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HRN216PKC
Honda HRN216PKC User Manual
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10-18
CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER
HRN216
7. OIL FILLER CAP / EXTENSION REMOV
AL/INST
ALLA
TION
O-RING
OIL FILLER CAP/DIPSTICK
OIL FILLER EXTENSION
OIL FILL
ER P
ACKING
6 x 14 mm SPECIAL BOL
T (2)
12 N•m (9 ft-lb)
INSTALLATION:
Be sure that no
dust or
foreign material e
nters
when installi
ng the O-ring.
Be careful not to p
inch the
O-ring.
140
142
Table of Contents
A FEW WORDS ABOUT SAFETY
1
INTRODUCTION
2
SAFETY MESSAGES
2
CONTENTS
2
Quick Identifier
3
1. SPECIFICATIONS
4
1. SPECIFICATIONS
5
DIMENSIONS, WEIGHTS, AND CAPACITIES
5
ENGINE
5
DRIVETRAIN
5
2. DIMENSIONAL DRAWINGS
6
PKA TYPE
6
VKA, VLA, VYA TYPES
7
3. WIRING DIAGRAM (VLA TYPE)
8
2. SERVICE INFORMATION
10
1. SERVICE RULES
10
2. SYMBOLS USED IN THIS MANUAL
10
3. SERIAL NUMBER LOCATIONS
11
4. SERVICE SPECIFICATIONS
12
5. TORQUE VALUES
13
STANDARD TORQUE VALUES
14
6. TOOLS
14
SPECIAL
14
COMMERCIALLY AVAILABLE
15
7. TROUBLESHOOTING
16
ENGINE
16
Hard Starting Using Recoil Starter Or Poor Engine Performance
16
Electric Starter Will Not Operate
17
Electric starter operates, but the engine cranks slowly or not at all
18
Battery Has Low Voltage (less than 12.7 V)
19
VIBRATION PROBLEMS
20
DRIVE SYSTEM (VKA/VLA/VYA types)
20
FLYWHEEL BRAKE (PKA/VKA/VLA TYPES)
21
8. TROUBLESHOOTING TECHNIQUES
22
COMPRESSION TEST
22
SPARK PLUG TEST
22
An assistant is required during this test.
22
CRANKSHAFT RUNOUT INSPECTION
23
INSPECTION
23
CHOKE CONTROL SYSTEM
24
CHARGE COIL OUTPUT CHECK
25
VLA TYPE ONLY
25
ENGINE STOP SWITCH SYSTEM INSPECTION
25
VLA TYPE ONLY
25
FUEL/ETHANOL TEST
26
SMART DRIVE TRANSMISSION
27
VKA/VLA/VYA TYPES
27
9. CABLE ROUTING AND TIES
30
PKA TYPE
30
VKA TYPE
31
VLA TYPE
32
VYA TYPE
33
10. TUBE and HARNESS ROUTING
34
PKA/VKA/VLA TYPES
34
11. MAIN HARNESS ROUTING (VLA TYPE)
39
3. MAINTENANCE
40
1. MAINTENANCE SCHEDULE
41
2. MAINTENANCE SPECIFICATIONS
42
3. ENGINE TUNE-UP SPECIFICATIONS
42
4. REAR SHIELD
42
5. BLADES
43
INSPECTION
43
REMOVAL/INSTALLATION
43
SHARPENING
44
6. ENGINE OIL
45
INSPECTION
45
OIL CHANGE
45
7. AIR FILTER CLEANING
46
CLEANING
46
8. GRASS BAG
47
INSPECTION
47
CLEANING
47
REPLACEMENT
47
9. SPARK PLUG INSPECTION
47
INSPECTION
47
10. SPARK ARRESTER CLEANING
48
CLEANING
48
11. COMBUSTION CHAMBER CLEANING
48
12. SMART DRIVE CABLE
49
CABLE ADJUSTMENT
49
13. FUEL TANK AND strainer
50
INSPECTION/CLEANING
50
FUEL TUBE INSPECTION
50
14. BLADE CONTROL OPERATION CHECK
51
FLYWHEEL BRAKE MODELS
51
ROTO-STOP®
51
15. FLYWHEEL BRAKE
51
INSPECTION
51
16. ROTO-STOP®
52
CABLE ADJUSTMENT
52
INSPECTION
52
BRAKE WEAR
52
CLUTCH WEAR
53
17. THROTTLE CABLE AND LINKAGE
53
18. VALVE CLEARANCE
54
CHECK
54
ADJUSTMENT
54
19. PINION GEAR
55
LUBRICATION
55
DISASSEMBLY
55
REASSEMBLY
56
20. GOVERNOR
60
PKA, VKA, VLA TYPES
60
ADJUSTMENT
60
VYA TYPE
61
ADJUSTMENT
61
4. BLADE HOLDER/ROTO-STOP®
62
1. BLADE HOLDER/DRIVE PULLEY
63
PKA TYPE
63
REMOVAL
64
INSTALLATION
64
VKA/VLA TYPES
65
REMOVAL
66
INSTALLATION
66
2. ROTO-STOP®/DRIVE PULLEY
67
PARTS REFERENCE
67
REMOVAL
68
INSPECTION
69
INSTALLATION
72
5. ENGINE REMOVAL/INSTALLATION
76
1. PKA/VKA TYPES
77
REMOVAL
77
INSTALLATION
78
2. VLA TYPE
79
REMOVAL
79
INSTALLATION
80
3. VYA TYPE
81
REMOVAL
81
INSTALLATION
82
6. MUFFLER
84
1. REMOVAL/INSTALLATION
85
7. RECOIL STARTER
86
1. TOP COVER REMOVAL/INSTALLATION
86
2. RECOIL REMOVAL/INSTALLATION
87
3. FAN COVER REMOVAL/INSTALLATION
88
4. RECOIL STARTER Inspection
89
5. RECOIL STARTER ROPE REPLACEMENT
89
6. REEL UNWOUND
91
8. FUEL SYSTEM
92
1. AIR CLEANER/CARBURETOR
93
REMOVAL/INSTALLATION
93
DISASSEMBLY/REASSEMBLY
94
INSPECTION
95
FLOAT LEVEL HEIGHT
95
PILOT SCREW AND LIMITER CAP REPLACEMENT
95
CLEANING
96
CHOKE CONTROL ASSEMBLY
101
Thermowax Installation
101
2. CONTROL BASE/GOVERNOR ARM
103
PKA/VKA/VLA TYPES
103
REMOVAL/INSTALLATION
103
VYA TYPE
104
REMOVAL/INSTALLATION
104
DISASSEMBLY/REASSEMBLY
105
3. FUEL TANK
106
DISASSEMBLY/REASSEMBLY
106
4. FUEL TUBE
107
REMOVAL/INSTALLATION
107
FUEL TUBE AND CLAMP CHANGES
107
9. IGNITION COIL/FLYWHEEL
108
1. IGNITION COIL
109
REMOVAL/INSTALLATION
109
PKA/VKA TYPES
109
SPARK TEST
112
INSPECTION
112
IGNITION COIL
112
Primary Side Resistance
112
Secondary Side Resistance
112
Engine Stop Switch
113
PKA/VKA/VLA TYPES
113
VYA TYPE
113
IGNITION COIL AIR GAP ADJUSTMENT
113
CHARGE COIL AND DIODE TEST
114
2. FLYWHEEL
115
DISASSEMBLY/REASSEMBLY
115
FLYWHEEL REMOVAL
116
REMOVAL
116
INSTALLATION
117
3. FLYWHEEL BRAKE LEVER / ENGINE STOP SWITCH
118
4. ELECTRIC STARTER (VLA TYPE)
119
STARTER MOTOR VOLTAGE INSPECTION
119
STARTER MOTOR REMOVAL/INSTALLATION
119
STARTER MAGNETIC SWITCH INSPECTION
120
STARTER MAGNETIC SWITCH REMOVAL/INSTALLATION
121
STARTER MOTOR INSPECTION
121
Pinion Gear
121
CLEANING AND INSPECTING THE PINION DAMPER ASSEMBLY
121
5. SIDE PLATE (VYA TYPE)
123
REMOVAL/INSTALLATION
123
10. CAMSHAFT/CRANKSHAFT/ PISTON/CYLINDER
124
1. CRANKCASE COVER REMOVAL/INSTALLATION
125
CRANKCASE COVER REMOVAL
125
2. BREATHER COVER REMOVAL/INSTALLATION
126
3. CYLINDER REMOVAL/INSTALLATION
127
REMOVAL
127
INSTALLATION
128
CYLINDER INSTALLATION
129
CYLINDER HEAD COVER INSTALLATION
129
4. CYLINDER HEAD DISASSEMBLY/ ASSEMBLY
130
5. CRANKSHAFT/CAMSHAFT/PISTON REMOVAL/INSTALLATION
131
DAMAGED CRANKSHAFT REPLACEMENT
132
REMOVAL
133
INSTALLATION
136
6. GOVERNOR REMOVAL/INSTALLATION
140
7. OIL FILLER CAP / EXTENSION REMOVAL/INSTALLATION
141
CRANKSHAFT INSTALLATION
142
CAM TIMING INSPECTION
142
PISTON/CONNECTING ROD CAP INSTALLATION
142
8. PISTON/CONNECTING ROD DISASSEMBLY/ASSEMBLY
143
9. CYLINDER COMPRESSION CHECK
144
10. CRANKSHAFT RUNOUT CHECK
145
11. CAMSHAFT/CYLINDER/PISTON/ VALVE INSPECTION
145
CAM LOBE HEIGHT
145
CAMSHAFT BORE I.D.
145
CAMSHAFT DECOMPRESSOR
146
ROCKER ARM I.D.
146
ROCKER ARM SHAFT BEARING I.D.
146
ROCKER ARM SHAFT O.D.
147
CYLINDER SLEEVE I.D.
147
PISTON SKIRT O.D.
147
PISTON-TO-CYLINDER CLEARANCE
147
PISTON RING WIDTH
148
PISTON RING SIDE CLEARANCE
148
PISTON RING END GAP
148
PISTON PIN O.D.
149
PISTON PIN BORE I.D.
149
CONNECTING ROD SMALL END I.D.
149
CONNECTING ROD BIG END I.D.
150
CRANKSHAFT MAIN JOURNAL O.D.
150
CRANKPIN O.D.
150
CONNECTING ROD BIG END AXIAL CLEARANCE
151
CONNECTING ROD BIG END OIL CLEARANCE
151
CRANKCASE COVER MAIN JOURNAL I.D.
151
CRANKCASE MAIN JOURNAL I.D.
152
CRANKSHAFT AXIAL CLEARANCE
152
VALVE SPRING FREE LENGTH/PERPENDICULARITY
152
VALVE FACE/VALVE STEM O.D.
153
VALVE GUIDE I.D.
153
GUIDE-TO-STEM CLEARANCE
153
VALVE SEAT WIDTH
154
VALVE SEAT RECONDITIONING
154
CRANKSHAFT OIL SEAL
157
CRANKCASE COVER SIDE
157
CRANKCASE SIDE
157
11. HANDLEBAR/ CABLES/CONTROLS
158
1. HANDLEBAR
159
REPLACEMENT
159
PKA TYPE
159
VKA TYPE
161
VLA TYPE
163
VYA TYPE
165
HANDLE LOCKING KNOB
167
REMOVAL
167
INSTALLATION
168
ROPE GUIDE INSTALLATION
169
2. SMART DRIVE CONTROL
170
REMOVAL
170
INSTALLATION
171
3. SMART DRIVE CABLE
173
REMOVAL
173
INSTALLATION
173
4. FLYWHEEL BRAKE CABLE
174
REMOVAL/INSTALLATION
174
5. ROTO-STOP CONTROL
175
REMOVAL
175
Disassembly
176
Reassembly
177
6. ROTO-STOP CABLE
179
Removal
179
Installation
181
7. THROTTLE CABLE
183
Removal/Installation
183
8. THROTTLE LEVER ASSEMBLY
183
Disassembly/Reassembly
183
Installation
183
9. BATTERY BOX
184
REMOVAL/INSTALLATION
184
INSPECTION
185
Starter Switch
185
Fuse (3 Amp/30 Amp)
185
Battery
185
Battery Load Test
185
12. VARIABLE MOWING SYSTEM/ MOWER DECK/WHEELS
186
1. VARIABLE MOWING SYSTEM
186
REMOVAL/INSTALLATION
186
REMOVAL
186
INSTALLATION
188
2. FRONT COVER
191
FRONT COVER REMOVAL/INSTALLATION
192
REMOVAL
192
INSTALLATION
193
3. CUTTER HOUSING
195
REMOVAL
195
HANDLEBAR STAYS
196
REMOVAL
196
INSTALLATION
196
4. REAR HOUSING
197
PARTS IDENTIFICATION
197
REMOVAL
198
INSTALLATION
201
5. REAR SHIELD
202
REMOVAL
202
INSTALLATION
203
13. TRANSMISSION/DRIVE BELT
204
1. TRANSMISSION/DRIVE BELT
204
VKA/VLA TYPES
204
REMOVAL
204
INSTALLATION
206
VYA TYPE
207
REMOVAL
207
INSTALLATION
210
2. DISASSEMBLY/REASSEMBLY
211
PINION GEAR
211
DISASSEMBLY
211
AXLE SHAFT
212
TRANSMISSION
213
4
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Honda HRN216PKC Specifications
General
Brand
Honda
Model
HRN216PKC
Category
Lawn Mower
Language
English
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