Honda HRD536 User Manual

2.4 Maintenance standards
PART ITEM STANDARD SERVICE LIMIT
Engine
Idle speed
HRD535/K1/K2 2100 ± 150 rpm
-
HRA536 - HRD536/K1/K2 1700 ± 150rpm
Maximum speed
HRD535/K1/K2 - HRD536/K1/K2
2900 rpm
-
HRA536
3100 rpm
Cylinder compression
HRD535/K1/K2 6.0 - 8.5 kg/cm
2
/600 rpm
-
HRA536 - HRD536/K1/K2 5.0 - 8.05 kg/cm
2
/600 rpm
carburetor
Main jet
HRD535/K1/K2 # 55
-
HRA536 - HRD536/K1/K2 # 65
Pilot screw opening
HRD535/K1/K2 1 - ½ turns out
-
HRA536 - HRD536/K1/K2 1 - 5/8 turns out
Float level 13.7 mm -
Spark plug Gap 0.7 - 0.8 mm -
Valves
Valve clearance
IN 0.15 ± 0.02 mm
-
EX 0.20 ± 0.02 mm
Stem O.D.
IN 5.480 mm 5.318 mm
EX 5.440 mm 5.275 mm
Guide I.D. IN/EX 5.500 mm 5.572 mm
Stem-to-guide clearance
IN 0.020 - 0.044 mm 0.10 mm
EX 0.060 - 0.087 mm 0.13 mm
Spring free lenght IN/EX
HRD535/K1/K2 30.5 mm 29.0 mm
HRA536 - HRD536/K1/K2 34.0 mm 32.5 mm
Cylinder head
Valve seat width IN/EX 0.8 mm 2.0 mm
Warpage - 0.10 mm
Piston
Skirt O.D.
HRD535/K1/K2 63.985 mm 63.815 mm
HRA536 - HRD536/K1/K2 67.985 mm 67.845 mm
Piston-to-cylinder clearance 0.015 - 0.050 mm 0.09 mm
Piston pin bore I.D.
HRD535/K1/K2 13.002 mm 13.048 mm
HRA536 - HRD536/K1/K2 18.002 mm 18.048 mm
Piston pin O.D.
HRD535/K1/K2 13.000 mm 12.954 mm
HRA536 - HRD536/K1/K2 18.000 mm 17.954 mm
Piston ring
Thickness
Top/Second 1.5 mm 1.37 mm
Oil 2.5 mm 2.37 mm
Side clearance Top/Second/Oil 0.015 - 0.045 mm 0.15 mm
End gap
Top/Second 0.20 - 0.40 mm 1.0 mm
Oil 0.15 - 0.35 mm 1.0 mm
Cylinder Bore I.D.
HRD535/K1/K2 64.0 mm 64.165 mm
HRA536 - HRD536/K1/K2 68.0 mm 68.165 mm
Connecting rod
Small end I.D.
HRD535/K1/K2 13.005 mm 13.07 mm
HRA536 - HRD536/K1/K2 18.005 mm 18.052 m)
Big end oil clearance 0.040 - 0.063 mm 0.12 mm
Big end side clearance 0.1 - 0.7 mm 1.1 mm
Crankshaft Crank pin O.D.
HRD535/K1/K2 25.970 mm 25.92 mm
HRA536 - HRD536/K1/K2 29.980 mm 29.92 mm
Camshaft
Cam height
IN 27.70 mm 27.45 mm
EX 27.75 mm 27.50 mm
Camshaft journal O.D. 13.984 mm 13.916 mm
Camshaft holder I.D. 14.0 mm 14.048 mm
Ignition coil
Primary coil resistance 0.8 - 1.2 Ù -
Secondary coil resistance 5.9 - 7.1 kÙ -
Spark plug resistance
HRD535/K1/K2 0.2 Ù -
HRA536 - HRD536/K1/K2 4-5kÙ -
Air gap 0.2 - 0.6 mm
Starter motor
Brush length 11 mm 6 mm
Commutateur Mica depth 1.6 mm 1.1 mm
Charging coil Resistance 3.0 - 4.0
Ù -
Blade brake
Lining thickness
HRD535/K1/K2 - HRD536 3.0 mm 2.0 mm
HRD535 Q /K1 Q /K2 Q - HRA536 - 4.6 mm
Clutch spring HRD535 Q /K1 Q /K2 Q - HRA536 - 35.5 mm
Return spring
HRD535/K1/K2 - HRD536/K1/K2 - 65 mm
HRD535 Q /K1 Q /K2 Q - HRA536 - 55.5 mm
-12-
HRA536 - HRD535 - HRD536
- SERVICE INFORMATION
+0
- 100
+0
- 100

Honda HRD536 Specifications

General

Engine	Honda GCV160
Engine Displacement	160 cc
Engine Type	4-stroke
Engine Displacement (Alternative)	0.16 litres
Cutting Height Adjustment	Single lever