Honda HRR216PKA Manual
Hide thumbs Also See for HRR216PKA:

Advertisement

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.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the HRR216PKA and is the answer not in the manual?

Questions and answers

Summary of Contents for Honda HRR216PKA

  • 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 HRR216PKA K8 ~ 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 NUMBER REQUIREMENTS. CONFORMS TO ANSI B 71.1 SAFETY STANDARD HRR2169PKA MZCG –– XXXXXXX AMERICAN HONDA MOTOR CO., INC. American Honda Motor Co., Inc. ALPHARETTA, GA 30005-8847 Alpharetta, GA 30005-8847 The K10 and K11 version numbers are fully shown after “K” VERSION HRR216.
  • Page 4 VERSION SERIAL NUMBERS IDENTIFIERS/FEATURES/CHANGES Engine serial number prefix Frame: • changed from GJARA to GJATA MZCG-1660001 ~ 1999999 Otherwise identical to K10 model • Engine: GJATA – 1000001 ~ 9999999...
  • Page 5 HRR216PKA NOTES...
  • Page 6: Specifications

    1. SPECIFICATIONS 1. SPECIFICATIONS 3. WIRING DIAGRAM ..........1-3 2.
  • Page 7 SPECIFICATIONS HRR216PKA 2. DIMENSIONAL DRAWINGS K8-K9: 1,534 mm (60.4 in) K10/K11: 1,512 mm (59.5 in) 620 mm (24.4 in) Cutting height set to 28 mm (1-1/8 in).
  • Page 8 HRR216PKA SPECIFICATIONS 3. WIRING DIAGRAM Black ENGINE SWITCH CONTACT OPEN STOP CLOSE SPARK IGNITION ENGINE STOP SWITCH PLUG COIL (NORMALLY CLOSED)
  • Page 9 SPECIFICATIONS HRR216PKA NOTES...
  • Page 10: Service Information

    8. TROUBLESHOOTING TECHNIQUES. . . 2-10 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 The frame serial number is located at the center rear of the deck. FRAME SERIAL NUMBER MEETS CPSC BLADE SAFETY REQUIREMENTS. CONFORMS TO ANSI B 71.1 SAFETY STANDARD HRR2169PKA MZCG –– XXXXXXX AMERICAN HONDA MOTOR CO., INC. American Honda Motor Co., Inc. ALPHARETTA, GA 30005-8847 Alpharetta, GA 30005-8847 ENGINE SERIAL NUMBER...
  • Page 12 HRR216PKA SERVICE INFORMATION 4. SERVICE SPECIFICATIONS PART ITEM STANDARD SERVICE LIMIT Maximum governed speed 2,950 ~ 3,100 rpm -------------------------------- Idle speed (K8 only) 1,700 ± 150 rpm Engine -------------------------------- Cylinder compression 490 kPa (5.0 kg/cm , 71 psi) at 600 rpm...
  • Page 13 SERVICE INFORMATION HRR216PKA 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 14 HRR216PKA 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 Alcohol tester 07AAJ-E85A100 Check percent of ethanol in fuel...
  • 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 HRR216PKA SERVICE INFORMATION 7. TROUBLESHOOTING ENGINE SERVICE BULLETIN #98 => Hard Starting or Won’t Start Using the Recoil Starter SERVICE BULLETIN #106 => 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 HRR216PKA 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. perform poorly. Fresh fuel Check the air filter.
  • Page 18 HRR216PKA 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 • Check crankshaft runout.
  • Page 19 SERVICE INFORMATION HRR216PKA 8. 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. Crank the engine briskly several times with the recoil starter and measure compression.
  • Page 20 HRR216PKA 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 21 SERVICE INFORMATION HRR216PKA 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 22 HRR216PKA 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 step...
  • Page 23 SERVICE INFORMATION HRR216PKA 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 24 HRR216PKA 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 25 SERVICE INFORMATION HRR216PKA CHOKE CONTROL SYSTEM (ACS) SERVICE BULLETIN #98 => SERVICE BULLETIN #106 => Partially or With the engine cold, Remove the carburetor. Turn Inspect the choke control Normal totally open remove the paper and hold the choke arm in the...
  • Page 26 HRR216PKA SERVICE INFORMATION SERVICE BULLETIN #100 => CHOKE CONTROL INSPECTION (K8 ONLY) 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 27 SERVICE INFORMATION HRR216PKA 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 28: Maintenance

    3. MAINTENANCE 1. MAINTENANCE SCHEDULE ..9. SPARK PLUG INSPECTION ... 2. MAINTENANCE SPECIFICATIONS ..10. SPARK ARRESTER CLEANING (OPTIONAL 3.
  • Page 29 MAINTENANCE HRR216PKA 2. MAINTENANCE SPECIFICATIONS Item Specification page Engine oil Capacity: 0.50 L (17 oz) * Refill amount: 0.35 ~ 0.40 L (12.0 ~ 13.5 oz) Use SAE 10W - 30 for general use. Air cleaner Clean with compressed air, not exceeding 207 kPa (30 psi).
  • Page 30 HRR216PKA MAINTENANCE 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 11-2).
  • Page 31 MAINTENANCE HRR216PKA REMOVAL 1. Turn the fuel valve to the OFF position, K8 model shown disconnect the spark plug, and tilt the mower on its right side. UPPER BLADE 2. Remove the two blade bolts and special LOWER BLADE washers from the blade control assembly. Use...
  • Page 32 HRR216PKA 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 33 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 34 CLEANING Wash a dirty grass bag with a garden hose, and allow it to dry completely before use. A wet bag will clog quickly REPLACEMENT Replace a worn or damaged bag with a Honda GRASS BAG BAG FRAME Genuine replacement bag or its equivalent.
  • Page 35 MAINTENANCE HRR216PKA 9. SPARK PLUG INSPECTION SPARK PLUG Recommended spark plug NGK BPR5ES 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 36 HRR216PKA MAINTENANCE 11. 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 37 MAINTENANCE HRR216PKA FUEL TUBE INSPECTION 1. Check the fuel tubes for deterioration, cracks, or signs of leakage. Replace the fuel tubes if necessary. 2. To replace the fuel tubes, drain the fuel into a suitable container. 3. Replace the fuel tubes with the correct low permeation fuel tubes.
  • Page 38 HRR216PKA MAINTENANCE 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. 2. Remove the fan cover/fuel tank 7-10).
  • Page 39 MAINTENANCE HRR216PKA 6. 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 7.
  • Page 40 HRR216PKA MAINTENANCE 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 41 MAINTENANCE HRR216PKA IDLE SPEED ADJUSTMENT (K8 MODEL ONLY) THROTTLE STOP SCREW 1. With the engine running at normal operating temperature, push the governor arm toward the carburetor and hold it in this position. 2. Adjust the throttle stop screw to obtain the specified idle speed.
  • Page 42: Engine Removal/Installation

    4. ENGINE REMOVAL/INSTALLATION 1. REMOVAL ......2. INSTALLATION ..... 1.
  • Page 43 ENGINE REMOVAL/INSTALLATION HRR216PKA 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. Install the Woodruff key in the crankshaft and position the blade holder on the crankshaft. Be sure the Woodruff key remains in place when installing.
  • Page 44: Muffler

    5. 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. A hot muffler can burn you. Be sure that the engine is cold before muffler removal/installation.
  • Page 45 MUFFLER HRR216PKA NOTES...
  • Page 46: Recoil Starter

    6. RECOIL STARTER 1. REMOVAL/INSTALLATION ... . 2. STARTER ROPE REPLACEMENT ..SERVICE REMINDER #4 => 1. REMOVAL/INSTALLATION • If the starter rope is frayed or worn out, replace the starter rope 6-2).
  • Page 47 RECOIL STARTER HRR216PKA 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 48 HRR216PKA 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.
  • Page 49 RECOIL STARTER HRR216PKA NOTES...
  • Page 50: Fuel System

    7. FUEL SYSTEM 1. AIR CLEANER/CARBURETOR 3. FUEL VALVE/GOVERNOR ARM..REMOVAL/REINSTALLATION ..4. FAN COVER/FUEL TANK (K8) ..7-10 2.
  • Page 51 FUEL SYSTEM HRR216PKA 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 52 HRR216PKA FUEL SYSTEM 2. CARBURETOR DISASSEMBLY/REASSEMBLY Clean the outside of the carburetor before disassembly. SERVICE BULLETIN #98 =>  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 HRR216PKA CLEANING Use Honda Carburetor Cleaner (P/N 08732-CC000) with its plastic spray nozzle to clean the carburetor ports. Some commercially available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as O-rings, floats, choke valves, and float valve seats. Check the container for instructions. If you are in doubt, do not use these products to clean Honda carburetors.
  • Page 54 HRR216PKA FUEL SYSTEM 6. Clean the main jet and nozzle bore thoroughly using MAIN JET AND carburetor cleaner and compressed air. NOZZLE BORE Inspect the inside of the bore for contamination. 7. Clean the pilot jet thoroughly by using the appropriate size jet cleaning tool, carburetor cleaner, and compressed air.
  • Page 55 FUEL SYSTEM HRR216PKA 9. Clean the float chamber vent hole with carburetor cleaner and compressed air. FLOAT CHAMBER VENT HOLE 10. Reinstall the 5 x 6 mm screw covering the pilot jet. THROTTLE SIDE 11. Check the slow speed air channels for obstructions.
  • Page 56 HRR216PKA FUEL SYSTEM 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 57 FUEL SYSTEM HRR216PKA Choke Assembly Installation 1. Install the choke assembly when the cylinder head temperature is less than 40 °C (104 °F). K9 MODEL HAS 2. Apply a small amount of Hondabond HT to the bottom and A ROUND lower third of the new thermowax.
  • Page 58 HRR216PKA FUEL SYSTEM 3. 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 59 FUEL SYSTEM HRR216PKA 4. FAN COVER/FUEL TANK (K8) 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. 4. Remove the fuel tank cap from the fuel tank. Unscrew the tether from the fuel filler threads.
  • Page 60 HRR216PKA FUEL SYSTEM 5. FAN COVER/FUEL TANK (K9 ~ K11) 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. 4. Remove the fuel tank cap from the fuel tank. Unscrew the tether from the fuel filler threads.
  • Page 61 FUEL SYSTEM HRR216PKA 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 FUEL CLIP Use pliers to open the fuel clip, and slide the fuel clip up the tube.
  • Page 62 HRR216PKA 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 63 FUEL SYSTEM HRR216PKA NOTES 7-14...
  • Page 64: Flywheel/Ignition Coil

    8. FLYWHEEL/IGNITION COIL 1. DISASSEMBLY/REASSEMBLY (K8) ..3. FLYWHEEL REMOVAL/ 2. DISASSEMBLY/REASSEMBLY (K9 ~ K11)..INSTALLATION ....4.
  • Page 65 FLYWHEEL/IGNITION COIL HRR216PKA 2. DISASSEMBLY/REASSEMBLY (K9 ~ K11) 1. Remove the recoil starter 6-1) and fan cover 7-10). 2. Remove the fan cover stud, 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 66 HRR216PKA FLYWHEEL/IGNITION COIL 3. FLYWHEEL REMOVAL/INSTALLATION REMOVAL 1. Remove the fan cover/fuel tank 7-10). K9 MODEL SHOWN  2. Hold the flywheel brake lever against the handlebar and secure it there with a strap or equivalent material. This FLYWHEEL HOLDER...
  • Page 67 FLYWHEEL/IGNITION COIL HRR216PKA 5. Position a commercially available 6-inch flywheel puller K8 MODEL 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 68 HRR216PKA FLYWHEEL/IGNITION COIL 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 INSTALLATION K9 MODEL SHOWN 1. Make sure the flywheel taper is free of dirt, oil, grease, and other foreign material before installation.
  • Page 69 FLYWHEEL/IGNITION COIL HRR216PKA 4. 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 70 9. CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 1. CAM PULLEY/ROCKER ARM..4. VALVES ......2.
  • Page 71: Cam Pulley/Crankshaft/Piston/ Cylinder Block

    CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216PKA 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 72 HRR216PKA CAM PULLEY/CRANKSHAFT/PISTON/ 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 73 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216PKA 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 74 HRR216PKA 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.
  • Page 75 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216PKA 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 76 HRR216PKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 3. PISTON DISASSEMBLY/REASSEMBLY TOP RING PISTON RINGS REASSEMBLY: INSPECTION: P. 9-16 MAKER MARK 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 77 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216PKA 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 78 HRR216PKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK 4. VALVES DISASSEMBLY/REASSEMBLY (K9 ~ K11 MODELS SHOWN) VALVE SPRING RETAINER (2)  DISASSEMBLY: Push down and slide the VALVE SPRING (2) retainer to the side, so the INSPECTION: P. 9-20 valve stem slips through the hole at the side of the retainer.
  • Page 79 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216PKA 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 80 HRR216PKA 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 81 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216PKA 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 82 HRR216PKA 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.
  • Page 83 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216PKA 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 84 HRR216PKA 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 2-12. Repeat the steps for the intake valve. 2. Measure the Rocker Arm Shaft O.D.
  • Page 85 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216PKA 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)
  • Page 86 HRR216PKA 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...
  • Page 87 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216PKA TIMING GEAR INSPECTION (K9 ~ K11) TIMING GEAR SLOT The plastic timing gear is separate from the crankshaft for the K9 ~ K11 models. Inspect the timing gear for excess wear, damage, or cracks and replace if necessary.
  • Page 88 HRR216PKA 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)
  • Page 89 CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216PKA 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.
  • Page 90: Handle Pipe

    10. HANDLE PIPE 1. HANDLE PIPE REPLACEMENT ..10-2 3. HANDLE LOCKING KNOB ... 10-8 2. HANDLE STAY REMOVAL/ INSTALLATION ....10-3 10-1...
  • Page 91 HANDLE PIPE HRR216PKA 1. HANDLE PIPE REPLACEMENT 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 92 HRR216PKA HANDLE PIPE 2. HANDLE STAY REMOVAL/ GUARD RETURN INSTALLATION SPRING (2) DISCHARGE GUARD K8 ~ K9 MODELS 1. Pry the push nut off the discharge guard shaft. PUSH NUT 2. Remove the discharge guard shaft, the left and right guard return springs, and the discharge guard.
  • Page 93 HANDLE PIPE HRR216PKA 6. Remove the rear scroll 11-1). 7. Move the rear adjusting lever all the way forward. 8. Remove the three 8 mm flange nuts and the left handle stay. REAR 9. Remove the three 8 mm flange nuts and the right ADJUSTING handle stay.
  • Page 94 HRR216PKA HANDLE PIPE K10 ~ K11 MODELS GUARD RETURN SPRING (2) 1. Remove the push nut from the discharge guard shaft DISCHARGE GUARD by prying it off with a thin flat tipped screwdriver. PUSH NUT 2. Remove the discharge guard shaft, left and right guard return springs, and the discharge guard.
  • Page 95 HANDLE PIPE HRR216PKA 7. Remove the rear wheel bolt, wheel, wheel washer, SPLIT PIN and flat washer on each side. FLAT WASHER 8. Remove the split pin from each side of the axle shaft. WHEEL BOLT WHEEL WASHER 9. Remove the 25 mm circlip from each side, and slide...
  • Page 96 HRR216PKA HANDLE PIPE 12. Installation is the reverse of removal. Refer to step 4 through step 22 page 13-18 for reassembly. LEFT SPRING RIGHT SPRING NOTE: The left and right discharge guard return springs are different. Position the springs so the hooks lead to the underside of the spring.
  • Page 97 HANDLE PIPE HRR216PKA 3. 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...
  • Page 98: Clip Director/Mower Deck/Wheels

    11. CLIP DIRECTOR/MOWER DECK/WHEELS 1. CLIP DIRECTOR (K9 ~ K11 ONLY)..11-1 3. WHEELS ......11-4 2.
  • Page 99 CLIP DIRECTOR/MOWER DECK/WHEELS HRR216PKA 2. MOWER DECK K8 MODEL Reference Reference Description Quantity Description Quantity Belt cover Right guard return spring Cutter housing Left guard return spring Rear shield Flange bolt (5/16-24X1") Front scroll Push nut (7.94 mm) Rear scroll...
  • Page 100 HRR216PKA CLIP DIRECTOR/MOWER DECK/WHEELS K9 ~ K11 MODELS Reference Reference Description Quantity Description Quantity Shutter lever Plain washer (6 mm) Tapping screw (5 x 16 mm) Nylock nut (6 mm) Shutter spring Flange bolt (6 x 10) Lock lever Special nut (6 x 7)
  • Page 101 CLIP DIRECTOR/MOWER DECK/WHEELS HRR216PKA 3. WHEELS REAR WHEEL K8 - K9 MODELS Right Side Shown             WHEEL WASHER  REASSEMBLY:   Install the washer as shown. WHEEL SIDE...
  • Page 102 HRR216PKA CLIP DIRECTOR/MOWER DECK/WHEELS K10 ~ K11 MODELS Right Side Shown             WHEEL WASHER  REASSEMBLY:   Install the washer as shown. WHEEL SIDE Reference # Description Quantity ...
  • Page 103 CLIP DIRECTOR/MOWER DECK/WHEELS HRR216PKA FRONT WHEEL Right Side Shown           WHEEL WASHER REASSEMBLY: Install the washer as shown. WHEEL SIDE Reference # Description Quantity  Front wheel shaft bolt  Wheel washer ...
  • Page 104 INDEX Flywheel brake inspection ..... . . 3-10 Fuel cap ........7-13 Air filter.
  • Page 105 INDEX HRR216PKA Cylinder clearance ......9-15 Disassembly/reassembly ..... . . 9-7 Wheels Piston ring inspection .

Table of Contents

Save PDF