Honda HRG416C1 Manual
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How to use this manual
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 their 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 man-
ual 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 (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, 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 precau-
tions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual 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 equipment hoisted 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 are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline.
• 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 all fuel-related parts.
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Summary of Contents for Honda HRG416C1

  • Page 1 Honda must determine the risks to their 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 As you read this manual, you will find information that is MUFFLER preceded by a symbol. The purpose of this message is to help prevent damage to this Honda product, other property, or the environment. HANDLEBAR/LEVER SAFETY MESSAGES FRONT WHEEL/REAR WHEEL/TRANSMISSION Your safety and the safety of others are very important.
  • Page 3 How to use this manual...
  • Page 4 OUTLINE OF CHANGES How to use this manual ITEM HRG416C/466C HRG416C1/466C1 GCV160H: GCV145H: ENGINE WELDED COLLAR CUTTER HOUSING/ CUTTER HOUSING CUTTER HOUSING BOLT/ COLLAR/ COLLAR (TORX) (HEXAGON) BOLT (8 x 30.5 mm) BOLT (8 x 30.5 mm)
  • Page 5 MEMO...
  • Page 6 dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ················· 1-2 SPECIFICATIONS·································· 1-2 TYPE IDENTIFICATION ·························· 1-2 DIMENSIONAL DRAWINGS ···················· 1-4...
  • Page 7 The engine serial number [1] is stamped on the left side of the crankcase. The frame serial number [2] is located on the rear of the cutter housing. Refer to these number when ordering parts and when making technical inquiries. TYPE IDENTIFICATION Model HRG416C1 HRG466C1 Type PKEH SKEH...
  • Page 8 Governor Centrifugal weight system Fuel tank capacity 0.91 Liters (0.240 US gal, 0.200 Imp gal) Fuel used Unleaded gasoline E10 Breather system Reed valve type FRAME Model HRG416C1 HRG466C1 Type PKEH SKEH PKEH SKEH SKEP Tire size Front 178 mm (7.0 in) Rear 212 mm (8.3 in)
  • Page 9 SPECIFICATIONS DIMENSIONAL DRAWINGS HRG416C1 395 mm (15.6 in) 369 mm 453 mm (14.5 in) (17.8 in) *2 DRIVE CLUTCH LEVER FLYWHEEL BRAKE LEVER (With drive clutch system) 980 mm (38.6 in) *2 556 mm (21.9 in) Without drive clutch system: 1,415 mm (55.7 in) *1, *2 With drive clutch system: 1,440 mm (56.7 in) *1, *2...
  • Page 10 SPECIFICATIONS HRG466C1 439 mm (17.3 in) 419 mm 497 mm (16.5 in) (19.6 in) *2 DRIVE CLUTCH LEVER FLYWHEEL BRAKE LEVER (With drive clutch system) 980 mm (38.6 in) *2 588 mm (23.1 in) Without drive clutch system: 1,445 mm (56.9 in) *1, *2 With drive clutch system: 1,470 mm (57.9 in) *1, *2 *1: Lever(s) off *2: Cut height set to 20 mm (0.8 in)
  • Page 11 MEMO...
  • Page 12 dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ················· 2-2 TOOLS ················································ 2-4 TORQUE VALUES ································· 2-3 CABLE/HARNESS ROUTING ·················· 2-5 LUBRICATION & SEAL POINT ················ 2-3...
  • Page 13 SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION Unit: mm (in) Part Item Standard Service limit Engine Maximum speed HRG416C1 2,900 (rpm) – (with blade) - 100 HRG466C1 2,800 (rpm) – - 100 Cylinder compression 0.45 MPa (4.6 kgf/cm , 65 psi) –...
  • Page 14 SERVICE INFORMATION TORQUE VALUES ENGINE TORQUE VALUES Torque values Thread Dia. Item Remarks x Pitch N·m kgf·m lbf·ft Crankcase cover bolt M8 x 1.25 Cylinder bolt M8 x 1.25 Spark plug M14 x 1.25 Connecting rod bolt M7 x 1.0 Apply engine oil to the threads and seating surface.
  • Page 15 SERVICE INFORMATION Material Location Remarks ThreeBond ® 1216E, Cylinder head cover mating surface See page 10-5 ® LOCTITE 5900, Cylinder mating surface See page 10-5 or equivalent Crankcase cover mating surface See page 10-2 ® ThreeBond 1216E, Thermo-wax square end See page 5-6 ®...
  • Page 16 SERVICE INFORMATION CABLE/HARNESS ROUTING FRAME RECOIL STARTER ROPE FLYWHEEL BRAKE CABLE WIRE BAND DRIVE CLUTCH CABLE (With drive clutch system) DRIVE CLUTCH CABLE (With drive clutch system) 2.0 mm (0.08 in) FLYWHEEL BRAKE CABLE WIRE BAND HRG416: (With drive clutch system) 200 mm (7.9 in) 250 mm (9.8 in) HRG446:...
  • Page 17 SERVICE INFORMATION ENGINE BREATHER TUBE Insert the breather tube to the crankcase cover until the paint mark on the tube aligns with the edge of the brake assembly. Paint mark FUEL TUBE FUEL TUBE (160 mm) (110 mm) BREATHER TUBE 90 °...
  • Page 18 SERVICE INFORMATION IGNITION COI CONNECTOR HIGH-TENSION CORD HARNESS BAND CLIP STOP SWITCH CORD HIGH-TENSION CORD HARNESS BAND CLIP FAN COVER STOP SWITCH CORD BREATHER TUBE...
  • Page 19 SERVICE INFORMATION ENGINE STOP SWITCH HARNESS BAND CLIP STOP SWITCH CONNECTOR STOP SWITCH CORD HARNESS BAND CLIP...
  • Page 20: Table Of Contents

    dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE ··················· 3-2 FLYWHEEL BRAKE CABLE CHECK/ ADJUSTMENT ······································ 3-5 ENGINE OIL LEVEL CHECK/CHANGE······ 3-3 VALVE CLEARANCE CHECK/ADJUSTMENT··························· 3-5 SPARK PLUG CHECK/ADJUSTMENT ······ 3-4 RECOIL AIR INLET CLEANING ··············· 3-6 SPARK PLUG REPLACEMENT ··············· 3-4 COMBUSTION CHAMBER CLEANING······ 3-7 FLYWHEEL BRAKE SHOE CHECK ··········...
  • Page 21: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE REGULAR SERVICE PERIOD (5) Perform at every indicated month or operating hour interval, whichever comes first. Refer Item First Every Every Every Every page Each month 3months 6months 2 years year or 100 hrs. 5 hrs. 25 hrs.
  • Page 22: Engine Oil Level Check/Change

    MAINTENANCE ENGINE OIL LEVEL CHECK/CHANGE CHECK Check the oil level with the engine stopped and the lawn mower on a level surface. Remove the oil filler cap/dipstick [1] and wipe the dipstick to clean. Insert the filler cap/dipstick into the oil filler neck, without screwing it in.
  • Page 23: Spark Plug Check/Adjustment

    MAINTENANCE SPARK PLUG CHECK/ADJUSTMENT Remove the spark plug (page 3-4). Clean the spark plug [1] electrodes with a wire brush [2] or special plug cleaner. Check the following and replace if necessary. – Insulator [3] and sealing washer [4] for damage –...
  • Page 24: Flywheel Brake Shoe Check

    MAINTENANCE FLYWHEEL BRAKE SHOE CHECK Remove the fan cover (page 5-3). Measure the thickness of the brake shoe lining [1]. 3.0 mm (0.12 in) SERVICE LIMIT: 3.0 mm (0.12 in) If the brake shoe lining thickness is less than the service limit, replace the brake assembly (page 8-3).
  • Page 25: Recoil Air Inlet Cleaning

    MAINTENANCE Insert a feeler gauge [1] between the tappet adjusting screw [2] and valve stem [3] to measure the valve clearance. VALVE CLEARANCE: IN/EX: 0.10 ± 0.02 mm (0.004 ± 0.001 in) If adjustment is necessary, proceed as follows. ADJUSTMENT Hold the tappet adjusting screw using the special tool and loosen the lock nut [4].
  • Page 26: Combustion Chamber Cleaning

    MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the cylinder (page 10-4). Prepare a cylinder of thick paper [1] or equivalent material with a large enough diameter to fit against the inner wall of the cylinder, and insert it into the cylinder for protection. Attach the cleaning brush to an electric drill [2] and clean the combustion chamber.
  • Page 27 MEMO...
  • Page 28 dummytext 4. TROUBLESHOOTING ENGINE TROUBLESHOOTING ················ 4-2...
  • Page 29 TROUBLESHOOTING ENGINE TROUBLESHOOTING TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START • Check the engine oil level before troubleshooting. • (*) Refer to page of base shop manual 62VH300. Operate the recoil starter and check whether the Check the recoil starter (page 7-2). Cannot be cranked engine cranks.
  • Page 30 TROUBLESHOOTING ENGINE SPEED DOES NOT INCREASE OR STABILIZE Clogged Check the air cleaner element (page 3-4*). Clean the air cleaner element (page 3-4*). Normal Abnormal Check the valve clearance (page 3-5). Adjust the valve clearance (page 3-6). Normal Abnormal Check the spark plug (page 3-4). Clean the electrodes and adjust the plug gap.
  • Page 31 MEMO...
  • Page 32 dummytext 5. FUEL SYSTEM TOP COVER CARBURETOR REMOVAL/INSTALLATION ····················· 5-2 DISASSEMBLY/ASSEMBLY···················· 5-7 FAN COVER CARBURETOR BODY CLEANING ··········· 5-8 REMOVAL/INSTALLATION ····················· 5-3 CARBURETOR INSPECTION ·················· 5-8 FUEL TANK REMOVAL/INSTALLATION ··· 5-4 THERMO-WAX INSPECTION··················· 5-9 AIR CLEANER REMOVAL/INSTALLATION ····················· 5-5 PILOT SCREW REPLACEMENT ·············· 5-9 CARBURETOR CHOKE REPLACEMENT ······················...
  • Page 33: Top Cover

    dummyhead dummyhead FUEL SYSTEM TOP COVER REMOVAL/INSTALLATION FUEL SYSTEM Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flames away. • Handle fuel only outdoors. • Wipe up spills immediately. Attach the fuel tank cap just after removing the top cover.
  • Page 34: Fan Cover

    dummyhead dummyhead FUEL SYSTEM FAN COVER REMOVAL/INSTALLATION Remove the top cover (page 5-2). FAN COVER CT BOLT (6 x 23 mm) (5)
  • Page 35: Removal/Installation

    dummyhead dummyhead FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flames away. • Handle fuel only outdoors. • Wipe up spills immediately. Before removal, drain the gasoline into an approved container.
  • Page 36: Air Cleaner Removal/Installation

    dummyhead dummyhead FUEL SYSTEM AIR CLEANER REMOVAL/INSTALLATION BREATHER TUBE INSTALLATION: Connect one end to the crankcase cover hole and then the other end to the air cleaner case (page 2-5). If it is hard to install, apply engine oil to the tube end.
  • Page 37 dummyhead dummyhead FUEL SYSTEM CARBURETOR REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flames away. • Handle fuel only outdoors. • Wipe up spills immediately. Turn the fuel valve to the OFF position. Remove the air cleaner case (page 5-5).
  • Page 38: Carburetor Disassembly/Assembly

    dummyhead dummyhead FUEL SYSTEM CARBURETOR DISASSEMBLY/ASSEMBLY Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flames away. • Handle fuel only outdoors. • Wipe up spills immediately. To prevent serious eye injury, always wear safety goggles or other eye protection when using compressed air.
  • Page 39: Carburetor Body Cleaning

    Check the container for instructions. If you are in doubt, do not use these products to clean a Honda carburetor. • High air pressure may damage the carburetor. Use low air pressure (0.2 MPa (30 psi) or less) when cleaning passages and ports.
  • Page 40: Thermo-Wax Inspection

    dummyhead dummyhead FUEL SYSTEM THERMO-WAX INSPECTION • Wear insulated gloves and adequate eye protection. Keep flammable materials away from the electric heating element. Do not let the thermo-wax or a thermometer touch the pan, or you will get a false reading.
  • Page 41: Choke Replacement

    dummyhead dummyhead FUEL SYSTEM CHOKE REPLACEMENT Remove the carburetor (page 5-6). Pull out the choke valve [1]. Remove the following. – Choke lever [2] – Spring [3] Install the following new parts. – Spring – Choke lever Insert a new choke valve plate into the slit [4] in the choke shaft.
  • Page 42 dummytext 6. GOVERNOR SYSTEM GOVERNOR ARM GOVERNOR ADJUSTMENT ···················· 6-3 REMOVAL/INSTALLATION ····················· 6-2 GOVERNOR REMOVAL/INSTALLATION··· 6-4...
  • Page 43 dummyhead dummyhead GOVERNOR SYSTEM GOVERNOR ARM GOVERNOR SYSTEM REMOVAL/INSTALLATION Remove the carburetor (page 5-6). After installation, adjust the governor (page 6-3). GOVERNOR ROD/ THROTTLE RETURN SPRING INSTALLATION: Install the governor rod through the throttle return spring as shown. PAINT MARK (Governor side) FUEL TUBE (110 mm) GOVERNOR...
  • Page 44 Check to make sure the governor arm and the carburetor throttle valve operate smoothly. Start the engine and warm it up to the normal operating temperature. Check the maximum governed speed with the blade installed. MAXIMUM GOVERNED SPEED: HRG416C1: 2,900 (rpm) –100 HRG466C1: 2,800 (rpm) –100...
  • Page 45 dummyhead dummyhead GOVERNOR SYSTEM GOVERNOR REMOVAL/INSTALLATION Remove the crankshaft (page 10-7). GOVERNOR SLIDER ASSEMBLY: Slide the governor weights to install the slider; then check to be sure the slider moves GOVERNOR WEIGHT HOLDER smoothly. CHECK: Before installing, check for wear and damage of the gear.
  • Page 46 dummytext 7. STARTING SYSTEM RECOIL STARTER REMOVAL/ RECOIL STARTER ROPE INSTALLATION ····································· 7-2 REPLACEMENT ···································· 7-3 RECOIL STARTER INSPECTION ············· 7-2...
  • Page 47 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER REMOVAL/ STARTING SYSTEM INSTALLATION Remove the top cover (page 5-2). BOLT (6 x 14 mm) (3) 8.5 N·m (0.9 kgf·m, 6.3 lbf·ft) RECOIL STARTER RECOIL STARTER INSPECTION Remove the recoil starter (page 7-2). Check the operation of the ratchets [1] by pulling the starter rope out several times.
  • Page 48 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER ROPE REPLACEMENT Remove the recoil starter (page 7-2). Pull the starter rope [1] until the starter rope is pulled out fully. To prevent the starter reel [1] from rewinding, hold the starter reel to the starter case [2] with a band or equivalent material [3] as shown.
  • Page 49 dummyhead dummyhead STARTING SYSTEM Remove the band or equivalent material [1] holding the starter reel [2] and carefully allow the starter reel to rewind. Check the operation of the ratchets by pulling the starter rope several times (page 7-2). Install the recoil starter (page 7-2). RECOIL STARTER ROPE BROKEN OR REEL UNWOUND Remove the recoil starter (page 7-2).
  • Page 50 dummytext 8. FLYWHEEL FLYWHEEL REMOVAL/INSTALLATION···· 8-2 ENGINE STOP SWITCH INSPECTION ······ 8-3 BRAKE ASSEMBLY REMOVAL/INSTALLATION ···················· 8-3...
  • Page 51 dummyhead dummyhead FLYWHEEL FLYWHEEL REMOVAL/INSTALLATION FLYWHEEL • Take care not to damage the fan blades during removal and installation of the flywheel. • Inserting a rod or screwdriver in the fan blades can damage the blades or the aluminum casting projections. •...
  • Page 52 dummyhead dummyhead FLYWHEEL BRAKE ASSEMBLY REMOVAL/INSTALLATION Remove the flywheel (page 8-2). • Route the wire harness properly (page 2-5). SCREW (4 x 12 mm) 1.8 N·m (0.2 kgf·m, 1.3 lbf·ft) BOLT (6 x 22 mm) WASHER (4 mm) BRAKE LEVER SPRING ENGINE STOP SWITCH STOP SWITCH CORD...
  • Page 53 dummyhead dummyhead MEMO...
  • Page 54 dummytext 9. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION········· 9-2...
  • Page 55 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION Remove the following: – Starter grip from the handlebar. – Blade holder (base shop manual 62VH300 page 14-5) – Drive belt (If equipped) (base shop manual 62VH300 page 14-5) • Route the cable properly (page 2-5). FLYWHEEL BRAKE CABLE DRIVE PULLEY REMOVAL/INSTALLATION:...
  • Page 56 dummytext 10. CRANKSHAFT/PISTON/VALVES CRANKCASE COVER PISTON/CONNECTING ROD REMOVAL/INSTALLATION ··················· 10-2 DISASSEMBLY/ASSEMBLY················· 10-10 BREATHER COVER CYLINDER COMPRESSION CHECK······ 10-11 REMOVAL/INSTALLATION ··················· 10-3 CRANKSHAFT RUNOUT CHECK·········· 10-11 CYLINDER REMOVAL/INSTALLATION ··················· 10-4 CAMSHAFT/CYLINDER/PISTON/VALVE INSPECTION ····································· 10-12 CYLINDER DISASSEMBLY/ASSEMBLY·················· 10-6 VALVE SEAT RECONDITIONING·········· 10-21 CRANKSHAFT/CAMSHAFT/PISTON CRANKSHAFT OIL SEAL REMOVAL/INSTALLATION ···················...
  • Page 57: Crankcase Cover Removal/Installation

    dummyhead dummyhead CRANKSHAFT/PISTON/VALVES CRANKCASE COVER CRANKSHAFT/PISTON/VALVES REMOVAL/INSTALLATION Set the piston at TDC on the compression stroke (page 3-5). Remove the brake assembly (page 8-3) • Assemble within 3 minutes after applying the liquid sealant. • Wait for approximately 30 minutes after assembly and before filling oil and starting the engine. CRANKCASE COVER (Bearing area) REMOVAL:...
  • Page 58: Breather Cover Removal/Installation

    dummyhead dummyhead CRANKSHAFT/PISTON/VALVES BREATHER COVER REMOVAL/INSTALLATION Remove the crankcase cover (page 10-2). BOLT (6 x 14 mm) BREATHER COVER SCREW (5 x 8 mm) BREATHER VALVE INSTALLATION: Install the breather valve as shown. CARNKCASE COVER SIDE 10-3...
  • Page 59 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES CYLINDER REMOVAL/INSTALLATION Drain the engine oil (page 3-3). Remove the following: – Crankcase cover (page 10-2) – Carburetor (page 5-6) – Muffler (page 11-2) Using too much force can deform the cylinder head cover. The cylinder head cover must be replaced if it is deformed.
  • Page 60: Cylinder

    dummyhead dummyhead CRANKSHAFT/PISTON/VALVES SEALANT APPLICATION • Assemble within 3 minutes after applying the liquid sealant. • Wait for approximately 30 minutes after assembly and before filling oil and starting the engine. CYLINDER Clean the mating surfaces of the cylinder [1] and the crankcase using a degreasing cleaning agent or a clean Φ1.0 –...
  • Page 61 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES CYLINDER DISASSEMBLY/ASSEMBLY Remove the cylinder (page 10-4). EXHAUST VALVE (Stem sliding surface and the stem end) VALVE STEM SEAL (Intake valve only) INTAKE VALVE (Stem sliding surface and the stem end) VALVE SPRING (2) (Whole surface) VALVE SPRING RETAINER (2) REMOVAL: Do not remove the valve spring retainers while the piston installed, or...
  • Page 62: Crankshaft/Camshaft/Piston

    dummyhead dummyhead CRANKSHAFT/PISTON/VALVES CRANKSHAFT/CAMSHAFT/PISTON REMOVAL/INSTALLATION Remove the engine (page 9-2). Remove the cylinder (page 10-4). CONNECTING ROD CAP (Bearing area) INSTALLATION: PISTON/CONNECTING ROD Align the projections [1] of the ASSEMBLY cap and connecting rod. CRANKSHAFT INSTALLATION: (Journal and crankpin) The mark [1] points toward the flywheel side [2].
  • Page 63 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES CRANKSHAFT INSTALLATION Set the piston at bottom dead center. Install the crankshaft [1] into the crankcase so that the camshaft [2] and the timing gear [3] are aligned the marks [4] as shown, and the projection [5] on the timing gear is inserted into the groove [6] in the crankshaft.
  • Page 64: Oil Filler Cap/Extension Removal/Installation

    dummyhead dummyhead CRANKSHAFT/PISTON/VALVES OIL FILLER CAP/EXTENSION REMOVAL/INSTALLATION Drain the engine oil (page 3-3). OIL FILLER CAP/DIPSTICK OIL FILLER PACKING OIL FILLER EXTENSION CT BOLT (6 x 14 mm) (2) 12 N·m (1.2 kgf·m, 9 lbf·ft) O-RING INSTALLATION: Be sure that no dust or foreign materials enter the crankcase.
  • Page 65: Piston/Connecting Rod Disassembly/Assembly

    dummyhead dummyhead CRANKSHAFT/PISTON/VALVES PISTON/CONNECTING ROD DISASSEMBLY/ASSEMBLY Remove the piston/connecting rod (page 10-7). PISTON RINGS (Entire surface) ASSEMBLY: To install the oil ring, install the spacer [1] first, and then install the side rails [2]. Be sure that the top ring [3] and second ring [4] Maker Mark are not interchanged.
  • Page 66: Cylinder Compression Check

    dummyhead dummyhead CRANKSHAFT/PISTON/VALVES CYLINDER COMPRESSION CHECK Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Start the engine and warm up to normal operating temperature.
  • Page 67: Camshaft/Cylinder/Piston/Valve

    dummyhead dummyhead CRANKSHAFT/PISTON/VALVES CAMSHAFT/CYLINDER/PISTON/VALVE INSPECTION CAM HEIGHT Measure the cam height. STANDARD: 33.779 – 34.179 mm (1.3299 – 1.3456 in) SERVICE LIMIT: 33.754 mm (1.3289 in) If the measurement is less than the service limit, replace the camshaft (page 10-7). CAMSHAFT I.D.
  • Page 68 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES ROCKER ARM SHAFT BEARING I.D. Measure the rocker arm shaft bearing I.D. STANDARD: 6.000 – 6.018 mm (0.2362 – 0.2369 in) SERVICE LIMIT: 6.043 mm (0.2379 in) If the measurement is more than the service limit, replace the cylinder (page 10-6). ROCKER ARM SHAFT O.D.
  • Page 69 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES PISTON SKIRT O.D. Measure and record the piston O.D. at a point 10 mm (0.4 in) from the bottom of the skirt and 90 degrees to the piston pin bore. STANDARD: 55.970 – 55.990 mm (2.2035 – 2.2043 in) 10 mm (0.4 in) SERVICE LIMIT: 55.85 mm (2.199 in) If the measurement is less than the service limit,...
  • Page 70 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES PISTON RING END GAP Before inspection, check whether the cylinder sleeve I.D. is within the specification. Put the piston ring [1] in the cylinder and then use the piston crown to push the ring down. This will make the piston ring horizontal so the ring end gap can be measured.
  • Page 71 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES PISTON PIN-TO-PISTON PIN BORE CLEARANCE Subtract the piston pin O.D. from the piston pin bore I.D. to obtain the piston pin-to-piston pin bore clearance. STANDARD: 0.002 – 0.022 mm (0.0001 – 0.0009 in) SERVICE LIMIT: 0.070 mm (0.0028 in) If the calculated clearance is more than the service limit, replace the piston pin and recheck the clearance.
  • Page 72 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES CRANKPIN O.D. Measure the crankpin O.D. of the crankshaft. STANDARD: 27.970 – 27.980 mm (1.1012 – 1.1016 in) SERVICE LIMIT: 27.920 mm (1.0992 in) If the measurement is less than the service limit, replace the crankshaft (page 10-7). CONNECTING ROD BIG END AXIAL CLEARANCE Measure the clearance between the connecting rod big...
  • Page 73 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES CRANKCASE COVER MAIN JOURNAL I.D. Measure the crankcase cover main journal I.D. STANDARD: 25.420 – 25.441 mm (1.0008 – 1.0016 in) SERVICE LIMIT: 25.466 mm (1.0026 in) If the measurement is more than the service limit, replace the crankcase cover (page 10-2). CRANKCASE MAIN JOURNAL I.D.
  • Page 74 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES PUSH ROD RUNOUT Check both ends of the push rod for wear. Check the push rod for straightness. If necessary, replace the push rod (page 10-4). VALVE FACE/VALVE STEM O.D. Inspect each valve for face irregularities. If necessary, replace the valve. Inspect each valve for bending or abnormal stem wear.
  • Page 75 dummyhead dummyhead CRANKSHAFT/PISTON/VALVES GUIDE-TO-STEM CLEARANCE Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the guide-to-stem clearance. STANDARD: IN: 0.020 – 0.047 mm (0.0008 – 0.0019 in) EX: 0.060 – 0.087 mm (0.0024 – 0.0034 in) SERVICE LIMIT: IN: 0.10 mm (0.004 in) EX: 0.12 mm (0.005 in) If the calculated clearance is more than the service limit,...
  • Page 76: Valve Seat Reconditioning

    dummyhead dummyhead CRANKSHAFT/PISTON/VALVES VALVE SEAT RECONDITIONING Inspect the valve seat contact area (page 10-20). Using a 45° seat cutter [1], remove any roughness or 45° irregularities from the seat. If the contact area is too high on the valve, removes material from the top edge using a 32°...
  • Page 77: Crankshaft Oil Seal

    dummyhead dummyhead CRANKSHAFT/PISTON/VALVES Lap the valves into their seats, using a commercially available valve lapper [1] and lapping compound. • Do not push the valve against the seat with force during lapping. Apply a light pass with the valve lapper. •...
  • Page 78 dummytext 11. MUFFLER MUFFLER REMOVAL/INSTALLATION···· 11-2 11-1...
  • Page 79 dummyhead dummyhead MUFFLER MUFFLER REMOVAL/INSTALLATION MUFFLER The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Allow it to cool before proceeding. Remove the top cover (page 5-2).
  • Page 80 dummytext 13. FRONT WHEEL/REAR WHEEL/TRANSMISSION FRONT WHEEL REMOVAL/INSTALLATION ··················· 13-2 13-1...
  • Page 81 dummyhead dummyhead FRONT WHEEL/REAR WHEEL/TRANSMISSION FRONT WHEEL FRONT WHEEL/REAR WHEEL/TRANSMISSION REMOVAL/INSTALLATION WHEEL WASHER INSTALLATION: Note the installation direction. CUTER HOUSING SIDE: WHEEL WASHER NUT (8 mm) (2) COLLAR HEIGHT ADJUST LEVER FRONT AXLE SHAFT BOLT (8 x 30.5 mm) (2) WHEEL WASHER (2) INSTALLATION: Note the installation direction.
  • Page 82 dummytext 15. IGNITION SYSTEM IGNITION SYSTEM DIAGRAM ··············· 15-2 IGNITION COIL AIR GAP/ CHECK/ADJUSTMENT························· 15-4 IGNITION SYSTEM TROUBLESHOOTING ·························· 15-2 SPARK TEST······································ 15-4 IGNITION COIL IGNITION COIL INSPECTION ················ 15-5 REMOVAL/INSTALLATION ··················· 15-3 15-1...
  • Page 83: Ignition System Diagram

    dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM DIAGRAM IGNITION SYSTEM IGNITION COIL ENGINE STOP SWITCH SPARK UNIT PLUG Bl: Black Engine ENGINE STOP SWITCH Condition IGNITION SYSTEM TROUBLESHOOTING NO SPARK AT SPARK PLUG Check the following before troubleshooting: – Loose connectors –...
  • Page 84: Ignition Coil Removal/Installation

    dummyhead dummyhead IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Remove the fan cover (page 5-3). After installation, adjust the ignition coil air gap (page 15-4). CT BOLT (6 x 23 mm) (2) IGNITION COIL STOP SWITCH CORD 15-3...
  • Page 85: Ignition Coil Air Gap/ Check/Adjustment

    dummyhead dummyhead IGNITION SYSTEM IGNITION COIL AIR GAP/ CHECK/ADJUSTMENT Remove the fan cover (page 5-3). Insert a feeler gauge [1] of proper thickness between the ignition coil [2] and flywheel [3]. IGNITION COIL AIR GAP: 0.30 – 0.50 mm (0.012 – 0.020 in) •...
  • Page 86: Ignition Coil Inspection

    dummyhead dummyhead IGNITION SYSTEM IGNITION COIL INSPECTION Remove the following Ignition coil (page 15-3). PRIMARY SIDE Measure the resistance of the primary coil by attaching the ohmmeter leads to the ignition coil terminal [1] and the iron core [2]. Except electric starter model: Resistance: 0.43 –...
  • Page 87 dummyhead dummyhead MEMO...
  • Page 88 INDEX INDEX AIR CLEANER RMOVAL/INSTALLATION ··················5-5 GOVERNOR ADJUSTMENT ···································6-3 BRAKE ASSEMBLY REMOVAL/INSTALLATION·········8-3 GOVERNOR ARM REMOVAL/INSTALLATION ···········6-2 BREATHER COVER REMOVAL/INSTALLATION ······ 10-3 GOVERNOR REMOVAL/INSTALLATION ··················6-4 CABLE/HARNESS ROUTING ··································2-5 IGNITION COIL AIR GAP/CHECK/ADJUSTMENT ····· 15-4 CAMSHAFT/CYLINDER/PISTON/VALVE IGNITION COIL INSPECTION ······························· 15-5 INSPECTION ··················································· 10-12 IGNITION COIL REMOVAL/INSTALLATION·············...

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