Honda HRS216PKA Manual
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A Few Words About Safety
How to use this manual
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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Summary of Contents for Honda HRS216PKA

  • 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: Table Of Contents

    CONTENTS INTRODUCTION SPECIFICATIONS This manual covers service and repair procedures for the Honda HRS216PKA, HRS216SKA, and HRS216VKA rotary mowers. SERVICE INFORMATION All information contained in this manual is based on the latest product information available at the time of printing. We MAINTENANCE reserve the right to make changes at any time without notice.
  • Page 3 HRS216PKA • HRS216SKA • HRS216VKA LAWN MOWER K VERSION IDENTIFICATION Throughout this manual, the K version is listed when the repair procedure varies by version. Identifying the K version of the mower is shown differently for K5 and K6 HRS models due to serial number label changes.
  • Page 4 MODELS AND FEATURES Model HRS216K5 HRS216K6 Type ● ● Push model ● Self-propelled, 1-speed ● Self-propelled, variable speed ● ● ● ● Single blade ○ ○ ○ ○ Twin blades ● ● ● ● Side-discharge door & chute ● = Standard equipment ○...
  • Page 5 HRS216PKA • HRS216SKA • HRS216VKA NOTES...
  • Page 6: Specifications

    1. SPECIFICATIONS ......... . . 1.
  • Page 7 SPECIFICATIONS HRS216PKA • HRS216SKA • HRS216VKA 2. DIMENSIONAL DRAWINGS K5 MODELS K5 SKA model shown 605 mm (23-7/8 in) SKA: 1,621 mm (63-7/8 in) PKA: 1,554 mm (61-1/8 in) K5 model wheel height adjusters are set to the 25 mm (1 in) position.
  • Page 8 HRS216PKA • HRS216SKA • HRS216VKA SPECIFICATIONS K6 MODELS K6 VKA model shown 610 mm (24 in) VKA: 1,532 mm (60-3/8 in) PKA: 1,512 mm (59-1/2 in) K6 model wheel height adjusters are set to the 28 mm (1-1/8 in) position.
  • Page 9 SPECIFICATIONS HRS216PKA • HRS216SKA • HRS216VKA 3. WIRING DIAGRAM Black ENGINE SWITCH CONTACT OPEN STOP CLOSE SPARK IGNITION ENGINE STOP SWITCH PLUG COIL (NORMALLY CLOSED)
  • Page 10: Service Information

    9. TROUBLESHOOTING TECHNIQUES. . . 2-16 1. SERVICE RULES • Use Honda Genuine parts or their exact equivalent. Lower quality parts can damage the mower or reduce its performance. • Install new gaskets, O-rings, and seals during reassembly. • This mower uses metric fasteners and SAE (non-metric) fasteners. Metric bolts, nuts, and screws are not interchangeable with non-metric fasteners.
  • Page 11 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA 3. SERIAL NUMBER LOCATIONS The engine serial number is located on the cylinder block above the oil cap/dipstick. The frame serial number is located at the left rear corner of the deck. For additional serial number information, see “LAWN MOWER K VERSION IDENTIFICATION”...
  • Page 12 HRS216PKA • HRS216SKA • HRS216VKA SERVICE INFORMATION 4. SERVICE SPECIFICATIONS PART ITEM STANDARD SERVICE LIMIT 2,950 ~ 3,050 rpm Maximum governed speed — Engine Cylinder compression — 420 kPa (4.3 kg/cm , 61 psi) at 600 rpm Carburetor Main jet —...
  • Page 13 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA 5. TORQUE VALUES SPECIAL FASTENERS TORQUE THREAD DIAMETER x ITEM PITCH N•m kg-m ft-lb M6 x 1.0 (ST) Air cleaner case bolt M6 x 1.0 Blade bolt special 49 ~ 59 5.0 ~ 6.0...
  • Page 14 HRS216PKA • HRS216SKA • HRS216VKA SERVICE INFORMATION 6. TOOLS SPECIAL ITEM TOOL NAME TOOL NUMBER APPLICATION Carburetor float level gauge 07401-0010000 Carburetor float level inspection Valve adjustment wrench, 3 mm 07908-KE90200 Valve clearance adjustment Multi-use flywheel holder 07APB-Z28A100 Flywheel removal...
  • 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 HRS216PKA • HRS216SKA • HRS216VKA SERVICE INFORMATION 7. TROUBLESHOOTING ENGINE SERVICE BULLETIN #106 => Hard Starting or Won’t Start Using the Recoil Starter Make sure the fuel valve is ON. Check the fuel level. Refuel. No fuel in tank Sufficient fuel in tank Confirm the fuel quality.
  • Page 17 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA SERVICE BULLETIN #106 => Poor Engine Performance Confirm the fuel quality. If gasoline is Stale fuel Drain the fuel system, and refill with more than 30 days old, the engine may fresh gasoline.
  • Page 18 HRS216PKA • HRS216SKA • HRS216VKA SERVICE INFORMATION VIBRATION PROBLEMS Grass and debris lodged Clean out mower deck. under mower deck. Tighten blade bolts 3-5). Blade bolts loose. • Inspect blades 3-3). Blades bent, damaged, or • Replace blades 3-5). unbalanced by improper •...
  • Page 19 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA 8. SMART DRIVE SYSTEM TROUBLESHOOTING (VKA TYPE) Lawn mower will not self-propel when the Smart Drive is engaged 2-10 Transmission propels the mower, but slips or slows down under load 2-11 Lawn mower continues to self-propel when the Smart Drive is released...
  • Page 20 HRS216PKA • HRS216SKA • HRS216VKA SERVICE INFORMATION TRANSMISSION PROPELS THE MOWER, BUT SLIPS OR SLOWS DOWN UNDER LOAD 1. Adjust the Smart Drive cable 3-9). 2. Inspect the belt and both pulleys for damage. Confirm that the transmission pulley is tight and not slipping on the...
  • Page 21 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA 2. Confirm there is no tension in the Smart Drive cable at the transmission control arm. If tension exists, proceed to the SMART Confirm there is no DRIVE DISASSEMBLY AND INSPECTION tension in the Smart...
  • Page 22 5. Thoroughly clean the bushing contact areas  26 x 36 mm on the axle using a Scotch-Brite™ pad. WASHER 6. Thoroughly apply a coat of Honda Marine 25 mm Apply grease. extreme pressure NLGI #2 GC-LB grease or CIRCLIP equivalent INSIDE the adjuster arms and on the axle surfaces.
  • Page 23 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA ONLY ONE WHEEL PROPELS OR ONE WHEEL INTERMITTENTLY STOPS ROTATING UNDER LOAD (CLICKING SOUND CAN BE HEARD)  1. Clean and inspect the pinion gears, wheel  PINION GEAR (12 tooth) gears, and ratchet keys.
  • Page 24 HRS216PKA • HRS216SKA • HRS216VKA SERVICE INFORMATION TRANSMISSION LEAKS OIL 1. Remove and clean the transmission 12-9), and check to identify the source of the leak. Note: Dark oil or a slight metallic residue in the oil is normal and usually does not indicate a problem.
  • Page 25 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA 9. TROUBLESHOOTING TECHNIQUES COMPRESSION TEST 1. Remove the spark plug and install a compression gauge in the spark plug hole. COMPRESSION GAUGE 2. Hold the flywheel brake lever against the handlebar. (commercially available) 3.
  • Page 26 HRS216PKA • HRS216SKA • HRS216VKA SERVICE INFORMATION 7. Measure the exhaust valve clearance using a feeler gauge. VALVE ADJUSTING ROCKER ARM LOCK NUT Exhaust Valve Clearance Specification: 0.16 ~ 0.24 mm (0.0063 ~ 0.0094 in) If the clearance is less than or equal to 0.24 mm (0.0094 in), the cam pulley decompressor is likely binding.
  • Page 27 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA EXHAUST ROCKER ARM PIVOT FREE-PLAY INSPECTION Perform this step if the compression measured greater than 80 psi and the exhaust valve clearance measurement was greater than 0.24 mm. 1. Loosen the three 6 mm flange bolts and remove the muffler ...
  • Page 28 HRS216PKA • HRS216SKA • HRS216VKA SERVICE INFORMATION 6. Attach a dial indicator with a magnetic base to the steel plate as shown. 7. Use the dial indicator to measure the rocker arm pivot free-play at locations A and B following the procedure in...
  • Page 29 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA 11. If the free-play measurement is within specification, readjust the valve clearance. If the free-play exceeds 0.16 mm (0.0063 in), install a new rocker arm and pin, adjust the valve clearance, and repeat the free-play measurement.
  • Page 30 HRS216PKA • HRS216SKA • HRS216VKA SERVICE INFORMATION SPARK PLUG TEST 1. Remove the spark plug, attach it to the spark plug cap, and ground the side electrode against the cylinder head cover.  WARNING Gasoline is highly flammable and explosive. If ignited, gasoline can burn you severely.
  • Page 31 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA CHOKE CONTROL SYSTEM (ACS) SERVICE BULLETIN #106 => Partially or With the engine cold, If the choke is open when the Replace the thermowax and Normal totally open remove the paper engine is cold, remove the...
  • Page 32 HRS216PKA • HRS216SKA • HRS216VKA SERVICE INFORMATION ENGINE STOP SWITCH INSPECTION 1. Remove the fan cover. 2. Disconnect the engine stop switch connector from the ignition coil primary terminal. ENGINE STOP SWITCH CONNECTOR 3. With the multimeter set to measure Ohms, connect one lead to the engine stop switch connector and the other lead to ground.
  • Page 33 SERVICE INFORMATION HRS216PKA • HRS216SKA • HRS216VKA 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.
  • Page 34: Maintenance

    3. MAINTENANCE 1. MAINTENANCE SCHEDULE ..9. SPARK ARRESTER CLEANING (OPTIONAL 2. MAINTENANCE SPECIFICATIONS ..PART) ......3.
  • Page 35 Blade bolt torque: 49 ~ 59 N•m (36 ~ 43 ft-lb) Rear wheel adjuster bushing 3-15 Inspect for corrosion or wear, and then apply Honda Marine (SKA / VKA types) extreme pressure NLGI #2 GC-LB grease or equivalent. Pinon gear (SKA / VKA types)
  • Page 36 HRS216PKA • HRS216SKA • HRS216VKA MAINTENANCE 4. REAR SHIELD During normal use the rear shield is subject to deterioration and wear. Check the rear shield for cracks or tears. If the rear shield is worn, replace it 11-2). The end of the rear shield shaft is crimped. To replace the shield, cut the shaft with a hacksaw and replace the shaft and install a new push nut.
  • Page 37 MAINTENANCE HRS216PKA • HRS216SKA • HRS216VKA REMOVAL 1. Turn the fuel valve to the OFF position, disconnect the spark plug cap, and tilt the BLADE mower on its right side. 2. Remove the two blade bolts and special SPECIAL WASHER (2) washers from the blade holder.
  • Page 38 HRS216PKA • HRS216SKA • HRS216VKA MAINTENANCE 3. Check blade balance by placing the clean, sharpened blade on a dowel or screwdriver, as shown. A balanced blade will stay horizontal. If one end of the blade dips, grind or file the heavy end until good balance is achieved.
  • Page 39 10W-30 The SAE oil viscosity and service classification are given in the API label 100°F on the oil container. Honda recommends that you use API service category SJ or later oil. 20 30 40°C OUTSIDE AIR TEMPERATURE...
  • Page 40 MAINTENANCE SCHEDULE 3-1). We recommend the use of a Honda Genuine air filter to ensure it seals and performs as designed. Using a non-Honda air filter can result in dirt bypassing the filter, causing damage to the engine or fuel system.
  • Page 41 MAINTENANCE HRS216PKA • HRS216SKA • HRS216VKA 8. SPARK PLUG INSPECTION Recommended spark plug NGK BPR5ES SPARK PLUG Using an incorrect spark plug can cause engine damage. Use the recommended spark plug or an exact equivalent. 1. Remove the spark plug with a 13/16 in (21 mm) spark plug wrench.
  • Page 42 HRS216PKA • HRS216SKA • HRS216VKA MAINTENANCE 10. SMART DRIVE CABLE (VKA TYPE) CABLE CHECK 1. With the engine off, use the multi-position adjuster to set the Smart Drive control in its lowest position. 2. Gradually push the Smart Drive control down while pulling the lawn mower backwards.
  • Page 43 MAINTENANCE HRS216PKA • HRS216SKA • HRS216VKA 4. Slide the tube clip back on the fuel tube. 5. Rotate the fuel tube to help release the tube from the fuel FUEL TANK tank, and then pull the tube from the tank fitting.
  • Page 44 HRS216PKA • HRS216SKA • HRS216VKA MAINTENANCE BRAKE SHOE INSPECTION 1. Remove the recoil starter 6-1). FLYWHEEL BRAKE SHOE 2. Remove the fan cover. 3. Measure the thickness of the brake shoe. Service limit 3.0 mm (0.12 in) 4. If brake shoe thickness is less than the service limit, replace the flywheel brake shoe.
  • Page 45 MAINTENANCE HRS216PKA • HRS216SKA • HRS216VKA 13. VALVE CLEARANCE INSPECTION AND ADJUSTMENT Valve clearance inspection and adjustment must be performed with the engine cold. 6 x 12 mm FLANGE BOLT (4) 1. Remove the spark plug cap from the spark plug.
  • Page 46 HRS216PKA • HRS216SKA • HRS216VKA MAINTENANCE 6. Insert a feeler gauge between the valve stem and the adjusting screw on the rocker arm. FEELER GAUGE Standard valve 0.15 ± 0.04 mm clearance (cold) 0.20 ± 0.04 mm VALVE TOOL: ADJUSTMENT...
  • Page 47 MAINTENANCE HRS216PKA • HRS216SKA • HRS216VKA 14. GOVERNOR SERVICE BULLETIN #106 => MAXIMUM SPEED ADJUSTMENT 1. With the engine off, loosen the governor arm nut on GOVERNOR ARM the governor arm. 2. Push the governor arm away from the carburetor to open the carburetor throttle valve fully.
  • Page 48 MAINTENANCE 15. REAR WHEEL ADJUSTER BUSHING SKA TYPE Remove and inspect the rear wheel adjuster bushings for wear. Apply Honda Marine extreme pressure NLGI #2 GC- LB grease or equivalent inside the adjuster bushing prior to assembly. right side shown ...
  • Page 49 7. Thoroughly clean the bushing contact areas on the axle using a Scotch-Brite™ pad. 25 mm CIRCLIP 8. Thoroughly apply a coat of Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent INSIDE the adjuster arms and on the axle surfaces. IMPORTANT: Only use an extreme pressure NLGI #2 GC-LB wheel bearing grease.
  • Page 50 COLLAR Left - inside or damage. Replace as necessary. Right - outside Grease only the inside of the 5. Apply Honda Marine extreme pressure NLGI #2 pinion gears. GC-LB grease or equivalent to the axle, ratchet RATCHET SPRING spring, and inside of the pinion gear.
  • Page 51 MAINTENANCE HRS216PKA • HRS216SKA • HRS216VKA NOTES 3-18...
  • Page 52: Engine Removal/Installation

    4. ENGINE REMOVAL/INSTALLATION 1. REMOVAL ......2. INSTALLATION ..... 1.
  • Page 53 ENGINE REMOVAL/INSTALLATION HRS216PKA • HRS216SKA • HRS216VKA 2. INSTALLATION 1. Set the engine on the mower deck and install the four 5/16-24 x 1" engine mounting flange bolts. TORQUE: 22 N•m (16 ft-lb) 2. SKA and VKA types only: • Reinstall the drive belt and pulley (SKA: 12-2), VKA: 12-3)).
  • Page 54: Muffler

    5. MUFFLER 1. REMOVAL/INSTALLATION ............5-1 1.
  • Page 55 MUFFLER HRS216PKA • HRS216SKA • HRS216VKA NOTES...
  • Page 56: Recoil Starter

    6. RECOIL STARTER 1. REMOVAL/INSTALLATION ... . 2. STARTER ROPE REPLACEMENT ..1. REMOVAL/INSTALLATION • If the starter rope is frayed or worn out, replace the starter rope 6-2).
  • Page 57 RECOIL STARTER HRS216PKA • HRS216SKA • HRS216VKA 2. STARTER ROPE REPLACEMENT Starter Rope and Reel Intact 1. Pull starter grip until the starter rope is pulled out fully. 2. To prevent the starter reel from rewinding, hold the starter reel and starter case with a band or equivalent material as shown.
  • Page 58 HRS216PKA • HRS216SKA • HRS216VKA RECOIL STARTER Starter Rope Broken Or Reel Unwound ALIGN STARTER REEL 1. Turn the starter reel in the direction of the arrow six turns. HOLES Align the rope hole in the starter case with the rope hole in the starter reel.
  • Page 59 RECOIL STARTER HRS216PKA • HRS216SKA • HRS216VKA NOTES...
  • Page 60: Fuel System

    7. FUEL SYSTEM 4. FUEL VALVE/GOVERNOR ARM..7-16 1. AIR CLEANER/CARBURETOR REMOVAL/INSTALLATION ... . 5. FAN COVER/FUEL TANK ... . 7-17 2.
  • Page 61 FUEL SYSTEM HRS216PKA • HRS216SKA • HRS216VKA 8. Remove the throttle return spring from the carburetor throttle lever. 9. Rotate the carburetor in the direction shown, and remove the governor rod from the carburetor throttle lever. The insulator, air guide, and gaskets do not need to be removed unless the gaskets are damaged and need to be replaced.
  • Page 62 HRS216PKA • HRS216SKA • HRS216VKA FUEL SYSTEM 2. CARBURETOR DISASSEMBLY/REASSEMBLY Clean the outside of the carburetor before disassembly.  WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and let it cool before handling fuel.
  • Page 63 HRS216PKA • HRS216SKA • HRS216VKA 3. CARBURETOR CLEANING Use the jet cleaner set special tool (P/N 07JPZ-001010B) and Honda Carburetor Cleaner (P/N 08732-CC000) with its plastic spray nozzle to clean the carburetor ports. Some commercially available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as O-rings, floats, choke valves, and float valve seats.
  • Page 64 HRS216PKA • HRS216SKA • HRS216VKA FUEL SYSTEM 2. Remove the set bolt, float chamber, float pin, float valve, and float. Clean and then inspect the float valve tip for damage and replace if necessary. See image on page 7-4. 3. Remove the main jet and the main nozzle.
  • Page 65 FUEL SYSTEM HRS216PKA • HRS216SKA • HRS216VKA 5. Remove the 5 x 6 mm screw covering the pilot jet. 6. Clean the float valve seat using carburetor cleaner and compressed air. FLOAT VALVE SEAT...
  • Page 66 HRS216PKA • HRS216SKA • HRS216VKA FUEL SYSTEM 7. Clean the main nozzle thoroughly using carburetor cleaner, appropriate size jet cleaning tool, and compressed air. Do not use a welding tip cleaning needle. NOTICE Using a welding tip cleaning needle or a jet needle that is too large may damage the carburetor.
  • Page 67 FUEL SYSTEM HRS216PKA • HRS216SKA • HRS216VKA 8. Clean the main jet by spraying carburetor cleaner through the jet and using the appropriate size jet cleaning tool and compressed air. Do not use a welding tip cleaning needle. NOTICE Using a welding tip cleaning needle or a jet needle that is too large may damage the carburetor.
  • Page 68 HRS216PKA • HRS216SKA • HRS216VKA FUEL SYSTEM 11. Clean the pilot jet thoroughly by using the appropriate size jet cleaning tool, carburetor cleaner, and compressed air. The passage is small and easily obstructed, so repeat several times. PILOT JET 12. Clean the high speed air passage with carburetor cleaner and compressed air.
  • Page 69 FUEL SYSTEM HRS216PKA • HRS216SKA • HRS216VKA 13. Clean the float chamber vent hole with carburetor cleaner and compressed air. FLOAT CHAMBER VENT HOLE 14. Clean the slow speed air passage. Spray carburetor cleaner and compressed air through the slow speed air passage.
  • Page 70 HRS216PKA • HRS216SKA • HRS216VKA FUEL SYSTEM 15. Reinstall the 5 x 6 mm screw covering the pilot jet. 16. Check the slow speed air channel for obstructions. Spray carburetor cleaner through the slow speed air passage. SLOW SPEED AIR PASSAGE...
  • Page 71 FUEL SYSTEM HRS216PKA • HRS216SKA • HRS216VKA 17. Reinstall the throttle stop screw and spring (if applicable) Tighten the screw just far enough so the throttle plate begins to open. Adjust so throttle plate just begins to open. 18. Reinstall the main nozzle and main jet, making sure the nozzle long end extends into the venturi.
  • Page 72 HRS216PKA • HRS216SKA • HRS216VKA FUEL SYSTEM 19. Install the float valve, float, and float chamber. Make sure the float chamber is installed correctly, making a good seal with the gasket. 20. Reinstall the carburetor on the engine, turn the fuel valve on, and check for fuel leaks.
  • Page 73 FUEL SYSTEM HRS216PKA • HRS216SKA • HRS216VKA CHOKE CONTROL ASSEMBLY Thermowax Removal Remove the existing thermowax from the cylinder barrel. If the existing thermowax is bonded in place with RTV sealant: a. Using small pliers or wire cutters, pull the center pin out of the thermowax (a).
  • Page 74 HRS216PKA • HRS216SKA • HRS216VKA FUEL SYSTEM Choke Assembly Installation 1. Install the choke assembly when the cylinder head temperature is less than 40 °C (104 °F). 2. Apply a small amount of Hondabond HT to the bottom and lower third of the new thermowax. Do not apply too much.
  • Page 75 FUEL SYSTEM HRS216PKA • HRS216SKA • HRS216VKA 4. FUEL VALVE/GOVERNOR ARM SERVICE BULLETIN #106 => DISASSEMBLY/REASSEMBLY 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.
  • Page 76 HRS216PKA • HRS216SKA • HRS216VKA FUEL SYSTEM 5. FAN COVER/FUEL TANK REMOVAL/INSTALLATION 1. Before removal, drain the gasoline into an approved container. 2. Remove the recoil starter and the fan cover. 3. Remove the fuel tube from the fuel tank.
  • Page 77 FUEL SYSTEM HRS216PKA • HRS216SKA • HRS216VKA FUEL TUBE REMOVAL/INSTALLATION 1. Turn the fuel valve to the OFF position, and install a fuel tube clamp on the fuel tube. FUEL VALVE Use pliers to open the fuel clip, and slide the fuel clip FUEL CLIP up the tube.
  • Page 78 HRS216PKA • HRS216SKA • HRS216VKA FUEL SYSTEM 6. EVAPORATIVE EMISSION CONTROL SYSTEM FUEL TANK CAP This engine has an EVAPORATIVE EMISSION CONTROL CANISTER built into the fuel tank cap to prevent the escape of gasoline vapors into the atmosphere. The cap also contains a ratchet mechanism to provide the operator with feedback to indicate that the cap is sealed.
  • Page 79 FUEL SYSTEM HRS216PKA • HRS216SKA • HRS216VKA NOTES 7-20...
  • Page 80: Flywheel / Ignition Coil

    8. FLYWHEEL / IGNITION COIL 1. DISASSEMBLY/REASSEMBLY ..8-2 3. IGNITION COIL ....8-5 2. FLYWHEEL REMOVAL/INSTALLATION . .8-3...
  • Page 81 FLYWHEEL / IGNITION COIL HRS216PKA • HRS216SKA • HRS216VKA 1. DISASSEMBLY/REASSEMBLY 1. Remove the recoil starter 6-1) and fan cover 7-17). 2. Remove the fan cover stud (black), the 6 x 20 mm flange bolt, and the ignition coil. 3. Remove the 14 mm special nut and the flywheel (page 8-3).
  • Page 82 HRS216PKA • HRS216SKA • HRS216VKA FLYWHEEL / IGNITION COIL 2. FLYWHEEL REMOVAL/INSTALLATION REMOVAL 1. Remove the fan cover/fuel tank 7-17).  2. Hold the flywheel brake lever against the handlebar and secure it there with a strap or equivalent material. This...
  • Page 83 FLYWHEEL / IGNITION COIL HRS216PKA • HRS216SKA • HRS216VKA STOP SWITCH WIRE ROUTING Be sure the stop switch wire is routed between the engine stop switch and the ignition primary coil as shown before installing the flywheel. ENGINE STOP SWITCH...
  • Page 84 HRS216PKA • HRS216SKA • HRS216VKA FLYWHEEL / IGNITION COIL 3. IGNITION COIL IGNITION COIL TEST 1. Measure the resistance of the primary ignition coil by PRIMARY touching one ohmmeter lead to the ignition coil’s flat COIL terminal while touching the other lead to the iron core.
  • Page 85 FLYWHEEL / IGNITION COIL HRS216PKA • HRS216SKA • HRS216VKA NOTES...
  • Page 86 9. CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 1. CAM PULLEY/ROCKER ARM..4. VALVES ......5.
  • Page 87: Cam Pulley/Crankshaft/Piston/ Cylinder Block

    CAM PULLEY/CRANKSHAFT/PISTON/ HRS216PKA • HRS216SKA • HRS216VKA CYLINDER BLOCK CAM PULLEY DECOMPRESSION WEIGHT INSPECTION 1. Rotate the flywheel until the cam pulley decompressor weight slot faces out. 2. Carefully inspect the weight position and confirm that it is fully retracted. If it is not fully retracted, replace the cam pulley (see “CAM PULLEY INSTALLATION”...
  • Page 88 CAM PULLEY/CRANKSHAFT/PISTON/ HRS216PKA • HRS216SKA • HRS216VKA CYLINDER BLOCK 3. Apply oil to the O-ring and install it on the cam pulley shaft. CAM PULLEY TIMING BELT 4. Install the cam pulley shaft in the cylinder block. CAM PULLEY 5. Hold the cam pulley alignment marks in line with the SHAFT cylinder head cover mating surface.
  • Page 89 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRS216PKA • HRS216SKA • HRS216VKA 2. OIL PAN/CRANKSHAFT/CYLINDER BLOCK REMOVAL/INSTALLATION Remove the cam pulley and rocker arm.  6 x 25 FLANGE BOLT (8) (Apply grease to the lips.) 12 N•m (9 ft-lb) 28 x 41.25 x 6 mm OIL SEAL...
  • Page 90 CAM PULLEY/CRANKSHAFT/PISTON/ HRS216PKA • HRS216SKA • HRS216VKA CYLINDER BLOCK OIL PAN REMOVAL RECESS 1. Set piston at TDC of compression stroke. 2. Remove the 6 x 25 mm flange bolts 3. Insert a screwdriver or equivalent tool into the recess as shown, and remove the oil pan from the cylinder block.
  • Page 91 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRS216PKA • HRS216SKA • HRS216VKA THRUST WASHER INSTALLATION THRUST WASHER 1. Install the timing belt on the timing belt pulley. 2. Install the thrust washer; note the installation direction. TIMING BELT CYLINDER BLOCK/OIL PAN ASSEMBLY CRANKSHAFT 1.
  • Page 92 CAM PULLEY/CRANKSHAFT/PISTON/ HRS216PKA • HRS216SKA • HRS216VKA CYLINDER BLOCK 3. PISTON DISASSEMBLY/REASSEMBLY TOP RING PISTON RINGS REASSEMBLY: P. 9-16 INSPECTION: MAKER MARK Chrome plated. Do not REASSEMBLY: interchange with SECOND RING. Install with the maker mark facing upward as shown.
  • Page 93 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRS216PKA • HRS216SKA • HRS216VKA PISTON CONNECTING ROD REASSEMBLY PISTON PIN PISTON 1. Apply oil to the piston pin, piston pin hole and the connecting rod small end. 2. Set the piston so that the 'FW' mark stamped at the back of the piston points down.
  • Page 94 CAM PULLEY/CRANKSHAFT/PISTON/ HRS216PKA • HRS216SKA • HRS216VKA CYLINDER BLOCK 4. VALVES DISASSEMBLY/REASSEMBLY VALVE SPRING RETAINER (2)  DISASSEMBLY: Push down and slide the VALVE SPRING (2) retainer to the side, so the P. 9-19 INSPECTION: valve stem slips through the hole at the side of the retainer.
  • Page 95 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRS216PKA • HRS216SKA • HRS216VKA COMBUSTION CHAMBER CLEANING 1. Prepare a cylinder of thick paper or equivalent material, with a diameter large enough to fit against the inner wall of the cylinder, and insert it into the cylinder for protection.
  • Page 96 CAM PULLEY/CRANKSHAFT/PISTON/ HRS216PKA • HRS216SKA • HRS216VKA CYLINDER BLOCK Valve seat reconditioning tools (commercially available) SOLID PILOT BAR, 5.50 mm (NWY PM 100055SH) SOLID PILOT BAR, 5.51 mm (NWY PM 100552S) VALVE SEAT CUTTER #115, 31° (NWY CU 115 VALVE SEAT CUTTER #122, 45° (NWY CU 122) VALVE SEAT CUTTER #111, 60°...
  • Page 97 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRS216PKA • HRS216SKA • HRS216VKA 3. Use the 31° and 60° cutters to narrow and adjust the valve seat so that it contacts the middle of the valve face. CONTACT TOO HIGH The 31° cutter removes material from the top edge. The 60°...
  • Page 98 CAM PULLEY/CRANKSHAFT/PISTON/ HRS216PKA • HRS216SKA • HRS216VKA CYLINDER BLOCK 5. GOVERNOR DISASSEMBLY/REASSEMBLY GOVERNOR HOLDER CLIP GOVERNOR WEIGHT HOLDER ASSEMBLY REASSEMBLY: REASSEMBLY: Insert firmly into the shaft Before installing, check for wear and damage of the gear. groove. Check that the weights move freely.
  • Page 99 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRS216PKA • HRS216SKA • HRS216VKA 6. COMPONENT INSPECTION CAM PULLEY HEIGHT INSPECTION Standard Service limit 37.394 mm (1.4722 in) 37.369 mm (1.4712 in) CAM PULLEY I.D. (BEARING) INSPECTION Standard Service limit 10.027 mm (0.3948 in) 10.075 mm (0.3967 in) CAM PULLEY DECOMPRESSOR INSPECTION Inspect the decompressor return spring for proper strength.
  • Page 100 CAM PULLEY/CRANKSHAFT/PISTON/ HRS216PKA • HRS216SKA • HRS216VKA CYLINDER BLOCK ROCKER ARM INSPECTION 1. To check the rocker arms for excessive free-play, follow the steps in “EXHAUST ROCKER ARM PIVOT FREE-PLAY INSPECTION” on page 2-18. Repeat the steps for the intake valve.
  • Page 101 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRS216PKA • HRS216SKA • HRS216VKA PISTON RING SIDE CLEARANCE INSPECTION Standard Service limit Top ring 0.055 ~ 0.089 mm 0.150 mm (0.002 ~ 0.004 in) (0.006 in) Second ring 0.015 ~ 0.049 mm 0.150 mm (0.0006 ~ 0.0019 in) (0.006 in)
  • Page 102 CAM PULLEY/CRANKSHAFT/PISTON/ HRS216PKA • HRS216SKA • HRS216VKA CYLINDER BLOCK CONNECTING ROD SMALL END I.D. INSPECTION Standard Service limit 13.005 mm (0.5120 in) 13.07 mm (0.515 in) CONNECTING ROD BIG END I.D. INSPECTION Standard Service limit 26.02 mm (1.024 in) 26.066 mm (1.0262 in) CRANKSHAFT MAIN JOURNAL O.D.
  • Page 103 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRS216PKA • HRS216SKA • HRS216VKA CRANK PIN O.D. INSPECTION Standard Service limit 25.98 mm (1.023 in) 25.92 mm (1.020 in) CONNECTING ROD BIG END AXIAL CLEARANCE INSPECTION Measure the clearances with a feeler gauge. Standard Service limit 0.1 ~ 0.4 mm...
  • Page 104 CAM PULLEY/CRANKSHAFT/PISTON/ HRS216PKA • HRS216SKA • HRS216VKA CYLINDER BLOCK CYLINDER BLOCK MAIN JOURNAL I.D. INSPECTION Standard Service limit 25.420 mm (1.0008 in) 25.466 mm (1.0026 in) Inspect the bearing surface for scoring or damage. If the bearing surface is worn or damaged, the cylinder block and crankshaft will require replacement.
  • Page 105 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRS216PKA • HRS216SKA • HRS216VKA VALVE FACE/STEM O.D. INSPECTION Inspect each valve face for pitting or wear irregularities. Inspect each valve stem for bending or abnormal stem wear. Replace the valve if necessary. Measure and record each valve stem.
  • Page 106: Handle Pipe/Cables

    10. HANDLE PIPE/CABLES 1. HANDLE PIPE REPLACEMENT ..10-2 10-12 4. HANDLE LOCKING KNOB (K6 TYPES) 2. HANDLE STAY REMOVAL ..10-6 5. SMART DRIVE CABLE (VKA TYPE) . . 10-13 3.
  • Page 107 HANDLE PIPE/CABLES HRS216PKA • HRS216SKA • HRS216VKA 1. HANDLE PIPE REPLACEMENT K5 PKA/SKA MODELS 1. Cut the cable ties securing the brake cable and drive clutch cable to the handle pipe. 2. Remove the 6 mm nylon nut, 6 x 60 mm hex bolt, and the flywheel brake cable assembly from the handle pipe assembly.
  • Page 108 HRS216PKA • HRS216SKA • HRS216VKA HANDLE PIPE/CABLES K6 PKA MODEL 1. Cut the cable ties securing the brake cable to the handle pipe. 2. Remove the 6 mm locking nut, 6 x 45 mm flange bolt, 6 mm plain washer, and the flywheel brake cable assembly from the handle pipe assembly.
  • Page 109 HANDLE PIPE/CABLES HRS216PKA • HRS216SKA • HRS216VKA K6 VKA MODEL 1. Cut the three cable ties securing the brake cable and Smart Drive cable to the handle pipe. Fully loosen the Smart Drive cable adjuster 3-9). 2. Remove the 6 mm locking nut, 6 x 45 mm flange bolt, 6 mm plain washer, and the flywheel brake cable assembly from the handle pipe assembly.
  • Page 110 HRS216PKA • HRS216SKA • HRS216VKA HANDLE PIPE/CABLES 8. Remove the Smart Drive cable from the lower grip bracket and then from the handle pipe assembly. 9. Remove the starter rope from the rope guide, and then remove the 6 mm locking nut and the rope guide.
  • Page 111 HANDLE PIPE/CABLES HRS216PKA • HRS216SKA • HRS216VKA 2. HANDLE STAY REMOVAL K5 PKA AND SKA MODELS 1. Release the handlebar locking knobs and allow the NYLON WASHER (2) handle pipe assembly to rest on the floor. 2. Remove the two special bolts and nylon washers,...
  • Page 112 HRS216PKA • HRS216SKA • HRS216VKA HANDLE PIPE/CABLES K6 PKA MODEL This procedure explains the removal and installation for both left and right handle stays. If only replacing one handle stay, NYLON WASHER (2) follow the instructions for only that side.
  • Page 113 HANDLE PIPE/CABLES HRS216PKA • HRS216SKA • HRS216VKA 6. Remove the one remaining 8 mm flange bolt and 8 mm flange nut holding each handle stay to the mower deck. Installation is the reverse of removal. 8 mm 8 mm RIGHT...
  • Page 114 HRS216PKA • HRS216SKA • HRS216VKA HANDLE PIPE/CABLES K6 VKA MODEL This procedure explains the removal and installation for both left and right handle stays. If only replacing one handle stay, NYLON WASHER (2) follow the instructions for only that side.
  • Page 115 HANDLE PIPE/CABLES HRS216PKA • HRS216SKA • HRS216VKA 6. Remove the pinion gear collars and wheel covers from WHEEL PINION each side. COVER GEAR COLLAR 7. Remove the remaining thrust collars, 13 mm washers, and circlips from each side. THRUST COLLAR...
  • Page 116 HRS216PKA • HRS216SKA • HRS216VKA HANDLE PIPE/CABLES 10. Remove the one remaining 8 mm flange bolt and 8 mm nut holding each handle stay to the mower deck. Installation is the reverse of removal. Refer to step 3 through step 20...
  • Page 117 HANDLE PIPE/CABLES HRS216PKA • HRS216SKA • HRS216VKA 3. HANDLE GRIP REMOVAL / INSTALLATION (VKA TYPE) 1. Remove the following, depending on the grip that needs replacement: HANDLE 45 ~ 50 mm SMART DRIVE • Smart Drive cable 10-13) GRIP (2) (1.75 ~ 2.0 in)
  • Page 118 HRS216PKA • HRS216SKA • HRS216VKA HANDLE PIPE/CABLES 5. Insert the 1/16” drift punch from the bottom to keep the two holes aligned. 6. From the top side, start the 2 x 12 mm roll pin and gently tap it in until it is flush with the knob.
  • Page 119 HANDLE PIPE/CABLES HRS216PKA • HRS216SKA • HRS216VKA 5. Remove the four 4 mm self-tapping screws and the UPPER CLUTCH GRIP upper and lower clutch grips. Carefully remove the multi-position adjuster and spring. UPPER BRACKET COVER 6. Remove the upper and lower bracket covers.
  • Page 120 HRS216PKA • HRS216SKA • HRS216VKA HANDLE PIPE/CABLES INSTALLATION If installing a new Smart Drive cable, fully loosen the cable adjuster before installing the new Smart Drive cable. 1. Route the upper end of the Smart Drive cable through the hole in the handle pipe until it's visible in the slot in HANDLE the top of the handle pipe.
  • Page 121 HANDLE PIPE/CABLES HRS216PKA • HRS216SKA • HRS216VKA 5. Grease the inside pin grooves of the upper and lower GRIP BRACKET (2) UPPER BRACKET bracket covers. COVER 5 x 37 mm 6. Snap the upper and lower bracket covers together with ROLLER PIN the roller pin located in the pin groove.
  • Page 122 HRS216PKA • HRS216SKA • HRS216VKA HANDLE PIPE/CABLES 9. Route the Smart Drive cable down through the hole in TRANSMISSION SNAP FITTING the cutter housing. CONTROL ARM 10. Attach the Smart Drive cable end on the control arm. CABLE HOLDER 11. Push the transmission as shown, align the Smart Drive...
  • Page 123 HANDLE PIPE/CABLES HRS216PKA • HRS216SKA • HRS216VKA 4. Separate the upper and lower bracket covers. UPPER BRACKET COVER Thoroughly clean the inside of the bracket 5 x 37 mm ROLLER PIN Verify the pin and covers and inner bracket. cable move smoothly.
  • Page 124: Mower Deck / Wheels

    11. MOWER DECK / WHEELS 1. MOWER DECK .....11-2 2. WHEELS ......11-3 11-1...
  • Page 125 MOWER DECK / WHEELS HRS216PKA • HRS216SKA • HRS216VKA 1. MOWER DECK                    Reference Description Quantity Shield shaft  Rear shield ...
  • Page 126 HRS216PKA • HRS216SKA • HRS216VKA MOWER DECK / WHEELS 2. WHEELS REAR WHEEL PKA TYPE right side shown          WHEEL WASHER  REASSEMBLY: Install the washer as shown.  WHEEL SIDE Quantity...
  • Page 127 MOWER DECK / WHEELS HRS216PKA • HRS216SKA • HRS216VKA SKA TYPE right side shown  PINION GEAR, 12T   Install with the punch   mark facing: Left - inside Right - outside      ...
  • Page 128 HRS216PKA • HRS216SKA • HRS216VKA MOWER DECK / WHEELS VKA TYPE WHEEL WASHER right side shown REASSEMBLY: Install the washer as shown.  WHEEL SIDE         Apply grease inside the  pinion gear.
  • Page 129 MOWER DECK / WHEELS HRS216PKA • HRS216SKA • HRS216VKA FRONT WHEEL K5 PKA and SKA MODELS  right side shown        WHEEL WASHER  REASSEMBLY: Install the washer as shown.    WHEEL SIDE ...
  • Page 130 HRS216PKA • HRS216SKA • HRS216VKA MOWER DECK / WHEELS K6 PKA and VKA MODELS right side shown         WHEEL WASHER  REASSEMBLY: Install the washer as shown.    WHEEL SIDE ...
  • Page 131 MOWER DECK / WHEELS HRS216PKA • HRS216SKA • HRS216VKA NOTES 11-8...
  • Page 132: Transmission / Drive Belt

    12. TRANSMISSION / DRIVE BELT 1. DRIVE BELT..... . . 12-2 3. TRANSMISSION INSTALLATION ..12-12 2.
  • Page 133 TRANSMISSION / DRIVE BELT HRS216PKA • HRS216SKA • HRS216VKA 1. DRIVE BELT K5 SKA MODEL REMOVAL/INSTALLATION 1. Turn the fuel valve to OFF. 2. Disconnect the spark plug cap. 3. Remove the two blade bolts and special washers from the blade holder. Use a wooden block to prevent the blades from turning when removing the bolts 3-5).
  • Page 134 HRS216PKA • HRS216SKA • HRS216VKA TRANSMISSION / DRIVE BELT K6 VKA MODEL REMOVAL/INSTALLATION 1. Turn the fuel valve OFF, and disconnect the spark plug cap. WOODRUFF KEY BELT GUIDE 2. Fully loosen the Smart Drive cable adjuster BLADE HOLDER 3-9).
  • Page 135 TRANSMISSION / DRIVE BELT HRS216PKA • HRS216SKA • HRS216VKA 10. Remove the rear scroll by removing the four 8 mm flange bolts and two 8 mm flange nuts. 8 mm FLANGE BOLT (4) REAR SCROLL 8 mm FLANGE NUT (2) 11.
  • Page 136 HRS216PKA • HRS216SKA • HRS216VKA TRANSMISSION / DRIVE BELT 15. Install in the reverse order of removal. Pay attention to the following: • Be sure to install the 10 mm hardened washer on the transmission input shaft before assembling the driven pulley.
  • Page 137 TRANSMISSION / DRIVE BELT HRS216PKA • HRS216SKA • HRS216VKA 2. TRANSMISSION REMOVAL K5 SKA MODEL 1. Drain the fuel tank 7-17) and engine oil 3-6). 6 x 10 mm 2. Disconnect the spark plug cap. FLANGE BOLTS 3. Turn the mower upside-down, but rest the handlebar on a support to prevent damage to the recoil starter cover.
  • Page 138 HRS216PKA • HRS216SKA • HRS216VKA TRANSMISSION / DRIVE BELT 9. Remove the 13 mm circlip, pinion collar, pinion gear, and wheel cover from each side. WHEEL COVER PINION GEAR PINION COLLAR 13 mm CIRCLIP 10. Remove the ratchet key and spring from each side.
  • Page 139 TRANSMISSION / DRIVE BELT HRS216PKA • HRS216SKA • HRS216VKA 12. Remove the 22 mm circlip from the RIGHT side (farthest away from the transmission) wheel adjuster. Carefully ADJUSTER ASSEMBLY remove the right side adjuster ensuring the seals are not damaged.
  • Page 140 HRS216PKA • HRS216SKA • HRS216VKA TRANSMISSION / DRIVE BELT K6 VKA MODEL 1. Disconnect the spark plug cap. 2. Drain the fuel tank 3-9) and engine oil 3-6). TRANSMISSION BELT TENSION SPRING CONTROL ARM 3. Loosen the Smart Drive cable adjuster 3-9).
  • Page 141 TRANSMISSION / DRIVE BELT HRS216PKA • HRS216SKA • HRS216VKA 13. Remove the 13 mm circlip, pinion gear collar, pinion RATCHET KEY gear, ratchet key, and ratchet return spring from each side. RATCHET RETURN SPRING 12-TOOTH PINION GEAR PINION GEAR 13 mm...
  • Page 142 HRS216PKA • HRS216SKA • HRS216VKA TRANSMISSION / DRIVE BELT 16. Remove the 25 mm circlip from each side, and slide ADJUSTER them and the 26 x 36 mm washers inward toward the ASSEMBLY transmission. 17. Remove the adjuster assembly from each side, taking care not to damage the seals.
  • Page 143 PUNCH MARK 2. Inspect the adjuster arm bushings and seals for wear and replace if necessary. 3. Thoroughly apply a coat of Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent INSIDE the adjuster arms and on the axle surfaces 3-15).
  • Page 144 Scotch-Brite™ pad. 25 mm CIRCLIP 5. Thoroughly apply a coat of Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent INSIDE the adjuster arms and on the axle surfaces. IMPORTANT: Only use an extreme pressure NLGI #2 GC-LB wheel bearing grease.
  • Page 145 HRS216PKA • HRS216SKA • HRS216VKA 10. Install a pinion gear collar and wheel cover. WHEEL PINION COVER GEAR COLLAR 11. Apply Honda Marine extreme pressure NLGI #2 GC-LB   RATCHET RETURN SPRING RATCHET KEY grease or equivalent to the areas shown. 12-TOOTH...
  • Page 146 HRS216PKA • HRS216SKA • HRS216VKA TRANSMISSION / DRIVE BELT 16. Install the return spring. TRANSMISSION BELT TENSION CONTROL ARM SPRING 17. Push down on the control arm, and install the Smart Drive cable end onto the transmission control arm. CABLE HOLDER 18.
  • Page 147 TRANSMISSION / DRIVE BELT HRS216PKA • HRS216SKA • HRS216VKA 4. TRANSMISSION DISASSEMBLY/REASSEMBLY K5 SKA MODEL The single-speed transmission is not serviceable. It must be replaced as a complete assembly. DRIVEN PULLEY SPRING PIN 12-16...
  • Page 148 HRS216PKA • HRS216SKA • HRS216VKA TRANSMISSION / DRIVE BELT K6 VKA MODEL DRIVEN PULLEY HALVES REMOVAL Hold the pinion shaft with a wrench, 10 mm FLANGE NUT and then remove the 10 mm flange nut. 39 N•m (29 ft-lb) INSTALLATION:...
  • Page 149 TRANSMISSION / DRIVE BELT HRS216PKA • HRS216SKA • HRS216VKA NOTES 12-18...
  • Page 150 INDEX Brake shoe inspection ......3-11 Brake spring installation ..... . . 3-11 Air filter.
  • Page 151 INDEX HRS216PKA • HRS216SKA • HRS216VKA Oil pan removal/installation ..... . . 9-4 Disassembly/reassembly ..... 12-17 Installation .

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