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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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Summary of Contents for Honda HRR216VKA K5

  • 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

    INTRODUCTION SPECIFICATIONS This manual covers service and repair procedures for the Honda HRR216VKA K5 through K11 model rotary mowers. SERVICE INFORMATION All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice.
  • Page 3 CONFORMS TO ANSI B 71.1 SAFETY STANDARD shown here. HRR2169VKA MZCG –– XXXXXXX AMERICAN HONDA MOTOR CO., INC. American Honda Motor Co., Inc. ALPHARETTA, GA 30005-8847 Alpharetta, GA 30005-8847 Use the information in the following table to identify the (K9 label shown) version you are repairing.
  • Page 4 HRR216VKA INTRODUCTION VERSION FRAME SERIAL NUMBERS ENGINE SERIAL NUMBERS IDENTIFIERS/FEATURES/CHANGES MZCG – 8670001 ~ 9999999 GJARA – 1000001 ~ 4840000 • Engine model prefix changed from also: GJAPA to GJARA ® MZCG – 1000001 ~ 1140000 • 3-in-1 Clip Director —no mulching plug ®...
  • Page 5 INTRODUCTION HRR216VKA NOTES...
  • Page 6: Specifications

    1. SPECIFICATIONS 1. SPECIFICATIONS ....3. WIRING DIAGRAM ..... . 2.
  • Page 7 SPECIFICATIONS HRR216VKA DRIVE TRAIN VERSION K5/K6 K8/K9/K10/K11 Type Variable Speed Slip Belt Ground speed 0 ~ 5.8 km/h, 0 ~ 1.6 m/s (0 ~ 3.6 mph) 0 ~ 6.5 km/h, 0 ~ 1.8 m/s (0 ~ 4.0 mph) Clutch type Slipping friction cone type V-belt slip Drive mechanism...
  • Page 8 HRR216VKA SPECIFICATIONS 2. DIMENSIONAL DRAWINGS K5 thru K7 *K5/K6: 966 mm (38.0 in) *K7: 961 mm (37.8 in) * Dimensions measured with the cutting height set in the lowest position.
  • Page 9 SPECIFICATIONS HRR216VKA K8 and K9 *1,014 mm (39.9 in) *1,534mm (60.4 in) 620 mm (24.4 in) 582 mm (22.9 in) * Dimensions measured with the cutting height set in the lowest position and the handlebar height set in the highest position.
  • Page 10 HRR216VKA SPECIFICATIONS /K11 *1,024 mm (40.3 in) *1,532 mm (60.3 in) 620 mm (24.4 in) 582 mm (22.9 in) * Dimensions measured with the cutting height set in the lowest position and the handlebar height set in the highest position.
  • Page 11 SPECIFICATIONS HRR216VKA 3. WIRING DIAGRAM SPARK IGNITION ENGINE STOP PLUG COIL SWITCH (NORMALLY CLOSED)
  • Page 12: Service Information

    2-30 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 13 FRAME SERIAL NUMBER MEETS CPSC BLADE SAFETY REQUIREMENTS. CONFORMS TO ANSI B 71.1 SAFETY STANDARD HRR2169VKA MZCG –– XXXXXXX AMERICAN HONDA MOTOR CO., INC. American Honda Motor Co, Inc. ALPHARETTA, GA 30005-8847 Alpharetta, GA 30005-8847 ENGINE SERIAL NUMBER 4. SERVICE SPECIFICATIONS...
  • Page 14 HRR216VKA SERVICE INFORMATION PART ITEM STANDARD SERVICE LIMIT Spark plug 0.7 - 0.8 mm (0.028 ~ 0.031 in) -------------------------------- Valve clearance (cold) 0.15 ± 0.04 mm -------------------------------- 0.20 ± 0.04 mm -------------------------------- Stem O.D. 5.48 mm (0.216 in) 5.318 mm (0.2094 in) Valves 5.44 mm (0.214 in) 5.275 mm (0.2077 in)
  • Page 15 SERVICE INFORMATION HRR216VKA 5. TORQUE VALUES SPECIAL FASTENERS THREAD DIAMETER x TORQUE ITEM PITCH N•m kgf•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 36 ~ 43 Blade holder bolt 3/8-24 x 1”...
  • Page 16 HRR216VKA 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 Flywheel holder 07APB-Z28A100 Flywheel removal Alcohol tester 07AAJ-E85A100 Check the percent of ethanol in the fuel...
  • Page 17 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 18 HRR216VKA SERVICE INFORMATION 7. DRIVE SYSTEM TROUBLESHOOTING Version Symptom See page Lawn mower will not self-propel when the Smart Drive is engaged Transmission propels the mower, but slips or slows down under load Lawn mower continues to self-propel when the Smart Drive is released Lawn mower is difficult to roll backwards, but stops propelling when the K5 thru K7 2-10...
  • Page 19 SERVICE INFORMATION HRR216VKA 3. Verify the transmission control arm moves when rotating the Smart Drive control. • If the control arm does not move, see “SMART DRIVE DISASSEMBLY AND INSPECTION” on page 11-23. • If the control arm moves, adjust the Smart Drive cable (see “CABLE ADJUSTMENT”...
  • Page 20 HRR216VKA SERVICE INFORMATION (K5 ~ K7) LAWN MOWER CONTINUES TO SELF-PROPEL WHEN THE SMART DRIVE IS RELEASED 1. Loosen the Smart Drive cable adjuster completely. LOCK NUT ADJUSTER LOOSEN 2. Confirm there is no tension in the Smart Drive cable at the transmission control arm.
  • Page 21 Remove the rear adjuster arms and clean and inspect the bushings and axle shaft. Replace any excessively worn bushings. Apply Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent to the inside of the bushings. ...
  • Page 22 HRR216VKA SERVICE INFORMATION (K5 ~ K7) ONLY ONE WHEEL PROPELS OR ONE WHEEL INTERMITTENTLY STOPS ROTATING UNDER LOAD (CLICKING SOUND CAN BE HEARD) 1. Clean and inspect the pinion gears, wheel gears, and ratchet keys.  PINION GEAR (12-tooth) 2. Apply general purpose grease to the ratchet Install with the RATCHET key, spring, and axle on the left and right sides.
  • Page 23 SERVICE INFORMATION HRR216VKA (K5 ~ K7) TRANSMISSION LEAKS OIL 1. Remove the transmission 13-1), clean it, and identify the source of the leak. Note: Dark oil or a slight metallic residue in the oil is normal and usually does not indicate a problem. 2.
  • Page 24 HRR216VKA SERVICE INFORMATION K8 thru K11 SERVICE BULLETIN #98 => SERVICE BULLETIN #104 => MOWER WILL NOT SELF-PROPEL WHEN THE SMART DRIVE IS ENGAGED 1. Inspect the drive belt, transmission input shaft, Smart Inspect the transmission control arm, Smart Drive cable, and pulley condition. Drive cable, and return spring for damage.
  • Page 25 SERVICE INFORMATION HRR216VKA (K8 ~ K11) LAWN MOWER CONTINUES TO SELF-PROPEL WHEN THE SMART DRIVE IS JAM NUT RELEASED ADJUSTER MARK 1. Loosen the Smart Drive cable adjuster completely. TIGHTEN LOOSEN 2. Confirm there is no tension in the Smart Drive cable at the transmission control arm.
  • Page 26 Replace any excessively worn bushings. Clean the axle shaft using a  26 x 44 mm WASHER 5. Thoroughly apply a coat of Honda Marine extreme pressure NLGI #2 GC-LB grease or 25 mm Apply grease. equivalent INSIDE the adjuster arms and on CIRCLIP the axle surfaces.
  • Page 27  1. Clean and inspect the pinion gears, wheel gears,  PINION GEAR (12 tooth) and ratchet keys. Install with the 2. Apply Honda Marine extreme pressure NLGI #2 punch mark R ATCHET  R ATCHET facing: GC-LB grease or equivalent to the ratchet key,...
  • Page 28 HRR216VKA SERVICE INFORMATION (K8 ~ K11) TRANSMISSION LEAKS OIL 1. Remove and clean the transmission 13-1), and check to identify the source of the leak. Note: Dark oil or a slight metallic residue in the oil is normal and usually does not indicate a problem. •...
  • Page 29 SERVICE INFORMATION HRR216VKA 8. ENGINE TROUBLESHOOTING SERVICE BULLETIN #94 => SERVICE BULLETIN #106 => HARD STARTING OR POOR PERFORMANCE SERVICE REMINDER #3 => Make sure the fuel valve is ON. SERVICE BULLETIN #98 => Check the fuel level. Refuel. No fuel in tank Sufficient fuel in tank Confirm the fuel quality.
  • Page 30 HRR216VKA SERVICE INFORMATION FUEL/ETHANOL TEST This test will determine the percent of ethanol in gasoline. Honda engines are approved to run on a content of 10% ethanol or less. Follow the directions on the tester shown below.  GAS/ALCOHOL TESTER...
  • Page 31 SERVICE INFORMATION HRR216VKA SPARK TEST 1. Remove the spark plug, attach it to the spark plug cap, and ground the side electrode against the cylinder head cover.  WARNING Gasoline is highly flammable and explosive. If ignited, gasoline can burn you severely. Before testing the spark plug: •...
  • Page 32 HRR216VKA SERVICE INFORMATION COMPRESSION TEST 1. Remove the spark plug and install a compression gauge in the spark plug hole. COMPRESSION GAUGE (commercially 2. Hold the flywheel brake lever against the handlebar. available) 3. Crank the engine several times with the recoil starter and measure compression.
  • Page 33 SERVICE INFORMATION HRR216VKA 6. 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 34 HRR216VKA SERVICE INFORMATION Exhaust Rocker Arm Pivot Free-Play Inspection Perform this procedure if the exhaust valve clearance measurement was greater than 0.24 mm. 1. Loosen the three 6 mm flange bolts and remove the muffler  heat shield.   2.
  • Page 35 SERVICE INFORMATION HRR216VKA 6. Attach a dial indicator with a magnetic base to the steel plate as shown. 7. Use the dial indicator to measure the rocker arm pivot free-play at locations A and B following the procedure in step FREE-PLAY MEASUREMENT POINTS 8.
  • Page 36 HRR216VKA SERVICE INFORMATION 11. If the free-play measurement is within specification, readjust the valve clearance. If the free-play exceeds 0.16 mm (0.0063 in), install a new rocker arm and pin, adjust the valve clearance, and repeat the free-play measurement. If the free-play is still excessive, the rocker tower bore is worn and the cylinder barrel or engine will require replacement.
  • Page 37 SERVICE INFORMATION HRR216VKA CHOKE CONTROL SYSTEM (ACS) (K5 ~ K7) SERVICE REMINDER #3 => With the engine cold, Partially Remove the carburetor. Turn and remove the paper or totally hold the choke arm in the choke normal element and check the open CLOSED position.
  • Page 38 SERVICE BULLETIN #106 => HRR216VKA SERVICE INFORMATION SERVICE BULLETIN #100 => CHOKE CONTROL SYSTEM (ACS) (K8 ~ K11) SERVICE BULLETIN #98 => SERVICE REMINDER #3 => With the engine cold, Partially or Remove the carburetor. Turn Inspect the choke control assembly remove the paper ele- totally open and hold the choke arm in the...
  • Page 39 SERVICE INFORMATION HRR216VKA SERVICE BULLETIN #100 => CHOKE CONTROL INSPECTION (K8 ~ K11) 1. Thread a flange nut onto an 8 x 20 mm or longer flange bolt until only 12 mm of threads are exposed beyond the nut. 12 mm 2.
  • Page 40 HRR216VKA SERVICE INFORMATION 9. FLYWHEEL BRAKE TROUBLESHOOTING Blade (engine) does not stop turning when the flywheel brake lever is released. Repair or replace the cable. Abnormal Check the flywheel brake cable for binding. Check the flywheel brake spring 3-12). Abnormal Correct as required 9-1).
  • Page 41 SERVICE INFORMATION HRR216VKA 10. TROUBLESHOOTING VIBRATION PROBLEMS Grass and debris lodged Clean out mower deck. under mower deck. Blades bolts loose. Tighten blade bolts 3-4). • Inspect blades 3-4). Blades bent, damaged, or • Replace blades 3-4). unbalanced by improper •...
  • Page 42: Maintenance

    3. MAINTENANCE 1. MAINTENANCE SCHEDULE ..10. SPARK ARRESTER CLEANING (OPTIONAL 2. MAINTENANCE SPECIFICATIONS ..PART) ......3.
  • Page 43 MAINTENANCE HRR216VKA 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 44 Blade bolt torque: 49 ~ 59 N•m (36 ~ 43 ft-lb) Grass bag Clean with a garden hose. Replace if worn or damaged. Rear wheel adjuster bushing Inspect for corrosion or wear, and then apply Honda Marine 3-16 extreme pressure NLGI #2 GC-LB grease or equivalent. 3. ENGINE TUNE-UP SPECIFICATIONS...
  • Page 45 MAINTENANCE HRR216VKA 4. REAR SHIELD During normal use, the rear shield is subject to deterioration and wear. Remove the grass bag and raise the discharge guard. Check the rear shield for cracks or tears. If the rear shield is worn, replace it. To remove the shield, pry the push nut off the shaft DISCHARGE GUARD using a flat blade screwdriver.
  • Page 46 HRR216VKA MAINTENANCE REMOVAL 1. Turn the fuel valve to the OFF position, UPPER BLADE disconnect the spark plug, and tilt the mower on its right side. LOWER BLADE 2. Remove the two blade bolts and special washers from the blade control assembly. Use SPECIAL a wooden block to prevent the blades from WASHER (2)
  • Page 47 MAINTENANCE HRR216VKA 3. Check blade balance by placing the clean, sharpened blade on a dowel or screwdriver, as shown. A balanced blade will stay horizontal. If one end of the blade dips, grind or file the heavy end until good balance is achieved. NOTICE An unbalanced blade will cause abnormal vibration that may eventually damage the mower.
  • Page 48 5W-30 • 10W-30 The SAE oil viscosity and service classification are given in the API label on the oil container. Honda recommends that 100°F you use API service category SJ or later oil.
  • Page 49 MAINTENANCE SCHEDULE. 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 50 HRR216VKA MAINTENANCE 9. 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 51 MAINTENANCE HRR216VKA 11. SMART DRIVE CABLE CABLE CHECK 1. With the engine off, use the multi-position adjuster to set the Smart Drive control in its lowest position. 2. Gradually push the Smart Drive control down while pulling the lawn mower backwards. The rear wheels should lock up before the Smart Drive paddles are straight down.
  • Page 52 HRR216VKA MAINTENANCE 12. FUEL TANK AND FILTER FUEL TANK DRAINING AND CLEANING FUEL TANK  WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and let it cool. •...
  • Page 53 Replace the fuel tubes if necessary. 2. To replace the fuel tubes, drain the fuel into a suitable container. Honda Power Equipment manufactured in 2009 and later uses low-permeation fuel tubes that have the CARB Executive Order (C-U-05-003, for example) printed on them.
  • Page 54 HRR216VKA MAINTENANCE FLYWHEEL BRAKE CABLE INSPECTION FLYWHEEL BRAKE LEVER 1. Start the engine outdoors. 2. Release the flywheel brake lever. The engine should stop in less than 3 seconds. If the flywheel brake does not operate properly, recheck the flywheel brake shoe. If the flywheel brake shoe is within the recommended service limit, check the engine stop switch circuit and check the flywheel brake cable for binding.
  • Page 55 MAINTENANCE HRR216VKA 7. Insert a feeler gauge between the valve stem and the FEELER GAUGE adjusting screw on the rocker arm. Standard valve 0.15 ± 0.04 mm clearance (cold) 0.20 ± 0.04 mm TOOL: VALVE ADJUSTMENT Valve adjustment wrench, 3 mm 07908-KE90200 LOCK NUT 8.
  • Page 56 Replace as necessary. facing:  RATCHET Left - inside SPRING 5. Apply Honda Marine extreme pressure NLGI #2 Right - outside GC-LB grease or equivalent to the pinion gear, axle, and ratchet spring. PINION GEAR AXLE COLLAR...
  • Page 57 8. Thoroughly clean the bushing contact areas on the axle using a Scotch-Brite™ pad. CIRCLIP 9. Thoroughly apply a coat of Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent INSIDE the adjuster arms and on the axle surfaces.
  • Page 58 HRR216VKA MAINTENANCE 17. GOVERNOR SERVICE BULLETIN #106 => MAXIMUM SPEED ADJUSTMENT 1. Loosen the governor arm nut on the governor arm. GOVERNOR ARM 2. Push the governor arm away from the carburetor to open the carburetor throttle valve fully. 3. Hold the carburetor throttle valve fully open, and turn the governor arm shaft clockwise fully.
  • Page 59 MAINTENANCE HRR216VKA IDLE SPEED ADJUSTMENT (K5 THRU K8) THROTTLE STOP 1. With the engine running at normal operating SCREW temperature, push the governor arm toward the carburetor and hold it in this position. 2. Adjust the throttle stop screw to obtain the specified idle speed.
  • Page 60: Blade Holder/Drive Belt

    4. BLADE HOLDER/DRIVE BELT 1. BLADE HOLDER ....4. DRIVE BELT (K8)....2.
  • Page 61 BLADE HOLDER/DRIVE BELT HRR216VKA 2. DRIVE BELT (K5, K6) REMOVAL 1. Disconnect the spark plug cap. 2. Drain the fuel tank and engine oil. BELT FLANGE BOLT (4) 3. Put a protective pad around the upper handle pipe. Tip COVER the mower upside down and secure the upper handle pipe in a bench vise.
  • Page 62 HRR216VKA BLADE HOLDER/DRIVE BELT INSTALLATION BELT TENSION ARM 1. Install the drive belt around the drive pulley. Be sure the drive belt is positioned between the driven pulley on the transmission and the belt tension spring. 2. Using a large flat blade screwdriver, hook the belt tension spring on the belt tension arm.
  • Page 63 BLADE HOLDER/DRIVE BELT HRR216VKA 3. DRIVE BELT (K7) REMOVAL 1. Disconnect the spark plug cap. BELT FLANGE BOLT (4) 2. Drain the fuel tank and engine oil. COVER 3. Put a protective pad around the upper handle pipe. Tip the mower up and secure the upper handle pipe in a bench vise.
  • Page 64 HRR216VKA BLADE HOLDER/DRIVE BELT INSTALLATION 1. Install the drive belt around the drive pulley. Be sure the drive belt is positioned between the driven pulley on the transmission and the belt tension spring. 2. Using a large flat blade screwdriver, hook the belt tension BELT spring on the belt tension arm.
  • Page 65 BLADE HOLDER/DRIVE BELT HRR216VKA 4. DRIVE BELT (K8) SERVICE BULLETIN #104 => REMOVAL 1. Turn the fuel valve OFF and disconnect the spark plug cap. 2. Completely loosen the Smart Drive cable (page 11-19). 3. Tilt the mower on its right side with the fuel filler cap up. 4.
  • Page 66 HRR216VKA BLADE HOLDER/DRIVE BELT 5. DRIVE BELT (K9/K10/K11) REMOVAL/INSTALLATION 1. Turn the fuel valve OFF. SERVICE BULLETIN #104 => 2. Disconnect the spark plug cap. ® 3. Move the Clip Director to the fully open (BAG) position. 4. Fully loosen the Smart Drive cable adjuster (page 11-19).
  • Page 67 BLADE HOLDER/DRIVE BELT HRR216VKA 11. Hold the end of the transmission input shaft with an adjustable wrench and remove the 10 mm flange nut. INPUT SHAFT 12. Remove the driven pulley, 10 mm washer, and the V-belt from the transmission. 13.
  • Page 68: Engine Removal/Installation

    5. ENGINE REMOVAL/INSTALLATION 1. REMOVAL ......2. INSTALLATION ..... 1.
  • Page 69 ENGINE REMOVAL/INSTALLATION HRR216VKA 2. INSTALLATION 1. Set the engine on the mower deck and install the four 5/16-24 x 1” engine mounting flange bolts. TORQUE: 22 N•m (16 ft-lbs) 2. Slide the V-belt over the drive pulley, and then slide the pulley on the crankshaft. 3.
  • Page 70: Muffler

    6. MUFFLER 1. REMOVAL/INSTALLATION ... . 1. REMOVAL/INSTALLATION  CAUTION The engine and muffler become very hot during operation, and they remain hot for a while after operation. Be sure that the engine is cold before muffler removal/installation.
  • Page 71 MUFFLER HRR216VKA NOTES...
  • Page 72: Recoil Starter

    7. RECOIL STARTER 1. REMOVAL/INSTALLATION ... . 2. STARTER ROPE REPLACEMENT ..1. REMOVAL/INSTALLATION SERVICE REMINDER #4 => • If the starter rope is frayed or worn out, replace the starter rope 7-2).
  • Page 73 RECOIL STARTER HRR216VKA 2. STARTER ROPE REPLACEMENT Starter Rope and Reel Intact 1. Pull starter grip until the starter rope is pulled out fully. 2. To prevent the starter reel from rewinding, hold the starter reel and starter case with a band or equivalent material as shown.
  • Page 74 HRR216VKA RECOIL STARTER Starter Rope Broken Or Reel Unwound ALIGN STARTER REEL HOLES 1. Turn the starter reel in the direction of the arrow six turns. Align the rope hole in the starter case with the rope hole in the starter reel. 2.
  • Page 75 RECOIL STARTER HRR216VKA NOTES...
  • Page 76: Fuel System

    8. FUEL SYSTEM 1. AIR CLEANER/CARBURETOR 3. FUEL VALVE/GOVERNOR ARM..8-21 REMOVAL/INSTALLATION ... . 4. FAN COVER/FUEL TANK ... . 8-24 2.
  • Page 77 FUEL SYSTEM HRR216VKA 8. Remove the throttle return spring from the carburetor throttle lever. 9. Rotate the carburetor in the direction shown, and remove the governor rod from the carburetor throttle lever. 10. The insulator, air guide, and gaskets do not need to be removed unless the gaskets are damaged and need to be replaced.
  • Page 78 HRR216VKA FUEL SYSTEM K6 ~ K7 VERSION SERVICE BULLETIN #98 => GOVERNOR ROD/THROTTLE RETURN SPRING REMOVAL: Remove the throttle return spring, and then rotate the carburetor in the direction shown and remove the governor rod from the carburetor. THROTTLE RETURN SPRING GOVERNOR ROD INSTALLATION: P.
  • Page 79 FUEL SYSTEM HRR216VKA K8 ~ K11 VERSION SERVICE BULLETIN #98 => K8 MODEL SHOWN GOVERNOR ROD/THROTTLE RETURN SPRING REMOVAL: Remove the throttle return spring, and then rotate the carburetor in the direction shown and remove the governor rod from the carburetor. THROTTLE RETURN SPRING GOVERNOR ROD INSTALLATION:...
  • Page 80 HRR216VKA FUEL SYSTEM 2. CARBURETOR DISASSEMBLY/REASSEMBLY Clean the outside of the carburetor before disassembly.  WARNING NOTICE Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Tampering is a violation of federal and California •...
  • Page 81 HRR216VKA CLEANING Use the jet cleaner set special tool (P/N 07JPZ-001010B) and Honda Carburetor Cleaner (P/N 08732-CC000) with its plastic spray nozzle to clean the carburetor ports. Some commercially available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as O-rings, floats, choke valves, and float valve seats.
  • Page 82 HRR216VKA FUEL SYSTEM 2. Remove the set bolt, float chamber, float pin, float valve, and float. Clean and then inspect the float valve tip for damage and replace if necessary. See image on the previous page. 3. Remove the main jet and the main nozzle. With the main jet removed, push down on the top of the main nozzle with a screwdriver.
  • Page 83 FUEL SYSTEM HRR216VKA 5. Remove the 5 x 6 mm screw covering the pilot jet. 6. Clean the float valve seat using carburetor cleaner and compressed air. FLOAT VALVE SEAT...
  • Page 84 HRR216VKA FUEL SYSTEM 7. Clean the main nozzle thoroughly using carburetor cleaner, appropriate size jet cleaning tool, and compressed air. Do not use a welding tip cleaning needle. NOTICE Using a welding tip cleaning needle or a jet needle that is too large may damage the carburetor.
  • Page 85 FUEL SYSTEM HRR216VKA 8. Clean the main jet by spraying carburetor cleaner through the jet and using the appropriate size jet cleaning tool and compressed air. Do not use a welding tip cleaning needle. NOTICE Using a welding tip cleaning needle or a jet needle that is too large may damage the carburetor.
  • Page 86 HRR216VKA FUEL SYSTEM 11. Clean the pilot jet thoroughly by using the appropriate size jet cleaning tool, carburetor cleaner, and compressed air. The passage is small and easily obstructed, so repeat several times. PILOT JET 12. Clean the high speed air passage with carburetor cleaner and compressed air.
  • Page 87 FUEL SYSTEM HRR216VKA 13. Clean the float chamber vent hole with carburetor cleaner and compressed air. FLOAT CHAMBER VENT HOLE 14. Clean the slow speed air passage. Spray carburetor cleaner and compressed air through the slow speed air passage. The passage is small, so repeat several times. SLOW SPEED AIR PASSAGE 8-12...
  • Page 88 HRR216VKA FUEL SYSTEM 15. Reinstall the 5 x 6 mm screw covering the pilot jet. 16. Check the slow speed air channel for obstructions. Spray carburetor cleaner through the slow speed air passage. SLOW SPEED AIR PASSAGE From the opposite end, confirm that a steady CHOKE SIDE stream of carburetor cleaner sprays out from around the transition ports.
  • Page 89 FUEL SYSTEM HRR216VKA 17. Reinstall the throttle stop screw and spring (if applicable) Tighten the screw just far enough so the throttle plate begins to open. Adjust so throttle plate just begins to open. 18. Reinstall the main nozzle and main jet, making sure the nozzle long end extends into the venturi.
  • Page 90 HRR216VKA FUEL SYSTEM 19. Install the float valve, float, and float chamber. Make sure the float chamber is installed correctly, making a good seal with the gasket. 20. Reinstall the carburetor on the engine, turn the fuel valve on, and check for fuel leaks. 21.
  • Page 91 FUEL SYSTEM HRR216VKA CHOKE CONTROL ASSEMBLY (K5) HEAT SINK Apply a 3 ~ 5 mm thick bead INSTALLATION of Hondabond HT to the bottom surface of the heat 1. Install the choke assembly when the cylinder head sink as shown. temperature is less than 40 °C (104 °F).
  • Page 92 HRR216VKA FUEL SYSTEM CHOKE CONTROL ASSEMBLY (K6 THRU K7) INSTALLATION THERMOWAX 1. Install the choke assembly when the cylinder head ASSEMBLY temperature is less than 40 °C (104 °F). 2. Install the thermowax assembly into the cylinder barrel. 3. Verify that the carburetor choke lever is in the fully closed position.
  • Page 93 FUEL SYSTEM HRR216VKA CHOKE CONTROL ASSEMBLY (K8 thru K11) Thermowax Installation The thermowax plunger MUST be fully retracted and the overall length of the thermowax must be 21.5 to 23.0 mm before installation. If the thermowax plunger is not fully retracted, proceed with the steps below to fully retract the plunger prior to reassembly.
  • Page 94 HRR216VKA FUEL SYSTEM Thermowax removal Follow the steps below if you need to remove the thermowax assembly. NOTICE Removing the thermowax assembly will ruin it. A new assembly will be required for replacement. 1. Use a small pair of pliers to pull the plunger out of the assembly. 2.
  • Page 95 FUEL SYSTEM HRR216VKA Choke Assembly Installation 1. Install the choke assembly when the cylinder head temperature is less than 40 °C (104 °F). 2. Apply a small amount of Hondabond HT or Loctite 5900 to the bottom and lower third of the new thermowax. Do not apply too much.
  • Page 96 HRR216VKA FUEL SYSTEM 3. FUEL VALVE/GOVERNOR ARM SERVICE BULLETIN #106 => DISASSEMBLY/REASSEMBLY (K5) GOVERNOR ARM/THROTTLE RETURN SPRING INSTALLATION: Install the governor rod through the throttle return spring as shown. Connect each to the governor arm and carburetor throttle arm as shown. GOVERNOR GOVERNOR ROD THROTTLE...
  • Page 97 FUEL SYSTEM HRR216VKA DISASSEMBLY/REASSEMBLY (K6 thru K11) GOVERNOR ARM/THROTTLE RETURN SPRING INSTALLATION: Install the governor rod through the throttle return spring as shown. Connect each to the governor arm and carburetor throttle arm as shown. GOVERNOR GOVERNOR ROD THROTTLE THROTTLE ARM LONG END LONG END THROTTLE RETURN SPRING...
  • Page 98 HRR216VKA FUEL SYSTEM FUEL TUBE AND CLAMP CHANGES Honda Power Equipment manufactured after January 1, 2009, uses low-permeation fuel tubes that have the CARB Executive Order (C-U-05-003, for example) printed on them. If you replace a low-permeation fuel tube, you must replace it with a low-permeation fuel tube that has the emissions-compliance identification number printed on it.
  • Page 99 FUEL SYSTEM HRR216VKA 4. FAN COVER/FUEL TANK REMOVAL/INSTALLATION (K5 thru K8) 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. 4. Remove the fuel tank cap from the fuel tank. Unscrew the tether from the fuel filler threads. 5.
  • Page 100 HRR216VKA FUEL SYSTEM REMOVAL/INSTALLATION (K9 thru K11) 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. 4. Remove the fuel tank cap from the fuel tank. Unscrew the tether from the fuel filler threads. 5.
  • Page 101 FUEL SYSTEM HRR216VKA FUEL TUBE REMOVAL 1. Drain the fuel from the fuel tank and carburetor. 2. Use pliers to open the fuel clip, and slide the fuel clip up the tube. FUEL VALVE FUEL CLIP 3. Rotate the fuel tube to help release the tube from the fuel valve fitting.
  • Page 102 HRR216VKA FUEL SYSTEM 5. EVAPORATIVE EMISSION CONTROL SYSTEM FUEL TANK CAP This engine has an EVAPORATIVE EMISSION CONTROL CANISTER built into the fuel tank cap to prevent the escape of gasoline vapors into the atmosphere. The cap also contains a ratchet mechanism to provide the operator with feedback to indicate that the cap is sealed.
  • Page 103 FUEL SYSTEM HRR216VKA NOTES 8-28...
  • Page 104: Flywheel/Ignition Coil

    9. FLYWHEEL/IGNITION COIL 1. DISASSEMBLY/REASSEMBLY ..3. IGNITION COIL ..... 2. FLYWHEEL REMOVAL/INSTALLATION . . 1.
  • Page 105 FLYWHEEL/IGNITION COIL HRR216VKA (K9 thru K11) 14 x 1.5 mm SPECIAL NUT REMOVAL AND INSTALLATION: P. 9-3 TORQUE: 52 N•m (38 ft-lb) FLYWHEEL INSTALLATION: P. 9-5 14 x 45 WASHER Use caution during disassembly and reassembly to prevent COOLING FAN damage.
  • Page 106 HRR216VKA FLYWHEEL/IGNITION COIL 2. FLYWHEEL REMOVAL/INSTALLATION REMOVAL 1. Remove the fan cover/fuel tank 7-1). K9 ~ K11 MODEL SHOWN  2. Disconnect the spark plug cap. FLYWHEEL HOLDER 3. Hold the flywheel brake lever against the handlebar and 07APB-Z28A100 secure it there with a strap or equivalent material. This allows the flywheel and crankshaft to turn.
  • Page 107 FLYWHEEL/IGNITION COIL HRR216VKA 6. Position a commercially available 6-inch flywheel puller K5 thru K8 VERSION on the flywheel with one of the puller jaws under the FLYWHEEL PULLER, OTC-1035 magnets (at the PULLER mark). (commercially available) Set a shop towel or equivalent cloth between the flywheel and the puller.
  • Page 108 HRR216VKA FLYWHEEL/IGNITION COIL STOP SWITCH WIRE ROUTING (K9 thru K11 VERSIONS) Be sure the stop switch wire is routed between the engine stop switch and the ignition primary coil as shown before installing the flywheel. 1. Route the stop wire under the cord clamper.
  • Page 109 FLYWHEEL/IGNITION COIL HRR216VKA 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. K5 ~ K8 Models Primary coil resistance 1.0 ~ 1.4 Ω...
  • Page 110 10. CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 1. CAM PULLEY/ROCKER ARM..10-1 4. VALVES ......10-9 2.
  • Page 111: Cam Pulley/Crankshaft/Piston/ Cylinder Block

    CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA CAM PULLEY DECOMPRESSOR INSPECTION 1. Rotate the flywheel until the cam pulley decompressor weight slot faces out. 2. Carefully inspect the weight position and confirm that it is fully retracted. If it is not fully retracted, replace the cam pulley 10-1).
  • Page 112 HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK ROCKER ARM SHAFT INSTALLATION Install the rocker arm shaft from the opposite side of the cam ROCKER ARM SHAFT pulley as shown. CAM PULLEY CYLINDER HEAD COVER INSTALLATION 1. Clean the mating surface of the cylinder block using a CYLINDER HEAD COVER VIEWED FROM BACK SIDE de-greasing cleaning agent and a clean shop towel.
  • Page 113 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA 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 INSTALLATION: Be careful not to damage the lip of the oil seal when installing the oil pan with the...
  • Page 114 HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK OIL PAN REMOVAL RECESS 1. Set piston at TDC of compression stroke. 2. Remove the 6 x 25 mm flange bolts 3. Insert a screwdriver or equivalent tool into the recess as shown, and remove the oil pan from the cylinder block. Be careful not to damage the sealing surfaces.
  • Page 115 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA 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. Align the mark on the cylinder block with the mark on the crankshaft.
  • Page 116 HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 3. PISTON DISASSEMBLY/REASSEMBLY TOP RING PISTON RINGS REASSEMBLY: MAKER MARK INSPECTION: P. 10-16 Chrome plated. Do not REASSEMBLY: interchange with SECOND RING. Install with the maker mark facing upward as shown. Do not interchange the top ring and the second ring.
  • Page 117 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA 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 118 HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ 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 INSPECTION: P. 10-20 valve stem slips through the hole at the side of the retainer.
  • Page 119 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA COMBUSTION CHAMBER CLEANING 1. Prepare a cylinder of thick paper or equivalent material, with a diameter large enough to fit against the inner wall of the cylinder, and insert it into the cylinder for protection. 2.
  • Page 120 HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK Valve seat reconditioning tools (commercially available) SOLID PILOT BAR, 5.50 mm (NWY PM 100055SH) SOLID PILOT BAR, 5.51 mm (NWY PM 100552S) VALVE SEAT CUTTER #115, 31° (NWY CU 115 VALVE SEAT CUTTER #122, 45° (NWY CU 122) VALVE SEAT CUTTER #111, 60°...
  • Page 121 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA 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 122 HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ 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. Be sure to install the governor weight before installing the crankshaft. 6 mm THRUST WASHER GOVERNOR SLIDER GOVERNOR HOLDER SHAFT...
  • Page 123 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA 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 124 HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK ROCKER ARM INSPECTION 1. To check the rocker arms for excessive free-play, follow the steps in “Exhaust Rocker Arm Pivot Free-Play Inspection” page 2-23. Repeat the steps for the intake valve. 2. Measure the Rocker Arm Shaft O.D. Standard Service limit 5.990 mm (0.2358 in)
  • Page 125 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA PISTON RING WIDTH INSPECTION Standard Service limit Top ring 0.93 ~ 0.95 mm 0.91 mm (0.036 ~ 0.037 in) (0.035 in) Second ring 0.97 ~ 0.99 mm 0.95 mm 0.038 ~ 0.039 in) (0.037 in) PISTON RING SIDE CLEARANCE INSPECTION Standard Service limit...
  • Page 126 HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK PISTON PIN BORE I.D. INSPECTION Standard Service limit 13.002 mm (0.5119 in) 13.048 mm (0.5137 in) 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)
  • Page 127 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA TIMING GEAR INSPECTION (K9~K11) TIMING GEAR SLOT BOSS The plastic timing gear is separate from the crankshaft in the K9, K10, and K11 versions. Inspect the timing gear for excess wear, damage, or cracks and replace if necessary.
  • Page 128 HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 3. Remove the connecting rod cap and measure the ® Plastigage with the scale on the Plastigage package to PLASTIGAGE determine the oil clearance. SCALE Standard oil clearance Service limit 0.040 ~ 0.063 mm 0.12 mm (0.0016 ~ 0.0025 in) (0.005 in) 4.
  • Page 129 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA VALVE SPRING FREE LENGTH INSPECTION Measure the free length of the valve springs. Standard Service limit 30.5 mm (1.20 in) 29.0 mm (1.14 in) Replace the springs if they are shorter than the service limit. VALVE FACE/STEM O.D.
  • Page 130: Handle Pipe/Cables/Smart Drive

    11. HANDLE PIPE/CABLES/SMART DRIVE 1. HANDLE PIPE REPLACEMENT ..11-1 4. HANDLE LOCKING KNOB ...11-10 2. HANDLE STAY/DISCHARGE GUARD . . .11-3 5. SMART DRIVE CABLE ....11-11 3.
  • Page 131 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA ROPE GUIDE 6 mm LOCKING NUT HEIGHT ADJUSTING HANDLE STAY (2) (K5~K9 style shown) SPRING (2) REPLACEMENT: P. 11-3 NYLON WASHER (2) SPECIAL BOLT (2) 8 mm PIN (2) 2 x 12 mm ROLL PIN (2) HEIGHT HANDLE LOCKING KNOB (2) ADJUSTING...
  • Page 132 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 2. HANDLE STAY/DISCHARGE GUARD REMOVAL/INSTALLATION GUARD RETURN K5 ~ K9 Models SPRING (2) 1. Pry the push nut off the discharge guard shaft. DISCHARGE GUARD 2. Remove the discharge guard shaft, the left and right PUSH NUT guard return springs, and the discharge guard.
  • Page 133 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 6. Remove the rear scroll 4-7). 7. Move the rear adjusting lever all the way forward. 8. Remove the three 8 mm flange nuts and the left handle stay. REAR ADJUSTING LEVER 8 mm LEFT FLANGE HANDLE NUT (3) STAY...
  • Page 134 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE K10/K11 Models GUARD RETURN This procedure is explains the removal and installation for SPRING (2) both left and right handle stays. If only replacing one DISCHARGE GUARD handle stay, follow the instructions for only that side. 1.
  • Page 135 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 7. Remove the wheel bolt, wheel, wheel washer, and flat washer on each side. FLAT WASHER WHEEL BOLT WHEEL WASHER 8. Remove the 13 mm circlip, pinion gear collar, 12 tooth RATCHET KEY pinion gear, ratchet key, and ratchet return spring from each side.
  • Page 136 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 10. Remove the remaining circlips, thrust collars, and 13 mm washers from each side. THRUST COLLAR 13 mm CIRCLIP 13 mm WASHER 11. Remove the 25 mm circlip from each side, and slide ADJUSTER them and the 25 mm washers inward towards the ASSEMBLY transmission.
  • Page 137 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 14. Remove the handle stay(s) by loosening the four HANDLE STAY 8 mm flange nuts. If removing the left-hand side handle stay, do not 8 mm FLANGE remove the forward-most nut that attaches the Smart BOLT (4) Drive cable bracket onto the mower deck.
  • Page 138 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 3. HANDLE GRIP REMOVAL/INSTALLATION 1. Remove the following, depending on the grip that needs replacement: HANDLE 45 ~ 50 mm SMART DRIVE GRIP (2) • Smart Drive cable 11-11) (1.75 ~ 2.0 in) CONTROL • Flywheel brake cable 11-1) •...
  • Page 139 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 4. HANDLE LOCKING KNOB REMOVAL 1/16” DRIFT PUNCH 1. Drive the 2 x 12 mm roll pin out with a 1/16” drift punch. 2. Separate the parts as shown. HANDLE LOCKING KNOB 2 x 12 mm ROLL PIN INSTALLATION LOWER...
  • Page 140 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 5. SMART DRIVE CABLE K5, K6 LOCK NUT REMOVAL 1. Drain the fuel tank. LOOSEN 2. Drain the engine oil. 3. Fully loosen the Smart Drive cable adjuster. 4. Cut the cable tie securing the flywheel brake control TIGHTEN cable to the Smart Drive cable.
  • Page 141 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 10. Put a protective pad around the upper handle pipe. Tip the mower up and secure the upper handle pipe in a CABLE bench vise. LOCKS 11. Remove the belt cover and drive belt 4-2). CABLE 12.
  • Page 142 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 7. Install a screwdriver between the mower deck and the transmission control arm. SCREWDRIVER 8. Remove the mower from the vise and set in its normal operating position. TRANSMISSION CONTROL ARM 9. Connect the upper end of the Smart Drive cable to the lower grip bracket.
  • Page 143 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 12. Grease the inside pin grooves of the upper and lower GRIP BRACKET (2) UPPER BRACKET bracket covers. COVER 5 x 37 mm 13. Snap the upper and lower bracket covers together with ROLLER PIN the roller pin located in the pin groove. Make sure the adjuster slots are located toward the rear of the mower.
  • Page 144 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE LOCK NUT REMOVAL LOOSEN 1. Drain the fuel tank. 2. Drain the engine oil. 3. Fully loosen the Smart Drive cable adjuster. TIGHTEN 4. Cut the cable tie securing the flywheel brake control cable to the Smart Drive cable. ADJUSTER 5.
  • Page 145 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 10. Put a protective pad around the upper handle pipe. Tip CABLE the mower up and secure the upper handle pipe in a HOLDER bench vise. 11. Remove the belt cover and drive belt 4-4). 12. Rotate the transmission 180° as shown. 13.
  • Page 146 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 7. Install a screwdriver between the mower deck and the transmission control arm. SCREWDRIVER 8. Remove the mower from the vise and set in its normal operating position. TRANSMISSION CONTROL ARM 9. Connect the upper end of the Smart Drive cable to the lower grip bracket.
  • Page 147 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 12. Grease the inside pin grooves of the upper and lower GRIP BRACKET (2) UPPER BRACKET bracket covers. COVER 5 x 37 mm ROLLER PIN 13. Snap the upper and lower bracket covers together with the roller pin located in the pin groove. Make sure the adjuster slots are located toward the rear of the mower.
  • Page 148 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 15. Place the upper clutch grip over the adjuster assembly and secure to the lower clutch grip with the four 4 mm self-tapping screws. UPPER CLUTCH GRIP 16. Rotate the Smart Drive control and confirm that the lower end of the Smart Drive cable moves the transmission control arm.
  • Page 149 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 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. UPPER GRIP BRACKET SPRING 7.
  • Page 150 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 2. Connect the upper end of the Smart Drive cable to the lower grip bracket. SMART DRIVE LOWER CABLE GRIP BRACKET 3. Fit the upper and lower grip brackets together around 4 mm SELF-TAPPING LOWER GRIP the handle pipe slot and secure with the four 4 mm SCREW (4) BRACKET...
  • Page 151 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 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 152 HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE 9. Route the Smart Drive cable down through the hole in SMART DRIVE CONTROL ARM the cutter housing. CABLE END SNAP 10. Attach the Smart Drive cable end on the control arm. FITTING SMART 11. Push the transmission as shown, align the Smart Drive DRIVE cable wire with the cable holder slot, and install the CABLE...
  • Page 153 HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA 4. Separate the upper and lower bracket covers. UPPER BRACKET COVER 5 x 37 mm ROLLER PIN Thoroughly clean the inside of the bracket Verify the pin and covers and inner bracket. cable move smoothly. 5. Slide the roller pin back and forth to confirm the pin and cable move smoothly.
  • Page 154: Clip Director/Mower Deck/Wheels

    12. CLIP DIRECTOR/MOWER DECK/WHEELS 1. CLIP DIRECTOR (K9~K11 ONLY) ..12-1 3. WHEELS ......12-5 2.
  • Page 155 CLIP DIRECTOR/MOWER DECK/WHEELS HRR216VKA 2. MOWER DECK SERVICE BULLETIN #67 => K5 thru K7 SCROLL PLATE MULCHING PLUG GUIDE PLATE SPRING (2) HINGE PLATE (2) GROMMETS REAR DOOR PUSH NUT SHIELD SHAFT DOOR SHAFT 6 mm NYLON LOCK REAR SHIELD COVER PUSH NUT 8 mm FLAT...
  • Page 156 HRR216VKA CLIP DIRECTOR/MOWER DECK/WHEELS K8 VERSION Reference Reference Description Quantity Description Quantity Belt cover Left guard return spring Cutter housing Flange bolt (5/16-24X1") Rear shield Push nut (7.94 mm) Front scroll Nylon locknut (8 mm) Rear scroll Plain washer (5/16) Rear shield shaft Flange nut (8 mm) Scroll plate...
  • Page 157 CLIP DIRECTOR/MOWER DECK/WHEELS HRR216VKA K9~K11 VERSIONS Reference Reference Description Quantity Description Quantity Special nut (6 x 7) Scroll ramp Cutter housing Left guard return spring Rear shield Grass bag plate Front scroll Scroll bolt Rear scroll Special bolt (6 x 12.5) Rear shield shaft (405 mm) Grass bag plate bolt Roto-Stop cover...
  • Page 158 HRR216VKA CLIP DIRECTOR/MOWER DECK/WHEELS 3. WHEELS FRONT WHEEL Right Side Shown ADJUSTER BOLT  GRIP ADJUSTER PLATE ADJUSTER ARM  WHEEL BOLT 5/16 in WASHER WHEEL WASHER REASSEMBLY: Install the washer as shown. COLLAR ADJUSTER PANEL WHEEL SIDE 8mm FLANGE NUT 12-5...
  • Page 159 CLIP DIRECTOR/MOWER DECK/WHEELS HRR216VKA REAR WHEEL For additional information on how to remove or install the rear wheel assembly, refer to the appropriate section in Chapter 13 for your model. K5 ~ K9 Models Right Side Shown WHEEL WASHER REASSEMBLY: Install the washer as shown.
  • Page 160 HRR216VKA CLIP DIRECTOR/MOWER DECK/WHEELS K10/K11 Models Right Side Shown WHEEL WASHER REASSEMBLY: Install the washer as shown. BEARING (2) GRIP WHEEL SIDE ADJUSTER PANEL/ HANDLE ADJUSTER STAY PLATE  13 x 27 x 1 mm THRUST WASHER WHEEL BUSHING BOLT Apply extreme pressure NLGI #2 GC-LB grease...
  • Page 161 CLIP DIRECTOR/MOWER DECK/WHEELS HRR216VKA NOTES 12-8...
  • Page 162: Transmission

    13. TRANSMISSION 1. TRANSMISSION (K5 AND K6) ..13-1 3. TRANSMISSION (K8 ~ K11) ..13-13 2. TRANSMISSION (K7) ....13-7 1.
  • Page 163 TRANSMISSION HRR216VKA 10.Remove the 13 mm circlip, pinion gear collar, pinion gear, RATCHET KEY ratchet return spring, and ratchet key from each side. RATCHET RETURN SPRING 12-TOOTH PINION GEAR PINION GEAR 13 mm COLLAR CIRCLIP 11. Remove the wheel cover and pinion gear collar from WHEEL PINION each side.
  • Page 164 HRR216VKA TRANSMISSION 13.Remove the 22 mm circlip from each side, and slide them ADJUSTER and the washers inward towards the transmission. ASSEMBLY 14.Remove the adjuster assembly from each side, taking care not to damage the seals.  WASHER CIRCLIP 15.Slide the transmission/axle to the right side, and then rotate it until the left side can be removed from the mower 22 mm deck.
  • Page 165 TRANSMISSION HRR216VKA DISASSEMBLY/REASSEMBLY (K5 VERSION up to MZCG - 7819952) 10 mm FLANGE NUT DRIVEN PULLEY BELT TENSION SPRING BELT SPRING PLATE 6 mm FLANGE NUT 12.7 x 22.2 x 6.4 mm OIL SEAL (2) 10 x 24 mm WASHER 6 x 14 mm 12 x 28.5 x 6.35 mm OIL SEAL FLANGE...
  • Page 166 HRR216VKA TRANSMISSION (K5 VERSION MZCG - 7819953 ~ 7999999) (K6 VERSION MZCG - 8000001 ~ 8199999) (K7 VERSION MZCG - 8200001 ~ 8282198) POLYMER PULLEY INSTALLATION: Use a 5 mm (3/15 in) drift punch to align the hole in the pulley with the pinion shaft pin hole.
  • Page 167 • Thoroughly apply a coat of multipurpose extreme TO TRANSMISSION) pressure wheel bearing grease to the adjuster arms (inside the seals), axle surfaces, pinion gears, ratchet springs, and ratchet keys. Use Honda Marine extreme pressure NLGI #2 GC-LB grease or equivalent. PUNCH MARK IMPORTANT:...
  • Page 168 HRR216VKA TRANSMISSION 2. TRANSMISSION (K7) (K7 VERSION MZCG - 8282199 and SUBSEQUENT) REMOVAL 1. Drain the fuel tank and engine oil. CABLE HOLDER SLOT 2. Loosen the Smart Drive cable adjuster 3-10). SNAP FITTING 3. Cut the cable ties attaching the flywheel brake cable and the Smart Drive cable to the handle pipe.
  • Page 169 TRANSMISSION HRR216VKA 11. Remove the pinion gear collars and wheel covers from WHEEL PINION each side. COVER GEAR COLLAR 12.Remove the remaining thrust collars and circlips from each side. THRUST COLLAR 13 mm WASHER 13 mm CIRCLIP 13.Remove the 22 mm circlip from each side, and slide them ADJUSTER and the washers inward towards the transmission.
  • Page 170 HRR216VKA TRANSMISSION 15.Remove the two 8 mm flange nuts and the left side 22 mm adjuster panel. CIRCLIP (2) 22 mm WASHER (2) 16.Slide the transmission/axle to the right side, then rotate it until the left side can be removed from the mower deck.
  • Page 171 TRANSMISSION HRR216VKA DISASSEMBLY/REASSEMBLY (K7 VERSION MZCG - 8282199 and SUBSEQUENT) POLYMER PULLEY INSTALLATION: Use a 5 mm (3/15 in) drift punch to align the hole in the pulley with the pinion shaft pin hole. Rotate the pulley until the pin hole is parallel to the belt tension arm. 5 x 35 mm SPRING PIN Press the spring pin into the pulley so that the pin is centered in the pinion shaft.
  • Page 172 NUT(2) 4. Thoroughly clean the bushing contact areas on the axle using a Scotch-Brite™ pad. 5. Thoroughly apply a coat of Honda Marine extreme ADJUSTER ARM pressure NLGI #2 GC-LB grease or equivalent INSIDE the adjuster arms and on the axle surfaces.
  • Page 173 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. PINION GEAR (12 TOOTH) IMPORTANT: Only use an extreme pressure NLGI #2 GC-LB wheel bearing grease.
  • Page 174 HRR216VKA TRANSMISSION 16.Rotate the transmission out slightly to install the Smart CABLE HOLDER Drive cable. SLOT SNAP 17.Connect the Smart Drive cable end onto the transmission FITTING control arm, and install the snap fitting into the clutch cable holder. 18.Install the drive belt, belt tension spring, and belt cover 4-5).
  • Page 175 TRANSMISSION HRR216VKA 12.Remove the wheel bolt, wheel, wheel washer, and flat washer from each side. FLAT WASHER WHEEL BOLT WHEEL WASHER 13.Remove the 13 mm circlip, pinion gear collar, pinion gear, RATCHET KEY ratchet key, and ratchet return spring from each side. RATCHET RETURN SPRING 12-TOOTH PINION GEAR...
  • Page 176 HRR216VKA TRANSMISSION 15.Remove the remaining thrust collars, 13 mm washers, THRUST COLLAR and circlips from each side. 13 mm WASHER 13 mm CIRCLIP 16.Remove the 25 mm circlip from each side, and slide them ADJUSTER and the 26 x 44 mm washers inward toward the ASSEMBLY transmission.
  • Page 177 TRANSMISSION HRR216VKA DISASSEMBLY/REASSEMBLY (up to MZCG-9506881) 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: Align the pulley pins opposite each other so that they fit into the small holes of the other pulley half.
  • Page 178 HRR216VKA TRANSMISSION (MZCG-9506882 ~ 9999999 and MZCG-1000001 ~ 1999999) 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: Align the pulley pins opposite each other so that they fit into the small holes of the other pulley half.
  • Page 179 ADJUSTER 5. Thoroughly clean the bushing contact areas on the axle PLATE using a Scotch-Brite™ pad. 6. Thoroughly apply a coat of Honda Marine extreme 26 x 44 mm pressure NLGI #2 GC-LB grease or equivalent INSIDE  WASHER the adjuster arms and on the axle surfaces.
  • Page 180 TRANSMISSION 11. Install a pinion gear collar and wheel cover. WHEEL PINION COVER GEAR COLLAR 12.Apply Honda Marine extreme pressure NLGI #2 GC-LB   RATCHET RETURN SPRING RATCHET KEY grease or equivalent to the areas shown. 12-TOOTH PINION GEAR...
  • Page 181 TRANSMISSION HRR216VKA 17.Install the return spring. TRANSMISSION CONTROL ARM 18.Push down on the control arm, and install the Smart Drive cable end onto the transmission control arm. 19.Position the belt on the drive pulley and install the drive BELT TENSION pulley on the crankshaft.
  • Page 182: Index

    INDEX Removal ........5-1 Stop switch ......2-20,9-5 Air filter.
  • Page 183 Special tools ........2-5 Specifications Maintenance Dimensions, weight, capacities ....1-1 Schedule .

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