WHEELS K10/K11 Models Right Side Shown WHEEL WASHER REASSEMBLY: Install the washer as shown. BEARING (2) GRIP WHEEL SIDE ADJUSTER PLATE  ADJUSTER PANEL/ HANDLE STAY 13 x 27 x 1 mm THRUST WASHER WHEEL BOLT BUSHING Apply extreme pressure NLGI #2 GC-LB grease inside bushing  CIRCLIP 8 mm FLANGE NUT (4) KEY PINION GEAR COLLAR COVER PINION GEAR (12 tooth) SEAL   Install with the punch mark facing: Left – inside Right – outside RETURN SPRING THRUST COLLAR PINION GEAR COLLAR 13 mm THRUST WASHER ADJUSTER ARM 25 mm CIRCLIP CIRCLIP 26 x 44 mm FLAT WASHER 12-7 CLIP DIRECTOR/MOWER DECK/WHEELS NOTES 12-8 HRR216VKA 13. TRANSMISSION 1. TRANSMISSION (K5 AND K6) . . . . . . . . 13-1 2. TRANSMISSION (K7) . . . . . . . . . . . . . . . 13-7 3. TRANSMISSION (K8 ~ K11) . . . . . . . . . 13-13 1. TRANSMISSION (K5 and K6) REMOVAL 1. Drain the fuel tank and engine oil. 2. Loosen the Smart Drive cable adjuster (P. 3-10). SNAP FITTING CABLE HOLDER SLOT 3. Cut the cable ties attaching the flywheel brake cable and the Smart Drive cable to the handle pipe. 4. Set the height adjusting lever in the highest cutting position. 5. Protect the upper handle pipe and tip the mower up and secure the upper handle pipe in a bench vise. 6. Remove the belt 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 holder, and disconnect the Smart Drive cable end from the transmission control arm. SMART DRIVE CABLE END TRANSMISSION CONTROL ARM BELT TENSION SPRING 9. Remove the wheel bolt, wheel, wheel washer, and flat washer from each side. FLAT WASHER WHEEL WASHER INSTALLATION: WHEEL BOLT Install curved side as shown: WHEEL 13-1 TRANSMISSION HRR216VKA 10.Remove the 13 mm circlip, pinion gear collar, pinion gear, ratchet return spring, and ratchet key from each side. RATCHET KEY RATCHET RETURN SPRING 12-TOOTH PINION GEAR PINION GEAR COLLAR 11. Remove the wheel cover and pinion gear collar from each side. 13 mm CIRCLIP PINION GEAR COLLAR WHEEL COVER 12.Remove the remaining collar, circlip, and washer from each side as shown. WASHER CIRCLIP COLLAR 13-2 HRR216VKA 13.Remove the 22 mm circlip from each side, and slide them and the washers inward towards the transmission. TRANSMISSION ADJUSTER ASSEMBLY 14.Remove the adjuster assembly from each side, taking care not to damage the seals.  WASHER CIRCLIP 15.Slide the transmission/axle to the right side, and then rotate it until the left side can be removed from the mower deck. Remove the transmission from the mower deck. 22 mm CIRCLIP (2) 22 mm WASHER (2) 13-3 TRANSMISSION HRR216VKA DISASSEMBLY/REASSEMBLY (K5 VERSION up to MZCG - 7819952) 10 mm FLANGE NUT DRIVEN PULLEY BELT TENSION SPRING BELT SPRING PLATE 6 mm FLANGE NUT 12.7 x 22.2 x 6.4 mm OIL SEAL (2) 10 x 24 mm WASHER 6 x 14 mm FLANGE BOLT (2) 12 x 28.5 x 6.35 mm OIL SEAL RETURN SPRING TRANSMISSION CONTROL ARM TENSIONER ARM 6 x 12 mm FLANGE BOLT (2) WIRE HOLDER 10 x 19 x 7 mm OIL SEAL SMART DRIVE CABLE 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. CAPACITY: 150 cc (5.1 oz) TOP OF 8 ~ 12 mm CASE (0.3 ~ 0.5 in) CASE O-RING REDUCTION COVER 6 x 12 mm FLANGE BOLT (4) 8.8 ~ 11.8 N•m (6.5 ~ 8.7 ft-lb) 13-4 REMOVAL/INSTALLATION: P. 11-11 REASSEMBLY: Be sure to use the correct Smart Drive cable. The part number is printed on the cable. Steel pulley type: 54510-VL0-B00 Plastic pulley type: 54510-VH7-L00 (15 mm longer than 54510-VL0-B00) HRR216VKA TRANSMISSION (K5 VERSION MZCG - 7819953 ~ 7999999) (K6 VERSION MZCG - 8000001 ~ 8199999) (K7 VERSION MZCG - 8200001 ~ 8282198) POLYMER PULLEY INSTALLATION: Use a 5 mm (3/15 in) drift punch to align the hole in the pulley with the pinion shaft pin hole. Rotate the pulley until the pin hole is parallel to the belt tension arm. Press the spring pin into the pulley so that the pin is centered in the pinion shaft. The end of the pin should be about 30 mm from the outside edges of the pulley. 6 x 14 mm FLANGE BOLT (2) 5 x 35 mm SPRING PIN 12.7 x 28.6 x 6.4 mm OIL SEAL 6 mm FLANGE NUT BELT TENSION SPRING BELT TENSION ARM 12.7 x 22.2 x 6.4 mm OIL SEAL (2) TENSION SPRING PLATE TRANSMISSION CONTROL ARM 10 x 19 x 7 mm OIL SEAL 6 x 14 mm FLANGE BOLT (2) RETURN SPRING WIRE HOLDER TRANSMISSION CASE INSTALLATION: Use SAE 10W-30 engine oil and fill to the capacity shown. PINION SHAFT 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. SMART DRIVE CABLE CAPACITY: 150 cc (5.1 oz) TOP OF 8 ~ 12 mm CASE (0.3 ~ 0.5 in) CASE O-RING REDUCTION COVER REMOVAL/INSTALLATION: P. 11-11 REASSEMBLY: Be sure to use the correct Smart Drive cable. The part number is printed on the cable. Steel pulley type: 54510-VL0-B00 Plastic pulley type: 54510-VH7-L00 (15 mm longer than 54510-VL0-B00) 6 x 12 mm FLANGE BOLT (4) 8.8 ~ 11.8 N•m (6.5 ~ 8.7 ft-lb) 13-5 TRANSMISSION HRR216VKA INSTALLATION 22 mm CIRCLIP (2) 1. Install the transmission in the reverse order of removal. 2. Position the 22 mm circlips and 22 mm washers on the transmission axle. 3. Rotate the transmission so that the pulley is facing toward the front of the mower, and install the transmission in the mower. Pay attention to the following points:. • Thoroughly apply a coat of multipurpose extreme pressure wheel bearing grease to the adjuster arms (inside the seals), axle surfaces, pinion 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 application of the correct grease is critical to ensure proper operation. LEFT SIDE (CLOSEST TO TRANSMISSION) PUNCH MARK INSIDE DO NOT USE anti-seize, white lithium, silicon, WD-40, or any other spray lubricant. • Make sure the punch mark on the pinion gear faces in (toward the mower deck) on the left axle, and the punch mark faces out (toward the wheel) on the right axle. • Install the curved wheel washers as shown on page 12-5. RIGHT SIDE PUNCH MARK OUTSIDE 13-6 22 mm WASHER (2) HRR216VKA TRANSMISSION 2. TRANSMISSION (K7) (K7 VERSION MZCG - 8282199 and SUBSEQUENT) REMOVAL 1. Drain the fuel tank and engine oil. 2. Loosen the Smart Drive cable adjuster (P. 3-10). 3. Cut the cable ties attaching the flywheel brake cable and the Smart Drive cable to the handle pipe. SNAP FITTING CABLE HOLDER SLOT 4. Set the height adjusting lever in the highest cutting position. 5. Protect the upper handle pipe and tip the mower up and secure the upper handle pipe in a bench vise. 6. Remove the belt cover, belt tension spring, and drive belt (P. 4-4). SMART DRIVE CABLE END BELT TENSION SPRING 7. Rotate the transmission out slightly (not too far or you'll kink the cable). TRANSMISSION CONTROL ARM 8. Use needle nose pliers to remove the snap fitting from the clutch cable holder, and disconnect the Smart Drive cable end from the transmission control arm. 9. Remove the wheel bolt, wheel, wheel washer, and flat washer from each side. FLAT WASHER WHEEL BOLT WHEEL WASHER 10.Remove the 13 mm circlip, pinion gear collar, pinion gear, ratchet key, and ratchet return spring from each side. RATCHET KEY RATCHET RETURN SPRING 12-TOOTH PINION GEAR PINION GEAR COLLAR 13 mm CIRCLIP 13-7 TRANSMISSION HRR216VKA 11. Remove the pinion gear collars and wheel covers from each side. WHEEL COVER PINION GEAR COLLAR 12.Remove the remaining thrust collars and circlips from each side. THRUST COLLAR 13 mm WASHER 13 mm CIRCLIP 13.Remove the 22 mm circlip from each side, and slide them and the washers inward towards the transmission. ADJUSTER ASSEMBLY 14.Remove the adjuster assembly from each side, taking care not to damage the seals. WASHER CIRCLIP 13-8 HRR216VKA TRANSMISSION 15.Remove the two 8 mm flange nuts and 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 CIRCLIP (2) 22 mm WASHER (2) ADJUSTER PANEL (LEFT) 8 mm FLANGE NUT(2) 13-9 TRANSMISSION HRR216VKA DISASSEMBLY/REASSEMBLY (K7 VERSION MZCG - 8282199 and SUBSEQUENT) POLYMER PULLEY INSTALLATION: Use a 5 mm (3/15 in) drift punch to align the hole in the pulley with the pinion shaft pin hole. Rotate the pulley until the pin hole is parallel to the belt tension arm. Press the spring pin into the pulley so that the pin is centered in the pinion shaft. The end of the pin should be about 30 mm from the outside edges of the pulley. 6 x 14 mm FLANGE BOLT (2) 5 x 35 mm SPRING PIN 12.7 x 28.6 x 6.4 mm OIL SEAL 6 mm FLANGE NUT BELT TENSION SPRING BELT TENSION ARM 12.7 x 22.2 x 6.4 mm OIL SEAL (2) TENSION SPRING PLATE TRANSMISSION CONTROL ARM 10 x 19 x 7 mm OIL SEAL 6 x 14 mm FLANGE BOLT (2) RETURN SPRING WIRE HOLDER PINION SHAFT TRANSMISSION CASE INSTALLATION: Use SAE 10W-30 engine oil and fill to the capacity shown. SMART DRIVE CABLE The correct oil level should be 10 ~ 12 mm (0.4 ~ 0.5 in) from the top of the transmission case when it is upside down. CAPACITY: 150 cc (5.1 oz) TOP OF 10 ~ 12 mm CASE (0.4 ~ 0.5 in) CASE O-RING REDUCTION COVER 6 x 12 mm FLANGE BOLT (4) 8.8 ~ 11.8 N•m (6.5 ~ 8.7 ft-lb) 13-10 HRR216VKA TRANSMISSION INSTALLATION 25 mm CIRCLIP (2) 1. Position the 25 mm circlips and 26 x 44 mm washers on the transmission axle as shown. 26 x 44 mm WASHER (2) 2. Rotate the transmission so that the pulley is facing toward the front of the mower, and install the transmission in the mower. 3. Install the left side adjuster panel ("L" is on the left side and "R" is on the right side. ADJUSTER PANEL 8 mm FLANGE NUT(2) 4. Thoroughly clean the bushing contact areas on the axle using a Scotch-Brite™ pad. 5. 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 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. ADJUSTER ARM ADJUSTER PLATE  26 x 44 mm WASHER 25 mm CIRCLIP 6. Slide the adjuster plate onto the right-hand (RH) adjusting arm. 7. Install the right-hand adjuster assembly on the right side, taking care not to damage the seals. 8. Slide a 26 x 44 mm washer onto the adjuster and secure with a 25 mm circlip. Clean bushing contact areas with a Scotch-Brite™ pad. 9. Install a thrust collar and secure with a 13 mm circlip. THRUST COLLAR 13 mm CIRCLIP 13-11 TRANSMISSION HRR216VKA 10.Install a pinion gear collar and wheel cover. 11. Apply Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent to the areas shown. PINION GEAR COLLAR RATCHET KEY  RATCHET RETURN SPRING PINION GEAR (12 TOOTH) 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.  14.Install a wheel washer, flat washer, wheel, and wheel bolt. PINION GEAR COLLAR 13 mm CIRCLIP FLAT WASHER 15.Repeat steps 4 -14 for the left side. WHEEL BOLT WHEEL WASHER REASSEMBLY: Install the washer as shown. WHEEL SIDE 13-12  Install with the punch mark facing: Left – inside Right – outside 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 side as shown. WHEEL COVER HRR216VKA 16.Rotate the transmission out slightly to install the Smart Drive cable. 17.Connect the Smart Drive cable end onto the transmission control arm, and install the snap fitting into the clutch cable holder. TRANSMISSION SNAP FITTING CABLE HOLDER SLOT 18.Install the drive belt, belt tension spring, and belt cover (P. 4-5). 19.Adjust the Smart Drive cable (P. 3-10). 20.Add fuel and engine oil. SMART DRIVE CABLE END BELT TENSION SPRING TRANSMISSION CONTROL ARM 3. TRANSMISSION (K8 ~ K11) REMOVAL 1. Disconnect the spark plug cap. 2. Drain the fuel tank (P. 3-11) and engine oil (P. 3-7). 3. Loosen the Smart Drive cable adjuster (P. 3-10). TRANSMISSION CONTROL ARM 4. Set the height adjusting lever in the highest cutting position. BELT TENSION SPRING 5. Protect the 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 and MZCG-1000001 ~ 1999999: Remove the belt guide. 9. Lift the drive pulley off the crankshaft and separate the belt from the drive pulley. Leave the belt attached to the transmission. SMART DRIVE CABLE CABLE HOLDER DRIVE BELT DRIVE PULLEY BELT GUIDE 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 the transmission control arm. 13-13 TRANSMISSION HRR216VKA 12.Remove the wheel bolt, wheel, wheel washer, and flat washer from each side. FLAT WASHER WHEEL BOLT WHEEL WASHER 13.Remove the 13 mm circlip, pinion gear collar, pinion gear, ratchet key, and ratchet return spring from each side. RATCHET KEY RATCHET RETURN SPRING 12-TOOTH PINION GEAR PINION GEAR COLLAR 14.Remove the pinion gear collars and wheel covers from each side. 13-14 13 mm CIRCLIP PINION GEAR COLLAR WHEEL COVER HRR216VKA TRANSMISSION 15.Remove the remaining thrust collars, 13 mm washers, and circlips from each side. THRUST COLLAR 13 mm WASHER 13 mm CIRCLIP 16.Remove the 25 mm circlip from each side, and slide them and the 26 x 44 mm washers inward toward the transmission. 17.Remove the adjuster assembly from each side, taking care not to damage the seals. ADJUSTER ASSEMBLY 26 x 44 mm WASHER 25 mm CIRCLIP 18.K8 and K9 models only: Remove the two 8 mm flange nuts and the left side adjuster panel. 22 mm CIRCLIP (2) 22 mm WASHER (2) 19.Slide the transmission/axle to the right side, and then rotate it until the left side can be removed from the mower deck; remove the transmission. ADJUSTER PANEL (LEFT) (K8/K9 only) 8 mm FLANGE NUT(2) 13-15 TRANSMISSION HRR216VKA DISASSEMBLY/REASSEMBLY (up to MZCG-9506881) DRIVEN PULLEY HALVES REMOVAL Hold the pinion shaft with a wrench, and then remove the 10 mm flange nut. INSTALLATION: Align the pulley pins opposite each other so that they fit into the small holes of the other pulley half. 10 mm FLANGE NUT 39 N•m (29 ft-lb) PINS 10 x 24 mm WASHER 12.7 x 22.2 x 6.4 mm OIL SEAL (2) 12.7 x 28.6 x 6.4 mm OIL SEAL 6 x 12 mm FLANGE BOLT (2) RETURN SPRING BELT GUIDE INSPECTION: P. 2-14 PINION SHAFT CABLE HOLDER CASE O-RING 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 top of the transmission case when it is upside down. CAPACITY: 65 cc (2.2 oz) TOP OF 18 ~ 20 mm CASE (0.71 ~ 0.79 in) SMART DRIVE CABLE REDUCTION COVER 6 x 12 mm FLANGE BOLT (4) 8.8 ~ 11.8 N•m (6.5 ~ 8.7 ft-lb) TRANSMISSION CONTROL ARM 13-16 ADJUSTMENT: P. 3-10 HRR216VKA TRANSMISSION (MZCG-9506882 ~ 9999999 and MZCG-1000001 ~ 1999999) DRIVEN PULLEY HALVES REMOVAL Hold the pinion shaft with a wrench, and then remove the 10 mm flange nut. INSTALLATION: Align the pulley pins opposite each other so that they fit into the small holes of the other pulley half. 10 mm FLANGE NUT 39 N•m (29 ft-lb) PINS 10 x 24 mm WASHER 12.7 x 22.2 x 6.4 mm OIL SEAL (2) 6 x 12 mm FLANGE BOLT (2) 12.7 x 28.6 x 6.4 mm OIL SEAL RETURN SPRING BELT GUIDE PINION SHAFT CABLE HOLDER CASE O-RING TRANSMISSION CASE INSTALLATION: Use SAE 10W-30 engine oil and fill to the capacity 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 18 ~ 20 mm CASE (0.71 ~ 0.79 in) SMART DRIVE CLUTCH CABLE REDUCTION COVER 6 x 12 mm FLANGE BOLT (4) 8.8 ~ 11.8 N•m (6.5 ~ 8.7 ft-lb) TRANSMISSION CONTROL ARM 13-17 TRANSMISSION HRR216VKA INSTALLATION 25 mm CIRCLIP (2) 1. Position the 25 mm circlips and 26 x 44 mm washers on the transmission axle as shown. 26 x 44 mm WASHER (2) 2. Rotate the transmission so that the pulley is facing toward the front of the mower, and install the transmission in the mower. 3. K8 and K9 models only: Install the left side adjuster panel (“L” is on the left side and “R” is on the right side). ADJUSTER PANEL (LEFT) (K8/K9 only) 8 mm FLANGE NUT(2) 4. Inspect the bushings and seal for wear and replace if necessary. 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 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. 7. Slide the adjuster plate onto the right hand (RH) adjusting arm. ADJUSTER ARM ADJUSTER PLATE 26 x 44 mm WASHER  25 mm CIRCLIP Clean bushing contact areas with a Scotch-Brite™ pad. 8. Install the right-hand adjuster assembly on the right side, taking care not to damage the seals. 9. Slide a 26 x 44 mm washer onto the adjuster and secure with a 25 mm circlip. 10.Install a thrust collar and 13 mm washer, and secure with a 13 mm circlip. THRUST COLLAR 13 mm WASHER 13 mm CIRCLIP 13-18 HRR216VKA TRANSMISSION 11. Install a pinion gear collar and wheel cover. 12.Apply Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent to the areas shown. RATCHET KEY  RATCHET RETURN SPRING  12-TOOTH 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. Install with the punch mark facing: Left – inside Right – outside 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. WHEEL COVER PINION GEAR COLLAR  15.Install a wheel washer, flat washer, wheel, and wheel bolt. PINION GEAR COLLAR 13 mm CIRCLIP FLAT WASHER 16.Repeat steps 4 -15 for the left side. WHEEL BOLT WHEEL WASHER REASSEMBLY: Install the washer as shown. Install the curved wheel washer in the direction shown. 13-19 TRANSMISSION HRR216VKA 17.Install the return spring. TRANSMISSION CONTROL ARM 18.Push down on the control arm, and install the Smart Drive cable end onto the transmission control arm. 19.Position the belt on the drive pulley and install the drive 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.Reconnect the spark plug cap. 24.Add fuel and engine oil. 25.Start the engine and adjust the Smart Drive cable (P. 3-10). 13-20 BELT TENSION SPRING SMART DRIVE CABLE CABLE HOLDER DRIVE BELT DRIVE PULLEY BELT GUIDE INDEX A Air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Air gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 B Blade holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Blades Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Torque spec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Breather tube installation . . . . . . . . . . . . . . . . . . . . . . . . 8-20 C Cam pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Carburetor Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . . . . 8-5 Float level height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Choke control assembly. . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Choke control system K5 ~ K7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 K8 ~ K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Clip Director removal/installation . . . . . . . . . . . . . . . . . . 12-1 Combustion chamber cleaning . . . . . . . . . . . . . . . . . . 10-10 Commercially available tools . . . . . . . . . . . . . . . . . . . . . . 2-6 Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Connecting rod Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Oil clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Crankshaft inspection . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Crankshaft runout check . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Cylinder barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Cylinder block inspection . . . . . . . . . . . . . . . . . . . . . . . 10-19 Cylinder block/oil pan assembly. . . . . . . . . . . . . . . . . . . 10-6 Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 D Deck K5 ~ K7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 K9 ~ K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Decompressor weight . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Discharge guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 Drive belt K5 ~ K6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 K7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 K9 ~ K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Drive system troubleshooting. . . . . . . . . . . . . . . . . 2-7~2-17 E Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . 8-27 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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/reassembly (K9 ~ K11) . . . . . . . . . . . . . . 9-2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Flywheel brake inspection . . . . . . . . . . . . . . . . . . . . . . . 3-12 Fuel cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 Fuel tank and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Fuel tank removal/installation K5 ~ K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 K9 ~ K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25 Fuel tube Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26 Fuel valve disassembly/reassembly . . . . . . . . . . . . . . . 8-22 G Governor Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . . 10-13 Max speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Governor arm disassembly/reassembly . . . . . . . . . . . . 8-21 Grass bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Guard, discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 H Handle grip removal/installation. . . . . . . . . . . . . . . . . . . 11-9 Handle locking knob . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 Handle pipe replacement. . . . . . . . . . . . . . . . . . . . . . . . 11-1 Handle stay removal/installation . . . . . . . . . . . . . . . . . . 11-3 I Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Idle speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Ignition coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Inspection Cam pulley height . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Cam pulley I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Cam pulley shaft O.D.. . . . . . . . . . . . . . . . . . . . . . . . 10-14 Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . 10-17,10-18 Crankshaft main journal . . . . . . . . . . . . . . . . . . . . . . 10-17 Cylinder block main journal. . . . . . . . . . . . . . . . . . . . 10-19 Decompressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Oil pan main journal . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Piston ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Piston-to-cylinder clearance . . . . . . . . . . . . . . . . . . . 10-15 Rocker arm shaft clearance . . . . . . . . . . . . . . . . . . . 10-15 Stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Timing gear (K9 ~ K11). . . . . . . . . . . . . . . . . . . . . . . 10-18 Valve face/stem O.D. . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Valve guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Valve seat width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 M Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Mower deck K5 ~ K7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 K8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 K9 ~ K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 O Oil Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Oil leak, transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Oil pan removal/installation . . . . . . . . . . . . . . . . . . . . . . 10-4 P Pinion gear lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Cylinder clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . . . 10-7 Piston ring inspection . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 R Rear discharge guard . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 Rear scroll (K9 ~ K11). . . . . . . . . . . . . . . . . . . . . . . 4-7,12-1 Rear scroll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Rear shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Rear wheel lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Recoil starter Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Starter rope replacement . . . . . . . . . . . . . . . . . . . . . . . 7-2 Removal, rear scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Rocker arm inspection . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Rocker arm shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 S Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-i Schedule, maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Scroll assembly (K9 ~ K11). . . . . . . . . . . . . . . . . . . 4-7,12-1 Scroll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Service rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Smart Drive Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Cable installation (K5 ~ K6) . . . . . . . . . . . . . . . . . . . 11-12 Cable installation (K7) . . . . . . . . . . . . . . . . . . . . . . . 11-16 Cable installation (K8 ~ K11) . . . . . . . . . . . . . . . . . . 11-20 Cable removal (K5 ~ K6) . . . . . . . . . . . . . . . . . . . . . 11-11 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, capacities . . . . . . . . . . . . . . . . . . 1-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2,2-3,8-5 Tune-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Stop switch inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 T Thermowax Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 Throttle return spring . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Timing gear inspection (K9 ~ K11) . . . . . . . . . . . . . . . 10-18 Tools Commercially available. . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Transmission Disassembly/reassembly (K5 ~ K7) . . . . . . . . . . . . . . 13-5 Disassembly/reassembly (K5) . . . . . . . . . . . . . . . . . . 13-4 Disassembly/reassembly (K7) . . . . . . . . . . . . . . . . . 13-10 Disassembly/reassembly (K8 ~ K11) . . . . . . . . . . . . 13-16 Installation (K5 ~ K6) . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 Installation (K7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11 Installation (K8 ~ K11) . . . . . . . . . . . . . . . . . . . . . . . 13-18 Oil leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Removal (K5 ~ K6) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Removal (K7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 Removal (K8 ~ K11) . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 Troubleshooting Drive system. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7~2-17 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Tune-up specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 V Valve Clearance adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . . . 10-9 Seat reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Vibration troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 2-19 W Wheels Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Rear (K10/K11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7 Rear (K5 ~ K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6