Honda HRN216 Series Manual
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Honda HRN216 Series Manual

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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.

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  • Page 1 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.
  • Page 2 HRN216 INTRODUCTION CONTENTS This manual covers service and repair procedures for all SPECIFICATIONS Honda HRN216 model rotary mowers listed below. Refer to the next page for more model and type information. SERVICE INFORMATION U.S.A. Canadian: Australian: HRN216PKA(A) HRN216PKC(A) HRN216PKU(A) MAINTENANCE...
  • Page 3 LAWN MOWER TYPE IDENTIFICATION TYPE Throughout this manual, an HRN216 lawn mower’s type is listed when the repair procedure varies from other HRN216 types. Refer to the serial number label located on the top of the mower deck behind the engine to determine the type of an HRN216 lawn mower. You may also use the information shown below to identify the type of SERIAL NUMBER LABEL HRN216 lawn mower you are repairing.
  • Page 4 1. SPECIFICATIONS 1. SPECIFICATIONS ....3. WIRING DIAGRAM (VLA TYPE) ..2. DIMENSIONAL DRAWINGS ...
  • Page 5 SPECIFICATIONS HRN216 1. SPECIFICATIONS DIMENSIONS, WEIGHTS, AND CAPACITIES Model Type Height* 1,025 mm (40.4 in) 1,037 mm (40.8 in) Length* 1,550 mm (61.0 in) Mower deck width 575 mm (22.6 in) Wheel base 676 mm (26.6 in) (cut height set to 27 mm [1 in]) Cutting width 530 mm (20.9 in) 27, 39, 51, 64, 76, 88, 100 mm...
  • Page 6 HRN216 SPECIFICATIONS 2. DIMENSIONAL DRAWINGS PKA TYPE 676 mm (26.6 in) 1,550 mm (61.0 in) Cutting height set to 27 mm (1 in) Handle in high position...
  • Page 7 SPECIFICATIONS HRN216 VKA, VLA, VYA TYPES (VKA type shown) 676 mm (26.6 in) 1,550 mm (61.0 in) Cutting height set to 27 mm (1 in) Handle in high position...
  • Page 8 HRN216 SPECIFICATIONS 3. WIRING DIAGRAM (VLA TYPE)
  • Page 9 SPECIFICATIONS HRN216 NOTES...
  • Page 10 6. TOOLS ......1. SERVICE RULES • Use Honda Genuine parts or their exact equivalent. Lower quality parts can damage the mower or reduce its performance.
  • Page 11 SERVICE INFORMATION HRN216 3. SERIAL NUMBER LOCATIONS The frame serial number is located on the rear of the mower deck behind the engine. The engine serial number is located on the crankcase below the fuel valve on the left-hand side of the engine. Refer to the frame serial number or engine serial number when ordering parts and when making technical inquiries.
  • Page 12 HRN216 SERVICE INFORMATION 4. SERVICE SPECIFICATIONS Unit: mm (in) Part Item Standard Service limit Engine Maximum governed speed 3,100 +0/-150 rpm Cylinder compression 0.50 MPa (5.1 kgf/cm , 73 psi)/600 rpm Valves Valve clearance IN/EX 0.10 ± 0.02 (0.004 ± 0.001) Valve stem O.D.
  • Page 13 SERVICE INFORMATION HRN216 5. TORQUE VALUES TORQUE THREAD DIAMETER x SPECIAL FASTENERS PITCH mm (in) N•m kg-m ft-lb Air cleaner case nut M6 x 1.0 Battery box bolt VLA type M6 x 1.0 Battery box halves screw VLA type Tapping screw, 4 x 16 0.05 BBC (Roto-Stop) assy.
  • Page 14 HRN216 SERVICE INFORMATION STANDARD TORQUE VALUES TORQUE STANDARD THREAD DIAMETER FASTENERS N•m kg-m ft-lb 3 mm 4 mm Screw 5 mm 6 mm 5 mm 6 mm Bolt and nut 8 mm 10 mm 12 mm 6 mm 8 mm Flange bolt and nut 10 mm 12 mm...
  • Page 15 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.
  • Page 16 HRN216 SERVICE INFORMATION 7. TROUBLESHOOTING ENGINE Hard Starting Using Recoil Starter Or Poor Engine Performance Make sure the fuel valve is ON. Check the fuel level. Refuel. No fuel in tank Sufficient fuel in tank Confirm the fuel quality. If gasoline is more than 30 Drain the fuel system, and refill with Stale fuel days old, the engine may be hard to start.
  • Page 17 SERVICE INFORMATION HRN216 Electric Starter Will Not Operate VLA type only Check the battery voltage. Charge the battery for 24 hours with Less than 12.7 V PN 06320-VH7-UA2 charger and replace if necessary 11-27). Go to 12.7 V or more “Battery Has Low Voltage (less than 12.7 V)”...
  • Page 18 HRN216 SERVICE INFORMATION Electric starter operates, but the engine cranks slowly or not at all VLA type only Go to “Hard Starting Using Recoil Will the engine start using the recoil? Starter Or Poor Engine Performance” page 2-7. Check the no load voltage at the battery. Charge the battery for 24 hours using Less than 12.7 V PN 06320-VH7-UA2 charger.
  • Page 19 SERVICE INFORMATION HRN216 Battery Has Low Voltage (less than 12.7 V) VLA type only Charge the battery for 24 hours using 06320-VH7-UA2 charger. Allow to rest for Replace the battery. Less than 12.7 V 1 hour and retest. 12.7 V or more Start the engine and verify the speed is 2950 ~ 3100 rpm 3-21).
  • Page 20 HRN216 SERVICE INFORMATION VIBRATION PROBLEMS Grass and debris lodged Clean out mower deck. under mower deck. Tighten blade bolts 3-4). Blades bolt(s) loose. Maximum engine speed too Readjust to specification high. 3-21). • Inspect blades 3-4). Blades bent, damaged, or •...
  • Page 21 SERVICE INFORMATION HRN216 FLYWHEEL BRAKE (PKA/VKA/VLA TYPES) Blade (engine) does not stop turning or takes longer than 3 seconds to stop when the flywheel brake lever is released. Abnormal Repair or replace the cable. Check the flywheel brake cable for binding. Check the flywheel brake spring 9-11).
  • Page 22 HRN216 SERVICE INFORMATION 8. TROUBLESHOOTING TECHNIQUES ....... . COMPRESSION TEST 2-13 CHARGE COIL OUTPUT CHECK 2-16...
  • Page 23 SERVICE INFORMATION HRN216 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. INSPECTION 1. Disconnect the spark plug cap, and remove the spark plug 3-8).
  • Page 24 HRN216 SERVICE INFORMATION CHOKE CONTROL SYSTEM With the engine cold, Remove the air cleaner case. Inspect the choke control Partially or remove the paper Push the choke valve open, Normal assembly linkage for smooth totally filter element and and let it go. Check that the operation.
  • Page 25 SERVICE INFORMATION HRN216 CHARGE COIL OUTPUT CHECK VLA TYPE ONLY The battery must be partially discharged prior to performing this test. If the battery voltage is 12.7 V, disconnect the spark plug and crank the electric starter several times until the battery voltage has reduced slightly. Adjust the engine speed to 2,950 ~ 3,100 rpm prior to performing this test.
  • Page 26 HRN216 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...
  • Page 27 SERVICE INFORMATION HRN216 SMART DRIVE TRANSMISSION VKA/VLA/VYA TYPES 1. MOWER WILL NOT SELF-PROPEL WHEN THE SMART DRIVE IS ENGAGED a. Inspect the drive belt, transmission input shaft, Smart Inspect the transmission control arm, Smart Drive cable, and pulley condition. Drive cable, and return spring for damage. b.
  • Page 28 HRN216 SERVICE INFORMATION 3. LAWN MOWER CONTINUES TO SELF-PROPEL WHEN THE SMART DRIVE IS RELEASED LOCK NUT a. Loosen the Smart Drive cable adjuster completely. ADJUSTER LOOSEN b. Confirm there is no tension in the Smart Drive Confirm there is no cable at the transmission control arm.
  • Page 29 SERVICE INFORMATION HRN216  4. ONLY ONE WHEEL PROPELS OR ONE WHEEL (left-hand side shown) INTERMITTENTLY STOPS ROTATING UNDER LOAD RATCHET KEYWAY Clean and inspect the pinion gear assemblies and wheel gears for damage and proper installation. Refer to page 3-16 to disassemble, grease, and reassemble the pinion gear assemblies.
  • Page 30 HRN216 SERVICE INFORMATION 9. CABLE ROUTING AND TIES PKA TYPE Loosely install the two upper cable ties around the handlebar and flywheel brake cable. Install the wire holder into the hole on the outside of the left handle stay. Insert the flywheel brake cable into the wire holder, and then tighten the wire holder around the cable.
  • Page 31 SERVICE INFORMATION HRN216 VKA TYPE Loosely install the two upper cable ties around the handlebar and flywheel brake cable. Install the wire holder into the hole on the outside of the left handle stay. Insert the flywheel brake cable into the wire holder, and then tighten the wire holder around the cable.
  • Page 32 HRN216 SERVICE INFORMATION VLA TYPE Loosely install the two upper cable ties around the handlebar and flywheel brake cable. Install the wire holder into the hole on the outside of the left handle stay. Insert the flywheel brake cable into the wire holder, and then tighten the wire holder around the cable.
  • Page 33 SERVICE INFORMATION HRN216 VYA TYPE Position the cable ties in the locations shown using the handlebar pivot bolts as a starting point for your measurements. Adjust and tighten the cable ties. Trim off any remaining tail from each cable tie, and then rotate the cable ties so that the head and cut edge are facing down.
  • Page 34 HRN216 SERVICE INFORMATION 10. TUBE AND HARNESS ROUTING PKA/VKA/VLA TYPES BREATHER TUBE Insert the breather tube to the crankcase cover until the paint mark on the tube aligns with the edge of the brake assy. FUEL TUBE BREATHER TUBE FUEL TUBE BREATHER TUBE FUEL TUBE FUEL TUBE...
  • Page 35 SERVICE INFORMATION HRN216 IGNITION COIL STOP SWITCH CORD (PKA/VKA types) HIGH-TENSION CORD STOP SWITCH CORD (PKA/VKA types) STOP SWITCH CORD (PKA/VKA/VLA types) HIGH-TENSION CORD 2-26...
  • Page 36 HRN216 SERVICE INFORMATION PKA/VKA types IGNITION COIL ENGINE STOP SWITCH HIGH-TENSION CORD STOP SWITCH CORD IGNITION COIL HIGH-TENSION CORD STOP SWITCH CORD VLA type (also see page 2-30) IGNITION COIL CHARGE COIL HIGH-TENSION CORD ENGINE STOP SWITCH STOP SWITCH CORD 2-27...
  • Page 37 SERVICE INFORMATION HRN216 VYA TYPE BREATHER TUBE Insert the breather tube to the crankcase cover until the paint mark on the tube aligns with the edge of the brake assy. FUEL TUBE BREATHER TUBE FUEL TUBE BREATHER TUBE FUEL TUBE BREATHER TUBE Attach the clip at 4.0 ±...
  • Page 38 HRN216 SERVICE INFORMATION IGNITION COIL STOP SWITCH CORD HIGH-TENSION CORD STOP SWITCH CORD HIGH-TENSION CORD 2-29...
  • Page 39 SERVICE INFORMATION HRN216 11. MAIN HARNESS ROUTING (VLA TYPE) BATTERY CHARGER CONNECTOR HARNESS GUIDE Disconnect the connector, and plug the Route the starter harness battery charger into the side of the through the metal harness connector closest to the battery box. guide.
  • Page 40 3. MAINTENANCE 1. MAINTENANCE SCHEDULE ..11. COMBUSTION CHAMBER CLEANING . . 2. MAINTENANCE SPECIFICATIONS ..12. SMART DRIVE CABLE ....3-10 3.
  • Page 41 MAINTENANCE HRN216 1. MAINTENANCE SCHEDULE 50 hours 150 hours Before 5 hours First 100 hours of use or of use or Item Action each of use or 25 hours of use or every every two page first month of use every year 6 months years...
  • Page 42 3-11 of the tank. Clean and inspect. Fuel tube Replace if damaged or deteriorated. 3-11 Clean and lubricate with grease. Use Honda Marine extreme Pinion gear 3-16 pressure NLGI #2 GC-LB grease or equivalent. 3. ENGINE TUNE-UP SPECIFICATIONS Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
  • Page 43 MAINTENANCE HRN216 5. BLADES INSPECTION 1. Turn the fuel valve to the OFF position. This will reduce the possibility of fuel leakage when the mower is tilted. BLADES 2. Disconnect the spark plug cap. 3. Tilt the mower on its right side, so the carburetor is up. 4.
  • Page 44 HRN216 MAINTENANCE SHARPENING CORRECT SHARPENING NOTICE TAPER 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. •...
  • Page 45 The SAE oil viscosity and service category are given in the 5W-30•10W-30 API label on the oil container. Honda recommends that 100°F you use API service category SJ or later oil. 20 30 40°C...
  • Page 46 This type of damage is not covered by the Distributor’s Limited Warranty. FILTER Only use a Honda Genuine air filter to ensure it seals and performs as designed. LATCH TABS 1.
  • Page 47 A wet bag will clog quickly FRAME REPLACEMENT Installation shown: PLASTIC Replace a worn or damaged bag with a Honda Genuine EDGE replacement bag. 1. Unclip the plastic edges of the bag from the frame. 2. Remove the bag from the frame.
  • Page 48 HRN216 MAINTENANCE 10. SPARK ARRESTER CLEANING (OPTIONAL PART) CLEANING The spark arrester must be serviced every 100 hours to keep it functioning as designed. Allow the engine to cool before proceeding with this procedure. 1. Allow the engine to cool. 2.
  • Page 49 MAINTENANCE HRN216 12. SMART DRIVE CABLE VKA/VLA/VYA TYPES ONLY CABLE ADJUSTMENT  WARNING The engine will be running and the cutting blades will be spinning during this procedure. If you come in contact with a spinning blade, it will cut you severely and can amputate fingers and toes.
  • Page 50 HRN216 MAINTENANCE 13. FUEL TANK AND STRAINER INSPECTION/CLEANING  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. •...
  • Page 51 MAINTENANCE HRN216 14. BLADE CONTROL OPERATION CHECK  DANGER The mower blades will rotate during this procedure. Rotating blades will amputate fingers, hands, and other extremities if contacted. Do not allow your hands or feet to come into contact with the rotating blades while preforming this procedure.
  • Page 52 HRN216 MAINTENANCE ® 16. ROTO-STOP VYA TYPE ONLY CABLE ADJUSTMENT 1. Turn the fuel valve to the OFF position and disconnect 2 ~ 3 mm the spark plug cap. (0.08 ~ 0.12 in) 2. Tip the mower on its right side (muffler side down) to prevent: •...
  • Page 53 MAINTENANCE HRN216 CLUTCH WEAR BRAKE FEELER CLUTCH PLATE With the blade control lever pushed forward against the GAUGE WEAR handlebar, use a clean feeler gauge to measure the distance between the brake plate and the driven disk. Standard Service limit Clutch 2.0 mm (0.08 in) 0.5 mm (0.02 in)
  • Page 54 HRN216 MAINTENANCE 18. VALVE CLEARANCE HEAD HEAD COVER COVER BOLT (4) Note: Valve clearance inspection and adjustment must be performed with the engine cold. CHECK 1. Disconnect the spark plug cap. 2. Remove the fan cover 7-3). 3. Remove the head cover bolts, and the head cover. Note: The cylinder head cover is made of very thin metal and becomes bent or damaged during removal.
  • Page 55 MAINTENANCE HRN216  19. PINION GEAR RATCHET KEYWAY LUBRICATION DISASSEMBLY 1. Remove the flange nut and the rear wheel. CIRCLIP AXLE 2. Remove the dust shield by pulling it away from the mower. SPRING 3. Remove the circlip, washer, and the pinion gear from the ...
  • Page 56 HRN216 MAINTENANCE REASSEMBLY Note: The ratchet key is unique for each side. The ratchet holder, pinion, and spring must be installed in the appropriate direction for the left and right wheel pinion assemblies. 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.
  • Page 57 MAINTENANCE HRN216 5. Install the appropriate ratchet key into the axle shaft and ratchet holder. The ratchet keys are different LEFT SIDE RIGHT SIDE for each side and are marked with an L (left) or an R (right) on each key. Use the ratchet key marked “L”...
  • Page 58 HRN216 MAINTENANCE 8. Install the pinion gear onto the axle shaft in the appropriate direction. The pinion gear has an L LEFT WHEEL RIGHT WHEEL (left) marking on one side and an R (right) marking on PINION GEAR the other side. The L marking should face outward when installing on the left-hand side axle and...
  • Page 59 MAINTENANCE HRN216 12.Install the dust shield onto the axle shaft while aligning the slot SPRING in the shield with the spring. DUST SLOT  SHIELD Ensure the spring tab is properly inserted into the slot, and that all four plastic tabs on the dust shield are clipped onto the axle ...
  • Page 60 HRN216 MAINTENANCE 20. GOVERNOR PKA, VKA, VLA TYPES ADJUSTMENT 1. With the engine stopped, loosen the governor arm nut on the governor arm. 2. Push the governor arm away from the carburetor to fully open the carburetor throttle valve. 3. Holding the carburetor throttle arm fully open, turn the governor arm shaft fully clockwise, and tighten the governor arm nut to the specified torque.
  • Page 61 MAINTENANCE HRN216 VYA TYPE ADJUSTMENT 1. Move the throttle lever to the FAST position. 2. Loosen the governor arm nut on the governor arm. 3. Push the governor arm away from the carburetor, and open the carburetor throttle valve fully. 4.
  • Page 62 ® 4. BLADE HOLDER/ROTO-STOP 1. BLADE HOLDER/DRIVE PULLEY ..2. ROTO-STOP®/DRIVE PULLEY..
  • Page 63 BLADE HOLDER/ROTO-STOP® HRN216 1. BLADE HOLDER/DRIVE PULLEY PKA TYPE BLADE HOLDER Align the slot in the WOODRUFF KEY blade holder with the Install the Woodruff key into Woodruff key in the the slot closest to the end of crankshaft. the crankshaft. 3/8-24 x 1 in SPECIAL BOLT TORQUE: 54 N•m (40 ft-lb)
  • Page 64 HRN216 BLADE HOLDER/ROTO-STOP® REMOVAL 1. Disconnect the spark plug cap. BLADE HOLDER 2. Turn the fuel valve to the OFF position, and tilt the mower on its side so the carburetor is up. 3. Use a pair of thick leather gloves to hold the blades with your hand to prevent the blades from turning.
  • Page 65 BLADE HOLDER/ROTO-STOP® HRN216 VKA/VLA TYPES DRIVE PULLEY “N” code marking identifies this drive pulley is for an WOODRUFF KEY HRN216VKA or VLA model. Visually verify this code is Install the Woodruff key into correct before installing. the slot closest to the end of the crankshaft.
  • Page 66 HRN216 BLADE HOLDER/ROTO-STOP® REMOVAL WOODRUFF KEY 1. Disconnect the spark plug cap. 2. Turn the fuel valve to the OFF position, and tilt the mower on its side so the carburetor is up. 3. Use a pair of thick leather gloves to hold the blades with your hand to prevent the blades from turning.
  • Page 67 BLADE HOLDER/ROTO-STOP® HRN216 ® 2. ROTO-STOP /DRIVE PULLEY VYA TYPE PARTS REFERENCE BEARING WOODRUFF KEY Replace if it doesn’t rotate Install in lower DRIVE PULLEY smoothly. keyway slot. “M” code marking identifies this BALL PLATE drive pulley is for an HRN216VYA model.
  • Page 68 HRN216 BLADE HOLDER/ROTO-STOP® REMOVAL 1. Inspect the blade brake and drive clutch wear 3-13). 2. Remove the top cover and recoil starter cover 7-2). 3. Turn the fuel valve to the OFF position, and disconnect the spark plug cap. Tilt the mower on its right side to prevent: •...
  • Page 69 BLADE HOLDER/ROTO-STOP® HRN216 7. Hold the flywheel nut with a ratchet and 19 mm socket, and then remove the 10 x 24 mm hex bolt on the CLUTCH SPRING Roto-Stop assembly. 10 x 24 mm SPECIAL HEX Remove the blade holder, clutch spring, and driven disk. BOLT Rotate the crankshaft so that the crankshaft keyway is up.
  • Page 70 HRN216 BLADE HOLDER/ROTO-STOP® 2. Clean the driven disk clutch and brake surface with a clean, dry shop towel. Replace the driven disk if it has been contaminated with oil. NOTICE Do not put the driven disk into the parts cleaner. If the driven disk is washed with parts cleaner, the driven disk will require replacement.
  • Page 71 BLADE HOLDER/ROTO-STOP® HRN216 5. Measure the clutch spring free-standing height: CLUTCH SPRING Service limit Clutch spring 6.8 mm (0.27 in) If the spring measures less than the service limit or appears damaged, replace the spring. 6. Inspect the blade holder bearing and the ball plate bearing.
  • Page 72 HRN216 BLADE HOLDER/ROTO-STOP® 8. Assemble the brake (it is not necessary to apply any lubrication to any of the Roto-Stop parts during assembly): a. Install the three balls into the ball plate. GROOVE b. Align the brake wear indicator with the brake plate groove, and slide the brake plate over the ball plate.
  • Page 73 BLADE HOLDER/ROTO-STOP® HRN216 2. Align the drive disk keyway with the key, and install the drive disk. Do not allow the key to move or fall out during assembly. DRIVE DISK Note The drive disk should have a “7” marking on it to signify the disk will fit the HRN216VYA model.
  • Page 74 HRN216 BLADE HOLDER/ROTO-STOP® 5. Attach the Roto-Stop cable to the ball plate. ROTO-STOP INNER CABLE BALL PLATE 6. Wrap the tips of the needle-nose pliers with 1 to 2 UPPER rounds of duct tape to prevent damage to the new spring ANCHOR POINT during installation.
  • Page 75 BLADE HOLDER/ROTO-STOP® HRN216 NOTES 4-14...
  • Page 76 5. ENGINE REMOVAL/INSTALLATION 1. PKA/VKA TYPES ..... . 3. VYA TYPE ..... . . 2.
  • Page 77 ENGINE REMOVAL/INSTALLATION HRN216 1. PKA/VKA TYPES REMOVAL FLYWHEEL BRAKE CABLE Z-FITTING BRACKET 1. Drain the gasoline from the fuel tank and carburetor into an approved container. 2. Remove the flywheel brake cable from its bracket, and disconnect the Z-fitting cable end from the engine. 3.
  • Page 78 HRN216 ENGINE REMOVAL/INSTALLATION 9. Support the engine, and remove the four 5/16-24 x 1 5/16-24 x 1 in BOLT (4) inch engine mounting bolts. 21.6 N•m (15.9 ft-lb) 10. Remove the engine. INSTALLATION Installation is done in the reverse order of removal. •...
  • Page 79 ENGINE REMOVAL/INSTALLATION HRN216 2. VLA TYPE REMOVAL FLYWHEEL BRAKE CABLE Z-FITTING BRACKET 1. Drain the gasoline from the fuel tank and carburetor into an approved container. 2. Remove the flywheel brake cable from its bracket, and disconnect the Z-fitting cable end from the engine. 3.
  • Page 80 HRN216 ENGINE REMOVAL/INSTALLATION 8. Disconnect battery charger connector on the handlebar RECOIL and then pull harness band clip out of the hole in the GRIP/ROPE handlebar. HARNESS GUIDE LOOP Remove the harness from the harness guide by sliding it through the opening in the loop. 9.
  • Page 81 ENGINE REMOVAL/INSTALLATION HRN216 3. VYA TYPE REMOVAL CLAMP 1. Drain the gasoline from the fuel tank and carburetor into an approved container. 2. Remove the throttle cable from the clamp, and THROTTLE CLAMP disconnect the cable end from the engine control base. SCREW 3.
  • Page 82 HRN216 ENGINE REMOVAL/INSTALLATION 7. Remove the top cover 7-1) and recoil 7-2). Hold TOP COVER the flywheel nut with a 19 mm socket while removing the center Roto-Stop special blade holder bolt. RECOIL 8. Pull the Roto-Stop brake assembly off the crankshaft as a complete assembly.
  • Page 83 ENGINE REMOVAL/INSTALLATION HRN216 NOTES...
  • Page 84 6. MUFFLER 1. REMOVAL/INSTALLATION ............
  • Page 85 MUFFLER HRN216 1. REMOVAL/INSTALLATION  CAUTION The engine and muffler become very hot during operation, and they remain hot for a while after operation. A hot engine or muffler can burn you. Be sure that the engine is cold before muffler removal/installation. SPARK ARRESTER [optional part] 4 x 6 mm SCREW INSTALLATION:...
  • Page 86 7. RECOIL STARTER 1. TOP COVER REMOVAL/INSTALLATION . 4. RECOIL STARTER INSPECTION..2. RECOIL REMOVAL/INSTALLATION..5. RECOIL STARTER ROPE REPLACEMENT 3. FAN COVER REMOVAL/INSTALLATION . 6. REEL UNWOUND ..... 1.
  • Page 87 RECOIL STARTER HRN216 2. RECOIL REMOVAL/INSTALLATION Remove the top cover 7-1). 6 x 14 mm BOLT (3) 8.5 N•m (6.3 ft-lb) RECOIL STARTER...
  • Page 88 HRN216 RECOIL STARTER 3. FAN COVER REMOVAL/INSTALLATION Remove the top cover 7-1), and then reinstall the fuel tank cap to prevent dirt or debris from entering the fuel tank. The recoil starter assembly does not need to be removed to remove the fan cover. Reassembly is the reverse order of removal.
  • Page 89 RECOIL STARTER HRN216 4. RECOIL STARTER INSPECTION 1. Remove the recoil starter 7-2). 2. Check the operation of the ratchets by pulling the starter rope out several times. RATCHETS 3. Check the tabs on the flywheel for damage. TABS 5. RECOIL STARTER ROPE REPLACEMENT 1.
  • Page 90 HRN216 RECOIL STARTER 3. To prevent the starter reel from rewinding, hold the starter reel and starter case with a band or equivalent material as shown. BAND STARTER REEL STARTER CASE 4. Untie the knots of the starter rope at the starter grip side and STARTER CASE the starter reel side, and remove the starter rope.
  • Page 91 RECOIL STARTER HRN216 6. REEL UNWOUND ALIGN HOLES 1. Remove the recoil starter 7-2). 2. Turn the starter reel in the direction of the arrow six turns. STARTER REEL Align the rope hole in the starter case with the rope hole in the starter reel.
  • Page 92 8. FUEL SYSTEM 1. AIR CLEANER/CARBURETOR..3. FUEL TANK ..... . . 8-15 2.
  • Page 93 FUEL SYSTEM HRN216 1. AIR CLEANER/CARBURETOR REMOVAL/INSTALLATION Before removal, completely drain the carburetor 3-11). Be sure the engine is cooled to room temperature before removing the carburetor. This is necessary to ensure the thermowax fully retracts. Be sure to install all gaskets exactly as shown. Otherwise, the gaskets may not align with the intake port. GOVERNOR ROD, THROTTLE RETURN SPRING INSTALLATION: THROTTLE RETURN SPRING...
  • Page 94 HRN216 FUEL SYSTEM DISASSEMBLY/REASSEMBLY • Clean the outside of the carburetor before disassembly. • The limiter cap is cemented on the pilot screw and should not be removed unless the carburetor is overhauled. Pilot screw removal is normally not required to clean the carburetor. ...
  • Page 95 FUEL SYSTEM HRN216 INSPECTION FLOAT LEVEL HEIGHT Place the carburetor in the position shown, and measure the distance between the float top and carburetor body when the float just contacts the seat without compressing the valve spring. FLOAT TOOL: Carburetor float level gauge: 07401-0010000 CARBURETOR ...
  • Page 96 FUEL SYSTEM CLEANING Use 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.
  • Page 97 FUEL SYSTEM HRN216 4. Remove the 5 x 6 mm screw covering the pilot jet. 5. Clean the float valve seat using carburetor cleaner and compressed air. FLOAT VALVE SEAT 6. Clean the main nozzle thoroughly using carburetor cleaner, appropriate size jet cleaning tool, and compressed air. Do not use a welding tip cleaning needle.
  • Page 98 HRN216 FUEL SYSTEM 8. Clean the main jet and nozzle bore thoroughly using carburetor MAIN JET AND cleaner and compressed air. NOZZLE BORE Inspect the inside of the bore for contamination. 9. Clean the pilot jet thoroughly by using the appropriate size jet cleaning tool, carburetor cleaner, and compressed air.
  • Page 99 FUEL SYSTEM HRN216 11. Clean the float chamber vent hole with carburetor cleaner and compressed air. FLOAT CHAMBER VENT HOLE 12. Clean the slow speed air/pilot screw passages. Spray carburetor cleaner and compressed air through the slow speed air passage. The passages are small, so repeat several times.
  • Page 100 HRN216 FUEL SYSTEM 15. Reinstall the main nozzle and main jet, making sure the nozzle long end extends into the venturi. 16. Install the float valve, float, and float chamber. • Make sure the float valve is properly attached to the float. •...
  • Page 101 FUEL SYSTEM HRN216 CHOKE CONTROL ASSEMBLY Thermowax Removal 1. Turn the fuel valve OFF and drain the fuel from the carburetor float chamber into an approved container. THERMOWAX 2. Remove the air cleaner cover and air cleaner element. 3. Remove the following parts in the order shown below. 1) Air cleaner case 2) Air cleaner gasket 3) Carburetor...
  • Page 102 HRN216 FUEL SYSTEM 3. Insert the new thermowax into the cylinder barrel and push it into the cavity until fully seated. The Hondabond HT will fill any gaps between the cylinder barrel and thermowax. 4. Remove any Hondabond HT from the front of the thermowax after installation.
  • Page 103 FUEL SYSTEM HRN216 2. CONTROL BASE/GOVERNOR ARM PKA/VKA/VLA TYPES REMOVAL/INSTALLATION 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. GOVERNOR THROTTLE ARM GOVERNOR ROD PAINT THROTTLE RETURN SPRING...
  • Page 104 HRN216 FUEL SYSTEM VYA TYPE REMOVAL/INSTALLATION Remove the air cleaner and carburetor 8-2). GOVERNOR ARM/THROTTLE RETURN SPRING GOVERNOR INSTALLATION: THROTTLE ARM GOVERNOR ROD PAINT Install the governor rod through the throttle return spring as shown. Connect each to the governor arm and carburetor throttle arm as shown.
  • Page 105 FUEL SYSTEM HRN216 DISASSEMBLY/REASSEMBLY SCREW (4 x 12 mm) WASHER (4 mm) ENGINE STOP SWITCH WIDE TERMINAL INSPECTION: P. 9-6 (to stop switch wire) CONTROL BASE CABLE HOLDER NARROW TERMINAL (not used) SCREW (5 x 16 mm) CONTROL LEVER RETURN SPRING LEVER SPRING 8-14...
  • Page 106 HRN216 FUEL SYSTEM 3. FUEL TANK DISASSEMBLY/REASSEMBLY Before removal, drain the gasoline into an approved container. Remove the top cover (page 7-1).  WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. •...
  • Page 107 FUEL TUBE AND CLAMP CHANGES All Honda Power Equipment manufactured after January 1, 2009, uses low-permeable fuel line. The low-permeable fuel line is easy to spot by the CARB Executive Order (for example: Q-11-012 EPA-15) printed on it. This CARB Executive order number may vary from this example depending on the date a fuel tube was manufactured.
  • Page 108 9. IGNITION COIL/FLYWHEEL 1. IGNITION COIL ..... . 4. ELECTRIC STARTER (VLA TYPE) ..9-12 2. FLYWHEEL ......5.
  • Page 109 IGNITION COIL/FLYWHEEL HRN216 1. IGNITION COIL REMOVAL/INSTALLATION PKA/VKA TYPES Remove the fan cover 7-1). After installation, adjust the ignition coil air gap 9-6). 6 x 23 mm BOLT (2) IGNITION COIL SPARK PLUG CAP STOP SWITCH CORD CONNECTOR...
  • Page 110 HRN216 IGNITION COIL/FLYWHEEL VLA TYPE Remove the fan cover 7-3). Disconnect the stop switch cord and charge coil connectors. After installation, adjust the ignition coil air gap 9-6). 6 x 23 mm BOLT (2) IGNITION COIL CHARGE COIL CONNECTOR STOP SWITCH CORD CONNECTOR SPARK PLUG CAP...
  • Page 111 IGNITION COIL/FLYWHEEL HRN216 VYA TYPE Remove the fan cover 7-3). After installation, adjust the ignition coil air gap 9-6). 6 x 23 mm BOLT (2) IGNITION COIL SPARK PLUG CAP STOP SWITCH CORD CONNECTOR...
  • Page 112 HRN216 IGNITION COIL/FLYWHEEL SPARK TEST HEAD COVER BOLT Inspect the following before performing the spark test. SPARK PLUG CAP • Faulty spark plug • Loose spark plug cap • Water in the spark plug cap (Leaking the ignition coil secondary voltage) •...
  • Page 113 IGNITION COIL/FLYWHEEL HRN216 Engine Stop Switch PKA/VKA/VLA TYPES Remove the engine stop switch 9-11). PLUNGER NARROW TERMINAL Wide terminal: •VLA type: There should be continuity when the plunger is pushed in. •PKA/VKA types: Not used Narrow terminal: •There should be continuity when the plunger is released. WIDE TERMINAL •There should be no continuity when the plunger is pushed (VLA type)
  • Page 114 HRN216 IGNITION COIL/FLYWHEEL Remove the feeler gauge, and then recheck the air gap. PKA/VKA/VYA TYPES IGNITION COIL Install the fan cover 7-3). 0.30 ~ 0.50 mm 0.30 ~ 0.50 mm (0.012 ~ 0.020 in) (0.012 ~ 0.020 in) VLA TYPE 0.30 ~ 0.50 mm IGNITION (0.012 ~ 0.020 in)
  • Page 115 IGNITION COIL/FLYWHEEL HRN216 2. FLYWHEEL DISASSEMBLY/REASSEMBLY 1. Remove the fan cover 7-3). 2. Remove the ignition coil 9-2). 3. Remove the electric starter (VLA type only) 9-12). FLYWHEEL NUT (14 mm) PKA/VKA/VLA types: 55 N•m (41 ft-lb) VYA type: 75 N•m (55 ft-lb) FLYWHEEL WOODRUFF KEY INSTALLATION:...
  • Page 116 HRN216 IGNITION COIL/FLYWHEEL FLYWHEEL REMOVAL  SPECIAL REMOVAL NUT, FLYWHEEL 14 mm HOLDER 1. Remove the top cover and fan cover 7-3). 2. Remove the ignition coil 9-2). 3. PKA/VKA/VLA types only: Pull the flywheel brake lever and secure the lever to the handlebar with a strap or equivalent material.
  • Page 117 IGNITION COIL/FLYWHEEL HRN216 INSTALLATION SPECIAL NUT, 14 mm TORQUE Make sure the flywheel taper is free of dirt, oil, grease and 55 N•m (41 ft-lb) WRENCH other foreign material before installation. (commercially available) Also, make sure there is no foreign material on the magnets. 1.
  • Page 118 HRN216 IGNITION COIL/FLYWHEEL 3. FLYWHEEL BRAKE LEVER / ENGINE STOP SWITCH PKA/VKA/VLA types only: Remove the fan cover 7-3). Remove the flywheel before removing the brake assembly 9-8). 6 x 22 mm BOLT 4 x 12 mm SCREW 1.8 N•m (1.3 ft-lb) WASHER WIDE TERMINAL (not used)
  • Page 119 IGNITION COIL/FLYWHEEL HRN216 4. ELECTRIC STARTER (VLA TYPE) STARTER MOTOR VOLTAGE INSPECTION 1. Turn the fuel valve OFF and disconnect the spark plug cap. 2. Slide the covers down from the starter motor connectors. 3. Set the voltmeter to measure 5 ~ 20 VDC and carefully connect the alligator clips to the connectors at the starter motor.
  • Page 120 HRN216 IGNITION COIL/FLYWHEEL 6. Remove the two 6 mm special bolts and the starter 6 mm SPECIAL BOLT (2) motor. 11 N•m (97 in•lb) It is not necessary to remove the flywheel when only removing the starter motor. STARTER MOTOR 7.
  • Page 121 IGNITION COIL/FLYWHEEL HRN216 STARTER MAGNETIC SWITCH STARTER MAGNETIC REMOVAL/INSTALLATION RED WIRE SWITCH 1. Disconnect the battery charging connector on the YELLOW WIRE handlebar 2-30). HARNESS 2. Open the harness clip, and then remove the four CLIP wires and main harness from the starter magnetic switch.
  • Page 122 HRN216 IGNITION COIL/FLYWHEEL 2. Thoroughly clean between the drive plate and damper using a rubber-compatible contact cleaner or brake cleaner. Use a cotton swab or other utensil to remove any residue from the damper rubber and drive plate. Do not use compressed air to remove residue as it may force cleaner or debris into the starter gearbox.
  • Page 123 IGNITION COIL/FLYWHEEL HRN216 5. SIDE PLATE (VYA TYPE) REMOVAL/INSTALLATION 1. Remove the flywheel 9-8). BOLT (6 x 14 mm) (2) SIDE PLATE STOP SWITCH CORD INSTALLATION: Connect to the wide terminal of the engine stop switch. 9-16...

  • Page 124: Table Of Contents

    10. CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER 1. CRANKCASE COVER 7. OIL FILLER CAP / EXTENSION REMOVAL/INSTALLATION ... 10-2 REMOVAL/INSTALLATION ..10-18 2. BREATHER COVER 8.

  • Page 125: Crankcase Cover Removal/Installation

    CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 1. CRANKCASE COVER REMOVAL/INSTALLATION Remove the flywheel 9-8). Be sure to reconnect the breather tube to the cover after installation 8-2). (Apply grease to the lips) OIL SEAL (28 x 41.25 x 6 mm) 8 x 25 mm BOLT (6) INSTALLATION: 24 N•m (18 ft-lb) Be careful not to damage the lip...

  • Page 126: Breather Cover Removal/Installation

    HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER 2. BREATHER COVER REMOVAL/INSTALLATION Remove the crankcase cover 10-2). 6 x 14 mm BOLT BREATHER COVER 5 x 8 mm SCREW BREATHER VALVE 10-3...

  • Page 127: Cylinder Removal/Installation

    CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 3. CYLINDER REMOVAL/INSTALLATION REMOVAL Drain the engine oil 3-6). Remove the following: – Crankcase cover 10-2) – Carburetor 8-2) – Muffler 6-2) – Rocker arms and push rods 10-7) (the piston and connecting rod are shown removed for clarity) 8 x 40 mm BOLT (2) CYLINDER HEAD REMOVAL:...
  • Page 128 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER INSTALLATION Install the camshaft and lifters before installing the cylinder 10-8). During reassembly, recheck the valve clearance (page 3-15). 8 x 40 mm BOLT (2) 24 N•m (18 ft-lb) CYLINDER HEAD COVER INSTALLATION: P. 10-6 Do not reuse if bent or damaged.
  • Page 129 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 CYLINDER INSTALLATION Clean the mating surfaces of the cylinder and the crankcase using a degreasing cleaning agent and a clean shop towel. Apply a bead [Ø 1.0 - 2.0 mm (Ø 0.04 - 0.08 in) in diameter] of liquid gasket (Hondabond HT, Loctite 5900, or equivalent).

  • Page 130: Cylinder Head Disassembly/ Assembly

    HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER 4. CYLINDER HEAD DISASSEMBLY/ ASSEMBLY Remove the cylinder 10-4). Note Rocker arm and push rod removal does not require cylinder removal. After assembly, readjust the valve clearance 3-15). VALVE SPRING RETAINER (2) REMOVAL: Do not remove the valve spring retainers while the piston is installed, or the valves will drop into the cylinder.

  • Page 131: Crankshaft/Camshaft/Piston Removal/Installation

    CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 5. CRANKSHAFT/CAMSHAFT/PISTON REMOVAL/INSTALLATION CRANKSHAFT INSTALLATION: P. 10-19 PISTON INSPECTION: Install the piston through the crankcase so that the “FW ” mark points toward CONNECTING ROD CAP the flywheel side. INSTALLATION: P. 10-19 CONNECTING ROD BOLT (2) 12 N•m (9 ft-lb) VALVE LIFTER BOLT (2) 10 N•m (7 ft-lb) VALVE LIFTER (2)
  • Page 132 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER DAMAGED CRANKSHAFT REPLACEMENT If the lawn mower develops a strong vibration (due to the blades striking an object such as a rock or tree root) and the crankshaft runout exceeds the service limit 2-14), replace the crankshaft following the steps starting on page 10-10.
  • Page 133 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 REMOVAL LOWER OIL SEAL 1. Remove the spark plug 3-8). BLADE BLADE HOLDER HOLDER 2. Drain the engine oil 3-6). BOLT 3. Tip the mower on its right-hand side so the carburetor is BLADE facing up, and then remove the blades, blade holder BOLT (2) WOODRUFF (PKA/VKA/VLA) or Roto-Stop (VYA), belt guide, and drive...
  • Page 134 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER 8. Remove the flywheel 9-8).  PKA/VKA/VLA types only: SPECIAL NUT, Pull the flywheel brake lever and secure the lever to the FLYWHEEL 14 mm HOLDER handlebar with a strap or equivalent material. This allows the flywheel and crankshaft to turn. Holding the flywheel with the flywheel holder special tool or a commercially available strap wrench, remove the 14 mm special nut.
  • Page 135 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 9. PKA/VKA/VLA types only: 8 x 25 mm Release the flywheel brake lever, and then completely FLANGE BOLT (6) CRANKCASE disconnect the lower end of the flywheel brake cable and COVER ASSY. Z-fitting from the brake assembly 11-17).
  • Page 136 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER INSTALLATION 1. If the lower crankcase seal showed signs of oil leakage before disassembly, replace the seal 10-8). LOWER OIL SEAL 2. Place the thrust washer into the crankcase and center it THRUST around the crankshaft boss. WASHER 3.
  • Page 137 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 6. Apply clean engine oil to the connecting rod, end cap, crankshaft, and connecting rod bolts. Reinstall the connecting rod to the crankshaft and tighten CONNECTING ROD BOLT (2) the connecting rod bolts to the specified torque 10-8).
  • Page 138 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER 11. VLA type only: 6 mm SPECIAL BOLT (2) Reinstall the electric starter motor 9-12) and tighten 11 N•m (97 in•lb) the two 6 mm bolts to the specified torque. TORQUE: 11 N•m (97 in•lb) STARTER MOTOR Reconnect the battery charger connector on the handlebar.
  • Page 139 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 15. VKA/VLA types only: Install the drive pulley, belt guide, blade holder and a new set of blades, and then tighten the center special bolt and two blade bolts to the specified torque 4-4). Be sure the blade holder Woodruff key is properly installed, and properly tighten the blade holder bolt.

  • Page 140: Governor Removal/Installation

    HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER 6. GOVERNOR REMOVAL/INSTALLATION Remove the crankcase cover 10-2). GOVERNOR WEIGHT HOLDER Before installing, check for wear and · GOVERNOR SLIDER damage of the gear. ASSEMBLY: Check that the weights move freely. Slide the governor weights to · install the slider;...

  • Page 141: Oil Filler Cap / Extension Removal/Installation

    CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 7. OIL FILLER CAP / EXTENSION REMOVAL/INSTALLATION OIL FILLER CAP/DIPSTICK OIL FILLER PACKING OIL FILLER EXTENSION O-RING INSTALLATION: Be sure that no dust or 6 x 14 mm SPECIAL BOLT (2) foreign material enters when installing the O-ring. 12 N•m (9 ft-lb) Be careful not to pinch the O-ring.
  • Page 142 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER CRANKSHAFT INSTALLATION If the cylinder and piston/connecting rod are already installed, remove the spark plug, and then set the piston at top dead center. Rotate the camshaft until the two alignment dots face the CAMSHAFT TIMING GEAR ALIGNMENT DOTS ALIGNMENT DOTS crankshaft bore hole in the crankcase.

  • Page 143: Piston/Connecting Rod Disassembly/Assembly

    CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 8. PISTON/CONNECTING ROD DISASSEMBLY/ASSEMBLY Remove the piston/connecting rod 10-20). PISTON RINGS ASSEMBLY: · Install with the manufacturers mark facing upward as shown. · Do not interchange the top ring and the second ring. MANUFACTURERS MARK · After assembly, check for smooth TOP RING movement of the piston rings.

  • Page 144: Cylinder Compression Check

    HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER Apply engine oil to the piston pin bore and the connecting rod small PISTON PIN FLYWHEEL end. CLIPS (2) MARK Apply engine oil to the piston pin and install it in the piston. Install the new piston pin clips. Install the piston/connecting rod into the cylinder 10-8).

  • Page 145: Crankshaft Runout Check

    CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 10. CRANKSHAFT RUNOUT CHECK P. 2-14 if the engine is still installed on the mower deck. When checking the crankshaft runout, do not allow the dial indicator tip to drop into the keyway. BOLT Use the bolt to rotate the crankshaft in the same direction the crankshaft spins during normal operation.
  • Page 146 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER CAMSHAFT DECOMPRESSOR Carefully inspect the decompressor weight position and confirm DECOMPRESSOR that it is fully retracted. The retracted position is where the decompressor pin is on the side of the slot closest to the camshaft bore. BORE If the weight is fully retracted, operate the decompressor by using a pick tool to move the decompressor weight to the opposite end of the slot, and then gently releasing.
  • Page 147 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 ROCKER ARM SHAFT O.D. Measure the rocker arm shaft O.D. STANDARD: 5.960 – 5.990 mm (0.2346 – 0.2358 in) SERVICE LIMIT: 5.953 mm (0.2344 in) If the measurement is less than the service limit, replace the rocker arm shaft.
  • Page 148 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER PISTON RING WIDTH Measure each piston ring width. STANDARD: Top: 0.935 – 0.950 mm (0.0368 – 0.0374 in) Second: 0.975 – 0.990 mm (0.0384 – 0.0390 in) Oil: 2.380 – 2.460 mm (0.0937 – 0.0969 in) SERVICE LIMIT: Top: 0.890 mm (0.0350 in) Second:...
  • Page 149 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 PISTON PIN O.D. Measure and record the piston pin O.D. at three points (both ends and middle). Take the minimum reading to determine piston pin O.D. STANDARD: 12.994 – 13.000 mm (0.5116 – 0.5118 in) SERVICE LIMIT: 12.954 mm (0.5100 in) If the measurement is less than the service limit, replace the piston pin.
  • Page 150 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER CONNECTING ROD BIG END I.D. Set the connecting rod cap to the connecting rod. Be sure the projections align properly. Apply engine oil to the connecting rod bolt threads and seating surface. Tighten the connecting rod bolts to the specified torque. TORQUE: 12 N•m (9 ft-lb) Measure the connecting rod big end I.D.
  • Page 151 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 CONNECTING ROD BIG END AXIAL CLEARANCE Measure the clearance between the connecting rod big end and crankshaft using a feeler gauge. STANDARD: 0.10 – 0.50 mm (0.004 – 0.020 in) SERVICE LIMIT: 0.80 mm (0.031 in) If the measurement is more than the service limit, replace the connecting rod and recheck the clearance.
  • Page 152 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER CRANKCASE MAIN JOURNAL I.D. Measure the crankcase main journal I.D. STANDARD: 28.020 – 28.041 mm (1.1031 – 1.1040 in) SERVICE LIMIT: 28.066 mm (1.1050 in) If the measurement is more than the service limit, replace the crankcase. CRANKSHAFT AXIAL CLEARANCE Measure the crankshaft axial play before removing the crankcase, crankcase cover, and rotating assembly.
  • Page 153 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 VALVE FACE/VALVE STEM O.D. Inspect each valve for face irregularities. If necessary, replace the valve. Inspect each valve for bending or abnormal stem wear. If necessary, replace the valve. VALVE FACE Measure and record each valve stem O.D. STANDARD: IN/EX: 5.465 –...
  • Page 154 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER VALVE SEAT WIDTH Remove the carbon deposits from the combustion chamber (page 3-9). Inspect each valve for face irregularities. VALVE SEAT If necessary, replace the valve. TOO HIGH Apply a light coat of Prussian Blue or erasable felt-tipped marker ink to each valve seat.
  • Page 155 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 Prepare a thick paper cylinder or equivalent material with a large enough diameter to fit against the cylinder wall of the cylinder. Insert the thick paper into the cylinder to protect the cylinder wall during valve seat reconditioning. THICK PAPER Valve seat cutters/grinder or equivalent valve seat re-facing...
  • Page 156 HRN216 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER The 31° cutter removes material from the top edge (contact too CONTACT TO STANDARD high). TOOLS: Cutter holder 5.50 mm NWY TW 505 (Commercially available) VALVE FACE Flat cutter, 30 mm (31° IN/EX) NWY CU 115 (Commercially available) The 60°...
  • Page 157 CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER HRN216 CRANKSHAFT OIL SEAL CRANKCASE COVER SIDE Remove the oil seal. Drive a new oil seal [1] in the position as shown using the special tools. INSTALLATION HEIGHT: 1.0 – 1.5 mm (0.04 – 0.06 in) TOOLS: Bearing driver attachment, 07947-6340400 1.0 –...
  • Page 158 11. HANDLEBAR/ CABLES/CONTROLS 1. HANDLEBAR ..... . . 11-2 6. ROTO-STOP CABLE ....11-22 2.
  • Page 159 HANDLEBAR/ CABLES/CONTROLS HRN216 1. HANDLEBAR REPLACEMENT PKA TYPE 1. Cut the two cable ties securing the flywheel brake cable to the handlebar. CABLE TIE (2) 2. Remove the 6 mm locking nut, 6 x 45 mm flange bolt, and the flywheel brake cable assembly from the 6 mm LOCKING NUT handlebar assembly.
  • Page 160 HRN216 HANDLEBAR/ CABLES/CONTROLS 5. Unlock both handle locking knobs and fold the handlebar over the mower into the storage position. HANDLE LOCKING 6. Remove both handle locking knobs 11-10). KNOBS 7. Have an assistant hold and support the handlebar and then remove the two special bolts and the handlebar from the handle stays.
  • Page 161 HANDLEBAR/ CABLES/CONTROLS HRN216 VKA TYPE 1. Cut the two cable ties securing the flywheel brake cable and Smart Drive cable to the handlebar. 2. Loosen the Smart Drive cable adjuster completely. CABLE TIE (2) 3. Remove the Smart Drive control 11-13).
  • Page 162 HRN216 HANDLEBAR/ CABLES/CONTROLS 7. Remove the recoil starter rope from the rope guide 11-12), and then remove the 6 mm locking nut, frame washer, and rope guide from the handlebar. 6 mm LOCKING FRAME WASHER ROPE GUIDE 8. Unlock both handle locking knobs and fold the HANDLE handlebar over the mower into the storage position.
  • Page 163 HANDLEBAR/ CABLES/CONTROLS HRN216 VLA TYPE 1. Cut the two cable ties securing the flywheel brake cable and Smart Drive cable to the handlebar. CABLE TIE (2) 2. Remove the battery box and wire harness from the 6 x 35 mm handlebar.
  • Page 164 HRN216 HANDLEBAR/ CABLES/CONTROLS 7. Remove the flywheel brake lever from the handlebar by pulling inward on the left-hand side of the lever until the end slides out of the handlebar. The right-hand side of the lever has a hooked end. Rotate the lever over the right-hand side of the handlebar to release the lever.
  • Page 165 HANDLEBAR/ CABLES/CONTROLS HRN216 VYA TYPE 1. Loosen the Smart Drive cable adjuster completely. JAM NUT TIGHTEN LOOSEN ADJUSTER MARK 2. Remove the Smart Drive control 11-13). 3. Remove the Smart Drive cable from the handlebar by pulling it down through the hole in the pipe. SMART DRIVE CABLE...
  • Page 166 HRN216 HANDLEBAR/ CABLES/CONTROLS 6. Remove the recoil starter rope from the rope guide 11-12), and then remove the 6 mm locking nut, frame washer, and rope guide from the handlebar. 6 mm LOCKING FRAME WASHER ROPE GUIDE 7. Unlock both handle locking knobs and fold the HANDLE handlebar over the mower into the storage position.
  • Page 167 HANDLEBAR/ CABLES/CONTROLS HRN216 HANDLE LOCKING KNOB REMOVAL 1. Unlock the handle locking knobs and then fold the handlebar over the mower into the storage position. 2. Depress the 8 mm pin with your finger from the back side so that the pin and pin clip protrude from the handle locking knob.
  • Page 168 HRN216 HANDLEBAR/ CABLES/CONTROLS INSTALLATION 8 mm PIN LOWER 1. Insert the height adjusting collar into the lower MOUNTING mounting hole in the handle so that the flat part is HOLE resting against the handle. 2. Slide the spring over the 8 mm pin. 3.
  • Page 169 HANDLEBAR/ CABLES/CONTROLS HRN216 ROPE GUIDE INSTALLATION Proper positioning of the rope guide is necessary to ensure the starter rope does not come out of the guide during normal use. 1. Insert the rope guide through the hole (inner side) on the right-side handlebar, and then loosely install the 6 mm locking nut onto the threaded end of the rope guide.
  • Page 170 HRN216 HANDLEBAR/ CABLES/CONTROLS 2. SMART DRIVE CONTROL REMOVAL 1. Fully loosen the Smart Drive cable adjuster 3-10). 2. Remove the four 4 mm self-tapping screws and the upper and lower clutch grips. 3. Carefully remove the multi-position adjuster and spring. 4.
  • Page 171 HANDLEBAR/ CABLES/CONTROLS HRN216 INSTALLATION If installing a new Smart Drive cable, fully loosen the cable adjuster before installing the new Smart Drive cable into the HANDLE Smart Drive control. SLOT CABLE 1. Route the upper end of the Smart Drive cable through the hole in the handlebar until it's visible in the slot in the top of the handlebar.
  • Page 172 HRN216 HANDLEBAR/ CABLES/CONTROLS 5. Grease the inside pin grooves of the upper and lower GRIP BRACKET (2) UPPER BRACKET bracket covers. COVER 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.
  • Page 173 HANDLEBAR/ CABLES/CONTROLS HRN216 3. SMART DRIVE CABLE REMOVAL 1. Fully loosen the Smart Drive cable adjuster 3-10). JAM NUT 2. Remove the Smart Drive control 11-13). 3. Cut the two cable ties securing the Smart Drive cable to the handlebar. TIGHTEN 4.
  • Page 174 HRN216 HANDLEBAR/ CABLES/CONTROLS 4. FLYWHEEL BRAKE CABLE PKA/VKA/VLA TYPES ONLY REMOVAL/INSTALLATION 1. Cut the two cable ties that secure the flywheel brake cable to the handlebar. 2. Hold the 6 mm locking nut in place with a wrench, and then fully loosen the 6 x 45 mm flange bolt to remove the flywheel brake cable assembly from the handlebar assembly.
  • Page 175 HANDLEBAR/ CABLES/CONTROLS HRN216 5. ROTO-STOP CONTROL VYA TYPE ONLY REMOVAL 2. Remove the 6 mm locking nut, 6 x 65 mm flange bolt, 6 mm plain washer, and the throttle lever assembly from the handle pipe. 3. Remove the blade control lever from the handle pipe, then from the Roto-Stop control assembly. 4.
  • Page 176 HRN216 HANDLEBAR/ CABLES/CONTROLS DISASSEMBLY ROTO-STOP ARM ASSEMBLY DISASSEMBLY/REASSEMBLY: ROTO-STOP PLAIN WASHER LOCK PIN LOCK RETURN SPRING CLUTCH LEVER LOCK LEVER ROTO-STOP 6 x 65 mm RIGHT CASE FLANGE BOLT PUSH KNOB ROTO-STOP SELF-TAPPING RETURN SPRING SCREW (4) ROTO-STOP CABLE INSTALLATION: P.
  • Page 177 HANDLEBAR/ CABLES/CONTROLS HRN216 REASSEMBLY ROTO-STOP 1. Install the Roto-Stop cable cylinder end in the Roto-Stop CABLE arm assembly. CYLINDER END  ROTO-STOP ARM ASSEMBLY 2. Install the Roto-Stop cable ferrule in the Roto-Stop left case. ROTO-STOP ARM ASSEMBLY 3. Install the Roto-Stop arm assembly in the Roto-Stop left case.
  • Page 178 HRN216 HANDLEBAR/ CABLES/CONTROLS 5. While holding the push knob in the Roto-Stop right case, PUSH ROTO-STOP carefully install the right case on the left case. KNOB RIGHT CASE • Confirm that the case halves seat together and install the four self-tapping screws. •...
  • Page 179 HANDLEBAR/ CABLES/CONTROLS HRN216 6. ROTO-STOP CABLE VYA TYPE ONLY  REMOVAL  1. Cut the three cable ties securing the Roto-Stop cable to  BLADE the handle pipe. CONTROL LEVER 2. Loosen the lock nut and turn the adjuster in the direction shown until it is fully seated.
  • Page 180 HRN216 HANDLEBAR/ CABLES/CONTROLS 8. Remove the Roto-Stop cable from the Roto-Stop left case. ROTO-STOP ARM ASSEMBLY 9. Remove Roto-Stop arm assembly from the Roto-Stop left case. ROTO-STOP CABLE ROTO-STOP LEFT CASE 10. Remove the Roto-Stop cable cylinder end from the Roto-Stop arm assembly.
  • Page 181 HANDLEBAR/ CABLES/CONTROLS HRN216 INSTALLATION 1. Install the Roto-Stop cable cylinder end in the Roto-Stop arm assembly. ROTO-STOP CABLE CYLINDER ROTO-STOP ARM ASSEMBLY 2. Install the Roto-Stop cable ferrule in the Roto-Stop left case. ROTO-STOP ARM ASSEMBLY 3. Install the Roto-Stop arm assembly in the Roto-Stop left case.
  • Page 182 HRN216 HANDLEBAR/ CABLES/CONTROLS 5. While holding the push knob in the Roto-Stop right case, PUSH ROTO-STOP carefully install the right case on the left case. KNOB RIGHT CASE • Confirm that the case halves seat together and install the four self-tapping screws. •...
  • Page 183 HANDLEBAR/ CABLES/CONTROLS HRN216 7. THROTTLE CABLE CLAMP REMOVAL/INSTALLATION THROTTLE 1. Cut the three cable ties securing the throttle cable to CLAMP the handle pipe. SCREW 2. Remove the throttle clamp screw and remove the cable from the engine. THROTTLE CABLE 3.
  • Page 184 2. Locate the battery charger adapter harness, and connect the adapter harness into the charge port connector that is closest to the battery. 3. Insert the connector on the Honda battery charger into the other end of the adapter harness.
  • Page 185 Honda battery charger. If using a Honda battery float charger, the charger may be left connected longer than 24 hours. If the Honda battery charger is not accessible, use a battery charger that charges at a maximum rate of 0.3 amps.
  • Page 186 12. VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS 1. VARIABLE MOWING SYSTEM ..12-1 4. REAR HOUSING ....12-12 2.
  • Page 187 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS HRN216 VYA type: Wear a pair of thick leather gloves and hold the blades UPPER BLADE with your hand to prevent the blades from turning, and LOWER then remove the two blade bolts, washers, and blades. BLADE Note Complete Roto-Stop brake assembly removal is not necessary.
  • Page 188 HRN216 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS 9. Separate the shutter from the Roto-Stop cover by rotating the shutter until the four tabs align with the cutouts in the Roto-Stop cover. SLOT SHUTTER SLOT ROTO-STOP COVER 10. Remove the Clip Director cover from the mower deck by SCREW (2) removing the two screws.
  • Page 189 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS HRN216 3. Install the shutter lever arm. LEVER ARM a. Insert the two 6 x 7 mm special nuts into the slots in the shutter. 6 x 7 mm SHOULDER b. Insert the shutter lever arm through the retaining slot in BOLT (2) the Roto-Stop cover, and then install the two shoulder bolts to attach the shutter lever arm to the shutter.
  • Page 190 HRN216 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS 6. PKA/VKA/VLA types: Insert the Woodruff key into the slot closest to the end of BLADE HOLDER the crankshaft. Be sure the blade holder Woodruff key is ASSEMBLY properly installed. Failure to do so will result in blade holder bolt failure that can cause the blade holder to come off.
  • Page 191 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS HRN216 2. FRONT COVER (Shown from underneath for clarity) AXLE NUT FRONT WHEEL  AXLE SPACER The larger lip side should  face toward the wheel. Apply grease to the inside of both axle spacers. FRONT AXLE ASSEMBLY ...
  • Page 192 HRN216 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS FRONT COVER REMOVAL/INSTALLATION REMOVAL 1. Place wooden blocks underneath the metal mower deck so that the mower is high enough off the ground to access underneath the mower deck with a wrench. Note Tipping the mower over on the right-hand side is not recommended because it will make it more difficult to remove the front cover and front axle assembly.
  • Page 193 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS HRN216 6. Slide the two 6 x 7 mm special nuts out of the front cover. 6 x 7 mm SPECIAL NUT (2) INSTALLATION 1. Apply grease inside the plastic sleeves, and then install the plastic sleeves over the front axle assembly so that RETAINING the retaining lip side of the sleeves face the wheels.
  • Page 194 HRN216 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS 4. Loosely install the four 6 mm flange bolts to the underside of the mower deck closest to the front 6 mm wheels. SHOULDER BOLT (2) 5. Loosely install the two 6 mm shoulder bolts and be sure the shoulder portion of the bolts fit through the metal mower deck.
  • Page 195 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS HRN216 3. CUTTER HOUSING REMOVAL 1. Remove the variable mowing system 12-1). 2. Remove the engine from the cutter housing 5-1). 3. Remove the front cover assembly from the cutter housing 12-12). 4. Remove the rear housing assembly from the cutter housing 12-13).
  • Page 196 HRN216 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS HANDLEBAR STAYS REMOVAL 1. Have an assistant support and hold the handlebar assembly in the mowing position during this procedure. If you do not have an assistant nearby, use an appropriate method that will support the handlebar securely in the mowing position (such as a support pole, hanging strap, etc).
  • Page 197 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS HRN216 4. REAR HOUSING PARTS IDENTIFICATION SERVICE BULLETIN #110 DISCHARGE GUARD RETURN SPRING (R) DISCHARGE GUARD SHAFT 6 x 12 mm FLANGE DISCHARGE BOLT (2) GUARD REAR HOUSING ASSEMBLY 6 x 12 mm FLANGE BOLT (2) DISCHARGE GUARD RETURN...
  • Page 198 HRN216 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS REMOVAL 1. Disconnect the spark plug cap 3-8). WOODRUFF 3/8-24 x 1 in 2. VKA/VLA types: SPECIAL BOLT DRIVE Remove the blades, blade holder, and belt guide, and 54 N•m (40 ft-lb) PULLEY then remove the drive belt from the drive pulley 4-13).
  • Page 199 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS HRN216 3. Remove the handlebar and both handlebar stays as an HANDLEBAR assembly. HANDLEBAR • PKA type: STAYS Remove the flywheel brake cable from the engine 5-2). • VKA type: Remove the flywheel brake cable from the engine 5-2) and the lower end of the Smart Drive cable from the transmission.
  • Page 200 HRN216 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS 5. Remove the four 6 mm flange bolts attaching the rear 6 mm housing from the metal mower deck, and then slide the FLANGE BOLT rear housing away from the deck.   Be sure to support the rear housing to prevent it from dropping while removing the flange bolts.
  • Page 201 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS HRN216 8. Remove the discharge guard by driving out the metal Apply downward shaft from one side. pressure to the springs. The discharge guard springs are under heavy tension and can fly out and injure you. Apply downward SHAFT pressure with a gloved hand to each spring as you remove the shaft to maintain control of the springs.
  • Page 202 HRN216 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS 5. REAR SHIELD SERVICE BULLETIN #110 REMOVAL 1. Move the rear wheel height adjuster to the lowest deck REAR HEIGHT height (position #1). ADJUSTER 2. Tip the mower on the right-hand side so that the air cleaner is facing up.
  • Page 203 VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS HRN216 INSTALLATION 1. Hold the rear shield in place, and then slide the shaft through the left-hand side of the rear housing, through the rear shield, and then into the right-hand side of rear REAR SHIELD housing.
  • Page 204 13. TRANSMISSION/DRIVE BELT 1. TRANSMISSION/DRIVE BELT..13-1 2. DISASSEMBLY/REASSEMBLY ..13-8 This chapter only applies to VKA, VLA, and VYA types. 1. TRANSMISSION/DRIVE BELT VKA/VLA TYPES REMOVAL JAM NUT 1.
  • Page 205 TRANSMISSION/DRIVE BELT HRN216 8. Push down on the transmission control arm (against spring tension), and disconnect the Smart Drive cable from the transmission control arm. 9. Remove the belt tension spring from the transmission BELT TENSION SPRING control arm. TRANSMISSION CONTROL ARM SMART DRIVE CABLE 10.
  • Page 206 HRN216 TRANSMISSION/DRIVE BELT INSTALLATION Install in the reverse order of removal. Pay attention to the following: Do not install belt in this • Be sure to install the 10 mm special hardened washer on the area. transmission input shaft before assembling the driven pulley. •...
  • Page 207 TRANSMISSION/DRIVE BELT HRN216 VYA TYPE REMOVAL JAM NUT 1. Drain the fuel tank 3-11) and engine oil 3-6). TIGHTEN 2. Disconnect the spark plug cap 3-8). 3. Fully loosen the Smart Drive cable adjuster. LOOSEN ADJUSTER MARK 4. Remove the blades. Use a pair of thick leather gloves to hold the blades with your hand to prevent the blades UPPER BLADE from turning, and then remove the two blade bolts and...
  • Page 208 HRN216 TRANSMISSION/DRIVE BELT 5. Disconnect the Roto-Stop return spring and then remove the lower end of Roto-Stop cable 4-2). UPPER ANCHOR POINT CLUTCH SPRING ROTO-STOP INNER CABLE BALL PLATE 6. Remove the top cover and recoil. Hold the flywheel nut TOP COVER with a 19 mm socket while removing the center Roto-Stop special blade holder bolt.
  • Page 209 TRANSMISSION/DRIVE BELT HRN216 9. Turn the mower upside down and rest the handlebar on 6 x 16 mm FLANGE a workbench. Protect the Smart Drive control and BOLT (4) AXLE handlebar with a protective cloth. HOLDER (2) 10. Remove the four 6 x 16 mm special bolts attaching the transmission assembly to the rear housing, and then remove the transmission assembly and drive belt together.
  • Page 210 HRN216 TRANSMISSION/DRIVE BELT INSTALLATION Do not install belt in this Installation is done in the reverse order of removal. Pay attention to area. the following: • Be sure to install the 10 mm special hardened washer on the transmission input shaft before assembling the driven pulley. •...
  • Page 211 TRANSMISSION/DRIVE BELT HRN216 2. DISASSEMBLY/REASSEMBLY PINION GEAR DISASSEMBLY page 3-17 for complete reassembly instructions. The ratchet key is unique for each side. The ratchet holder, pinion, and spring must be installed in the appropriate direction for the left and right wheel pinion assemblies. ...
  • Page 212 HRN216 TRANSMISSION/DRIVE BELT AXLE SHAFT TRANSMISSION ASSEMBLY REMOVAL: P. 13-1 DISASSEMBLY: P. 13-10 INSTALLATION: P. 13-3 CIRCLIP ADJUSTER GRIP ADJUSTER PLATE, REAR DRIVESHAFT BUSHING DRIVESHAFT BUSHING AXLE SHAFT CIRCLIP AXLE BEARING (2) INSPECTION: Remove the bearing from the bushing and check that it spins without a rough or gritty feeling.
  • Page 213 TRANSMISSION/DRIVE BELT HRN216 TRANSMISSION DRIVEN PULLEY HALVES 10 mm FLANGE NUT REMOVAL 27 N•m (20 ft-lb) 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 DRIVE BELT holes of the other pulley...
  • Page 214 14. INDEX HRN216 Air Cleaner Grass Bag Cleaning ........3-7 Cleaning .
  • Page 215 HRN216 Thermowax installation ......8-10 Throttle Cable ........11-26 Lever assembly .

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