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Thank you for purchasing a Honda lawn mower.
This manual covers the operation and maintenance of the Honda
HRJ196/HRJ216 lawn mowers.
We want to help you get the best results from your mower and to
operate it safely. This manual contains the information on how to do
that; please read it carefully.
This manual should be considered a permanent part of the lawn
mower and should remain with it, if it is resold.
If you have a problem or questions concerning the mower, contact
your supplying dealer.
We recommend that you read the guarantee policy to fully understand
your rights and responsibilities. The guarantee policy is a separate
document provided by your dealer.
Honda Motor Co., Ltd. reserves the right to make changes at any time
without notice and without incurring any obligation.
No part of this publication may be reproduced without written
permission.
SAFETY MESSAGES
Pay special attention to statements preceded by the following words;
Each message tells you what the hazard is, what can happen, and
what you can do to avoid or reduce injury.
DAMAGE PREVENTION MESSAGES
You will also see other important messages that are preceded by the
following word:
Your lawn mower or other property can be damaged if you
don't follow instructions.
The purpose of these messages is to help prevent damage to your
lawn mower, other property, or the environment.
Do not use this lawn mower except for mowing.
Honda Motor Co., Ltd. 2011, All Rights Reserved
You WILL be KILLED or SERIOUSLY HURT if you
don't follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you
don't follow instructions.
You CAN be HURT if you don't follow
instructions.
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Table of Contents
Related Manuals for Honda HRJ216K2
Summary of Contents for Honda HRJ216K2
- Page 1 The guarantee policy is a separate document provided by your dealer. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission.
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Page 2: Table Of Contents
CONTENTS 1. SAFETY INSTRUCTIONS ..............SAFETY LABEL LOCATIONS ................. 2. COMPONENT IDENTIFICATION ............3. CONTROLS ..................12 DESCRIPTION OF CONTROLS ..............12 Fuel Valve ..................... 12 Throttle Lever ....................12 Flywheel Brake Lever ................. . 13 Drive Clutch Lever (HRJ216 Model) ............ - Page 3 6. TRANSPORTING/STORAGE ............. 41 BEFORE LOADING ..................41 LOADING AND UNLOADING ............... . 41 STORAGE PREPARATION ................42 Handlebar Folding ..................45 STORAGE PRECAUTIONS ................46 REMOVAL FROM STORAGE ................ . 46 7. MAINTENANCE ................. .
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Page 4: Safety Instructions
SAFETY INSTRUCTIONS − To ensure safe operation Read and understand the Owner’s Manual before operating the mower. Failure to do so could result in personal injury or equipment damage. Read instructions carefully, become familiar with controls and proper use of equipment. Know how to stop the engine rapidly. Never allow children or people unfamiliar with these instructions to use the lawn mower. - Page 5 Before using, always visually inspect to see that the blade, blade bolt(s) and mower housing are not worn or damaged. Replace worn or damaged blade and bolt(s) in sets to preserve balance. Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.
- Page 6 Never pick up or carry a lawn mower while the engine is running. Stop the engine and disconnect the spark plug cap: − Before clearing a blockage or unclogging the lawn mower. − Before checking, cleaning or working on the lawn mower. −...
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Page 7: Safety Label Locations
SAFETY LABEL LOCATIONS These labels warn you of potential hazards that can cause serious injury. Carefully read the meaning of each label. If a label comes off or becomes hard to read, contact your dealer for a replacement. Also, after a repair or parts replacement, check that the label is attached to the new parts. -
Page 8: Component Identification
COMPONENT IDENTIFICATION HRJ196 Model (PDHH, PWHH and PWHX Types) FLYWHEEL BRAKE LEVER HANDLEBAR AIR CLEANER HOSE (PWHH and PWHX Types) FUEL FILLER CAP AIR CLEANER STARTER GRIP GRASS BAG (PWHH Type) OIL FILLER CAP/DIPSTICK MUFFLER ENGINE SERIAL NUMBER... - Page 9 THROTTLE LEVER DISCHARGE GUARD FRAME SERIAL NUMBER SPARK PLUG CAP HANDLEBAR LOCKING KNOB (2) CUTTING HEIGHT ADJUSTMENT LEVER CUTTER HOUSING FRONT GUARD FUEL VALVE...
- Page 10 HRJ216 Model (TDHH, TWHH and TWHX Types) FLYWHEEL BRAKE LEVER HANDLEBAR DRIVE CLUTCH LEVER AIR CLEANER HOSE (TWHH and TWHX Types) FUEL FILLER CAP AIR CLEANER STARTER GRIP GRASS BAG (TWHH Type) CUTTING HEIGHT ADJUSTMENT LEVER OIL FILLER CAP/DIPSTICK ENGINE SERIAL NUMBER MUFFLER...
- Page 11 THROTTLE LEVER SHIFT LEVER DISCHARGE GUARD FRAME SERIAL NUMBER SPARK PLUG CAP HANDLEBAR LOCKING KNOB (2) CUTTER HOUSING FRONT GUARD FUEL VALVE Record the frame and engine serial numbers and date of purchase in the space below. You will need these serial numbers when ordering parts and when making technical or warranty inquiries.
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Page 12: Controls
CONTROLS DESCRIPTION OF CONTROLS Fuel Valve ..The fuel valve opens and closes the fuel passage from the fuel tank to the carburetor. The fuel valve must be ON to start and operate the mower. The fuel valve should be kept OFF when the mower is not use. -
Page 13: Flywheel Brake Lever
Flywheel Brake Lever This lever is connected to the engine flywheel brake and the ignition switch. The engine will not start unless this lever is pushed forward. HRJ196 Model: STOP FLYWHEEL BRAKE LEVER HRJ216 Model: STOP FLYWHEEL BRAKE LEVER... -
Page 14: Drive Clutch Lever (Hrj216 Model)
Drive Clutch Lever (HRJ216 Model) The drive clutch lever engages (push forward) and disengages (release) the transmission that drives the rear wheels. The drive clutch lever should only be engaged after the engine has been started. DRIVE CLUTCH LEVER ENGAGE DISENGAGE... -
Page 15: Cutting Height Adjustment Lever
Cutting Height Adjustment Lever All wheels of the mower can be adjusted to one of lever settings. The cutting height figures are approximate. The actual height of cut grass will vary with lawn and soil conditions. Move the adjuster forward to lower and back to raise the cutter housing. -
Page 16: Shift Lever (Hrj216 Model)
Shift Lever (HRJ216 Model) The shift lever selects and controls the self-propelled drive speed. (MEDIUM) (SLOW) (FAST) SHIFT LEVER 1st (SLOW) For mowing thick grass or maneuvering in small areas. 2nd (MEDIUM) For intermediate self-propelled mowing speed. 3rd (FAST) For maximum self-propelled transport speed. -
Page 17: Front Guard
Front Guard Do not step on the front guard. Do not use the front guard to lift the lawn mower. Replace the front guard at an authorized Honda service dealer whenever it is deformed. HRJ196 Model: HRJ216 Model: FRONT GUARD... -
Page 18: Pre-Operation Checks
PRE-OPERATION CHECKS ARE YOU READY TO MOW? Be sure to wear protective clothing. Long pants and eye protection can lower your risk of injury from thrown objects. Wear footwear that protects your feet and won’t let you slip if you mow on slopes or uneven ground. -
Page 19: Check Your Mower
CHECK YOUR MOWER Blade Before each use, check the cutter blade for damage or excessive wear. To avoid severe personal injury, disconnect the spark plug cap to prevent accidental starting, and wear heavy gloves to protect your hands from the cutter blade. Stop the engine and turn the fuel valve to the OFF position. - Page 20 Inspect the blades for wear and damage. Check that the blade setting bolts and the blade disc holder bolt are tight (see page BLADE BLADE DISC HOLDER BOLT BLADE SETTING BOLTS BLADE Never operate the mower with a worn, damaged, split or dented blade.
- Page 21 When a blade needs sharpening or replacement, take the lawn mower to an authorized Honda servicing dealer. Or, if you have a torque wrench and other proper tools, you can remove and install the blade...
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Page 22: Engine Oil Level
Engine Oil Level Check the engine oil level with the engine stopped and the mower on a level surface. Remove the oil filler cap, and wipe the dipstick clean. Insert and remove the dipstick without screwing it into the filler neck. Check the oil level shown on the dipstick. -
Page 23: Fuel
Fuel Refuel in a well-ventilated area before starting the engine. If the engine has been running, allow it to cool. See page for fuel recommendations. FUEL FILLER CAP UPPER LIMIT Remove the fuel filler cap and check the fuel level. Refill the tank if the fuel level is low. -
Page 24: Air Cleaner
Air Cleaner Inspection Make sure the air filters are clean and in good condition. A dirty air filter will restrict air flow to the carburetor, reducing engine performance. Refer to page for air cleaner service. AIR CLEANER NUTS AIR CLEANER HOSE (PWHH, PWHX, TWHH and TWHX Types) FOAM FILTER ELEMENT... - Page 25 Installation Raise the discharge guard, and hook the grass bag frame onto the cutter housing as shown. Release the discharge guard to secure the grass bag in place. DISCHARGE GUARD GRASS BAG HANDLE GRASS BAG FRAME Removal Raise the discharge guard, grasp the grass bag handle and remove the grass bag.
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Page 26: Cutting Height
Cutting Height Check the cutter housing cutting height settings. The lowest setting is approximately 16 mm and the highest setting is 75 mm (HRJ196 Model), 16 mm and the highest setting is 76 mm (HRJ216 Model). To adjust cutting height, pull the adjustment lever toward the wheel, and move it into another notch. -
Page 27: Operation
OPERATION MOWING PRECAUTIONS Before operating the mower for the first time, please review the SAFETY INSTRUCTIONS beginning on page and SAFE MOWING PRACTICES on pages Even if you have operated other mowers, take time to become familiar with how this mower works and practice in a safe area until you build up your skills. - Page 28 Move the throttle lever to the proper starting position. COLD ENGINE: Move the throttle lever to the CHOKE position. HRJ196 Model: HRJ216 Model: CHOKE CHOKE THROTTLE LEVER THROTTLE LEVER WARM ENGINE: Move the throttle lever to the HIGH position. HRJ196 Model: HRJ216 Model: HIGH HIGH...
- Page 29 HRJ216 Model: Release the drive clutch lever. If the drive clutch lever is engaged, the mower will move forward when you operate the starter. By standing in the back side of the mower at the operating position, push the flywheel brake lever forward and hold it against the handlebar.
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Page 30: Operating The Controls For Mowing
OPERATING THE CONTROLS FOR MOWING Throttle Lever For best cut quality, always mow with the throttle lever in the HIGH position. When the blade rotates at the preset fast speed, it creates a strong fan action that lifts and cuts grass more efficiently. Do not try to increase the preset engine speed, the blade could fracture and come apart. -
Page 31: Drive Clutch Lever (Hrj216 Model)
Drive Clutch Lever (HRJ216 Model) Push the drive clutch lever forward and hold it against the handlebar to propel the mower forward. Release the drive clutch lever to stop the mower’s forward movement. Always release the drive clutch lever before starting the engine. If the drive clutch is engaged, the mower will move forward when you operate the starter. -
Page 32: Shift Lever (Hrj216 Model)
Shift Lever (HRJ216 Model) With the drive clutch released, move the shift lever to select 1st (slow), 2nd (medium) or 3rd (fast). Do not use the throttle lever to adjust your forward speed. Forward speed should be adjusted with the shift lever, not the throttle lever. The throttle lever must remain in the ‘‘HIGH’’... -
Page 33: Stopping The Engine
STOPPING THE ENGINE Emergency Engine Stop HRJ196 Model: Release the flywheel brake lever. STOP FLYWHEEL BRAKE LEVER HRJ216 Model: Release the drive clutch lever and flywheel brake lever. STOP FLYWHEEL BRAKE LEVER DRIVE CLUTCH LEVER... -
Page 34: Normal Engine Stop
Normal Engine Stop Move the throttle lever to the LOW position. HRJ196 Model: HRJ216 Model: THROTTLE LEVER THROTTLE LEVER Release the drive clutch lever (HRJ216 Model). DISENGAGE DRIVE CLUTCH LEVER... - Page 35 Release the flywheel brake lever. HRJ196 Model: FLYWHEEL BRAKE LEVER STOP HRJ216 Model: FLYWHEEL BRAKE LEVER STOP When the mower is not in use, turn the fuel valve to the OFF position. FUEL VALVE...
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Page 36: Safe Mowing Practices
SAFE MOWING PRACTICES For your safety, keep all four wheels on the ground and be careful to avoid losing your footing and your control of the mower. Keep a firm grip on the handlebar, and walk, never run, with the mower. Be very careful when mowing uneven or rough ground. - Page 37 Obstacles Use the side of the mower to cut close to large obstacles, such as fences or walls. Release the drive clutch lever to disengage the drive when mowing around trees and other obstacles. Push the mower around obstacles for better directional control. Be careful when mowing over obstacles embedded in the lawn, such as sprinkler heads, paving, edging, etc.
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Page 38: Mowing Tips
MOWING TIPS Cutting Height Consult a local nursery or lawn and garden center for cutting height recommendations and advice about specific types of grasses and growing conditions in your area. If you look closely, you’ll see that most grass has stems and leaves. If you cut off the leaves, you’ll scalp the lawn. - Page 39 Blade Speed The blade must spin very fast to cut properly. Always use the HIGH throttle setting, and keep the engine running at maximum rpm. If engine speed drops, it could mean the engine is being overloaded by the blade trying to cut too much grass. Mow a narrower swath, move the mower slower, or raise the cutting height.
- Page 40 Clear a clogged deck with a stick, not by your hands. Mowing Patterns Your Honda mower will work most efficiently if you use the following mowing patterns as much as possible. Cutter housing and...
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Page 41: Transporting/Storage
TRANSPORTING/STORAGE BEFORE LOADING Stop the engine and turn the fuel valve to the OFF position. This will prevent carburetor flooding and reduce the possibility of fuel leakage. If the engine has been running, allow it to cool for at least 15 minutes before loading the mower on the transport vehicle. -
Page 42: Storage Preparation
STORAGE PREPARATION Proper storage preparation is essential for keeping your lawn mower trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your lawn mower’s function and appearance, and will make the engine easier to start when you use the lawn mower again. - Page 43 Fuel Gasoline will oxidize and deteriorate in storage. Old gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your mower deteriorates during storage, you may need to have the carburetor and other fuel system components serviced or replaced.
- Page 44 Draining the Fuel Tank and Carburetor Empty the fuel tank into an approved gasoline container. Remove the carburetor drain bolt with a 10 mm wrench, and drain the carburetor bowl fuel into an approved container. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
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Page 45: Handlebar Folding
Handlebar Folding Remove the grass bag (if installed). Loosen or remove the two handlebar locking knobs. Pull the handlebar struts to release them from the locating grooves, then swing the handlebar forward with the flywheel brake lever and drive clutch lever (HRJ216 Model) held by your hand. Don’t allow the cables and air cleaner hose (applicable type) to be bent or pinched. -
Page 46: Storage Precautions
STORAGE PRECAUTIONS If your mower will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well-ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. -
Page 47: Maintenance
Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic. The maintenance schedule applies to normal operating conditions. If you operate your mower... -
Page 48: Maintenance Safety
Remember that an authorized Honda servicing dealer knows your mower best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new, Honda genuine parts or their equivalents for repair and replacement. -
Page 49: Maintenance Schedule
These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures. Change engine oil every 25 hours when used heavy load or in high ambient temperature. -
Page 50: Engine Maintenance
ENGINE MAINTENANCE Engine Oil Change Drain the used oil while the engine is warm. Warm oil drains quickly and completely. Turn the fuel valve to the OFF position to reduce the possibility of fuel leakage (see page Wipe the oil filler area clean, then remove the oil filler cap/dipstick. Place a suitable container next to the mower to catch the used oil, then tilt the mower on its right side. -
Page 51: Engine Oil Recommendations
After changing the engine oil, and before starting the engine, check the oil level with the mower on a level surface: Wipe the dipstick clean. Insert and remove the dipstick without screwing it into the filler neck. Check the oil level shown on the dipstick. If the oil level is low, add oil to reach the upper limit mark on the dipstick. -
Page 52: Air Cleaner Service
Air Cleaner Service Dirty air cleaner will restrict air flow to the carburetor, reducing engine performance. If you operate the mower in very dusty areas, clean the air cleaner more often than specified in the MAINTENANCE SCHEDULE. Operating the engine without an air filters, or damaged filters, will allow dirt to enter the engine, causing rapid engine wear. -
Page 53: Flywheel Brake Lever Operation Inspection
Start the engine outdoors and move the throttle lever to the HIGH position. Release the flywheel brake lever; the engine should stop quickly. If it does not, take your mower to an authorized Honda servicing dealer for repair. Spark Plug Service... - Page 54 Use a spark plug wrench to remove the spark plug. Inspect the plug; replace it if the electrode is worn, or if the insulator is cracked or chipped. Clean plug completely if you are going to reuse it. Measure the spark plug gap with a suitable gauge. The gap should be 0.7 0.8 mm.
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Page 55: Carburetor Modification For Altitude Operation
If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda servicing dealer. Running the engine with persistent spark knock or pinging can cause engine damage. -
Page 56: Blade Removal And Installation
To avoid weakening the blade, or causing imbalance or poor cutting, the blade should be sharpened by trained staff at an authorized Honda servicing dealer. If replacing the blade, use a Honda genuine replacement blade or equivalent. - Page 57 Illustration showing the blade disc holder bolt, washer, blade/blade disc, blade holder, woodruff key, and thrust washer removed. THRUST WASHER WOODRUFF KEY WASHER BLADE DISC HOLDER BOLT BLADE HOLDER BLADE/BLADE DISC Remove the blade setting bolt, blade, spring washer, blade washer and self-lock nut from the blade disc.
- Page 58 The blade setting bolts are specially designed for the mower. Should you ever have to replace them, use only Honda genuine parts. Otherwise, the blade may detach from the mower and cause serious injury.
- Page 59 Install the thrust washer, woodruff key, blade holder, blade/blade disc, washer and blade disc holder bolt. THRUST WASHER WOODRUFF KEY WASHER BLADE DISC HOLDER BOLT BLADE HOLDER BLADE/BLADE DISC Hold the blade disc firmly, and install the blade disc holder bolt. BLADE DISC BLADE DISC’S HOLE...
- Page 60 Honda servicing dealer. A bent blade can be the cause of serious personal injury or accident. If you don’t have a torque wrench, have an authorized Honda servicing dealer tighten the blade setting bolts and the blade disc holder bolt before you use the mower. If the blade setting bolts and the blade disc holder bolt are overtightened, they could break.
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Page 61: Grass Bag Cleaning And Replacement (Pwhh And Twhh Types)
Wash the bag with a garden hose, and allow it to dry completely before use; a wet bag will clog quickly. Grass Bag Replacement Replace a worn or damaged bag with a Honda genuine bag or its equivalent. Bag Removal Unclip the plastic edges of the bag from the frame. -
Page 62: Troubleshooting
Start engine with throttle lever in HIGH position. Take mower to an Fuel filter clogged, Replace or repair authorized Honda carburetor malfunction, faulty components as servicing dealer, or ignition malfunction, necessary. refer to shop manual. valves stuck, etc. - Page 63 Replace unbalanced by damaged blade improper sharpening. (p. 56). Take mower to an Mechanical damage, Replace or repair authorized Honda such as a bent faulty components as servicing dealer for crankshaft. necessary. repair. MOWING AND BAGGING PROBLEMS Poor Cut Quality or...
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Page 64: Specifications
SPECIFICATIONS MOWER MODELS Model HRJ196 HRJ216K2 Description Code MADC MACC Type Manually propelled Self-propelled DIMENSIONS, WEIGHTS AND CAPACITIES Model HRJ196 HRJ216K2 Type PDHH PWHH PWHX TDHH TWHH TWHX Overall Length 1,560 mm 1,715 mm Overall Width 505 mm 570 mm... - Page 65 ENGINE DESIGN AND PERFORMANCE Model HRJ196 HRJ216K2 Engine Model GXV160H2 Engine Type 4-stroke, over head valve forced air-cooled Displacement 163 cm Bore and Stroke Ø 68.0 × 45.0 mm Compression Ratio 8.0:1 Engine Net Power 3.2 kW (4.3 HP) at 3,600 rpm (PDHH and TDHH types) 2.7 kW (3.6 HP) at 3,000 rpm (PWHH and TWHH types)
- Page 66 DRIVE TRAIN (HRJ216 Model) Mechanism from engine to transmission Shaft drive Clutch Type Dog clutch Operation Manual lever Transmission Type Gear transmission Operation Remote control Number of speeds 3 Speeds Lubrication system Oil bath and splash Lubricant Hypoid gear oil SAE ＃...
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Page 67: Set-Up Instruction
SET-UP INSTRUCTION Unpacking Remove all protective cardboards from the mower, including the piece around the handlebar. Grass Bag Installation Refer to page for grass bag installation. Handlebar Setup Remove the locking knobs from the handlebar mounting section of the cutter housing. Set the lower section of the handlebar to the handlebar mounting section of the cutter housing enough so you can raise the handlebar into the normal position. - Page 68 Secure the wires and air cleaner hose with the wire band as shown below (PWHH and TWHH Types). Secure the wires with the wire band as shown below (PDHH and TDHH Types). HRJ196 Model: PWHH Type View from arrow of sections WIRE BAND (4) 30 mm 200 mm...
- Page 69 HRJ216 Model: TWHH Type View from arrow of sections WIRE BAND (4) 40 mm 170 mm 40 mm 70 mm 100 mm HRJ216 Model: TDHH Type View from arrow of sections WIRE BAND (2) 210 mm 70 mm...
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Page 70: Index
INDEX SAFE MOWING PRACTICES .............. . 36 SAFETY INSTRUCTIONS ..............Front Guard ..................17 MAINTENANCE ..................47 MAINTENANCE SAFETY ..............48 THE IMPORTANCE OF MAINTENANCE ..........47 MAINTENANCE SCHEDULE .............. . 49 CONTROLS ................... 12 DESCRIPTION OF CONTROLS ............ - Page 71 Air Cleaner Hose (PWHH, PWHX and TWHX) ........24 Air Cleaner ................... . 24 Air Cleaner Service ................52 Drive Clutch Lever (HRJ216 Model) ..........14, 31 COMPONENT IDENTIFICATION ............STARTING THE ENGINE ..............27 Cutting Height ..................
- Page 72 Produced by: Jialing-Honda Motors Co., Ltd. NO. 1 Guan Yuenan Road, Yubei District, Chongqing, P. R. China Phone: +86-23-62793100 Published by Honda Motors Co., Ltd. 2012.04 Printed in China SDT No. GB26509-2011...