216 Vka

A Few Words About Safety
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SERVICE INFORMATION
.
I S AD
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.
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This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
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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
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that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
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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.
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Improper service or repairs can create an
unsafe condition that can cause your customer
or others to be seriously hurt or killed.
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Follow the procedures and precautions in this
manual and other service materials carefully.
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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
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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
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conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
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Failure to properly follow instructions and

precautions can cause you to be seriously hurt
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or killed.
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Follow the procedures and precautions in this

manual carefully.
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Important Safety Precautions

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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:
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• 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.
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• 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.
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Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
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help eliminate several potential hazards:

• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
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• 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.
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• Use only a nonflammable solvent, not gasoline, to clean parts.

• Never store gasoline in an open container.
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• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
HRR216VKA
INTRODUCTION CONTENTS
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This manual covers service and repair procedures for the SPECIFICATIONS 1
.
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Honda HRR216VKA K5 through K9 model rotary mowers.
2
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All information contained in this manual is based on the latest SERVICE INFORMATION
product information available at the time of printing. We
reserve the right to make changes at any time without notice.
3
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MAINTENANCE
No part of this publication may be reproduced, stored in a
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retrieval system, or transmitted, in any form by any means,
electronic, mechanical, photocopying, recording, or
BLADE HOLDER/DRIVE BELT 4
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otherwise, without prior written permission of the publisher.
This includes text, figures, and tables. ENGINE REMOVAL/
5
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As you read this manual, you will find information that is INSTALLATION
preceded by a NOTICE symbol. The purpose of this
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message is to help prevent damage to the mower, other MUFFLER 6
property, or the environment.
RECOIL STARTER 7
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SAFETY MESSAGES
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Your safety and the safety of others are very important. To
help you make informed decisions, we have provided safety
FUEL SYSTEM 8
messages and other safety information throughout this
manual. Of course, it is not practical or possible to warn you FLYWHEEL/IGNITION COIL 9
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about all the hazards associated with servicing these
mowers. You must use your own good judgment. CAM PULLEY/CRANKSHAFT/
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You will find important safety information in a variety of forms, PISTON/ CYLINDER BLOCK
10
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including:
HANDLE PIPE/CABLES/SMART
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• Safety Labels – on the mower.

DRIVE
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• Safety Messages – preceded by a safety alert symbol
and one of three signal words: DANGER, WARNING, or
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CAUTION. CLIP DIRECTOR/MOWER DECK/

12
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These signal words mean: WHEELS

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 DANGER
You WILL be KILLED or
SERIOUSLY HURT if you don’t TRANSMISSION 13
follow instructions.
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INDEX
 WARNING
You CAN be KILLED or
SERIOUSLY HURT if you don’t
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 CAUTION
You CAN be HURT if you don’t
• Instructions – how to service these mowers correctly and
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safely.
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American Honda Motor Co., Inc.

Service Communications Department
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INTRODUCTION HRR216VKA
LAWN MOWER K VERSION IDENTIFICATION
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Throughout this manual the K version is listed when MEETS CPSC BLADE SAFETY
the repair procedure varies by version. The K version K VERSION
.
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NUMBER REQUIREMENTS.
number is the seventh digit in the model number as CONFORMS TO ANSI B 71.1 SAFETY STANDARD
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shown here. HRR2169VKA XX
MZCG –– XXXXXXX
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AMERICAN
AmericanHONDA
Honda MOTOR CO.,
Motor Co., INC.
Inc.
ALPHARETTA, GA
Alpharetta, GA 30005-8847
30005-8847
Use the information in the following table to identify the
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version you are repairing.
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VERSION FRAME SERIAL NUMBERS ENGINE SERIAL NUMBERS IDENTIFIERS/FEATURES/CHANGES
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K5 MZCG – 7800001 thru GJAEA – 1000001 and later • HRR216VKA model introduced with
7999999 adjustable Smart Drive, fixed
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throttle, Automatic Choke
System (ACS), and quick-release
handle adjustment
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• Running change at s/n 7819953—
transmission pulley changed from
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steel to plastic and additional
internal transmission improvements
implemented
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K6 MZCG – 8000001 thru GJAPA – 1000001 thru • Engine model prefix changed from
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8199999 9999999 GJAEA to GJAPA

• Fluorinated fuel tube applied to meet
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2009 CARB/EPA regulation

• Wheel color changed from white to
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gray (running change after first

4,000 units)
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K7 MZCG – 8200001 thru • Maximum cutting height increased

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8399999 from 3.25 to 4 inches

• New front adjuster arms and rear
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adjuster panels
• Smart Drive™ transmission
changed to a smaller design
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K8 MZCG – 8400001 thru • New square Auto Choke System™

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8669999 thermowax
• Slip belt Smart Drive transmission
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• Grass bag frame and mount

redesigned
• Grass bag mount changed to plastic
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• Deep rear discharge door

implemented to allow rear discharge
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to the ground
• Mulching plug redesigned to work
with new deep rear discharge door
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HRR216VKA INTRODUCTION
VERSION FRAME SERIAL NUMBERS ENGINE SERIAL NUMBERS IDENTIFIERS/FEATURES/CHANGES
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K9 MZCG – 8670001 and later GJARA – 1000001 and later • Engine model prefix changed from
.
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GJAPA to GJARA
• 3-in-1 Clip Director®—no mulching
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plug
• New MicroCut® blades
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• Rear scroll and belt cover changed
from steel to plastic
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• Plastic ramp added to the inside of
the cutting housing to improve
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mulching performance
• New style fan cover
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• Engine changes including:
– New aluminum carburetor
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– Round intake port
– New flywheel brake and stop
switch design
– New flywheel with separate
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cooling fan
– New orange air filter element (no
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steel mesh)
– Nylon crankshaft timing gear
– New breather tube and air cleaner
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case
– Laser etched serial number
– New ignition coil
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– New fan cover studs (collars

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removed)
– New camshaft decompressor
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components
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INTRODUCTION
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NOTES
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HRR216VKA
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1. SPECIFICATIONS
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 1-1 3. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 1-5
2. DIMENSIONAL DRAWINGS . . . . . . . . . . . 1-3
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1. SPECIFICATIONS
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DIMENSIONS, WEIGHTS, AND CAPACITIES
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VERSION
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K5/K6 K7 K8 K9
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Height 966 mm (38.0 in) 961 mm (37.8 in) 1014 mm (39.9 in)
Length 1600 mm (63.0 in) 1620 mm (63.8 in) 1534 mm (60.4 in)
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Mower deck width 582 mm (22.9 in)
Wheel base 630 mm (24.8 in) 620 mm (24.4 in)
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(cut height set to
28 mm [1-1/4 in])
Cutting width 530 mm (21.0 in)
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Cutting height 19, 28, 41.5, 54, 67, 28, 44, 60, 75, 90, 102 mm
(6 positions) 79 mm (1-1/8, 1-3/4, 2-1/2, 3, 3-1/2, 4 in)
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(3/4, 1-1/8, 1-3/4, 2-1/4,
2-3/4, 3-1/4 in)
Dry weight 37.6 kg (82.9 lbs) 37.2 kg (82.0 lbs) 36.5 kg (80.5 lbs)
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Wet weight 38.8 kg (85.8 lbs) 38.4 kg (84.7 lbs) 37.5 kg (82.7 lbs)
Grass bag capacity 84.5 L (2.4 bushels; 3.0 cu ft, 22.3 US gal)
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Fuel tank capacity 0.93 L (0.25 US gal)

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Engine oil capacity 0.50 L (17 oz) (Refill amount: 0.35 ~ 0.40 L [12.0 ~ 13.5 oz])
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Ground speed 0 ~ 5.8 Km/hr (0 ~ 3.6 mi/hr) 0 ~ 6.5 Km/hr (0 ~ 4.0 mi/hr)
ENGINE
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Engine model GCV160A

Engine type 4-stroke, overhead-cam, single-cylinder
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Displacement 160 cc (9.8 cu in)

Bore x stroke 64 x 50 mm (2.52 x 1.97 in)
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Compression ratio 8.5 : 1

Maximum governed speed 2,950 ~ 3,100 rpm
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Ignition system Transistorized magneto ignition

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Ignition timing 20° B.T.D.C.

Fuel supply system Gravity feed with a manual shut-off valve
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Lubrication system Splash type

Cooling system Forced air
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Starting system Recoil starter

Stopping system Ignition primary circuit ground and a flywheel brake
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Carburetor Horizontal-type, butterfly valve

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Air cleaner Dry (paper) type

Governor Centrifugal mechanical governor
Fuel used Unleaded gasoline with a pump octane number 86 or higher
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SPECIFICATIONS HRR216VKA
DRIVE TRAIN
VERSION
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K5/K6 K7 K8/K9
.
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Type Variable Speed Slip Belt
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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
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Drive mechanism V-belt
Lubrication type SAE 10W-30 engine oil SJ or later
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Lubrication amount 150 cc (5.1 oz) 65 cc (2.2 oz)
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FEATURES
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VERSION
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K5/K6/K7 K8 K9
Smart Drive System   
Twin blades  
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MicroCut® twin blades 
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Grass bag   
Mulching plug  
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ACS (Auto Choke System)   
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Clip Director® 
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Best-In-Class engine 
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 = standard equipment
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HRR216VKA SPECIFICATIONS
2. DIMENSIONAL DRAWINGS
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K5 thru K7
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1 *K5/K6: 966 mm (38.0 in)
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*K7: 961 mm (37.8 in)
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in)
.0
(63 n)
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m 8i
0 0 m (63.
6
1, mm
6:
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5 /K ,620
*K 7: 1
*K
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in
58
2 2 4.8 )
m (
m .4 in
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m
(2
2. 3 0 m (24
9 6 m
in 6:
) 5 /K 20 m
K :6
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K7
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* Dimensions measured with the cutting height set in the lowest position.
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SPECIFICATIONS HRR216VKA
K8 and K9
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*1,014 mm (39.9 in)
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*1,534mm (60.4 in)
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620 mm (24.4 in)

582 mm (22.9 in)
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* Dimensions measured with the cutting height set in the lowest

position and the handlebar height set in the highest position.
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HRR216VKA SPECIFICATIONS
3. WIRING DIAGRAM
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SPARK IGNITION ENGINE STOP
PLUG COIL SWITCH
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(NORMALLY
CLOSED)
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SPECIFICATIONS
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NOTES
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HRR216VKA
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2. SERVICE INFORMATION
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1. SERVICE RULES . . . . . . . . . . . . . . . . . . . . 2-1 7. DRIVE SYSTEM TROUBLESHOOTING . . 2-7
2. SYMBOLS USED IN THIS MANUAL. . . . . 2-1 8. ENGINE TROUBLESHOOTING. . . . . . . . 2-18
.
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3. SERIAL NUMBER LOCATIONS . . . . . . . . 2-2 9. FLYWHEEL BRAKE
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4. SERVICE SPECIFICATIONS . . . . . . . . . . . 2-2 TROUBLESHOOTING . . . . . . . . . . . . . . . 2-29
5. TORQUE VALUES . . . . . . . . . . . . . . . . . . . 2-4 10. TROUBLESHOOTING VIBRATION
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6. TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . 2-30
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1. SERVICE RULES
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• 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.
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• This mower uses metric fasteners and SAE (non-metric) fasteners. Metric bolts, nuts, and screws are not interchangeable with
non-metric fasteners. The use of incorrect tools and fasteners may damage the mower.
• When tightening nuts and bolts, begin with the larger-diameter or inner bolts, and tighten diagonally to the specified torque
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values, unless a particular tightening sequence is specified.
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• When tightening self-tapping screws, be especially careful to avoid cross-threading or overtightening.
• Clean parts in nonflammable solvent after disassembly.
• Lubricate sliding surfaces before reassembly.
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• After reassembly, check parts installation and operation.
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2. SYMBOLS USED IN THIS MANUAL

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As you read this manual, you may find the following symbols with the instructions.
 A special tool is required to perform the procedure.

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(commercially Commercially available tools are distinguished by the words (commercially available). They are not
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available) available through the American Honda Parts Department. Most commercially available tools shown in this
shop manual can be ordered through the Tool and Equipment program by calling (888) 424-6857. Refer to
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
the Tool and Equipment program catalogue for a complete tool listing.
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Apply grease

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Apply oil
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OxO(O) Indicates the diameter, length, and quantity of metric flange bolts used.
P. O-O Indicates the reference page.
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SERVICE INFORMATION HRR216VKA
3. SERIAL NUMBER LOCATIONS
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The engine serial number is located on the cylinder block near the muffler. Refer to the engine serial number when
.
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ordering parts and when making technical inquiries.
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The frame serial number is located at the center rear of the deck.
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FRAME SERIAL NUMBER
MEETS CPSC BLADE SAFETY
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REQUIREMENTS.
CONFORMS TO ANSI B 71.1 SAFETY STANDARD
HRR2169VKA XX
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MZCG –– XXXXXXX
AMERICAN
AmericanHONDA
Honda MOTOR CO.,
Motor Co, INC.
Inc.
ALPHARETTA, GA
Alpharetta, GA 30005-8847
30005-8847
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N
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H
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ENGINE SERIAL NUMBER
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H
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D
A
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4. SERVICE SPECIFICATIONS
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PART ITEM STANDARD VERSIONS

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Maximum governed speed 2,950 ~ 3,100 rpm

Engine Idle speed (K5 thru K8 only) 1,700 ± 150 rpm ------------------
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Cylinder compression 490 kPa (5.0 kg/cm2, 71 psi) at 600 rpm

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Main jet #70

Carburetor
Float height 9.2 mm (0.36 in) K5
BB65E A
Pilot screw opening N/A
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Main jet #68

Carburetor
BB75E A
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Main jet #68
Carburetor
Float height 7.2 mm (0.28 in) K6, K7
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BB75E B
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Main jet #68

Carburetor
BB75E C
Main jet #60
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Carburetor
BB76A A
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HRR216VKA SERVICE INFORMATION
PART ITEM STANDARD SERVICE LIMIT
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Spark plug Gap 0.7 - 0.8 mm (0.028 ~ 0.031 in) --------------------------------
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Valve clearance (cold) IN 0.15 ± 0.04 mm --------------------------------
EX 0.20 ± 0.04 mm --------------------------------
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Stem O.D. IN 5.48 mm (0.216 in) 5.318 mm (0.2094 in)
Valves EX 5.44 mm (0.214 in) 5.275 mm (0.2077 in)
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Guide I.D. IN/EX 5.50 mm (0.217 in) 5.572 mm (0.2194 in)
Seat width IN/EX 0.7 mm (0.028 in) 1.8 mm (0.07 in)
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Spring free length IN/EX 30.5 mm (1.20 in) 29.0 mm (1.14 in)
Skirt O.D. K5~K8 63.961 ~ 63.985 mm (2.5181 ~ 2.5190 in) 63.880 mm (2.5129 in)
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K9 63.966 ~ 63.990 mm (2.5183 ~ 2.5193 in) 63.880 mm (2.5129 in)
Piston-to-cylinder clearance
Piston K5~K8 0.015 ~ 0.054 mm (0.0005 ~ 0.0021 in) 0.12 mm (0.005 in)
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K9 0.010 ~ 0.049 mm (0.0004 ~ 0.0019 in) 0.12 mm (0.005 in)
Piston pin bore I.D. 13.002 mm (0.5119 in) 13.048 mm (0.5137 in)
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Pin O.D. 13.000 mm (0.5118 in) 12.954 mm (0.5100 in)
Ring width Top 0.93 ~ 0.95 mm (0.036 ~ 0.037 in) 0.91 mm (0.035 in)
Second 0.97 ~ 0.99 mm (0.038 ~ 0.039 in) 0.95 mm (0.037 in)
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Oil 2.5 mm (0.10 in) 2.37 mm (0.093 in)
Ring side clearance Top 0.055 ~ 0.089 mm (0.002 ~ 0.004 in) 0.150 mm (0.006 in)
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Piston rings Second 0.015 ~ 0.049 mm (0.0006~0.0019 in) 0.150 mm (0.006 in)
Oil 0.015 ~ 0.045 mm (0.0006~0.0018 in) 0.150 mm (0.006 in)
Ring end gap Top 0.20 ~ 0.35 mm (0.008 ~ 0.014 in) 1.00 mm (0.040 in)
Second 0.35 ~ 0.50 mm (0.014 ~ 0.020 in) 1.00 mm (0.040 in)
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Oil 0.20 ~ 0.70 mm (0.008 ~ 0.030 in) 1.00 mm (0.040 in)
Sleeve I.D. K5~K8 64.105 mm (2.5238 in)
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Cylinder 64.000 ~ 64.015 mm (2.5197 ~ 2.5203 in)

K9 64.110 mm (2.5240 in)
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Small end I.D. 13.005 mm (0.5120 in) 13.07 mm (0.515 in)

Big end I.D. 26.02 mm (1.024 in) 26.066 mm (1.0262 in)
Connecting rod
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Big end oil clearance 0.040 ~ 0.063 mm (0.0016 ~ 0.0025 in) 0.12 mm (0.005 in)
Big and axial clearance 0.1 ~ 0.4 mm (0.004 ~ 0.016 in) 0.8 mm (0.031 in)
Main journal O.D. PTO side 27.993 mm (1.1021 in) 27.933 mm (1.0997 in)
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Crankshaft Flywheel side 25.393 mm (0.9997 in) 25.333 mm (0.9974 in)

Crank pin O.D. 25.98 mm (1.023 in) 25.92 mm (1.020 in)
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Main journal I.D. 25.420 mm (1.0008 in) 25.466 mm (1.0026 in)

Cylinder block
Crankshaft axial clearance 0.15 ~ 0.75 mm (0.006 ~ 0.030 in) 1.0 mm (0.04 in)
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Oil pan Main journal I.D. 28.020 mm (1.1031 in) 28.066 mm (1.1050 in)
Cam height 37.394 mm (1.4722 in) 37.369 mm (1.4712 in)
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Cam pulley Cam Pulley I.D. (Bearing) 10.027 mm (0.3948 in) 10.075 mm (0.3967 in)
Cam pulley shaft O.D. 9.987 mm (0.3932 in) 9.920 mm (0.3906 in)
Rocker arm I.D. 6.000 mm (0.2362 in) 6.043 mm (0.2379 in)
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Rocker arm Rocker arm shaft O.D. 5.990 mm (0.2358 in) 5.953 mm (0.2344 in)
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Rocker arm shaft bearing I.D. 6.000 mm (0.2362 in) 6.043 mm (0.2379 in)
Resistance Primary coil 1.0 ~ 1.4 Ω -----------------------------------
Ignition coil (K5 thru K8) Secondary coil 10.6 ~ 12.8 kΩ -----------------------------------
Air gap (at flywheel) 0.2 ~ 0.4 mm (0.008 ~ 0.016 in) -----------------------------------
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Resistance Primary coil 1.0 ~ 1.2 Ω -----------------------------------

Ignition coil (K9) Secondary coil 10 ~ 40 kΩ -----------------------------------
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Air gap (at flywheel) 0.2 ~ 0.5 mm (0.008 ~ 0.020 in) -----------------------------------
Flywheel brake Brake shoe thickness ----------------------------------------------------------- 3.0 mm (0.12 in)
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5. TORQUE VALUES
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SPECIAL FASTENERS
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THREAD DIAMETER x TORQUE
ITEM PITCH
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N•m kgf•m ft-lb
M6 x 1.0 (ST) 10 1.0 7.4
Air cleaner case bolt
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M6 x 1.0 10 1.0 7.4
Blade bolt special 49 ~ 59 5.0 ~ 6.0 36 ~ 43
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Blade holder bolt 3/8-24 x 1” special 49 ~ 59 5.0 ~ 6.0 36 ~ 43
D UT
Breather cover bolt M6 x 1.0 12 1.2 8.7
Connecting rod bolt M7 x 1.0 special 12 1.2 8.7
A A
Cylinder head cover bolt M6 x 1.0 (ST) 12 1.2 8.7
M NO
Engine stop switch assembly M4 x 0.7 1.6 0.16 1.18
Fan cover stud bolt M6 x 1.0 12 1.2 8.7
.- O
Flywheel nut M14 x 1.5 52 5.3 38
Fuel valve bracket screw M5 x 0.6 4.5 0.45 2.2
.A US
Governor arm nut M6 x 1.0 10 1.0 7.4
Governor holder bolt M6 x 1.0 12 1.2 8.7
IS O
Muffler bolt M6 x 1.0 (ST) 12 1.2 8.7
S N
Oil pan bolt M6 x 1.0 (ST) 12 1.2 8.7

A IÓ
Recoil starter nut M6 x 1.0 8.5 0.85 6.1

Spark plug M14 x 1.25 20 2.0 14
IR UC
Valve adjusting lock nut M5 x 0.5 special 8 0.8 5.8

D B
Use standard torque values for fasteners that are not listed above.
A RI
(ST) Indicates a self-tapping bolt.

M ST
STANDARD FASTENERS
STANDARD TORQUE
DI
THREAD DIAMETER
FASTENERS N•m kg-m ft-lb
5 mm 3.9 0.4 2.9
20 U
Screw
6 mm 8.8 0.9 6.5
20 O S
5 mm 4.9 0.5 3.6

6 mm 9.8 1.0 7.2
1- ID
Bolt and nut 8 mm 21 2.1 15

10 mm 34 3.5 25
-0 HIB
12 mm 54 5.5 40
6 mm 12 1.2 8.7
03 O
Flange bolt and nut 8 mm 26 2.7 20

10 mm 39 4.0 29
PR
2-4
6. TOOLS
.A O
SPECIAL
.
IS D
ITEM TOOL NAME TOOL NUMBER APPLICATION
S ZA
1 Carburetor float level gauge 07401-0010000 Carburetor float level inspection
A RI
2 Valve adjustment wrench, 3 mm 07908-KE90200 Valve clearance adjustment
3 Flywheel holder 07APB-Z28A100 Flywheel removal
IR O
4 Alcohol tester 07AAJ-E85A100 Check the percent of ethanol in the fuel
D UT
A A
1 2 3
M NO
.- O
.A US
IS O
S N
4
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-5
COMMERCIALLY AVAILABLE
.A O
ITEM TOOL NAME TOOL NUMBER APPLICATION
1A Dial indicator and magnetic base FPL-72-520-300
.
IS D
Crankshaft runout check and crankshaft axial
1B Dial indicator magnetic base FFL-72-585-010 clearance check
S ZA
2 Compression gauge SUN-EEP-V303A Compression test
A RI
3 Flywheel puller OTC-1035 Flywheel removal
Combustion chamber cleaning
IR O
4 Procured locally Clean combustion chamber
brush and drill extension
D UT
5 Spring scale SAMIN12MRP Smart Drive™ adjustment
6 Digital multimeter FLU-88 Electrical component testing
A A
7A Valve seat cutter, 31° NWY CU 115
M NO
7B Valve seat cutter, 45° NWY CU 122
7C Valve seat cutter, 60° NWY CU 111
7D Solid pilot bar, 5.50 mm NWY PM 10055SH
.- O
7E Solid pilot bar, 5.51 mm NWY PM 100552S Valve seat reconditioning
.A US
7F T-wrench, #505 NWY TW 505
7G T-wrench adaptor, #503-1 NWY TW 503-1
IS O
7H T-wrench extension, 6 in NWY TW 503-6H
7I Accessory package #246 NWY KACC 246
S N
A IÓ
1A 2 3 4 5
IR UC
D B
A RI
5
M ST
1B
DI
AUTOMOTIVE METER
F I
C
20 U
ZERO MIN MAX RANGE HOLD H
60°
RPM %DUTY ALERT
SMOOTH + TRIGGER
Hz ms-PULSE -
:
6
mV
7
20 O S
V mA
RPM
~V
A
mA
A
~
B 45°
OFF
A 31°
A mA COM
:
V
RPM D E
H
1- ID
400mA MAX
FUSED
10A MAX 1000V MAX
FUSED
!
G
-0 HIB
Commercially available tools are distinguished by the words (commercially available). They are not available through
the 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
03 O
and Equipment program catalog for a complete tool listing.

PR
2-6
7. DRIVE SYSTEM TROUBLESHOOTING
.A O
.
IS D
Version Symptom See page
S ZA
Lawn mower will not self-propel when the Smart Drive is engaged 2-7
Transmission propels the mower, but slips or slows down under load 2-8
A RI
Lawn mower continues to self-propel when the Smart Drive is released 2-9
K5 thru K7 Lawn mower is difficult to roll backwards, but stops propelling when the
IR O
2-10
Smart Drive is released
D UT
Only one wheel propels or one wheel intermittently stops rotating under load 2-11
(clicking sound can be heard)
A A
Transmission leaks oil 2-12
Lawn mower will not self-propel when the Smart Drive is engaged 2-13
M NO
Transmission propels the mower, but slips or slows down under load 2-13
Lawn mower continues to self-propel when the Smart Drive is released 2-14
.- O
K8 thru K9 Lawn mower is difficult to roll backwards, but stops propelling when the 2-15
Smart Drive is released
.A US
Only one wheel propels or one wheel intermittently stops rotating under load 2-16
(clicking sound can be heard)
Transmission leaks oil 2-17
IS O
S N
K5 thru K7 SERVICE BULLETIN #94 =>

A IÓ
LAWN MOWER WILL NOT SELF-PROPEL WHEN THE SMART DRIVE IS ENGAGED
IR UC
1. Inspect the drive belt, transmission input shaft, Smart

Drive cable, and pulley condition. Inspect the
transmission
Inspect the drive belt,
D B
2. Inspect the transmission control arm. Replace the control control arm for
pulley, and input shaft. damage.
arm if it is damaged.
A RI
M ST
DI
20 U
20 O S
.
1- ID
-0 HIB
03 O
PR
2-7
3. Verify the transmission control arm moves when rotating

the Smart Drive control.
.A O
• If the control arm does not move, see “SMART DRIVE
.
IS D
DISASSEMBLY AND INSPECTION” on page 11-19.
S ZA
• If the control arm moves, adjust the Smart Drive cable
(see “CABLE ADJUSTMENT” on page 3-10.)
A RI
IR O
D UT
A A
M NO
Confirm the transmission control
arm moves when rotating the Smart
Drive control.
.
.- O
(K5 ~ K7) TRANSMISSION PROPELS THE
.A US
MOWER, BUT SLIPS OR SLOWS DOWN UNDER LOAD
1. Adjust the Smart Drive cable (P. 3-10).
CONTROL
2. Have an assistant engage the Smart Drive control while
IS O
ARM
you inspect the transmission control arm position.
S N
If the control arm contacts the transmission case as

shown, the clutch is worn and transmission replacement
A IÓ
is necessary.
IR UC
D B
A RI
No contact between the control arm

M ST
and transmission case with the

Smart Drive control engaged.
.
DI
3. Position the mower on a smooth concrete surface.

Hold the mower from moving forward
20 U
4. Start the engine and firmly engage the Smart Drive and engage the Smart Drive control
control while holding the lawn mower from moving on a smooth concrete surface.
20 O S
forward. The rear wheels should spin (slip) on the

concrete surface.
If the wheels intermittently stop and/or a clicking sound
1- ID
can be heard, inspect the pinion gears and ratchets

(page 2-11).
-0 HIB
If both wheels stop, but no ratcheting or clicking sound

can be heard, the clutch may be worn and transmission
replacement is necessary.
03 O
PR
2-8
(K5 ~ K7) LAWN MOWER CONTINUES TO SELF-PROPEL WHEN THE SMART DRIVE IS
RELEASED
.A O
1. Loosen the Smart Drive cable adjuster completely. LOCK NUT
.
IS D
ADJUSTER
S ZA
A RI
IR O
LOOSEN
D UT
A A
M NO
.- O
.A US
. IS O
2. Confirm there is no tension in the Smart Drive cable
at the transmission control arm.
S N
If tension exists, proceed to “SMART DRIVE DISASSEMBLY

AND INSPECTION” on page 11-19.
A IÓ
3. Inspect the transmission control arm return spring. If the

IR UC
spring is broken, missing, or damaged, replace it. Confirm there is

no tension in the
4. Place the mower on its wheels and roll it backwards. Smart Drive
D B
• If it rolls easily, then adjust the Smart Drive cable cable.

(page 3-10).
A RI
• If the mower is difficult to roll backwards, refer to “(K5 ~ K7)

M ST
THE LAWN MOWER IS DIFFICULT TO ROLL Inspect the

control arm
BACKWARDS, BUT DOES STOP PROPELLING WHEN
return spring.
THE SMART DRIVE IS RELEASED” on page 2-10.
DI
• If the Smart Drive is still engaged (stuck) and won’t roll

backwards and propels when running, replace the transmission.
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-9
(K5 ~ K7) THE LAWN MOWER IS DIFFICULT TO ROLL BACKWARDS, BUT DOES STOP
PROPELLING WHEN THE SMART DRIVE IS RELEASED
.A O
1. Raise the mower to the highest cutting height
.
IS D
to prevent the rear shield from creating extra
S ZA
roll-back drag.
2. With the engine off and the Smart Drive Slowly pull the mower backwards and
A RI
control released, place a commercially measure the roll-back force. Maximum
available spring scale on the handlebar. continuous force is 49 N (11 lb).
IR O
Slowly and steadily pull the mower
backwards and measure the continuous
D UT
roll-back force.
• Continuous roll-back force should be less
A A
than 49 N (11 lb).
SPRING SCALE,
• If the roll-back force exceeds 49 N (11 lb),
M NO
SAMIN12MRP
refer to steps 1 thru 3 on page 2-9. (Commercially
available)
.- O
.
.A US
3. Check the roll-back force once again. If the
force exceeds 49 N (11 lb), continue as ADJUSTER ARM AND AXLE
follows: Clean and inspect the rear
adjuster bushings and axle.
IS O
Remove the rear adjuster arms and clean
and inspect the bushings and axle shaft.
S N
Replace any excessively worn bushings.

Apply general purpose grease to the inside of
A IÓ
the bushings.
IR UC
4. Go to the Smart Drive Cable Adjustment

procedure (P. 3-10). 26 x 44 mm
WASHER
D B
25 mm
Apply grease.
A RI
CIRCLIP
M ST
DI
ADJUSTER
PLATE
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-10
(K5 ~ K7) ONLY ONE WHEEL PROPELS OR ONE WHEEL INTERMITTENTLY STOPS
ROTATING UNDER LOAD (CLICKING SOUND CAN BE HEARD)
.A O
1. Clean and inspect the pinion gears,
.
IS D
wheel gears, and ratchet keys.

PINION GEAR (12-tooth)
S ZA
2. Apply general purpose grease to the Install with the
RATCHET
ratchet key, spring, and axle on the left KEY punch mark

RATCHET facing:
and right sides.
A RI
SPRING Left - inside
3. Be sure the correct pinion gears are Right - outside
IR O
installed: AXLE
3 mm
D UT
8-inch wheels use 12-tooth pinion gears.
SPACER 13 mm
CIRCLIP
A A
M NO
FLAT WASHER
WHEEL WASHER
.- O
REASSEMBLY:
Install the washer as
.A US
shown.
WHEEL
IS O
SIDE WHEEL BOLT
REAR WHEEL
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-11
(K5 ~ K7) TRANSMISSION LEAKS OIL

1. Remove the transmission (P. 13-1), clean it, and identify the source of the leak.
.A O
Note: Dark oil or a slight metallic residue in the oil is normal and usually does not indicate a problem.
.
IS D
2. Replace the leaking seal(s) or O-ring as shown below.
S ZA
3. Fill the transmission to the proper level with SAE 10W-30 oil.
4. Reinstall the transmission, and proceed to the Smart Drive Cable Adjustment procedure (P. 3-10)
A RI
IR O
K5/K6
D UT
AXLE SHAFT OIL SEAL
INPUT SHAFT OIL SEAL
SHIFT SHAFT OIL SEAL
TRANSMISSION CASE
A A
INSTALLATION: Use SAE
10W-30 engine oil and fill to the
M NO
capacity shown below.
The correct oil level should be
8 ~ 12 mm (0.3 ~ 0.5 in) from the
top of the transmission case
.- O
when it is upside down. AXLE SHAFT OIL SEAL
.A US
CAPACITY: 150 cc (5.0 oz)
TOP OF 8 ~ 12 mm
CASE (0.3 ~ 0.5 in)
IS O
CASE O-RING
S N
A IÓ
IR UC
K7
D B
10 x 19 x 7 mm
A RI
OIL SEAL
M ST
12.7 x 28.6 x 6.4 mm OIL SEAL
12.7 x 28.6 x 6.4 mm

OIL SEAL (2)
DI
TRANSMISSION CASE
20 U
INSTALLATION: Use SAE 10W-30

20 O S
engine oil and fill to the capacity

shown.
10 ~ 12 mm (0.4 ~ 0.5 in) from the top
1- ID
of the transmission case when it is

upside down.
-0 HIB

TOP OF CASE O-RING
10 ~ 12 mm
CASE (0.4 ~ 0.5 in)
03 O
PR
2-12
SERVICE BULLETIN #98 => SERVICE BULLETIN #104 =>

K8 thru K9
.A O
MOWER WILL NOT SELF-PROPEL WHEN THE SMART DRIVE IS ENGAGED
.
IS D
1. Inspect the drive belt, transmission input shaft, Smart
Drive cable, and pulley condition. Inspect the transmission control arm, Smart
S ZA
Drive cable, and return spring for damage.
2. Inspect the transmission control arm, Smart Drive cable,
and return spring. Replace as necessary.
A RI
3. Verify the transmission pivots and the control arm moves
IR O
when rotating the Smart Drive control.
D UT
• If the control arm does not move, go to “SMART DRIVE
DISASSEMBLY AND INSPECTION” on page 11-19.
A A
• If the control arm moves, go to “CABLE
ADJUSTMENT” on page 3-10.
M NO
.- O
.A US
IS O
S N
Inspect the drive

A IÓ
belt, pulley, and

input shaft.
IR UC
.
D B
(K8 ~ K9) TRANSMISSION PROPELS THE MOWER, BUT SLIPS OR SLOWS DOWN UNDER
A RI
LOAD
M ST
1. Adjust the Smart Drive cable (P. 3-10).

2. Inspect the belt and both pulleys for damage. Confirm that
DI
the transmission pulley is tight and not slipping on the Hold the mower from moving
input shaft. forward and engage the Smart
Drive control on a smooth
20 U
3. Position the mower on a smooth concrete surface. concrete surface.

20 O S
4. Start the engine and firmly engage the Smart Drive control
while holding the lawn mower from moving forward. The
rear wheels should spin (slip) on the concrete surface.
1- ID
If the wheels intermittently stop and/or a clicking sound

can be heard, inspect the pinion gears and ratchets
-0 HIB
(see P. 2-16).
If both wheels stop but no ratcheting or clicking sound can
be heard, the clutch may be worn and transmission
03 O
replacement is necessary.
PR
2-13
(K8 ~ K9) LAWN MOWER CONTINUES TO

SELF-PROPEL WHEN THE SMART DRIVE IS JAM NUT
.A O
RELEASED ADJUSTER
.
IS D
MARK
1. Loosen the Smart Drive cable adjuster completely.
S ZA
TIGHTEN
A RI
LOOSEN
IR O
D UT
A A
M NO
.- O
.A US
.
.
2. Confirm there is no tension in the Smart Drive

IS O
cable at the transmission control arm. Confirm there is no
S N
If tension exists, proceed to the SMART tension in the Smart

Drive cable.
DRIVE DISASSEMBLY AND INSPECTION
A IÓ
procedure on page 11-19.

IR UC
3. Inspect the transmission control arm return

spring. If the spring is broken, missing, or
damaged, replace it. Inspect the
D B
control arm
4. Push the control arm up to remove all the return spring.
A RI
slack from the belt. Inspect the clearance

between the outside of the belt and the belt
M ST
guides.
Belt Guide Clearance:
DI
• Driven Pulley Belt Guide Clearance:

2 ~ 3 mm
20 U
• Drive Pulley Belt Guide Clearance:

20 O S
3 ~ 4 mm DRIVE PULLEY BELT GUIDE DRIVEN PULLEY BELT GUIDE

CLEARANCE CLEARANCE
5. If the clearance is out of specification, adjust
3 ~ 4 mm (0.118 ~ 0.157 in) 2 ~ 3 mm (0.079 ~ 0.118 in)
or replace the belt and belt guide(s).
1- ID
DRIVEN
BELT
-0 HIB
PULLEY
DRIVE
PULLEY
BELT
03 O
BELT GUIDE
PR
BELT GUIDE
2-14
(K8 ~ K9) LAWN MOWER IS DIFFICULT TO ROLL BACKWARDS, BUT STOPS

PROPELLING WHEN THE SMART DRIVE IS RELEASED
.A O
1. Raise the mower to the highest cutting height
.
IS D
to prevent the rear shield from creating extra
S ZA
roll-back drag.
2. With the engine off and the Smart Drive Slowly pull the mower backwards and
control released, place a commercially
A RI
measure the roll-back force. Maximum
available spring scale on the handlebar. continuous force is 58 N (13 lb).
Slowly and steadily pull the mower
IR O
backwards and measure the continuous
D UT
roll-back force.
• Continuous roll-back force should be less
A A
than 58 N (13 lb).
• If the roll-back force exceeds 58 N (13 lb), SPRING SCALE,
M NO
SAMIN12MRP
refer to steps 1 thru 3 under “(K8 ~ K9) (Commercially
LAWN MOWER CONTINUES TO available)
SELF-PROPEL WHEN THE SMART
.- O
DRIVE IS RELEASED” on page 2-14.
.A US
3. Check the roll-back force once again. If the ADJUSTER ARM AND AXLE
force exceeds 58 N (13 lb), continue as Clean and inspect the rear
follows: adjuster bushings and axle.
IS O
Remove the rear adjuster arms and clean
and inspect the bushings and axle shaft.
S N
Replace any excessively worn bushings.

Apply general purpose grease to the inside
A IÓ

26 x 44 mm
of the bushings. WASHER
IR UC
4. Proceed to the Smart Drive Cable 25 mm

Apply grease.
Adjustment procedure (P. 3-10). CIRCLIP
D B
A RI
M ST
ADJUSTER
PLATE
DI
.
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-15
(K8 ~ K9) ONLY ONE WHEEL PROPELS OR ONE WHEEL INTERMITTENTLY STOPS
ROTATING UNDER LOAD (CLICKING SOUND CAN BE HEARD)
.A O
1. Clean and inspect the pinion gears, wheel
.
IS D
PINION GEAR (12 tooth)
gears, and ratchet keys.
Install with the
S ZA
RATCHET
2. Apply general purpose grease to the KEY punch mark

RATCHET facing:
ratchet key, spring, and axle on the left and SPRING Left - inside
A RI
right sides. Right - outside
3. Be sure the correct pinion gears are AXLE
IR O
installed: 3 mm
SPACER
D UT
13 mm
8-inch wheels use 12-tooth pinion gears.
CIRCLIP
A A
M NO
FLAT WASHER
WHEEL WASHER
REASSEMBLY:
.- O
shown.
.A US
WHEEL
SIDE WHEEL BOLT
REAR WHEEL
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-16
(K8 ~ K9) TRANSMISSION LEAKS OIL

1. Remove and clean the transmission (P. 13-1), and check to identify the source of the leak.
.A O
Note: Dark oil or a slight metallic residue in the oil is normal and usually does not indicate a problem.
.
IS D
• Replace the leaking seal(s) or O-ring as shown below.
S ZA
• Fill the transmission to the proper level with SAE 10W-30 oil.
2. Reinstall the transmission, and proceed to the Smart Drive Cable Adjustment procedure (P. 3-10).
A RI
IR O
D UT
AXLE SHAFT OIL SEAL INPUT SHAFT OIL SEAL
A A
M NO
AXLE SHAFT OIL SEAL
.- O
TRANSMISSION CASE
.A US
shown.
IS O
18 ~ 20 mm (0.71 ~ 0.79 in) from the
top of the transmission case when it is CASE O-RING
S N
upside down.
A IÓ

TOP OF 18 ~ 20 mm
CASE (0.71 ~ 0.79 in)
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-17
SERVICE BULLETIN #94 =>

8. ENGINE TROUBLESHOOTING
.A O
HARD STARTING OR POOR PERFORMANCE SERVICE REMINDER #3 =>
.
IS D
S ZA
Make sure the fuel valve is ON. SERVICE BULLETIN #98 =>
Check the fuel level. No fuel in tank Refuel.
A RI
Sufficient fuel in tank
IR O
Confirm the fuel quality. If gasoline is more than 30 Drain the fuel system, and refill with
Stale fuel
D UT
days old, the engine may be hard to start (P. 2-19). fresh gasoline.
Fresh fuel
A A
Check the air filter. Clogged Clean or replace the air filter.
Clean
M NO
Check the choke butterfly with the engine cold. Choke partially open See “CHOKE CONTROL SYSTEM
(ACS) (K8 • K9)” ON page 2-27.
Choke closed
.- O
.A US
Check the fuel filter. Clogged Clean or replace the fuel filter.
Clean IS O
Check the spark arrester (if equipped). Clogged Clean or replace the spark arrester.
Clean
S N
A IÓ
• Install a new spark plug, then restart

Remove the spark plug and inspect (P. 3-9). Wet the engine.
Dry • Check the carburetor for flooding.
IR UC
Install the spark plug in the plug cap and perform the • Check the ignition coil air gap (P. 9-6).
spark test (P. 2-20). No or weak spark • Check the engine stop switch (P. 2-20.
D B
Good spark
A RI
Check the valve clearance

Install a compression gauge in the spark plug hole (P. 3-13), and then perform the cylinder
M ST
(P. 2-21) and crank the engine several times. Compression

is too high compression test.
Compression normal If the cylinder compression is too high,
DI
go to “STARTING DECOMPRESSION
SYSTEM INSPECTION” on page 2-21.
Remove (P. 8-1), disassemble (P. 8-5), and clean the
20 U
carburetor (P. 8-6). Compression Check the valve clearance (P. 3-13),
is too low and then perform the cylinder
20 O S
compression test. If the cylinder

compression is still too low, perform a
Install the spark plug and restart the engine.
leak down test.
If the air leak down test shows air
1- ID
leakage, check the following as

determined by the test:
-0 HIB
- Valve sticking open (P. 3-13)

- Valve seat width (P. 10-20)
- Valve face irregularly worn (P. 10-10)
- Piston ring side clearance (P. 10-16)
03 O
- Piston ring width (P. 10-16)

PR
- Piston ring end gap (P. 10-16)

- Piston skirt O.D. (P. 10-15)
- Cylinder sleeve I.D. (P. 10-15)
2-18
FUEL/ETHANOL TEST
This test will determine the percent of ethanol in gasoline. Honda engines are approved to run on a content of 10%
.A O
ethanol or less.
.
IS D
Follow the directions on the tester shown below.
S ZA

A I
R TOR
GAS/ALCOHOL TESTER Directions:
90%
PN 07AAJ-E85A100
Step 1
Add gasoline
85%
to this line
Add water to the
80% water line.
U
75% Step 2
A A
I S INOAPPROVED MANNER
Add gasoline to the
70% gasoline line.
DO NOT SMOKE OR USE NEAR FLAMEI

M NO
D
65%
Step 3
60% Replace cap and
shake vigorously.
.- O
55%
Step 4
.A US
50% Stand vial vertically
with cap upright. Let
45%
stand for 10 minutes.
40%
Step 5
35% If bubbles remain,
lightly tap vial to
S N
30% disperse bubbles for

DISCARD GASOLINE SAMPLE
better accuracy.
A IÓ
25%
Step 6
20%
IR UC
Locate the
15% gasoline/water
seperation line and
10% read scale. The
D B
seperation line will

5% indicate the
A RI
per centage of
alcohol, if present.
M ST
to this line
Add water
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-19
SPARK TEST
1. Remove the spark plug, attach it to the spark plug cap,
.A O
and ground the side electrode against the cylinder head
.
IS D
cover.
 WARNING
S ZA
Gasoline is highly flammable and explosive. If ignited,
A RI
gasoline can burn you severely.
Before testing the spark plug:
IR O
• Be sure there is no spilled fuel near the engine.
D UT
• Place the spark plug away from the spark plug hole.
A A
2. Hold the flywheel brake lever against the handlebar.
3. Pull the recoil starter and check to see if sparks jump
M NO
across the electrodes.
.- O
ENGINE STOP SWITCH INSPECTION
.A US
1. Remove the fan cover.
2. Disconnect the engine stop switch connector from the
ignition coil primary terminal. ENGINE STOP SWITCH CONNECTOR
(K9 model shown)
IS O
3. With the multimeter set to measure Ohms, connect one
lead to the engine stop switch connector and the other
S N
lead to ground.
A IÓ
There should be continuity when the flywheel brake lever

is released.
IR UC
There should be no continuity when the flywheel brake

lever is held against the handlebar.
D B
IGNITION PRIMARY TERMINAL

A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-20
COMPRESSION TEST
1. Remove the spark plug and install a compression gauge
.A O
in the spark plug hole. COMPRESSION
GAUGE
.
IS D
2. Hold the flywheel brake lever against the handlebar. (commercially
available)
S ZA
3. Crank the engine several times with the recoil starter and
measure compression.
A RI
490 kPa (71 psi)
Compression*
at 600 rpm
IR O
*Decompression mechanism engaged.
D UT
A compression test reading above 550kPa (80 psi)
indicates the decompression system may not be working
A A
correctly. See STARTING DECOMPRESSION SYSTEM
INSPECTION below.
M NO
.- O
.A US
.
STARTING DECOMPRESSION SYSTEM

IS O
INSPECTION
S N
The engine must be completely cool before proceeding.

1. If there is gasoline in the fuel tank, drain it into an approved container.
A IÓ
2. Remove the recoil starter and fan cover (P. 7-1).

IR UC
Do not tilt the fan cover with fuel in the tank; this will saturate the charcoal in the fuel cap and prevent it from
venting properly.
D B
3. Remove the four 6 mm flange bolts and remove the cylinder head cover.
4. Disconnect the spark plug cap.
A RI
5. Rotate the flywheel until the engine is at TDC (top dead

M ST
center) of the compression stroke. The cam pulley lobe

will face directly out, away from the block as shown.
DI
20 U
20 O S
1- ID
TOP DEAD CENTER

-0 HIB
03 O
PR
2-21
6. Measure the exhaust valve clearance using a feeler gauge.

VALVE ADJUSTING
LOCK NUT ROCKER ARM
.A O
Exhaust Valve Clearance Specification:
0.16 ~ 0.24 mm (0.0063 ~ 0.0094 in).
.
IS D
S ZA
If the clearance is less than or equal to 0.24 mm (0.0094 in.),
the cam pulley decompressor is likely binding. Go to Cam
Pulley Decompressor Inspection below.
A RI
IR O
If the valve clearance is greater than 0.24 mm (0.0094 in.) go
to Exhaust Rocker Arm Pivot Free-Play Inspection
D UT
(P. 2-23).
Exhaust Valve Stem
A A
Exhaust Valve Maximum
Clearance Specification
M NO
0.24 mm (0.0094 in.)
.- O
Cam Pulley Decompressor Inspection
.A US
Perform this procedure if the valve clearance measurement is less than or equal to 0.24 mm (0.0094 in.).
IS O
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
S N
cam pulley (P. 10-1).

A IÓ
3. If the weight is fully retracted, operate the decompressor by

very slowly moving it to the opposite end of the slot and
IR UC
gently releasing. Repeat several times. If the weight fails to

completely return on its own at any time (by spring force),
replace the cam pulley (P. 10-1).
D B
A RI
M ST
DI
DECOMPRESSOR WEIGHT
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-22
Exhaust Rocker Arm Pivot Free-Play Inspection

Perform this procedure if the exhaust valve clearance measurement was greater than 0.24 mm.
.A O
1. Loosen the three 6 mm flange bolts and remove the muffler

.
IS D
heat shield.
S ZA

A RI
IR O
D UT
A A

M NO
2. With the engine positioned at TDC of the compression stroke
(cam pulley lobe facing out), remove the exhaust rocker pin
.- O
and rocker arm.
.A US
3. Closely inspect the rocker arm for cracks and damage.
Inspect the rocker pin for excessive wear or grooves. If the
rocker arm is damaged and/or the pin appears significantly
IS O
worn, replace both parts before proceeding.
Inspect rocker arm Inspect rocker pin
for cracks. for wear grooves.
S N
A IÓ
4. Fabricate a plate with the indicated dimensions

IR UC
using 1/4 inch or thicker steel. 9/16 in. (15 mm)
∅ 5/16 in.
D B
2 in.
A RI
M ST
7 in.
DI
5. Attach the fabricated steel plate to the muffler shield boss

using a 6 x 20 mm flange bolt.
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-23
6. Attach a dial indicator with a magnetic base to the steel plate

as shown.
.A O
.
IS D
S ZA
A RI
IR O
D UT
A A
7. Use the dial indicator to measure the rocker arm pivot
free-play at locations A and B following the procedure in
M NO
step 8.
.- O
.A US
IS O
B
FREE-PLAY
S N
MEASUREMENT POINTS
A IÓ
8. Position the dial indicator against the exhaust rocker arm above the pivot pin in location A shown in step 7.
IR UC
9. Push and hold the tappet screw against the exhaust valve.
10. While holding the tappet screw against the valve (maintain zero valve lash), move the rocker back and forth at
the pivot point and measure the rocker arm pivot point free-play with the dial indicator. Repeat the measurement
D B
with the dial indicator at location B.

A RI
Maximum Allowable Rocker Arm Free-Play = 0.16 mm (0.0063 in.)

M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-24
11. If the free-play measurement is within specification, readjust

the valve clearance.
.A O
If the free-play exceeds 0.16 mm (0.0063 in.), install a new
.
IS D
rocker arm and pin, adjust the valve clearance, and repeat
the free-play measurement.
S ZA
If the free-play is still excessive, the rocker tower bore is worn
and the cylinder barrel or engine will require replacement.
A RI
IR O
Excessive free-play with a
new rocker arm and pin
D UT
installed indicates worn
rocker tower holes.
A A
12. Clean the cylinder barrel mating surface with a degreasing
M NO
agent and a shop towel.
.- O
.A US
IS O
S N
A IÓ
Clean the cylinder barrel mating surface.

IR UC
13. Apply Hondabond HT (P/N 08718-0004) or Locktite 5900 to a

D B
new cylinder head cover in the areas shown. Assemble

within 10 minutes after applying the liquid gasket. Tighten the
A RI
head cover bolts evenly in several steps to the specified

torque. Wait for approximately 20 minutes after assembly
M ST
before filling with oil and starting the engine.

DI
TORQUE: 12 N•m (9 ft-lb)

14. Reinstall the muffler heat shield, fan cover, and recoil starter.
20 U
15. Start the engine and check operation.

20 O S
1- ID
Apply liquid gasket to the back side of the new

-0 HIB
cylinder head cover.
.
03 O
PR
2-25
CHOKE CONTROL SYSTEM (ACS) (K5 THRU K7) SERVICE REMINDER #3 =>
.A O
With the engine cold, Partially Remove the carburetor. Turn and
remove the paper or totally hold the choke arm in the choke Not
.
IS D
element and check the open CLOSED position. Push the choke normal
S ZA
choke valve. valve open, and let it go. Check that Replace the carburetor.
the choke valve snaps back to the
Closed choke CLOSED position.
A RI
IR O
D UT
A A
M NO
.- O
Normal
.A US
Replace the choke control
assembly.
Does not Hard to

IS O
Start the engine and Check the choke valve for freedom Replace the carburetor
flutter move
check to see if the of movement. assembly.
S N
choke flutters and Moves freely

A IÓ
opens as the engine

warms up. System operates normally. Replace the choke
IR UC
control assembly.
Flutters
D B
See if the choke valve Does not Does not open:

opens after 5-8 minutes open or Check that the ACS control is installed
A RI
(opening time will vary opens correctly. The choke lever tab may be on
based on load and slowly the wrong side of the carburetor choke
M ST
ambient temperature). lever post, which will cause the choke to CHOKE
remain closed. LEVER
Choke
DI
If the ACS is installed correctly, replace TAB

opens
the carburetor assembly (P. 8-1).
fully
20 U
System operates
20 O S
normally.
CARBURETOR CHOKE
LEVER POST
1- ID
Opens slowly:
-0 HIB
• (K5 only) Apply Hondabond HT to heat sink and push heat sink against
cylinder barrel to ensure good heat transfer (P. 8-16).
• (K6~K9) Replace the thermowax (P. 8-17 or P. 8-18).
• Be sure a BPR5ES spark plug is installed and not the cooler BPR6ES
03 O
plug. The BPR5ES is less susceptible to fouling on ACS equipped

PR
engines.
2-26
HRR216VKA SERVICE BULLETIN #100 => SERVICE INFORMATION
CHOKE CONTROL SYSTEM (ACS) (K8 • K9) SERVICE REMINDER #3 => SERVICE BULLETIN #98 =>
.A O
With the engine cold, Partially or Remove the carburetor. Turn Inspect the choke control assembly
.
IS D
remove the paper ele- totally open and hold the choke arm in the Normal linkage for smooth operation
S ZA
ment and check the choke CLOSED position. Push (P. 2-28). If it operates properly,
choke valve. the choke valve open, and let it replace the thermowax (P. 8-18).
go. Check that the choke valve
CHOKE CHOKE
A RI
Closed snaps back to the choke CONTROL CONTROL
CLOSED position. ASSEMBLY LINKAGE
IR O
D UT
A A
THERMOWAX
M NO
ASSEMBLY
.- O
Abnormal
.A US
Replace the carburetor (P. 8-1)
IS O
Opens too
slowly or Allow the engine to cool. Push
S N
Start the engine and does not the choke valve open and Hard to Replace the carburetor assembly
check to see if the choke open release it. The choke should move
A IÓ
(P. 8-1) and the spark plug

opens within 3 minutes. open smoothly and snap closed (P. 3-9).
when released.
IR UC
Normal
D B
Check that the choke control assembly is installed correctly.

Remove the carburetor and
The choke lever tab may be on the wrong side of the choke
A RI
inspect the choke control

lever post, which will prevent the choke from opening. This
assembly linkage for smooth
problem can occur if the carburetor is installed when the
M ST
operation (P. 2-28). If it

engine is still warm.
operates properly, replace the
thermowax assembly
DI
(P. 8-18).
Normal
CHOKE LEVER TAB CHOKE CHOKE
CONTROL CONTROL
20 U
ASSEMBLY LINKAGE
20 O S
1- ID
THERMOWAX
ASSEMBLY
-0 HIB
CARBURETOR CHOKE
LEVER POST
03 O
PR
2-27

CHOKE CONTROL INSPECTION (K8 ONLY)
1. Thread a flange nut onto an 8 x 20 mm or longer flange bolt
.A O
until only 12 mm of threads are exposed beyond the nut.
.
IS D
S ZA
A RI
IR O
D UT
12 mm
A A
2. Position the end of the bolt against the auto-choke plunger
M NO
and slowly push it until the flange nut seats and then slowly Push the bolt against
the plunger.
release the bolt.
Do this slowly several times and make sure the choke control
.- O
operates smoothly and springs back when released. If the
auto-choke assembly does not return smoothly, it must be
.A US
replaced.
IS O
Make sure choke
does not bind.
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-28
9. FLYWHEEL BRAKE TROUBLESHOOTING
.A O
Blade (engine) does not stop turning when
.
IS D
the flywheel brake lever is released.
S ZA
Abnormal Repair or replace the cable.
Check the flywheel brake cable for binding.
A RI
IR O
OK
D UT
Check the flywheel brake spring (P. 3-12). Abnormal Correct as required (P. 9-1).
A A
OK
M NO
Check the engine stop switch (go to step 1
on page 2-20). Replace engine stop switch
Abnormal
(P. 9-1).
.- O
OK
.A US
Check flywheel brake pad (P. 3-12). Abnormal Replace flywheel brake pad
(P. 9-1).
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
2-29
10. TROUBLESHOOTING VIBRATION PROBLEMS
.A O
Grass and debris lodged Yes Clean out mower deck.
.
IS D
under mower deck.
S ZA
No
Yes Tighten blade bolts (P. 3-4).

Blades bolts loose.
A RI
No
IR O
Blades bent, damaged, or • Inspect blades (P. 3-4).
D UT
Yes • Replace blades (P. 3-4).
unbalanced by improper
sharpening. • Check crankshaft runout.
(P. 2-30).
No
A A
M NO
Engine speed excessive Yes Check/adjust the engine rpm.
No
Engine mounting bolts Tighten the bolts (P. 5-2).
.- O
Yes
loose.
.A US
No
Mechanical damage, such Yes

as a bent crankshaft. Check crankshaft runout
IS O
(P. 2-30).
S N
A IÓ
CRANKSHAFT RUNOUT INSPECTION

If the mower has excessive vibration, or if blade replacement is required
IR UC
because of damage caused by an object hitting the blade, inspect the

crankshaft runout.
1. Turn the fuel valve to the OFF position, and tilt the mower on its side
D B
so the carburetor is up.

A RI
2. Disconnect the spark plug cap, and remove the spark plug (P. 3-9).
M ST
3. Remove the blades, blade holder, and drive pulley (P. 4-1).
4. Attach the dial indicator magnetic base to the lower deck surface.
DI
5. Position the tip of the dial indicator perpendicular and

5-10 mm (0.20-0.39 in) from the end of the crankshaft.
20 U
DIAL INDICATOR
6. Zero the dial indicator. (Commercially
20 O S
available)
NOTICE
BLADE HOLDER
When checking the crankshaft runout, do not allow the dial indicator BOLT
1- ID
tip to drop into the keyway or the dial indicator tip can be damaged.
7. Use the blade holder bolt and a wrench to rotate the crankshaft.
-0 HIB
Record the runout. 90°
Service limit
Crankshaft
03 O
90°
0.20 mm (0.008 in)
PR
5-10 mm
8. Replace the crankshaft if runout exceeds the service limit. (0.20-0.39 in)
2-30
3. MAINTENANCE
.A O
1. MAINTENANCE SCHEDULE . . . . . . . . . . 3-2 10. SPARK ARRESTER CLEANING (OPTIONAL
2. MAINTENANCE SPECIFICATIONS . . . . . 3-3 PART) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
.
IS D
3. ENGINE TUNE-UP SPECIFICATIONS . . . 3-3 11. SMART DRIVE CABLE . . . . . . . . . . . . . . 3-10
S ZA
4. REAR SHIELD . . . . . . . . . . . . . . . . . . . . . . 3-4 12. FUEL TANK AND FILTER . . . . . . . . . . . . .3-11
5. BLADES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 13. FLYWHEEL BRAKE. . . . . . . . . . . . . . . . . 3-12
A RI
6. ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . 3-7 14. VALVE CLEARANCE. . . . . . . . . . . . . . . . 3-13
IR O
7. AIR FILTER CLEANING. . . . . . . . . . . . . . . 3-8 15. PINION GEAR . . . . . . . . . . . . . . . . . . . . . 3-15
8. GRASS BAG . . . . . . . . . . . . . . . . . . . . . . . 3-8 16. REAR WHEEL ADJUSTER BUSHING . . 3-16
D UT
9. SPARK PLUG INSPECTION . . . . . . . . . . . 3-9 17. GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . 3-17
A A
M NO
.- O
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
3-1
MAINTENANCE HRR216VKA
1. MAINTENANCE SCHEDULE
.A O
.
IS D
50 hours 150 hours
Before 5 hours First 100 hours
of use or of use or See
S ZA
Item Action each of use or 25 hours of use or
every every two page
use first month of use every year
6 months years
A RI
Rear shield Check O 3-4
IR O
Blades Inspect O 3-4
D UT
Blade mounting bolts Inspect O 3-6
Check O 3-7
Engine oil
A A
Change O O (1) O O 3-7
Check O
M NO
Air filter Clean O (2) O (2) O (2) 3-8
Replace O
.- O
Grass bag Check O 3-8
.A US
Blade control operation Check O O 3-12
Check O
Spark plug 3-9
IS O
Replace O
Spark arrester (optional
Clean
O 3-9
S N
part)
A IÓ
Smart Drive cable Adjust O O O O O 3-10

Fuel tank/filter Clean O 3-11
IR UC
Flywheel brake pad Check O 3-12

Check- O
D B
Valve clearance 3-13

adjust
A RI
Pinion gears Grease O 3-15

M ST
Rear wheel adjuster Inspect- O 3-16

bushings grease
Fuel lines Check Check every 2 years and replace if necessary 3-12
DI
(1) Change engine oil every 25 hours when used under heavy load or in high outside air temperatures.
(2) Service more frequently when used in dusty areas.
20 U
Failure to follow this maintenance schedule could result in non-warrantable failures.

20 O S
1- ID
-0 HIB
03 O
PR
3-2
HRR216VKA MAINTENANCE
2. MAINTENANCE SPECIFICATIONS
.A O
.
IS D
Item Specification See
page
S ZA
Engine oil Capacity: 0.50 L (17 oz) 3-7
* Refill amount: 0.35 ~ 0.40 L (12.0 ~ 13.5 oz)
A RI
Use SAE 10W - 30 for general use.
IR O
Air cleaner Clean with compressed air, not exceeding 207 kPa (30 psi). 3-8
D UT
Spark plug NGK-BPR5ES 3-9
Gap: 0.70 ~ 0.80 mm (0.028 ~ 0.031 in)
A A
Spark Arrester (optional) Brush carbon deposits from screen. 3-9
M NO
Fuel tank Back flush with nonflammable solvent. 3-11
Fuel filter Remove the fuel filter from the fuel line and clean. 3-11
.- O
Fuel line Replace if damaged or deteriorated. 3-12
.A US
Valve clearance (cold) Intake:. . . . . . . . . . . . . . . . . . . . . . . . .0.15 ± 0.04 mm 3-13
Exhaust: . . . . . . . . . . . . . . . . . . . . . . .0.20 ± 0.04 mm
Governor arm Adjust so shaft is rotated fully clockwise at full throttle. Check the 3-15
IS O
engine rpm after adjusting.
Flywheel brake cable No adjustment. Inspect for proper operation only. 3-13
S N
A IÓ
Flywheel brake mechanism Brake shoe thickness service limit: 3.0 mm (0.12 in) 3-12
Pinion gear Lubricate with NLGI #2 grease 3-17

IR UC
Blades and blade bolts Sharpen or replace as necessary. 3-4

Blade bolt torque: 49 ~ 59 N•m (36 ~ 43 ft-lb)
D B
Grass bag Clean with a garden hose. Replace if worn or damaged. 3-8
A RI
Rear wheel adjuster bushing Inspect for corrosion or wear, and then apply grease. 3-17
M ST
3. ENGINE TUNE-UP SPECIFICATIONS

DI
Item Specification See

20 U
page
20 O S
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 3-9
Engine idle speed (K5 thru K8 only) 1,700 ± 150 rpm 3-17
1- ID
Valve clearance (cold) Intake: . . . . . . . . . . . . . . . . . . . . . . . . 0.15 ± 0.04 mm 3-13

Exhaust: . . . . . . . . . . . . . . . . . . . . . . 0.20 ± 0.04 mm
-0 HIB
Other specifications No other adjustments needed.

03 O
PR
3-3
4. REAR SHIELD
.A O
During normal use the rear shield is subject to
.
IS D
deterioration and wear. Remove the grass bag and
S ZA
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
A RI
DISCHARGE GUARD
using a flat blade screw driver. If the shaft is crimped
at the end, cut the shaft with a small hacksaw and
IR O
replace the shaft.
D UT
REAR SHIELD
A A
5. BLADES
M NO
INSPECTION (K9 Blades Shown)
.- O
1. Turn the fuel valve to the OFF position. This will reduce the K9 MODEL SHOWN
possibility of fuel leakage when the mower is tilted.
.A US
3. Tilt the mower on its right side, so the carburetor is up.
BLADE
IS O
4. Inspect the blades for damage, cracks, and excessive wear, BOLTS
rust, or corrosion.
S N
5. Verify the blade bolts are tight. BLADES

A IÓ
6. If the blades are bent or severely damaged, check the

crankshaft runout (P. 2-30).
IR UC
7. Dull blades can be sharpened, but blades that

D B
are worn out, bent, cracked, or otherwise

A RI
damaged must be replaced.

M ST
Normal Trailing
edge
DI
EXCESSIVELY WORN
Trailing edge
20 U
NORMAL WORN BENT CRACKED

20 O S
1- ID
-0 HIB
03 O
PR
3-4
REMOVAL
1. Turn the fuel valve to the OFF position,
.A O
disconnect the spark plug, and tilt the mower UPPER BLADE
.
IS D
on its right side.
LOWER BLADE
S ZA
2. Remove the two blade bolts and special
washers from the blade control assembly. Use
a wooden block to prevent the blades from SPECIAL
A RI
WASHER (2)
turning when removing the bolts (page 3-6).
IR O
3. Clean dirt and grass from around the blade
mounting area.
D UT
BLADE BOLT (2)
A A
M NO
SHARPENING CORRECT SHARPENING
NOTICE
.- O
Do not sharpen a blade that is damaged or excessively worn or
corroded.
.A US
1. Grind or file the blades no more than necessary to
remove nicks and restore straight, sharp cutting edges.
IS O
• Always wear eye protection when operating a grinder.
TAPER
• Wear heavy gloves to protect your hands.
S N
• Grind or file the upper surface of the blades only. The

A IÓ
cutting edge must be even with the lower surface of the

blades.
IR UC
• Taper the blade profile, removing material from the

blade tip, never the inner end of the cutting surface.
D B
Grinding or filing a step in the blades can create a

weak point, causing cracks to develop in the blades 30° ~ 40°
A RI
during mower operation.

M ST
• Maintain the original bevel angle (30° ~ 40°) while

sharpening. Do not alter the angle.
DI
• Remove equal amounts of material from both cutting

edges to preserve symmetry and balance.
20 U
2. After sharpening, dress the cutting edges with a file so

20 O S
they will not be razor-sharp. Razor-sharp edges will

0.1 ~ 0.3 mm
easily chip and will quickly become dull. (0.004 ~ 0.012 in)
The blades should be 0.1 ~ 0.3 mm (0.004 ~ 0.012 in)
1- ID
thick at the cutting edges.

-0 HIB
03 O
PR
3-5
3. Check blade balance by placing the clean,

sharpened blade on a dowel or screwdriver, as
.A O
shown. A balanced blade will stay horizontal. If
one end of the blade dips, grind or file the heavy
.
IS D
end until good balance is achieved.
S ZA
NOTICE
A RI
An unbalanced blade will cause abnormal
vibration that may eventually damage the mower.
IR O
D UT
INSTALLATION
A A
1. Inspect the blade bolts for any signs of damage.
M NO
K9 BLADES
If they are damaged, they must be replaced. SHOWN
2. Install the blades using the two blade bolts and
special washers, as shown.
.- O
UPPER BLADE
Install the special washers with the concave side
.A US
toward the blades and the convex side toward the
head of the bolts.
The blade bolts are specially designed for this
IS O
LOWER BLADE
application and must not be replaced with other
bolts. BLADE BOLT [2]
AND WASHER [2]
S N
SPECIAL WASHER
A IÓ
DIRECTION
IR UC
3. Tighten the blade bolts to the torque specification WOODEN BLOCK

below.
D B
TORQUE: 49 ~ 59 N•m (36 ~ 43 ft-lb)

A RI
M ST
DI
TORQUE
WRENCH
20 U
TORQUE:
36 ~ 43 ft-lb
20 O S
1- ID
-0 HIB
03 O
PR
3-6
6. ENGINE OIL
.A O
OIL LEVEL CHECK
.
IS D
1. Run the engine for a few minutes prior to
S ZA
draining to allow complete and rapid draining.
2. To check the oil level, remove the oil filler cap
A RI
and wipe the dipstick clean.
FILLER CAP/
3. Insert the dipstick in the oil filler neck, but don’t
IR O
DIPSTICK
screw it in. Remove the dipstick and check the oil
UPPER
D UT
level. LIMIT
4. Add the recommended oil to the upper limit mark LOWER
LIMIT
on the dipstick. Do not overfill.
A A
5. Tighten the oil filler cap securely.
M NO
OIL CHANGE
1. Check that the fuel tank cap is tightened securely.
.- O
2. Remove the oil filler cap. Tilt the engine toward the oil filler cap side and
.A US
drain the used oil into a suitable container.
Please dispose of used motor oil in a manner that is compatible with the
environment. We suggest you take used oil in a sealed container to your
IS O
local recycling center or service station for reclamation. Do not throw it in
the trash or pour it on the ground or down a drain.
S N

A IÓ
CAUTION
Used engine oil contains substances that have been
IR UC
identified as carcinogenic.
If repeatedly left in contact with the skin for prolonged
periods, it may cause skin cancer.
D B
Wash your hands thoroughly with soap and water as soon as

A RI
possible after contact with used engine oil.

M ST
3. Refill with the recommended oil to the upper limit mark on the dipstick.
Check the oil level with the mower on a level surface, and the dipstick fully
inserted but not screwed in.
DI
Engine oil 0.50 L (17 oz)

20 U
capacity Refill amount: 0.35 ~ 0.40 L

(12.0 ~ 13.5 oz)
20 O S
Oil is a major factor affecting performance and service life. Use 4-stroke
automotive detergent oil.
1- ID
SAE 10W-30 is recommended for general use. Other

-0 HIB
viscosities shown in the chart may be used when the average

30
temperature in your area is within the recommended range.
5W-30 • 10W-30
The SAE oil viscosity and service classification are given in
03 O
the API label on the oil container. Honda recommends that 0 20 40 60 80 100°F
you use API service category SJ or later oil.
PR
-20 -10 0 10 20 30 40°C

OUTSIDE AIR TEMPERATURE
3-7
7. AIR FILTER CLEANING
.A O
A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If the engine is operated in dusty
.
IS D
areas, clean the air filter more often than specified in the MAINTENANCE SCHEDULE.
S ZA
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.
A RI
NOTICE
Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine, causing rapid
IR O
engine wear. This type of damage is not covered by the Distributor’s Limited Warranty.
D UT
1. With the engine stopped, press the latch tabs on
the top of the air cleaner and remove the air
A A
cleaner cover.
2. Remove the paper filter from the air cleaner
M NO
housing.
AIR CLEANER
3. Inspect the filter and replace it if it is damaged. HOUSING
O
4. Clean the filter. Tap the filter several times on a
.- O
N
D
A
hard surface to remove dirt, or blow with COVER
.A US
TABS
compressed air not exceeding 207 kPa (30 psi)
through the filter from the inside. Never try to
brush off dirt; brushing will force dirt into the
COVER
IS O
fibers. FILTER
5. Wipe dirt from the inside of the air cleaner
S N
housing and cover using a moist rag.

A IÓ
Be careful to prevent dirt from entering the air duct leading to the carburetor.
6. Reinstall the filter and air cleaner cover.
IR UC
8. GRASS BAG
D B
A RI
INSPECTION
M ST
The grass bag is subject to wear during normal use. Inspect the bag for excessive wear or holes or tearing, and
replace if necessary.
DI
CLEANING
Wash a dirty grass bag with a garden hose, and allow it to dry completely before use. A wet bag will clog quickly.
20 U
REPLACEMENT
20 O S
Replace a worn or damaged bag with a Honda GRASS BAG

Genuine replacement bag or its equivalent. BAG FRAME HANDLE
1. Unclip the plastic edges of the bag from the
1- ID
frame.
-0 HIB
2. Remove the bag from the frame.

3. Insert the frame into the replacement bag, as
shown.
03 O
4. Clip the plastic edges of the bag onto the frame,

PR
as shown. PLASTIC CLIP GRASS BAG
3-8
9. SPARK PLUG INSPECTION
.A O
.
IS D
Recommended spark plug NGK BPR5ES
S ZA
SPARK PLUG
An incorrect spark plug can cause engine damage. Use the
recommended spark plug or an exact equivalent.
A RI
1. Remove the spark plug with a 13/16 in (21 mm) spark plug
wrench.
IR O
2. Visually inspect the spark plug. Discard the plug if the
D UT
insulator is cracked or chipped.
SPARK PLUG CAP
A A
M NO
3. Measure the plug gap with a wire-type gauge. If
necessary, adjust the gap by bending the side electrode. 0.028 ~ 0.031 in
(0.7 ~ 0.8 mm)
.- O
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
.A US
4. Make sure the sealing washer is in good condition and replace if SEALING
necessary. WASHER
IS O
5. Install the plug finger-tight to seat the washer, then tighten with a plug
wrench to compress the sealing washer:
S N
Tighten a new plug 1/2 turn after the plug seats.

A IÓ
Tighten a reused plug 1/8 ~ 1/4 turn after the plug seats.
IR UC
NOTICE
A loose spark plug can overheat and damage the engine. Overtightening can
D B
damage the threads in the cylinder head.

A RI
10. SPARK ARRESTER

M ST
SETSCREW
CLEANING
DI
(OPTIONAL PART)
20 U
The spark arrester must be serviced every 100 hours

20 O S
to keep it functioning as designed.

1. Remove the three flange bolts from the muffler
A
D
protector.
N
O
H
1- ID
2. Remove the 4 x 6 mm self-tapping screw from

the spark arrester, and remove the spark
-0 HIB
arrester from the muffler. Be careful not to

damage the spark arrester screen.
SPARK ARRESTER
3. Check for carbon deposits around the exhaust
03 O
port and spark arrester. Clean with a wire brush, FLANGE BOLT (3) HEAT SHIELD
PR
if necessary. Replace the spark arrester if there

are any breaks or tears.
4. Install the spark arrester and muffler protector in the reverse order of disassembly.
3-9
11. SMART DRIVE CABLE
.A O
CABLE CHECK
.
IS D
1. With the engine off, use the multi-position adjuster to set the Smart Drive
S ZA
control in its lowest position.
2. Gradually push the Smart Drive control down while pulling the lawn
A RI
mower backwards.
The rear wheels should lock up before the Smart Drive paddles are
IR O
straight up-and-down. Ideally, they should lock up at approximately the
D UT
5:00 o’clock position.
3. If they don’t, perform the cable adjustment procedure below.
A A
CABLE ADJUSTMENT
M NO
ADJUSTER JAM NUT
1. With the engine off, loosen the adjuster jam nut. MARK
2. Without pushing the Smart Drive control, pull the lawn mower backwards
to check wheel resistance.
.- O
3. If no wheel resistance exists, mark the adjuster and TIGHTEN the TIGHTEN
.A US
adjuster one turn at a time until the wheels lock-up when pulling rearward.
LOOSEN
4. Turn the adjuster in the LOOSEN direction 8 complete revolutions.
IS O
5. Tighten the jam nut to lock the adjuster in place.
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
3-10
12. FUEL TANK AND FILTER
.A O
FUEL TANK DRAINING AND CLEANING FUEL TANK
.
IS D

S ZA
WARNING
Gasoline is highly flammable and explosive.
A RI
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
IR O
• Handle fuel only outdoors.
• Wipe up spills immediately.
D UT
1. Turn the fuel valve to the OFF position.
A A
2. Loosen the carburetor bowl set bolt and drain the fuel
bowl into an approved container.
M NO
FUEL TUBE TUBE CLIP
3. Turn the fuel valve to the ON position and allow the FUEL FILTER
remaining fuel in the tank to fully drain.
4. Slide the tube clip back on the fuel tube.
.- O
5. Rotate the fuel tube to help release the tube from the fuel
.A US
tank, and then pull the tube from the tank fitting.
NOTICE
IS O
Do not pry against the fuel tank with a screwdriver or
other tool, or the fuel tank may become damaged.
S N
6. Remove the fuel filter from the fuel tube.

A IÓ
7. Inspect the fuel filter for sediment and other foreign

IR UC
material. Inspect for tears or other damage.

8. Wash with solvent to clean, and dry thoroughly before
installation. Replace if necessary.
D B
9. If the fuel filter is dirty, remove and clean the fuel tank
A RI
(P. 8-23).
M ST
10. Insert the fuel filter into the fuel tank fitting.
11. Connect the fuel tube to the fuel tank fitting.
DI
12. Position the fuel tube clip over the fuel tank fitting.
13. After assembly, check for fuel leaks.
20 U
20 O S
1- ID
-0 HIB
03 O
PR
3-11
FUEL TUBE INSPECTION

1. Check the fuel tubes for deterioration, cracks, or signs of
.A O
leakage. Replace the fuel tubes if necessary.
.
IS D
2. To replace the fuel tubes, drain the fuel into a suitable
S ZA
container.
Honda Power Equipment manufactured in 2009 and later uses
A RI
low-permeation fuel tubes that have the CARB Executive
Order (C-U-05-003, for example) printed on them.
IR O
If you replace a low-permeation fuel tube, you must replace it
D UT
with a low-permeation fuel tube that has the emissions-
compliance identification number printed on it. If you replace a
regular fuel tube, you can replace it with a regular fuel tube. FUEL TUBE
A A
EMISSIONS-COMPLIANCE
Two styles of fuel tube clamps have been used. If you replace FUEL VALVE IDENTIFICATION NUMBER
M NO
the clamps, use the same style that is currently on the mower.
“D” STYLE CLAMP WIRE STYLE CLAMP
.- O
13. FLYWHEEL BRAKE K5 thru K8
.A US
3.0 mm (0.12 in)
INSPECTION
1. Remove the recoil starter (P. 7-1).
IS O
2. Remove the fan cover.
S N
3. Measure the thickness of the brake shoe.

A IÓ
Service limit 3.0 mm (0.12 in)

IR UC
FLYWHEEL BRAKE SHOE
4. If brake shoe thickness is less than the service limit, replace the K9
flywheel brake shoe.
D B
A RI
M ST
DI
K9 Flywheel Brake Spring Installation

20 U
Install the flywheel brake spring as shown. Make sure the hook on
20 O S
the long end of the spring is attached down through the hole in the
flywheel brake arm.
1- ID
-0 HIB
03 O
PR
3-12
FLYWHEEL BRAKE CABLE INSPECTION. FLYWHEEL

1. Start the engine outdoors. BRAKE LEVER
.A O
2. Release the flywheel brake lever. The engine should stop in
.
IS D
less than 3 seconds.
S ZA
If the flywheel brake does not operate properly, recheck the
flywheel brake shoe. If the flywheel brake shoe is within the
A RI
recommended service limit, replace the cable (P. 11-1).
IR O
14. VALVE CLEARANCE
D UT
INSPECTION AND ADJUSTMENT
A A
Valve clearance inspection and adjustment must be
performed with the engine cold.
M NO
6 x 12 mm FLANGE
1. Remove the spark plug cap from the spark plug. BOLT (4)
2. Remove the fan cover/fuel tank (P. 8-24).
.- O
3. Remove the four flange bolts from the cylinder head
cover.
.A US
4. Remove the cylinder head cover by prying slowly at each
corner.
IS O
Discard the head cover and replace it with a new one. CYLINDER HEAD
COVER
(Replace)
S N
A IÓ
5. To position the piston at top dead center of the

compression stroke (both valves are fully closed), rotate FAN COVER/FUEL TANK MOUNTING STUD
IR UC
the engine until the cam lobe is pointing away from the
flywheel.
D B
6. Align the flywheel arrow alignment mark with the right

rear fan cover/fuel tank mounting stud (K5 thru K8 only).
A RI
ARROW
M ST
ALIGNMENT
MARK
(K5 thru K8
ONLY)
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
CAM LOBE POINTING STRAIGHT OUT
3-13
7. Insert a feeler gauge between the valve stem and the

adjusting screw on the rocker arm. FEELER GAUGE
.A O
.
IS D
Standard valve IN 0.15 ± 0.04 mm
clearance (cold)
S ZA
EX 0.20 ± 0.04 mm
A RI
TOOL: VALVE
ADJUSTMENT
Valve adjustment wrench, 3 mm 07908-KE90200 LOCK NUT
IR O
8. If adjustment is necessary:
D UT
a. Hold the adjustment screw using the special tool, and
loosen the lock nut.

A A
VALVE
b. Turn the adjustment screw to obtain the specified ADJUSTMENT
intake and exhaust valve clearance. WRENCH, 3 mm
M NO
07908-KE90200
c. Hold the adjusting screw using the special tool, and
tighten the lock nut.
VALVE ADJUSTMENT
.- O
TORQUE:8 N•m (5.8 ft-lb) SCREW VALVE ADJUSTMENT
LOCK NUT
.A US
d. Recheck valve clearance after tightening the lock nut.
8 N•m (5.8 ft-lb)
9. Thoroughly clean the old sealant from the cylinder
head surface using an abrasive cloth and brake
IS O
cleaner.
10. Apply liquid gasket (Hondabond HT, Three Bond 1216, VALVE STEM
S N
or equivalent) to a new cylinder head cover sealing

A IÓ
surface, and install the cylinder head cover (P. 10-3). To increase valve clearance, screw out.
To decrease valve clearance, screw in.
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
3-14
15. PINION GEAR
.A O
LUBRICATION
.
IS D
1. Remove the 8 x 12 mm wheel bolt and the rear PINION GEAR
(12 tooth)
S ZA
wheel.
2. Remove the wheel washer and the flat washer.
A RI
3. Remove the 13 mm circlip, 3 mm collar, and the

pinion gear. RATCHET KEY
IR O
3 mm PINION Install with the
4. Lubricate the axle and the ratchet spring. Use punch mark
D UT
GEAR COLLAR
general purpose NLGI #2 grease. facing:

RATCHET Left - inside
5. Reassemble in the reverse order of SPRING Right - outside
A A
disassembly.
AXLE 3 mm PINION
M NO
GEAR COLLAR
13 mm
CIRCLIP
.- O
.A US
FLAT WASHER
WHEEL WASHER
IS O
REASSEMBLY:
Install the washer as shown.
S N
A IÓ
WHEEL BOLT
WHEEL
SIDE
IR UC
REAR WHEEL
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
3-15
16. REAR WHEEL ADJUSTER BUSHING
.A O
LUBRICATION
.
IS D
1. Drain the fuel and engine oil.
S ZA
PINION GEAR
2. Put a protective pad around
the upper handle pipe. Turn
A RI
the lawn mower over. Tip it UP

and secure the upper handle
RATCHET KEY
IR O
pipe in a vise.
THRUST COLLAR Install with the
D UT
3. Remove the rear wheel, pinion RATCHET punch mark
gear, ratchet key and spring, SPRING FLAT WASHER facing:
Left - inside

wheel cover, and all collars Right - outside
A A
and circlips from the
transmission axle.
M NO
3 mm PINION GEAR
4. (K5 thru K8 only): Remove the AXLE COLLAR (2)
rear scroll and drive belt 13 mm CIRCLIP (2)
(P. 4-2), and disconnect the
.- O
tension spring.
.A US
WHEEL COVER
IS O
WHEEL WASHER
S N
REASSEMBLY:
WHEEL BOLT
A IÓ

IR UC
WHEEL REAR WHEEL

SIDE
D B
A RI
5. Remove the 22 mm circlip, and then slide the

M ST
ADJUSTER
circlip and the washer inward toward the ASSEMBLY
transmission.
DI
6. Remove the adjuster assembly, taking care not

to damage the seal.
20 U

7. Inspect the bushing and seals for wear and WASHER
20 O S
replace as necessary.
8. Grease the bushing and seal, and then reinstall CIRCLIP
the adjuster assembly and secure with the
1- ID
washer and circlip.

9. Reassemble the rear wheel in the reverse order
-0 HIB
of removal, applying grease as shown.

10. Perform this procedure for the other side.
03 O
PR
3-16
17. GOVERNOR
.A O
MAXIMUM SPEED ADJUSTMENT
.
IS D
1. Loosen the governor arm nut on the governor arm. GOVERNOR ARM
S ZA
2. Push the governor arm away from the carburetor to
open the carburetor throttle valve fully.
A RI
3. Hold the carburetor throttle valve fully open, and turn
the governor arm shaft clockwise fully. Tighten the FUEL VALVE
IR O
PLATE GOVERNOR
governor arm nut to the specified torque. ARM SHAFT
D UT
TORQUE:10 N•m (7 ft•lb)
GOVERNOR
4. Verify that the governor arm and the carburetor throttle SPRING TAB GOVERNOR
A A
valve arm operate smoothly. SPRING
5. Start the engine and warm it up to the normal
M NO
operating temperature.
6. Have an assistant hold the flywheel brake lever while
you perform the maximum engine speed adjustment.
.- O
BEND BEND
GOVERNOR
.A US
 INCREASE ARM NUT
DECREASE
DANGER SPEED SPEED
The blades are rotating during this procedure.
The rotating blades can cause amputation. Do
IS O
not allow your hands or feet to come into contact
with the rotating blades while performing this
S N
procedure.
A IÓ
7. Check the maximum engine speed.

IR UC
Maximum speed 2,950 ~ 3,100 rpm

(no load)
D B
8. If adjustment is necessary, bend the governor spring tab on

A RI
the fuel valve plate very slightly.

M ST
• Left increases spring tension and engine speed.

• Right decreases spring tension and engine speed.
DI
IDLE SPEED ADJUSTMENT (K5 THRU K8)

1. With the engine running at normal operating THROTTLE STOP
20 U
SCREW
temperature, push the governor arm toward the
20 O S
carburetor and hold it in this position.

2. Adjust the throttle stop screw to obtain the specified
idle speed.
1- ID
Engine idle speed 1,700 ± 150 rpm

-0 HIB
03 O
PR
3-17
3-18
PR
MAINTENANCE
03 O
-0 HIB
1- ID
20 O S
20 U
DI
M ST
A RI
D B
NOTES
IR UC
A IÓ
S N
IS O
.A US
.- O
M NO
A A
D UT
IR O
A RI
S ZA
HRR216VKA
IS D
.A O
.
4. BLADE HOLDER/DRIVE BELT
.A O
1. BLADE HOLDER . . . . . . . . . . . . . . . . . . . . 4-1 4. DRIVE BELT (K8). . . . . . . . . . . . . . . . . . . . 4-6
2. DRIVE BELT (K5, K6) . . . . . . . . . . . . . . . . 4-2 5. DRIVE BELT (K9). . . . . . . . . . . . . . . . . . . . 4-7
.
IS D
3. DRIVE BELT (K7). . . . . . . . . . . . . . . . . . . . 4-4
S ZA
1. BLADE HOLDER
A RI
IR O
REMOVAL/INSTALLATION
D UT
1. Turn the fuel valve to the OFF position. This K9 BLADES SHOWN
will reduce the possibility of fuel leakage WOODRUFF KEY
when the mower is tilted.
A A
UPPER BLADE BLADE HOLDER
M NO
3. Tilt the mower on its right side so the LOWER BLADE
carburetor is up.
4. Remove the two blade bolts and special
.- O
washers, and then remove the blades SPECIAL
WASHER (2)
.A US
(page 3-5).
5. Remove the 3/8-24 x 1” flange bolt and
remove the blade holder. 3/8-24 X 1”
IS O
FLANGE
6. Install in the reverse order of removal. Pay BOLT
attention to the following: DRIVE PULLEY
S N
BLADE BOLT (2)

• Note that the keyway for the blade holder
A IÓ
Woodruff key is on the opposite side of the

crankshaft from the slot for the drive pulley
IR UC
key.
• Use a torque wrench to tighten the blade bolts
D B
and blade holder bolt.

A RI
TORQUE:49 ~ 59 N•m (36 ~ 43 ft-lbs)

M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
4-1
BLADE HOLDER/DRIVE BELT HRR216VKA
2. DRIVE BELT (K5, K6)
.A O
REMOVAL
.
IS D
S ZA
2. Drain the fuel tank and engine oil.
BELT FLANGE BOLT (4)
3. Put a protective pad around the upper handle pipe. Tip COVER
A RI
the mower upside down and secure the upper handle
pipe in a bench vise.
IR O
4. Remove the 4 flange bolts and the belt cover. SCREW-
D UT
DRIVER
5. Place a large screwdriver between the belt tension arm
and transmission cover. Rotate the transmission to
A A
loosen and remove the drive belt from the driven pulley. BELT TENSION ARM
M NO
6. Remove the belt from the drive pulley.
.- O
.A US
IS O
DRIVEN PULLEY
S N
DRIVE
A IÓ
BELT
IR UC
DRIVE PULLEY
D B
A RI
7. Remove the belt tension spring from the tension arm by

using a large flat blade screwdriver and lifting the spring SCREWDRIVER BELT TENSION ARM
M ST
hook off the tension arm as shown.

8. Remove the belt from the lawn mower.
DI
20 U
20 O S
1- ID
BELT TENSION
-0 HIB
SPRING
03 O
PR
4-2
HRR216VKA BLADE HOLDER/DRIVE BELT
INSTALLATION
BELT TENSION ARM
.A O
1. Install the drive belt around the drive pulley.
Be sure the drive belt is positioned between the driven
.
IS D
pulley on the transmission and the belt tension spring.
S ZA
2. Using a large flat blade screwdriver, hook the belt
tension spring on the belt tension arm.
A RI
IR O
D UT
DRIVEN
PULLEY
A A
BELT
DRIVE TENSION
M NO
BELT SPRING
.- O
BELT
and transmission cover. Rotate the transmission as
COVER
shown, and install the drive belt around the driven
.A US
pulley.
4. Install the belt cover.
IS O
S N
BELT TENSION ARM

A IÓ
IR UC
D B
A RI
M ST
DRIVE
DI
PULLEY DRIVE
BELT
20 U
20 O S
1- ID
-0 HIB
03 O
PR
4-3
3. DRIVE BELT (K7)
.A O
REMOVAL
.
IS D
S ZA
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
A RI
bench vise. SCREW-
IR O
DRIVER
4. Remove the 4 flange bolts and the belt cover.
D UT
and transmission cover. Rotate the transmission to BELT TENSION
loosen and remove the drive belt from the driven pulley. ARM
A A
6. Remove the belt from the drive pulley.
M NO
.- O
.A US
IS O
DRIVE
BELT
S N
A IÓ
DRIVEN PULLEY
IR UC
DRIVE PULLEY
D B
7. Remove the belt tension spring from the tension arm by

A RI
BELT TENSION ARM

using a large flat blade screwdriver and lifting the spring
hook off the tension arm as shown.
M ST
8. Remove the belt from the lawn mower.

DI
20 U
20 O S
DRIVE BELT
1- ID
-0 HIB
SCREWDRIVER
03 O
BELT BELT
PR
TENSION TENSION
ARM SPRING
4-4
INSTALLATION
.A O
1. Install the drive belt around the
drive pulley.
.
IS D
Be sure the drive belt is positioned
S ZA
between the driven pulley on the
transmission and the belt tension
spring.
A RI
2. Using a large flat blade
IR O
screwdriver, hook the belt tension BELT
spring on the belt tension arm.
D UT
TENSION
ARM
A A
DRIVEN PULLEY BELT
TENSION
SCREWDRIVER
M NO
SPRING
DRIVE
BELT
.- O
DRIVE BELT
.A US
3. Place a large screwdriver between
the belt tension arm and
IS O
COVER
transmission cover. Rotate the
transmission as shown, and install
S N
the drive belt around the driven

A IÓ
pulley.
4. Install the belt cover. SCREW-
IR UC
DRIVER
BELT
D B
TENSION
ARM
A RI
M ST
DI
20 U
20 O S
DRIVEN PULLEY
DRIVE
BELT
1- ID
-0 HIB
DRIVE PULLEY
03 O
PR
4-5
4. DRIVE BELT (K8) SERVICE BULLETIN #104 =>
.A O
REMOVAL
.
IS D
1. Turn the fuel valve OFF and disconnect the spark plug cap.
S ZA
2. Completely loosen the Smart Drive cable (page 11-15).
3. Tilt the mower on its right side with the fuel filler cap up.
A RI
4. Remove the blades and the blade holder (page 3-4).
IR O
5. Remove the rear scroll and belt cover assembly (page 4-4).
D UT
6. Remove the drive pulley and the drive belt from the crankshaft. Do not remove the belt guide.
7. Disconnect the drive cable and the return spring from the transmission.
A A
8. Hold the input shaft end with an adjustable wrench, and then remove the 10 mm flange nut.
M NO
9. Remove the driven pulley, 10 x 24 mm washer, and the drive belt from the transmission.
SMART DRIVE CABLE
.- O
INPUT SHAFT
.A US
RETURN SPRING
IS O
S N
10 mm FLANGE NUT
40 N•m (30 ft•lb)
A IÓ
IR UC
DRIVE BELT
D B
A RI
12 x 24 mm WASHER
BELT
GUIDE
M ST
DI
DRIVE
DRIVEN
PULLEY
PULLEY
20 U
20 O S
INSTALLATION
1. Install in the reverse order of removal. Be sure to do the following items:
1- ID
• Be sure to install the 12 x 24 mm washer on the transmission input shaft before assembling the pulley.
-0 HIB
• Align the holes in the transmission pulley halves when reassembling the pulley.
• Be sure to tighten the blade holder and blade bolts using a torque wrench.
2. Adjust the Smart Drive cable (page 3-10).
03 O
3. Start the engine and test the drive system.

PR
4-6
5. DRIVE BELT (K9)
.A O
REMOVAL/INSTALLATION SERVICE BULLETIN #104 =>
.
IS D
S ZA
1. Turn the fuel valve OFF.
A RI
3. Move the Clip Director® to the fully open (BAG)
position.
IR O
4. Fully loosen the Smart Drive cable adjuster
D UT
(page 11-15).
5. Turn the mower on its right side with the gas
A A
filler cap up.
M NO
6. Remove the blades and blade holder
(page 3-4).
.- O
7. Remove the three 6 x 10 mm flange bolts [1],
two 6 x 8 mm shoulder bolts [2], and one [1]
.A US
shoulder screw [3], and then remove the rear
scroll.
[2]
IS O
S N
[3]
A IÓ
[2]
IR UC
[1]
D B
[1]
A RI
8. Remove the Woodruff key, slide the drive pulley

M ST
away from the engine, and remove the V-belt

from the drive pulley. Do not remove the belt
DI
guide.
V-BELT
20 U
9. Rotate the transmission and remove the Smart

20 O S
Drive cable and the return spring. DRIVE PULLEY
BELT GUIDE
1- ID
-0 HIB
03 O
PR
4-7
10. Hold the end of the transmission input shaft

with an adjustable wrench and remove the
.A O
10 mm flange nut.
INPUT SHAFT
.
IS D
11. Remove the driven pulley, 10 mm washer, and
the V-belt from the transmission.
S ZA
12. Install in the reverse order of removal. Pay
attention to the following:
A RI
• Be sure to install the 10 mm washer on the FLANGE NUT
10 mm
IR O
transmission input shaft before assembling
the driven pulley.
D UT
• Align the holes in the driven pulley halves
A A
when reassembling the pulley.
• Be sure the blade holder Woodruff key is
M NO
installed.
It is easy for the key to fall out during
.- O
installation. If it is not installed, the blade
holder bolt will eventually break, allowing the
.A US
blade and blade holder to fall off during
operation.
• Be sure the Clip Director® is fully open (BAG)
IS O
when installing the rear scroll.
• Align the lower Clip Director® hinge pin with
S N
the hole in the scroll. SPECIAL NUT

A IÓ
• Use a long flat blade screwdriver and a piece

of tape to hold the upper special nut in place
IR UC
while installing the shoulder screw in the

center of the rear scroll.
D B
• Readjust the Smart Drive cable (P. 3-10).

A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
4-8
5. ENGINE REMOVAL/INSTALLATION
.A O
1. REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 5-2
.
IS D
S ZA
1. REMOVAL
1. Drain the gasoline from the fuel tank into an
A RI
K9 BLADES SHOWN
approved container.
IR O
ENGINE MOUNTING BOLT (4)
2. Drain the engine oil (page 3-7).
UPPER BLADE
D UT
3. Release the recoil starter rope from the handlebar WOODRUFF KEY
rope guide.
BLADE HOLDER
LOWER BLADE
A A
4. Disconnect the flywheel brake cable from the
engine.
M NO
5. Remove the blades. SPECIAL
WASHER (2)
6. Remove the 3/8-24 x 1" flange bolt and remove the
blade holder and Woodruff key.
.- O
7. Slide the drive pulley off the crankshaft and remove
.A US
the V-belt.
8. Support the engine, remove the four 5/16-24 x 1" DRIVE PULLEY
BLADE BOLT (2)
engine mounting flange bolts, and remove the
IS O
3/8-24 x 1" FLANGE BOLT
engine.
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
5-1
ENGINE REMOVAL/INSTALLATION HRR216VKA
2. INSTALLATION
.A O
1. Set the engine on the mower deck and install the four 5/16-24 x 1” engine mounting flange bolts.
.
IS D
TORQUE: 22 N•m (16 ft-lbs)
S ZA
2. Slide the V-belt over the drive pulley, and then slide the pulley on the crankshaft.
3. Install the Woodruff key and attach the blade holder using the 3/8-24 x 1" flange bolt. Be sure the Woodruff key
A RI
remains in place when installing the blade holder.
IR O
TORQUE: 49 ~ 59 N•m (36 ~ 43 ft-lbs)
4. Attach the blades using the two special bolts and
D UT
washers. BLADE HOLDER
UPPER BLADE
TORQUE: 49 ~ 59 N•m (36 ~ 43 ft-lbs) LOWER BLADE
A A
WASHER
SPECIAL BLADE BOLT
M NO
5. Connect the flywheel brake cable to the engine.
6. Attach the recoil starter rope to the handlebar rope guide.
.- O
7. Add oil (page 3-7) and gasoline before starting the engine.
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
5-2
6. MUFFLER
.A O
1. REMOVAL/INSTALLATION. . . . . . . . . . . . 6-1
.
IS D
S ZA
1. REMOVAL/INSTALLATION
 CAUTION
A RI
IR O
The engine and muffler become very hot during operation, and
they remain hot for a while after operation. Be sure that the
D UT
engine is cold before muffler removal/installation.
A A
4 x 6 mm
SPARK ARRESTER (optional part) SELF-TAPPING SCREW
M NO
INSTALLATION: (optional part)
Install after removing the carbon from
the screen with a wire brush. SPARK ARRESTER
IDENTIFICATION PLATE
(optional part)
.- O
.A US
IS O
S N
A IÓ
6 x 12 mm
SCREW, (3) MUFFLER GASKET
IR UC
(optional part)
Install a gasket anytime the
muffler has been removed.
D B
MUFFLER
A RI
INSTALLATION:
• Use a plastic hammer to loosen carbon deposits from
M ST
the muffler, and then remove the carbon deposits from

MUFFLER muffler.
PROTECTOR • Do not tap on the muffler seal flange to avoid damaging
DI
this part. If the seal flange is dented or damaged, replace

the muffler.
6 x 79 mm FLANGE BOLT (2) • Check the cylinder exhaust port for damage, and install
20 U
the muffler.
12 N•m (9 ft-lb)
20 O S
MUFFLER SEAL
FLANGE
1- ID
-0 HIB
03 O
EXHAUST PORT
PR
6-1
6-2
MUFFLER
PR
03 O
-0 HIB
1- ID
20 O S
20 U
DI
M ST
A RI
D B
NOTES
IR UC
A IÓ
S N
IS O
.A US
.- O
M NO
A A
D UT
IR O
A RI
S ZA
HRR216VKA
IS D
.A O
.
7. RECOIL STARTER
.A O
1. REMOVAL/INSTALLATION . . . . . . . . . . . . 7-1 2. STARTER ROPE REPLACEMENT . . . . . . 7-2
.
IS D
SERVICE REMINDER #4 =>
S ZA
1. REMOVAL/INSTALLATION
• If the starter rope is frayed or worn out, replace the starter rope (P. 7-2).
A RI
• Do not disassemble the recoil starter assembly
IR O
.
D UT
RECOIL STARTER
ASSEMBLY
A A
M NO
6 mm FLANGE NUT (3)
8.3 N•m (6.1 ft-lb)
.- O
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
7-1
RECOIL STARTER HRR216VKA
2. STARTER ROPE REPLACEMENT
.A O
Starter Rope and Reel Intact
.
IS D
1. Pull starter grip until the starter rope is pulled out fully.
S ZA
2. To prevent the starter reel from rewinding, hold the starter
reel and starter case with a band or equivalent material as
A RI
shown.
3. Untie the knots of the starter rope at the starter grip side
IR O
and the starter reel side, and remove the starter rope.
D UT
4. Pass the new starter rope through the starter grip and
make a knot at the end of the rope.
A A
5. Pass the other end of the starter rope through the rope
hole in the starter case and through the rope hole in the
M NO
starter reel, and make a slip knot at the end of the rope.
6. Remove the band holding the starter reel and carefully
allow the starter reel to rewind.
.- O
7. Check the operation of the ratchets by pulling the starter
.A US
rope several times.
IS O
BAND
STARTER CASE
STARTER REEL
S N
A IÓ
IR UC
STARTER
REEL
D B
A RI
M ST
STARTER
ROPE
DI
STARTER GRIP
20 U
20 O S
1- ID
-0 HIB
RATCHETS
03 O
PR
7-2
HRR216VKA RECOIL STARTER
Starter Rope Broken Or Reel Unwound ALIGN

STARTER REEL
1. Turn the starter reel in the direction of the arrow six turns. HOLES
.A O
Align the rope hole in the starter case with the rope hole in
.
IS D
the starter reel.
S ZA
2. Pass the starter rope through the starter grip and make a
knot at the end of the rope.
A RI
3. Pass the other end of the starter rope through the rope
hole in the starter case and through the rope hole in the
IR O
starter reel, and make a slip knot at the end of the rope.
D UT
4. Remove the band holding the starter reel and carefully STARTER CASE
allow the starter reel to rewind.
5. Check the operation of the ratchets by pulling the starter
A A
rope several times.
M NO
STARTER
REEL
.- O
.A US
STARTER
ROPE
IS O
STARTER GRIP
S N
A IÓ
IR UC
D B
A RI
RATCHETS
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
7-3
7-4
PR
03 O
RECOIL STARTER
-0 HIB
1- ID
20 O S
20 U
DI
M ST
A RI
D B
NOTES
IR UC
A IÓ
S N
IS O
.A US
.- O
M NO
A A
D UT
IR O
A RI
S ZA
HRR216VKA
IS D
.A O
.
8. FUEL SYSTEM
.A O
1. AIR CLEANER/CARBURETOR 3. FUEL VALVE/GOVERNOR ARM. . . . . . . 8-21
REMOVAL/REINSTALLATION . . . . . . . . . 8-1 4. FAN COVER/FUEL TANK . . . . . . . . . . . . 8-24
.
IS D
2. CARBURETOR 5. EVAPORATIVE EMISSION CONTROL
S ZA
DISASSEMBLY/REASSEMBLY. . . . . . . . . 8-5 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
A RI
IR O
1. AIR CLEANER/CARBURETOR REMOVAL/REINSTALLATION
D UT
NOTICE
A A
If the carburetor is removed before the engine has completely cooled, the thermowax plunger may still be extended.
The plunger will not retract when the thermowax assembly is allowed to cool after removal without a continuous force
M NO
applied (see page 8-18). Before removing the carburetor, allow the engine to cool long enough for the choke to
completely close. This typically requires about 20 minutes.
.- O
WARNING
.A US
IS O
• Wipe up spills immediately.
S N
1. Turn the fuel valve to the OFF position.

A IÓ
2. Completely drain the carburetor (page 3-11).

IR UC
3. Remove the air cleaner cover and air filter.

4. Remove one 6 x 86 mm flange bolt securing the air cleaner case, and temporarily replace it with a 6 x 83 mm
D B
stud. Install and hand-tighten the stud.

A RI
5. While pushing the air cleaner case toward the engine, remove the other 6 x 83 mm flange bolt, and temporarily
install another 6 x 83 mm stud.
M ST
FUEL VALVE
DI
6 x 86 mm
FLANGE BOLT (2)
20 U
20 O S
1- ID
AIR CLEANER CASE

-0 HIB
AIR CLEANER
COVER
6 x 83 mm STUD (2)
Temporarily installed.
AIR FILTER
03 O
P/N 90013-ZG9-T00
PR
6. Pull the breather tube from the engine, and then remove the air cleaner case from the studs.
7. Hold the carburetor assembly together and remove it from the studs.
8-1
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.
.A O
10. The insulator, air guide, and gaskets do not need to be removed unless the gaskets are damaged and need to
.
IS D
be replaced. Reinstall in the reverse order from removal.
S ZA
K5 VERSION
A RI
GOVERNOR ROD/THROTTLE RETURN SPRING
THROTTLE RETURN SPRING REMOVAL:
IR O
INSTALLATION: P. 8-21 GOVERNOR ROD Remove the throttle return spring, and then rotate the
INSTALLATION: P. 8-21 carburetor in the direction shown and remove the
D UT
governor rod from the carburetor.
A A
M NO
.- O
GOVERNOR SPRING
INSTALLATION: P. 8-21
.A US
CARBURETOR
DISASSEMBLY/REASSEMBLY:
P. 8-5
CLEANING: P. 8-6
IS O
INSPECTION: P. 8-15
S N
CONTROL BASE
A IÓ
INSULATOR DISASSEMBLY/REASSEMBLY:
GASKET P. 8-21
IR UC
Replace.

D B
CHOKE CONTROL ASSEMBLY AIR GUIDE

A RI
TROUBLESHOOTING: P. 2-26 6 x 45 mm
INSTALLATION: P. 8-16 CARBURETOR
GASKET FLANGE BOLT
M ST
Replace.
TUBE CLIP (4)
IDENTIFICATION:
DI
CRANKCASE BREATHER TUBE

P. 8-23
6 x 83 mm FLANGE BOLT (2)
20 U
9.8 N•m (7.2 ft-lb)

20 O S
PAPER ELEMENT
CLEANING: P. 3-8
1- ID
AIR CLEANER
-0 HIB
GASKET
03 O
6 x 83 mm STUD (2)
PR
PART NUMBER: 90013-ZG9-T00 AIR CLEANER

Temporarily install to make carburetor COVER
installation easier.
8-2
HRR216VKA FUEL SYSTEM
K6 ~ K7 VERSION SERVICE BULLETIN #98 =>
.A O
.
IS D
REMOVAL:
S ZA
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
A RI
INSTALLATION: P. 8-22 GOVERNOR ROD
IR O
D UT
GOVERNOR SPRING
A A
FUEL VALVE ASSEMBLY
M NO
P. 8-22
B12 TUBE CLIP (2)
.- O
IDENTIFICATION: P. 8-23
.A US
6 x 28 mm
FLANGE BOLT
6 x 12 mm
THERMOWAX ASSEMBLY FLANGE BOLT
IS O
B8 TUBE CLIP (2)
S N
INSULATOR CARBURETOR IDENTIFICATION: P. 8-23

A IÓ
GASKET GASKET
Replace. Replace.
IR UC
CHOKE CONTROL ASSEMBLY SPACER

(without heat sink)
TROUBLESHOOTING: P. 2-26 AIR GUIDE
D B
INSTALLATION: P. 8-17 GASKET AIR CLEANER

GASKET
A RI
Replace.
Replace.
CARBURETOR
M ST
P. 8-5
CLEANING: P. 8-6
INSPECTION: P. 8-15
DI
PAPER ELEMENT
AIR CLEANING: P. 3-8
20 U
CRANKCASE BREATHER TUBE CLEANER

CASE
20 O S
1- ID
-0 HIB
6 x 83 mm STUD (2)
PART NUMBER: 90013-ZG9-T00
03 O

Temporarily install to make carburetor AIR CLEANER COVER
installation easier. 10 N•m (7 ft•lb)
PR
8-3
K8 ~ K9 VERSION SERVICE BULLETIN #98 =>
.A O
K8 MODEL SHOWN
.
IS D
S ZA
REMOVAL:
Remove the throttle return spring, and then rotate the carburetor in the
A RI
direction shown and remove the governor rod from the carburetor.
IR O
INSTALLATION: P. 8-21 GOVERNOR ROD
D UT
A A
M NO
.- O
GOVERNOR SPRING
.A US
THERMOWAX ASSEMBLY
INSPECTION: P. 8-18 FUEL VALVE ASSEMBLY
Apply a small amount of B12 TUBE CLIP (2)
IS O
Hondabond HT to the
bottom and lower third of
the new thermowax. Do
S N
6 x 28 mm
not apply too much. FLANGE BOLT
A IÓ
6 x 12 mm
FLANGE BOLT
IR UC
K9 MODEL B8 TUBE CLIP (2)

HAS A ROUND
INTAKE PORT CARBURETOR
D B
INSULATOR K8 GASKET (K8 ONLY)

GASKET
A RI
K9 Replace.
Replace.
M ST
SPACER (K8 ONLY)
CHOKE CONTROL ASSEMBLY AIR GUIDE

TROUBLESHOOTING: P. 2-27 GASKET AIR CLEANER
DI
INSTALLATION: P. 2-27 Replace. GASKET

Replace.
CARBURETOR
20 U
P. 8-5 AIR
20 O S
CLEANING: P. 8-6 AIR

CLEANER CLEANER
INSPECTION: P. 8-15 CASE (K9)
CASE (K8)
1- ID
CRANKCASE BREATHER TUBE

-0 HIB
03 O
PR
8-4
2. CARBURETOR DISASSEMBLY/REASSEMBLY
.A O
Clean the outside of the carburetor before disassembly.
.
IS D
S ZA
 WARNING NOTICE
Tampering is a violation of Federal and California law.
A RI
IR O
• Handle fuel only outdoors. 5 x 6 mm ACCESS SCREW
D UT
• Wipe up spills immediately. INSPECTION:
Remove access screw PILOT JET
to clean the slow (non-removable)
PART ITEM STANDARD VERSIONS speed jet.
A A
Carburetor Main jet #70 REASSEMBLY:
K5
BB65E A Float height 9.2 mm (0.36 in) Clean thoroughly with
M NO
Carburetor Main jet #68 compressed air.
K5
BB75E A Float height 7.2 mm (0.28 in)
Carburetor Main jet #68
K6, K7
BB75E B Float height 7.2 mm (0.28 in)
.- O
K8
.A US
BB75E C Float height 7.2 mm (0.28 in)
K9 THROTTLE STOP SCREW
BB76A A Float height
IS O 10.2 mm (0.40 in) (K5 ~ K8)
CARBURETOR BODY
CLEANING: P. 8-6 FLOAT VALVE
S N
REASSEMBLY: REASSEMBLY:
Clean internal passages and orifices with
A IÓ
Check for worn float valve seat and

compressed air before installation. float valve before installation.
IR UC
MAIN NOZZLE
REASSEMBLY: FLOAT VALVE
Clean thoroughly with compressed air
D B
before installation.
A RI
M ST
MAIN JET OK REPLACE

DI
Standard main jet size: P. 2-2

REASSEMBLY:
Clean thoroughly
FLOAT PIN
20 U
with compressed
air before
20 O S
installation.
SET GASKET
FLOAT
1- ID
REASSEMBLY:
Check for smooth movement after installation. FLOAT CHAMBER
-0 HIB
INSPECTION: P. 8-15
SET BOLT
03 O
REASSEMBLY:
After assembly, check for any
SEALING
PR
signs of fuel leakage.

WASHER
8-5
CLEANING
Use the jet cleaner set special tool (P/N 07JPZ-001010B) and Honda Carburetor Cleaner (P/N 08732-CC000) with
.A O
its plastic spray nozzle to clean the carburetor ports.
.
IS D
Some commercially-available chemical carburetor cleaners are very caustic. These cleaners may damage plastic
S ZA
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.
A RI
NOTICE
High air pressure may damage the carburetor. Use low pressure settings when cleaning passages.
IR O
BEFORE CLEANING
D UT
• If a significant amount of water, contamination, or deteriorated gasoline is inside the float chamber, inspect and
clean the inside of the fuel tank and fuel filter screen.
A A
• Carefully inspect all the gaskets for damage and replace as necessary.
M NO
• Be sure the work surface is clean.
• Use compressed air pressure of 207 kPa (30 psi) maximum.
.- O
 CAUTION
.A US
Always wear a face shield or safety glasses when using carburetor
cleaner or compressed air. Applying pressure into small passages can
cause fluid and air to shoot back into your face.
IS O
S N
CLEANING PROCEDURE
A IÓ
1. Thoroughly clean the outside of the carburetor body using carburetor cleaner and compressed air.
Inspect the carburetor body, throttle and choke levers, and pilot screw (including limiter cap) for damage. If any
IR UC
damage exists, carburetor replacement may be necessary.

D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-6
2. Remove the set bolt, float chamber, float pin, float

valve, and float.
.A O
Clean and then inspect the float valve tip for damage
.
IS D
and replace if necessary. See image above.
S ZA
A RI
IR O
D UT
A A
3. Remove the main jet and the main nozzle.
M NO
With the main jet removed, push down on the top of
the main nozzle with a screwdriver.
If the nozzle does not come out, spray carburetor
.- O
cleaner around the nozzle to loosen it and tap the
.A US
carburetor on the workbench. SCREWDRIVER
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
4. Remove the throttle stop screw and spring (if

applicable).
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-7
5. Remove the 5 x 6 mm screw covering the pilot jet.
.A O
.
IS D
S ZA
A RI
IR O
D UT
A A
M NO
.- O
6. Clean the float valve seat using carburetor cleaner
.A US
and compressed air.
FLOAT VALVE
SEAT
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-8
7. Clean the main nozzle thoroughly using carburetor cleaner, appropriate

size jet cleaning tool, and compressed air. Do not use a welding tip
.A O
cleaning needle.
.
IS D
NOTICE
S ZA
Using a welding tip cleaning needle or a jet needle that is too large may
damage the carburetor. Never force a needle, and never use a needle
A RI
with a bent or damaged tip.
Inspect the center and side holes for damage or contamination by
IR O
holding the main nozzle up to a light to verify they are clean.
D UT
A A
M NO
.- O
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-9
8. Clean the main jet by spraying carburetor cleaner through

the jet and using the appropriate size jet cleaning tool and
.A O
compressed air. Do not use a welding tip cleaning needle.
.
IS D
NOTICE
S ZA
Using a welding tip cleaning needle or a jet needle that is
too large may damage the carburetor. Never force a
A RI
needle, and never use a needle with a bent or damaged
tip.
IR O
Carefully inspect the main jet for damage or
D UT
contamination.
A A
M NO
.- O
.A US
IS O
S N
JET CLEANER
A IÓ
07JPZ-001010B
IR UC
D B
A RI
9. Clean the main jet and nozzle bore thoroughly using

carburetor cleaner and compressed air. MAIN JET AND
M ST
NOZZLE BORE
10. Inspect the inside of the bore for contamination.
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-10
11. Clean the pilot jet thoroughly by using the appropriate

size jet cleaning tool, carburetor cleaner, and
.A O
compressed air.
.
IS D
The passage is small and easily obstructed, so repeat
several times.
S ZA
A RI
IR O
D UT
PILOT JET
A A
M NO
.- O
.A US
12. Clean the high speed air passage with carburetor
cleaner and compressed air.
IS O
HIGH SPEED
AIR PASSAGE
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-11
13. Clean the float chamber vent hole with carburetor

cleaner and compressed air.
.A O
FLOAT CHAMBER
VENT HOLE
.
IS D
S ZA
A RI
IR O
D UT
A A
M NO
.- O
.A US
14. Clean the slow speed air passage.
Spray carburetor cleaner and compressed air through
the slow speed air passage.
IS O
The passage is small, so repeat several times.
S N
SLOW SPEED AIR
PASSAGE
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-12
15. Reinstall the 5 x 6 mm screw covering the pilot jet.
.A O
.
IS D
S ZA
A RI
IR O
D UT
A A
M NO
.- O
.A US
16. Check the slow speed air channel for obstructions.
Spray carburetor cleaner through the slow speed
air passage. SLOW SPEED
IS O
AIR PASSAGE
From the opposite end, confirm that a steady
stream of carburetor cleaner sprays out from CHOKE SIDE
S N
around the transition ports.

A IÓ
IR UC
THROTTLE SIDE
D B
A RI
M ST
DI
Steady stream around

the transition ports.
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-13
17. Reinstall the throttle stop screw and spring (if

applicable)
.A O
Tighten the screw just far enough so the throttle plate
.
IS D
begins to open.
S ZA
A RI
IR O
Adjust so throttle
D UT
plate just begins
to open.
A A
M NO
.- O
.A US
18. Reinstall the main nozzle and main jet, making sure
the nozzle long end extends into the venturi.
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
Nozzle extension
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-14
19. Install the float valve, float, and float chamber. Make
sure the float chamber is installed correctly, making a
.A O
good seal with the gasket.
.
IS D
20. Reinstall the carburetor on the engine, turn the fuel
valve on, and check for fuel leaks.
S ZA
21. Start the engine and allow it to warm up for several
minutes. Then adjust the idle speed (P. 3-17) and
A RI
check the maximum no load engine speed (P. 3-17).
IR O
D UT
A A
M NO
FLOAT LEVEL HEIGHT INSPECTION
Place the carburetor in the position as shown and measure
.- O
the distance between the float top and the carburetor body
when the float contacts the seat.
.A US
TOOL:
Float level gauge 07401-0010000
FLOAT HEIGHT: See page 2-2
IS O
If the height is out of specification, replace the float and/or
S N
the float valve. Recheck the float height.


A IÓ
FLOAT LEVEL GAUGE

IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-15
CHOKE CONTROL ASSEMBLY (K5) HEAT SINK
.A O
Apply a 3 ~ 5 mm thick bead
INSTALLATION of Hondabond HT to the
bottom surface of the heat
.
IS D
1. Install the choke assembly when the cylinder head sink as shown.
S ZA
temperature is less than 40°C (104°F).
2. Apply a small amount (3 ~ 5 mm thick bead) of
A RI
Hondabond HT Silicone (P/N 08718-0004) to the bottom
of the auto-choke assembly heat sink as shown. Do not
IR O
apply too much; only a small amount is needed.
D UT
3. Verify that the carburetor choke lever is in the fully closed
position.
A A
4. Install the carburetor and choke assembly (P. 8-2).
5. After installation, verify that there is clearance between
M NO
choke lever A and the carburetor choke lever.
CHOKE LEVER A
.- O
.A US
IS O
S N
A IÓ
IR UC
D B
CLEARANCE
EXISTS
A RI
CARBURETOR
CHOKE LEVER
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-16
CHOKE CONTROL ASSEMBLY (K6 THRU K7)
.A O
INSTALLATION
THERMOWAX
.
IS D
1. Install the choke assembly when the cylinder head ASSEMBLY
S ZA
2. Install the thermowax assembly into the cylinder barrel.
A RI
3. Verify that the carburetor choke lever is in the fully
closed position.
IR O
4. Install the carburetor and choke assembly (P. 8-3). INSULATOR
GASKET
D UT
5. After installation, verify that there is clearance between Replace.
CHOKE
choke lever A and the carburetor choke lever. ASSEMBLY
A A
CHOKE LEVER A
M NO
.- O
.A US
IS O
S N
A IÓ
IR UC
CLEARANCE
EXISTS CARBURETOR
CHOKE LEVER
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-17
CHOKE CONTROL ASSEMBLY (K8 thru K9)
.A O
Thermowax Installation
.
IS D
The thermowax plunger MUST be fully retracted and the overall length of the
thermowax must be 21.5 to 23.0 mm before installation.
S ZA
If the thermowax plunger is not fully retracted, proceed with the steps below to
fully retract the plunger prior to reassembly. If the length is less than 21.5 mm
A RI
and/or wax is visible around the plunger, replace the thermowax assembly.
21.5~23.0 mm
IR O
D UT
1. Position a pair of pliers on the thermowax assembly as shown. Do not
apply force yet.
A A
M NO
.- O
2. Place the thermowax under warm tap water (not exceeding 40°C or 104°F)
and gently squeeze pliers until the plunger is fully retracted.
.A US
Be careful not to apply too much force or bend the thermo plunger. Only
15 N (3.4 lbs) of force is required to push the plunger in.
IS O
Measure the thermowax and confirm the length is 21.5 to 23.0 mm.
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-18
Thermowax removal
Follow the steps below if you need to remove the thermowax assembly.
.A O
.
IS D
NOTICE
Removing the thermowax assembly will ruin it. A new assembly will be required for replacement.
S ZA
1. Use a small pair of pliers to pull the plunger out of the assembly.
A RI
IR O
D UT
A A
M NO
.- O
2. Screw a one-inch or longer #6 screw into the thermowax where the
plunger was removed.
.A US
IS O
S N
A IÓ
IR UC
D B
3. Use a pair of pliers to carefully pull the thermowax assembly out of the
A RI
cylinder barrel. Pull the thermowax straight out. Be careful not to damage
any points used for prying.
M ST
DI
20 U
20 O S
4. Use a knife or small scraper to remove the old sealant from the cylinder
barrel.
1- ID
Carburetor cleaner or brake cleaner and a small wire brush can help
-0 HIB
remove the sealant. Use compressed air to blow residue from the cylinder
barrel.
Removing the sealant, particularly in the rear of the socket, is important;
03 O
the new thermowax assembly must be pushed completely into the socket
to operate the choke properly.
PR
8-19
Choke Assembly Installation

1. Install the choke assembly when the cylinder head
.A O
.
IS D
2. Apply a small amount of Hondabond HT or Locktite 5900 to
S ZA
the bottom and lower third of the new thermowax. Do not
apply too much.
A RI
3. Install the thermowax assembly into the cylinder barrel. The
plunger must remain fully retracted during assembly.
IR O
4. Verify that the carburetor choke lever is in the fully closed THERMOWAX ASSEMBLY
D UT
position.
5. Install the carburetor and choke assembly (page 8-4).
A A
CHOKE
ASSEMBLY
M NO
HONDABOND HT
INSULATOR
GASKET
Replace.
.- O
.A US
6. After installation, verify that there is clearance between choke CHOKE LEVER A
lever A and the carburetor choke lever.
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
CLEARANCE CARBURETOR
EXISTS CHOKE LEVER
20 U
BREATHER TUBE
20 O S
Installation
Connect the end with the white mark to the breather cover hole as
WHITE
1- ID
shown. Connect the other end to the air cleaner case. MARK
-0 HIB
BREATHER BREATHER
03 O
TUBE COVER
PR
8-20
3. FUEL VALVE/GOVERNOR ARM
.A O
DISASSEMBLY/REASSEMBLY (K5)
.
IS D
GOVERNOR ARM/THROTTLE RETURN SPRING
S ZA
INSTALLATION:
Install the governor rod through the throttle return spring as shown. Connect each to the
governor arm and carburetor throttle arm as shown.
A RI
GOVERNOR
GOVERNOR ROD ARM
IR O
THROTTLE ARM
LONG END
D UT
A A
M NO
LONG END
.- O
.A US
IS O
S N
A IÓ
IR UC
D B
GOVERNOR ARM
A RI
ADJUSTMENT: P. 3-17
GOVERNOR SPRING
GOVERNOR ARM
M ST
REASSEMBLY: Install with BOLT

the short end side toward the GOVERNOR ARM NUT
governor arm.
9.8 N•m (7.2 ft-lb)
DI
FUEL TUBE
20 U
CONTROL BASE
20 O S
1- ID
6 x 45 mm 5 x 10 mm SCREW-WASHER
FLANGE BOLT
2.9 N•m (2.2 ft-lb)
-0 HIB
COLLAR
FUEL VALVE
5.5 x 150 mm FUEL HOSE
03 O
TUBE CLIP (4)

PR
8-21
DISASSEMBLY/REASSEMBLY (K6 thru K9)
.A O
GOVERNOR ARM/THROTTLE RETURN SPRING
.
IS D
INSTALLATION:
Install the governor rod through the throttle return spring as shown. Connect each to the
S ZA
governor arm and carburetor throttle arm as shown.
GOVERNOR
GOVERNOR ROD ARM
A RI
THROTTLE ARM
LONG END
IR O
D UT
A A
LONG END
M NO
.- O
LOW PERMEATION FUEL TUBE WITH
EMISSIONS COMPLIANCE ID NUMBER
.A US
IS O
S N
A IÓ
4.5 x 110 mm FUEL TUBE

IR UC
REASSEMBLY:
Inspect for cracks or deterioration before installation, and replace
if necessary.
Only use the correct low permeation fuel tube when replacing. GOVERNOR ARM
D B
The fuel tube must contain the emissions-compliance

identification number.
A RI
GOVERNOR SPRING
M ST
REASSEMBLY: Install
with the short end side
toward the governor arm.
DI
FUEL VALVE GOVERNOR ARM NUT

BRACKET 10 N•m (7 ft-lb)
20 U
GOVERNOR
ARM BOLT
20 O S
TUBE CLIP (2)

Use the same style 6 x 12 mm SELF-TAPPING SCREW
clips originally 2.3 ~ 2.8 N•m (20 ~ 24 in-lb)
equipped on the
unit.
1- ID
7.3 x 160 mm FUEL TUBE

REASSEMBLY:
Inspect for cracks or deterioration before
-0 HIB
installation, and replace if necessary with

low permeation fuel tube.
6 x 12 mm FUEL VALVE
FLANGE BOLT
03 O
TUBE CLIP (2)

PR
6 x 28 mm
FLANGE BOLT
8-22
FUEL TUBE AND CLAMP CHANGES
.A O
Honda Power Equipment manufactured after January 1,
2009, uses low-permeation fuel tubes that have the
.
IS D
CARB Executive Order (C-U-05-003, for example) printed
S ZA
on them.
If you replace a low-permeation fuel tube, you must
A RI
replace it with a low-permeation fuel tube that has the
emissions-compliance identification number printed on it.
IR O
If you replace a regular fuel tube, you can replace it with
a regular fuel tube.
D UT
“D” STYLE CLAMP WIRE STYLE CLAMP
Two styles of fuel tube clamps are used. If you replace
the clamps, use the same style that is currently on the
A A
mower.
M NO
.- O
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-23
4. FAN COVER/FUEL TANK
.A O
REMOVAL/INSTALLATION (K5 thru K8)
.
IS D
1. Before removal, drain the gasoline into an approved container.
S ZA
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.
A RI
5. Unscrew the tank mount nut from the fuel filler threads, and remove the fuel filler neck seal.
6. Using a screwdriver, pry the tank mount clip locking leg from the right tank mount.
IR O
7. Slide fuel tank mount rubber B from the right tank mount, and then remove the fuel tank from the fan cover.
D UT
8. Fuel tank installation is the reverse of its removal.
A A
WARNING FUEL TANK CAP
OPERATION: (P. 8-27)
M NO
.- O
• Wipe up spills immediately. TANK MOUNT NUT
Gently tighten
.A US
the new tank
TETHER
mount nut,
using tongue
FUEL FILLER NECK SEAL and groove
RIGHT TANK
IS O
MOUNT pliers, until the
alignment mark
TANK SIDE
S N
LEFT TANK is in the position

MOUNT as shown.
A IÓ
TANK
MOUNT NUT
ALIGNMENT
IR UC
FUEL LEVEL MARK

GAUGE ALIGNMENT POSITION
MARK RANGE
D B
TANK MOUNT RUBBER B

FAN COVER
A RI
13.5 mm
(0.5 in) INSTALLATION:
Check that the high-tension cord and the stop
M ST
switch wire are securely set in the groove in the

fan cover as shown.
STOP SWITCH WIRE
DI
FUEL TANK
INSTALLATION:
Wash with solvent to remove the
20 U
sediment, and dry thoroughly before

installation.
20 O S
INSPECTION (K8): P. 8-27

1- ID
FUEL
FILTER
TANK MOUNT CLIP HIGH-TENSION CORD
-0 HIB
FUEL TANK
MOUNT TUBE CLIP (2)
TANK MOUNT TANK MOUNT RUBBER A
RUBBER B
03 O
8.0 mm
TANK MOUNT FUEL TUBE (0.31 in)
CLIP
PR
REMOVAL/INSTALLATION: P. 8-26
INSPECTION: Inspect for cracks or
deterioration before installation, and
8-24
REMOVAL/INSTALLATION (K9)
1. Before removal, drain the gasoline into an approved container.
.A O
2. Remove the recoil starter and the fan cover.
.
IS D
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.
S ZA
5. Unscrew the tank mount nut from the fuel filler threads and turn the fan cover over.
6. Press the latch on the tank mount clip as shown below and remove the clip, and then remove the fuel tank from
A RI
the fan cover.
7. Fuel tank installation is the reverse of its removal.
IR O
D UT
 WARNING FUEL TANK CAP
OPERATION: (P. 8-27)
A A
You can be burned or seriously injured when handling fuel. TANK MOUNT NUT
M NO
Gently
• Handle fuel only outdoors. tighten the
• Wipe up spills immediately. new tank
mount nut,
TETHER using
.- O
tongue and
groove
.A US
pliers, until
the
TANK
alignment MOUNT NUT
FUEL FILLER NECK SEAL
IS O
mark is in ALIGNMENT
the MARK
position
TANK SIDE
S N
shown. ALIGNMENT POSITION

MARK RANGE
A IÓ
TANK MOUNT CLIP

PRESS HERE TO RELEASE
IR UC
FAN COVER
INSTALLATION:
Check that the high-tension cord
is securely set in the groove in
D B
the fan cover as shown.

A RI
M ST
DI
TANK MOUNT RUBBER B
13.5 mm
(0.5 in)
20 U
HIGH-TENSION CORD
20 O S
FUEL TANK TANK MOUNT RUBBER A

1- ID
INSTALLATION: 8.5 mm
Wash with solvent to remove the FUEL STRAINER (0.33 in)
sediment, and dry thoroughly before
-0 HIB
installation. TUBE CLIP (2)

INSPECTION (K8): P. 8-27
03 O
FUEL TUBE
PR
INSPECTION: Inspect for cracks or

deterioration before installation, and
8-25
FUEL TUBE REMOVAL

1. Drain the fuel from the fuel tank and carburetor.
.A O
2. Use pliers to open the fuel clip, and slide the fuel clip
.
IS D
up the tube. FUEL VALVE
FUEL CLIP
S ZA
3. Rotate the fuel tube to help release the tube from the
fuel valve fitting.
A RI
IR O
D UT
A A
M NO
4. Gently pull the fuel tube from the fuel valve. Do not pry
against the fuel valve with a screwdriver or other tool
when removing the fuel tube.
.- O
NOTICE
.A US
If the fuel tube is pried off the fuel valve with a tool, the
fuel valve may be damaged.
IS O
5. Remove the other end of the fuel tube from the fuel
tank using the same procedure. The filter will come out
S N
of the tank along with the fuel tube.

A IÓ
FUEL FILTER
FUEL TUBE INSTALLATION
IR UC
1. Attach the ends of the fuel tube to the fuel valve and
fuel tank. Be sure the filter is inserted into the tank
outlet prior to installing the fuel tube
D B
2. Position the fuel tube clips over the fuel valve and fuel tank fitting.
A RI
3. Fill with fuel and check for fuel leaks and repair as necessary.
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
8-26
5. EVAPORATIVE EMISSION CONTROL SYSTEM
.A O
FUEL TANK CAP
.
IS D
This engine has an EVAPORATIVE EMISSION CONTROL CANISTER built into the fuel tank cap to prevent the
S ZA
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.
A RI
Charging
IR O
Gasoline vapor produced in the fuel tank at high ambient
temperature is absorbed and stored by the charcoal in the
D UT
canister, which is built into the fuel tank cap.
A A
M NO
.- O
Purging
.A US
When the pressure in the fuel tank decreases because of low
ambient temperature or consumption of gasoline, the air drawn
through the canister releases the stored gasoline vapor from the
IS O
charcoal. The released gasoline vapor returns to the fuel tank.
S N
A IÓ
IR UC
FUEL TUBES
If the mower has low-permeation fuel tubes you must use only
D B
low-permeation fuel tubes as replacements. These fuel tubes

A RI
have the emissions-compliance identification number printed on

the tube as shown in this example.
M ST
DI
FUEL TANK
Low-permeation fuel tanks have a light colored (grayish) inner
INNER
20 U
liner. If the fuel tank is scratched deeply enough that the light gray OUTER
LAYER LAYER
inner liner can be seen from outside the tank, the fuel tank must
20 O S
be replaced.
1- ID
-0 HIB
DEEP
03 O
SCRATCH
PR
If the outer layer is scratched deeply enough for the

light gray inner layer to show, replace the fuel tank.
8-27
8-28
PR
FUEL SYSTEM
03 O
-0 HIB
1- ID
20 O S
20 U
DI
M ST
A RI
D B
NOTES
IR UC
A IÓ
S N
IS O
.A US
.- O
M NO
A A
D UT
IR O
A RI
S ZA
HRR216VKA
IS D
.A O
.
9. FLYWHEEL/IGNITION COIL
1. DISASSEMBLY/REASSEMBLY . . . . . . . . . 9-1 3. IGNITION COIL . . . . . . . . . . . . . . . . . . . . . 9-6
.A O
2. FLYWHEEL REMOVAL/INSTALLATION . . 9-3
.
IS D
1. DISASSEMBLY/REASSEMBLY
S ZA
(K5 thru K8)
A RI
1. Remove the recoil starter (P. 7-1) and fan cover (P. 8-24).
2. Remove the fan cover stud, the 6 x 20 mm flange bolt, and the ignition coil.
IR O
3. Remove the 14 mm special nut and the flywheel (page 9-3).
D UT
4. Remove the wire from the brake assembly; then remove the 6 x 23 mm and 6 x 14 mm flange bolts and the brake
assembly.
A A
14 mm SPECIAL NUT
M NO
4 x 12 mm SCREW WASHER
TORQUE: 1.8 N•m (1.3 ft-lb)
52 N•m (38 ft-lb)
.- O
6 x 23 FLANGE
FLYWHEEL BOLT
.A US
4 mm WASHER
REMOVAL: P. 9-3 BRAKE
When disassembling and LEVER
reassembling, take care SPRING
IS O
not to damage the fan
blades. ENGINE STOP SWITCH
S N
6 x 20 INSPECTION: P. 2-20
FAN COVER STUD BOLT (3) FLANGE
A IÓ
BOLT
12 N•m (9 ft-lb)
IR UC
IGNITION COIL
FLYWHEEL BRAKE
D B
INSPECTION: P. 9-6
ADJUSTMENT: P. 9-6 INSPECTION: P. 3-12
A RI
M ST
6 x 14 FLANGE BOLT
HIGH TENSION CORD

DI
STOP SWITCH WIRE

REASSEMBLY:
Check for cracked or CLIP A
damaged insulation;
20 U
20 O S
BREATHER
25 x 18 mm SPECIAL COVER
WOODRUFF KEY
1- ID
REASSEMBLY:
When installing the BREATHER VALVE 6 x 14 FLANGE BOLT
flywheel, check to be sure
-0 HIB
that the woodruff key 12 N•m (9 ft-lb)

remains in its slot on the BREATHER COVER GASKET
crankshaft.
Do not reuse.
03 O
PR
9-1
FLYWHEEL/IGNITION COIL HRR216VKA
(K9)
.A O
.
IS D
14 x 1.5 mm SPECIAL NUT
S ZA
REMOVAL AND INSTALLATION: P. 9-3
FLYWHEEL TORQUE: 75 N•m (55 ft-lb)
A RI
INSTALLATION: P. 9-5 14 x 45 WASHER
Use caution during disassembly
IR O
and reassembly to prevent COOLING FAN
damage.
D UT
A A
6 x 20 mm
M NO
FLANGE BOLT WIRE CLAMP
ENGINE STOP SWITCH
5 x 16 mm
SPECIAL BOLT (2) INSPECTION: P. 2-20
.- O
FAN COVER STUD BOLT (3)
.A US
12 N•m (8.9 ft-lb) 5 mm PLAIN
WASHER
IGNITION COIL TENSIONER BRAKE
SPRING CABLE
IS O
INSPECTION: P. 9-6 BRACKET
ADJUSTMENT: P. 9-6 SPECIAL
BOLT
S N
A IÓ
IR UC
HIGH TENSION CORD

D B
REASSEMBLY: SPECIAL
WASHER
A RI
Check for cracked or

damaged insulation; 6 x 14 mm
replace the coil if BRAKE LEVER FLANGE BOLT
M ST
necessary. SPRING
STOP SWITCH WIRE FLYWHEEL BRAKE ARM
(see P. 9-5 for routing)
25 x 18 mm SPECIAL
DI
BREATHER
WOODRUFF KEY VALVE INSPECTION: P. 3-12
REASSEMBLY:
20 U
When installing the flywheel, CRANKCASE BREATHER 6 x 14 mm FLANGE BOLT

check to be sure that the COVER AND GASKET
20 O S
woodruff key remains in its slot

on the crankshaft. 12 N•m (8.9 ft-lb)
Replace as an assembly
1- ID
-0 HIB
03 O
PR
9-2
HRR216VKA FLYWHEEL/IGNITION COIL
2. FLYWHEEL REMOVAL/INSTALLATION
.A O
REMOVAL
.
IS D
1. Remove the fan cover/fuel tank (P. 7-1). K9 MODEL SHOWN

S ZA
FLYWHEEL HOLDER
3. Hold the flywheel brake lever against the handlebar and 07APB-Z28A100
A RI
secure it there with a strap or equivalent material. This
allows the flywheel and crankshaft to turn.
IR O
4. Hold the flywheel with the special tool and a breaker bar,
D UT
and remove the 14 mm special nut with a wrench.
NOTICE
A A
Inserting a rod or screwdriver in the fan blades can
M NO
damage the blades or the aluminum casting projections.
5. Remove the plastic cooling fan (K9 models).
.- O
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
9-3
6. Position a commercially available 6-inch flywheel puller K5 thru K8 VERSION

on the flywheel with one of the puller jaws under the
.A O
magnets (at the PULLER mark). FLYWHEEL PULLER, OTC-1035
(commercially available)
.
IS D
Set a shop towel or equivalent cloth between the
flywheel and the puller.
S ZA
7. Tighten the flywheel puller, and then tap the end of the
puller with a brass hammer to remove the flywheel.
A RI
IR O
D UT
A A
M NO
.- O
.A US
IS O
SHOP TOWEL
S N
PULLER
A IÓ
MARK
IR UC
K9 VERSION
PULLER MARK
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
9-4
HRR216VKA FLYWHEEL/IGNITION COIL
STOP SWITCH WIRE ROUTING (k9 VERSION)

Be sure the stop switch wire is
.A O
routed between the engine stop
2
.
IS D
switch and the ignition primary coil
as shown before installing the
S ZA
flywheel. 1
3
1. Route the stop wire under the
A RI
cord clamper.
IR O
2. Push the stop switch wire
between the spring tensioner
D UT
and the barrel. Do not pinch,
cut, or damage the wire.
A A
ENGINE
3. Run the stop switch wire under STOP
the spring tensioner, then up 4 SWITCH
M NO
and over the cord rest on the
spring tensioner.
4. Run the stop switch wire under the ignition coil between the coil mounting bosses.
.- O
.A US
INSTALLATION K9 MODEL SHOWN
1. Make sure the flywheel taper is free of dirt, oil, grease,

TORQUE WRENCH
and other foreign material before installation. 52 N•m (38 ft-lb)
IS O
FLYWHEEL HOLDER
2. Make sure there is no foreign material on the magnets. 07APB-Z28A100
S N
3. Be sure the woodruff key is set in the keyway properly.

A IÓ
4. Install the flywheel.

5. Apply oil to the threads.
IR UC
6. Hold the flywheel with the special tool and tighten the
14 mm special nut with a torque wrench.
D B

A RI
7. Remove the strap or equivalent material from the

flywheel brake lever.
M ST
8. Install and adjust the ignition coil (P. 9-6).

DI
9. Install the fan cover/fuel tank (P. 7-1).

10. Check the operation of the flywheel brake (P. 3-12).
20 U
20 O S
1- ID
-0 HIB
03 O
PR
9-5
3. IGNITION COIL
.A O
IGNITION COIL TEST
.
IS D
1. Measure the resistance of the primary ignition coil by
S ZA
touching one ohmmeter lead to the ignition coil’s flat
terminal while touching the other lead to the iron core.
A RI
1.0 ~ 1.4 Ω (K5 ~ K8)
Primary coil resistance
1.0 ~ 1.2 Ω (K9) PRIMARY
IR O
COIL
D UT
2. Measure the resistance of the secondary ignition coil by
touching one ohmmeter lead to the spark plug cap while
touching the other lead to the iron core.
A A
SPARK PLUG CAP
IRON CORE (SECONDARY COIL)
10.6 ~ 12.8 kΩ (K5 ~ K8)
M NO
Secondary coil resistance
10 ~ 40 kΩ (K9)
3. Replace the ignition/charge coil if either of the above tests is out of specification.
.- O
.A US
AIR GAP ADJUSTMENT
IGNITION
Adjustment is required only when the ignition/charge coil or
IS O
COIL
the flywheel has been removed.
S N
1. Loosen the ignition/charge coil bolts.

K5~K8 0.2 ~ 0.4 mm
A IÓ
2. Insert a long feeler gauge of the proper thickness (0.008 ~ 0.016 in

between the legs of the coil assembly and the flywheel. K9 0.2 ~ 0.5 mm
(0.008 ~ 0.020 in)
IR UC
Specified clearance: (K5 ~ K8) 0.2 ~ 0.4 mm

0.008 ~ 0.016
(K9) 0.2 ~ 0.5 mm
D B
(0.008 ~ 0.020 in)

A RI
3. Avoid the magnetic part of the flywheel. FLYWHEEL

M ST
4. All gaps must be adjusted simultaneously.

5. Push the coil assembly firmly toward the flywheel and tighten the bolts.
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
9-6
10. CAM PULLEY/CRANKSHAFT/PISTON/
CYLINDER BLOCK
.A O
.
IS D
1. CAM PULLEY/ROCKER ARM. . . . . . . . . 10-1 4. VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
2. OIL PAN/CRANKSHAFT/ 5. GOVERNOR . . . . . . . . . . . . . . . . . . . . . . 10-13
S ZA
CYLINDER BLOCK . . . . . . . . . . . . . . . . . 10-4 6. COMPONENT INSPECTION . . . . . . . . . 10-14
3. PISTON. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
A RI
IR O
1. CAM PULLEY/ROCKER ARM
D UT
A A
M NO
CYLINDER HEAD COVER (Replace) FLANGE BOLT, 6 x 12 mm (4)
INSTALLATION: P. 10-3 12 N•m (8.7 ft-lb)
.- O
.A US
VALVE ADJUSTING SCREW (2)
ADJUSTMENT: P. 3-14

IS O
EXHAUST ROCKER ARM
INSPECTION: P. 10-15
S N
A IÓ
 
VALVE ADJUSTING
IR UC
LOCK NUT (2)

7.8 N•m (5.8 ft-lb)

D B
A RI

ROCKER ARM SHAFT (2)
M ST
CAM PULLEY
DECOMPRESSOR WEIGHT INSPECTION: P. 10-15
INSPECTION: P. 10-2
DI
Take care not to drop the cam
pulley.
20 U
INTAKE ROCKER ARM

20 O S
CAM PULLEY SHAFT

1- ID
INSPECTION: P. 10-2
K9 VERSION HAS A
-0 HIB
ROUND INTAKE PORT

O-RING,
6.8 x 1.9 mm TIMING BELT
Replace.
03 O
PR

10-1
CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK HRR216VKA
CAM PULLEY DECOMPRESSOR INSPECTION

1. Rotate the flywheel until the cam pulley decompressor
.A O
weight slot faces out.
.
IS D
2. Carefully inspect the weight position and confirm that it is
S ZA
fully retracted. If it is not fully retracted, replace the cam
pulley (P. 10-1).
3. If the weight is fully retracted, operate the decompressor
A RI
by very slowly moving it to the opposite end of the slot
and gently releasing. Repeat several times. If the weight
IR O
fails to completely return on its own at any time (by spring
D UT
force), replace the cam pulley (P. 10-1).
DECOMPRESSOR WEIGHT
A A
M NO
CAM PULLEY INSTALLATION
1. Turn the crankshaft so that the long crankshaft key ALIGNMENT
groove (PTO side) faces up as shown. MARKS CAM PULLEY
.- O
The two woodruff key grooves will face down.
CYLINDER
.A US
2. Install the cam pulley on the timing belt so that the cam HEAD COVER
MATING
pulley alignment marks are in line with the cylinder head SURFACE
cover mating surface.
IS O
Install the cam pulley on the timing belt with care not to
turn the crankshaft.
S N
A IÓ
IR UC
D B
A RI
M ST
DI
WOODRUFF KEY GROOVE (2)

VIEW FROM PTO SIDE
20 U
3. Apply oil to a new O-ring and install it on the cam pulley

20 O S
shaft. CAM PULLEY TIMING BELT

4. Install the cam pulley shaft in the cylinder block.
CAM PULLEY
1- ID
5. Hold the cam pulley alignment marks in line with the SHAFT
cylinder head cover mating surface. Check again that the
-0 HIB
crankshaft key groove is facing up.

6. If the key groove is not facing up, repeat the procedure
from step 1.

O-RING,
03 O
6.8 x 1.9 mm
PR
10-2
HRR216VKA CAM PULLEY/CRANKSHAFT/PISTON/ CYLINDER BLOCK
ROCKER ARM SHAFT INSTALLATION

Install the rocker arm shaft from the opposite side of the cam
.A O
ROCKER ARM SHAFT
pulley as shown.
.
IS D
S ZA
A RI
IR O
D UT
A A
CAM PULLEY
CYLINDER HEAD COVER INSTALLATION
M NO
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. (New)
.- O
2. Apply liquid gasket (Hondabond HT or Locktite 5900) to a
new cylinder head cover, specifically to the inner wall of the
.A US
groove and bolt hole in the cylinder head cover.
LIQUID GASKET
Assemble within 10 minutes after applying the liquid APPLICATION
gasket. AREA
IS O
3. Wait for approximately 20 minutes after assembly before
S N
filling with oil and starting the engine.

A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
10-3
2. OIL PAN/CRANKSHAFT/CYLINDER BLOCK
.A O
.
IS D
Remove the cam pulley and rocker arm.
S ZA
6 x 25 FLANGE BOLT (8) 
(Apply grease to the lips.)
A RI
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
IR O
seal when installing the oil pan with the
D UT
oil seal.
OIL PAN ASSEMBLY
A A
INSPECTION:
P. 10-19
M NO
REMOVAL: P. 10-5
ASSEMBLY: P. 10-6
8 x 20 mm DOWEL PIN (2)
.- O
TIMING BELT
INSTALLATION:
.A US
Check that the belt is not
worn or cracked and do
not bend or twist the belt.
IS O
THRUST WASHER PISTON ASSEMBLY
S N
INSTALLATION: P. 10-6 DISASSEMBLY/REASSEMBLY: P. 10-7
A IÓ
CRANKSHAFT INSTALLATION: P. 10-5


IR UC
INSTALLATION:
Be careful not to
CYLINDER BLOCK
damage the oil seal.
INSPECTION:
D B
After installation, clean


the crankshaft tapered P. 10-19
A RI
surface. ASSEMBLY: P. 10-4

K9 model has a round
intake port.
M ST

DI
20 U
20 O S

CONNECTING ROD BOLT (2)
12 N•m (9 ft-lb) K9 model has a
 removable plastic timing (Apply grease to the lips.)
gear. See page 10-18.
1- ID
25.4 x 62 x 6 mm OIL SEAL

CONNECTING ROD CAP
-0 HIB
03 O
PR
10-4
OIL PAN REMOVAL RECESS

1. Set piston at TDC of compression stroke.
.A O
2. Remove the 6 x 25 mm flange bolts
.
IS D
3. Insert a screw driver or equivalent tool into the recess as
S ZA
shown, and remove the oil pan from the cylinder block.
Be careful not to damage the sealing surfaces. Use a tool
A RI
that fits tightly into the recesses. Twist the tool to break the
sealant loose. Do not drive the tool into the sealing
IR O
surfaces with a hammer.
D UT
A A
PISTON ASSEMBLY/CONNECTING ROD CAP
INSTALLATION
M NO
1. Apply oil to the inner wall of the cylinder and
MODEL MARK
to the outer surface of the piston.
2. Install the piston assembly in the cylinder so that the model
.- O
mark (ZL8, Z8B, or Z2A) by the piston pin hole and the
.A US
longer side of the connecting rod big end are at the right
side. (The crankshaft must be at the top dead center of the
compression stroke.)
IS O
The model mark on the piston must be positioned toward
the oil pan.
S N
NOTICE CONNECTING
A IÓ
ROD WITH THE

Take care not to break the piston ring when installing the LONG END
IR UC
piston assembly in the cylinder.

3. Apply clean engine oil to the cylinder block crankshaft
bearing area, and install the crankshaft in the cylinder
D B
block.
A RI
4. Apply oil to the connecting rod big end bearing and the
crank pin; then connect the connecting rod to the crank pin.
M ST
DI
5. Apply oil to the connecting rod cap bearing.

6. Install so that the projection by the oil dipper and the
20 U
projection of the connecting rod face in the same direction.

Note that the oil dipper must be on the right- hand side at
20 O S
this time.
7. Tighten the connecting rod bolts to the specified torque.
1- ID

-0 HIB
OIL DIPPER PROJECTIONS

03 O
PR
10-5
THRUST WASHER INSTALLATION

THRUST WASHER
1. Install the timing belt on the timing belt pulley.
.A O
2. Install the thrust washer; note the installation direction.
.
IS D
S ZA
A RI
TIMING BELT
IR O
D UT
CYLINDER BLOCK/OIL PAN ASSEMBLY
A A
1. Align the mark on the cylinder block with the mark on the CRANKSHAFT
crankshaft.
M NO
2. Install the cam pulley (P. 10-2). MARK
.- O
.A US
CYLINDER
BLOCK
IS O MARK
S N
3. Clean the mating surfaces of the cylinder block and the oil
A IÓ
pan using a degreasing cleaning agent or a clean shop

LIQUID GASKET
towel. APPLICATION
IR UC
AREA
4. Install the two 8 x 20 mm dowel pins in the cylinder block. CYLINDER
BLOCK
5. Apply a bead 1.5 - 2.0 mm (0.06 - 0.08 in) of liquid gasket
D B
(ThreeBond 1216, Hondabond HT, or Locktite 5900) to the

A RI
cylinder block.
6. Install the oil pan on the cylinder block.
M ST
Assemble within 10 minutes after applying the liquid

gasket. 8 x 20 mm 8 x 20 mm
DI
DOWEL PIN DOWEL PIN

If it is hard to install the oil pan securely, assemble by
turning the crankshaft a little.
20 U
7. Loosely tighten each 6 x 25 mm flange bolt, and then

20 O S
tighten to the specified torque in the numbered sequence.

1- ID
8. Wait for approximately 20 minutes after assembly before

filling it with oil and starting the engine.
-0 HIB
03 O
PR
10-6
3. PISTON
.A O
DISASSEMBLY/REASSEMBLY
.
IS D
S ZA
TOP RING
PISTON RINGS
REASSEMBLY:
INSPECTION: P. 10-16 MAKER MARK
Chrome plated. Do not
A RI
REASSEMBLY: interchange with SECOND RING.
Install with the maker mark facing upward as
shown.
IR O
Do not interchange the top ring and the
120°
second ring.
D UT
After assembly, check for smooth movement
120°
of the piston ring. 120°
Stagger the piston ring end gaps 120° apart.
A A
Do not align with the piston pin.
TOP RING
M NO
SECOND RING
(chrome plated)
SECOND RING
10 mm
(0.4 in) EXPANDER RING
.- O
OIL RING REASSEMBLY:
Install the expander in the
.A US
piston oil ring groove first.
10 mm
(0.4 in)
OIL CONTROL RING (2)
IS O
REASSEMBLY:
Space the side rail end gaps at
S N
least 20 mm (0.8 in) apart.

A IÓ
IR UC
PISTON
PISTON PIN CLIP (2)
D B
REASSEMBLY:
Install by setting one end of MODEL MARK (ZL8, Z8B, or Z2A)
A RI
the clip in the piston groove,

holding the other end with
 PISTON PIN
M ST
long nosed pliers, and rotating

the clip in. INSPECTION: P. 10-16
Do not align the end gap of
DI
the clip with the cutout in the

piston pin bore.
20 U
CLIP
20 O S
1- ID
-0 HIB
CUTOUT
03 O
CONNECTING ROD
PR
REASSEMBLY: P. 10-8
10-7
PISTON CONNECTING ROD REASSEMBLY PISTON PISTON PIN

1. Apply oil to the piston pin, piston pin hole and the connecting
.A O
rod small end.
.
IS D
2. Set the piston so that the 'FW' mark stamped at the back of
S ZA
the piston points down.
PISTON PIN CLIP (2)
3. Set the connecting rod in the piston so that the model mark
A RI
(ZL8, Z8B, or Z2A) by the piston pin hole and the longer side
of the connecting rod large face to the right-hand side. FW MARK
IR O
4. Apply oil to the piston pin and install it in the piston.
D UT
MODEL
5. Install new piston pin clips. MARK
(ZL8, Z8B,
6. Install the piston/connecting rod assembly in the cylinder or Z2A)
A A
block (P. 10-10).
M NO
CONNECTING ROD
.- O
WTH THE LONG END
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
10-8
4. VALVES
.A O
.
IS D
S ZA
VALVE SPRING RETAINER (2)
DISASSEMBLY: 
A RI
Push down and slide the VALVE SPRING (2)
retainer to the side, so the
valve stem slips through the
IR O
hole at the side of the
D UT
retainer. VALVE STEM SEAL
(INTAKE ONLY)
A A
M NO
Do not remove the valve
spring retainer while the piston
is installed, or the valves will
drop into the SPARK PLUG
.- O
cylinder. INSPECTION: P. 3-9
Standard spark plug:
.A US
BPR5ES (NGK)
K9 VERSION HAS A
IS O
ROUND INTAKE PORT
VALVE GUIDE
S N
A IÓ
IR UC
CYLINDER BLOCK
CLEANING: P. 10-10
D B
A RI
M ST

EXHAUST VALVE
DI
REASSEMBLY:
Before installation,
remove carbon deposits
20 U
and inspect the valve.

20 O S
INTAKE VALVE
REASSEMBLY:
Do not interchange with the
exhaust valve.
1- ID
VALVE HEAD DIAMETER

IN: 25 mm (0.98 in)
-0 HIB
EX: 24 mm (0.94 in)

03 O
PR
10-9
COMBUSTION CHAMBER CLEANING

1. Prepare a cylinder of thick paper or equivalent material,
.A O
with a diameter large enough to fit against the inner wall of
.
IS D
the cylinder, and insert it into the cylinder for protection.
S ZA
2. Attach a combustion chamber cleaning brush
(commercially available) to an electric drill and clean the
combustion chamber.
A RI
Be sure to insert thick paper into the cylinder to protect the
IR O
inner wall of the cylinder during cleaning of the combustion
chamber.
D UT
THICK PAPER OR
Do not press the cleaning brush with force against the EQUIVALENT
combustion chamber.
A A
ELECTRIC
DRILL
M NO
VALVE SEAT RECONDITIONING
.- O
Valve Seat Inspection
.A US
1. Thoroughly clean the combustion chambers and valve
seats to remove carbon deposits (page 10-10).
IS O
2. Apply a light coat of Prussian Blue compound or erasable
felt-tipped marker ink to the valve faces.
S N
3. Insert the valves, and then lift them and snap them closed
A IÓ
against their seats several times. Be sure the valve does

not rotate on the seat. VALVE FACE
IR UC
The transferred marking compound will show any area of

the seat that is not concentric and may require valve seat
reconditioning.
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
10-10
Valve seat reconditioning tools (commercially available). SOLID PILOT BAR, 5.50 mm (NWY PM 100055SH)
SOLID PILOT BAR, 5.51 mm (NWY PM 100552S)
.A O
VALVE SEAT CUTTER #115, 31° (NWY CU 115
VALVE SEAT CUTTER #122, 45° (NWY CU 122)
.
IS D
VALVE SEAT CUTTER #111, 60° (NWY CU 111)
T-WRENCH #505 (NWY TW #503-1)
T-WRENCH ADAPTOR (NWY TW 503-1)
S ZA
T-WRENCH EXTENSION, 6 in (NWY TW 503-6H)
ACCESSORY PACKAGE (NWY TW #246)
A RI
ACCESSORY
VALVE SEAT T-WRENCH PACKAGE
IR O
CUTTER
D UT
A A
31° 60°
M NO
45° 45°
60°
31°
.- O
.A US
SOLID PILOT
BARS
T-WRENCH
T-WRENCH EXTENSION, 6 in
IS O
ADAPTOR
S N
Reconditioning Procedure
A IÓ
1. Prepare a thick paper cylinder or equivalent material with

a large enough diameter to fit against the cylinder wall of
IR UC
the cylinder block.

2. Insert the thick paper into the cylinder to protect the
cylinder wall during valve seat reconditioning.
D B
A RI
M ST
DI
20 U
20 O S
THICK PAPER OR
EQUIVALENT
1- ID
-0 HIB
03 O
PR
10-11
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
.A O
The 31° cutter removes material from the top edge. The
60° cutter removes material from the bottom edge. Be
.
IS D
31°
sure that the width of the finished valve seat is within
S ZA
specification.
CONTACT TOO LOW
A RI
60°
IR O
D UT
A A
Always turn the cutter clockwise, never
counterclockwise. Continue to turn the cutter as you VALVE SEAT CUTTER
M NO
(commercially available)
remove it from the valve seat. Always follow the valve
seat cutter manufacturer’s instructions.
.- O
NOTICE
.A US
Avoid removing excess material from the valve seats.
Remove only enough material to clean up the seats, and
avoid going over the valve seat width service limit.
4. Make a light pass with the 45° cutter to remove any
IS O
possible burrs at the edge of the seat.
S N
A IÓ
VALVE SEAT WIDTH

IR UC
Standard Service limit

0.7 mm (0.028 in) 1.8 mm (0.07 in)
D B
1. After resurfacing the seats, inspect for even valve

seating. Apply Prussian Blue or erasable felt-tipped
A RI
marker ink to the valve faces. 0.7 mm (0.28 in)

M ST
Insert the valves into the cylinder block; then lift and
snap them closed against their seats several times. Be
sure the valves do not rotate in their seats.
DI
The seating surface, as shown by the transferred

marking compound, should have a good contact all the
20 U
way around the valve face.

20 O S
2. Lap the valves into their seats using a 4 mm tube and

some commercially available lapping compound.
1- ID
NOTICE
4 mm TUBE
To avoid severe engine damage, be sure to remove all (commercially
-0 HIB
available)
lapping compound from the cylinder block before
assembly.
3. Check the valve clearance after reassembly (P. 3-13).
03 O
PR
10-12
5. GOVERNOR
.A O
.
IS D
S ZA
GOVERNOR HOLDER CLIP
GOVERNOR WEIGHT HOLDER ASSEMBLY
REASSEMBLY:
REASSEMBLY: Insert firmly into the shaft
A RI
Before installing, check for wear and damage of the gear. groove.
Check that the weights move freely.
IR O
Be sure to install the governor weight before installing the crankshaft.
6 mm THRUST WASHER
D UT
GOVERNOR HOLDER SHAFT GOVERNOR SLIDER
GROOVE REASSEMBLY:
A A
Spread the governor
OIL FILLER CAP /DIPSTICK weights to install the slider;
M NO
then check to be sure the
slider moves smoothly.
LOCK WASHER
REASSEMBLY:

.- O
Install the notch over
.A US
the rib on the oil pan.
GASKET 6 x 14 FLANGE BOLT (2)
12 N•m (9 lb-ft)
OIL FILLER EXTENSION

IS O
REASSEMBLY:
Hand tighten until the O-ring is 6 mm WASHER
S N
compressed, then bend up the two

REASSEMBLY:
lock washer edges to secure
gasketthe oil
A IÓ
Install inside the case.

filler extension.
IR UC
GOVERNOR ARM SHAFT

O-RING
D B
A RI
M ST
DI
RIB
20 U
8 mm LOCK PIN
REASSEMBLY:
20 O S
GOVERNOR ARM SHAFT

OIL PAN Install the lock pin
INSPECTION: P. 10-19 immediately after
installing the governor
arm shaft and move the
1- ID
shaft over against the

governor slider.
-0 HIB
The lock pin must be

installed with the straight
side of the pin against
the groove in the shaft.
03 O
GROOVE LOCK PIN

PR
10-13
6. COMPONENT INSPECTION
.A O
CAM PULLEY HEIGHT INSPECTION
.
IS D
S ZA
37.394 mm (1.4722 in) 37.369 mm (1.4712 in)
A RI
IR O
D UT
A A
CAM PULLEY I.D. (BEARING) INSPECTION
M NO
10.027 mm (0.3948 in) 10.075 mm (0.3967 in)
.- O
.A US
IS O
CAM PULLEY DECOMPRESSOR INSPECTION
ARM PIN
Inspect the decompressor return spring for proper strength.
S N
Check the decompressor arm and pin for proper movement and
A IÓ
wear.
IR UC
D B
A RI
SPRING
M ST
CAM PULLEY SHAFT O.D. INSPECTION

DI

9.987 mm (0.3932 in) 9.920 mm (0.3906 in)
20 U
20 O S
1- ID
-0 HIB
03 O
PR
10-14
ROCKER ARM INSPECTION

1. To check the rocker arms for excessive free-play, follow the
.A O
steps in “Exhaust Rocker Arm Pivot Free-Play Inspection”
.
IS D
on page 2-23. Repeat the steps for the intake valve.
S ZA
2. Measure the Rocker Arm Shaft O.D.
A RI
5.990 mm (0.2358 in) 5.953 mm (0.2344 in)
IR O
D UT
A A
M NO
PISTON-TO-CYLINDER CLEARANCE
INSPECTION
.- O
1. Measure and record the Cylinder I.D. at three levels in both
the “X” axis (perpendicular to crankshaft) and the “Y” axis.
.A US
Take the maximum reading to determine cylinder wear and
taper.
IS O
64.000 ~ 64.015 mm 64.105 mm (2.5238 in) (K5~K8)
(2.5197 ~ 2.5203 in) 64.110 mm (2.7209 in) (K9)
S N
A IÓ
If the cylinder I.D. is worn beyond the service limit, it must

be replaced. Do not hone the cylinder.
IR UC
2. Measure and record the Piston O.D. at a point

10 mm (0.4 in) from the bottom of the skirt and 90° to the
piston pin bore.
D B

A RI
63.961 ~ 63.985 mm (K5~K8)

M ST
(2.5181 ~ 2.5190 in)

63.880 mm (2.5149 in)
63.966 ~ 63.990 mm (K9)
(2.5183 ~ 2.5193 in)
DI
3. Subtract the Piston O.D. from the Cylinder I.D. to

determine the Piston-to-Cylinder clearance.
20 U

20 O S
0.015 ~ 0.054 mm (K5~K8)

(0.0006 ~ 0.0021 in) 0.12 mm
0.010 ~ 0.049 mm (K9) (0.005 in)
1- ID
(0.0004 ~ 0.0019 in)

-0 HIB
Do not hone the aluminum cylinder when replacing rings.

03 O
PR
10-15
PISTON RING WIDTH INSPECTION
.A O
Top ring 0.93 ~ 0.95 mm 0.91 mm
.
IS D
(0.036 ~ 0.037 in) (0.035 in)
S ZA
Second ring 0.97 ~ 0.99 mm 0.95 mm
0.038 ~ 0.039 in) (0.037 in)
A RI
IR O
D UT
PISTON RING SIDE CLEARANCE INSPECTION
A A
M NO
Top ring 0.055 ~ 0.089 mm 0.150 mm
(0.002 ~ 0.004 in) (0.006 in)
Second ring 0.015 ~ 0.049 mm 0.150 mm
(0.0006 ~ 0.0019 in) (0.006 in)
.- O
.A US
IS O
PISTON RING END GAP INSPECTION
S N
Use the top of the piston to position the ring horizontally in the
A IÓ
cylinder.
IR UC

Top ring 0.20 ~ 0.35 mm 1.00 mm
(0.008 ~ 0.014 in) (0.040 in)
D B
Second ring 0.35 ~ 0.50 mm 1.00 mm

A RI
(0.014 ~ 0.020 in) (0.040 in)

Oil ring 0.20 ~ 0.70 mm 1.00 mm
M ST
(0.008 ~ 0.030 in) (0.040 in)

DI
NOTICE
Do not hone the cylinder when replacing the piston rings.
20 U
PISTON PIN O.D. INSPECTION

20 O S

13.000 mm (0.5118 in) 12.954 mm (0.5100 in)
1- ID
-0 HIB
03 O
PR
10-16
PISTON PIN BORE I.D. INSPECTION
.A O
13.002 mm (0.5119 in) 13.048 mm (0.5137 in)
.
IS D
S ZA
A RI
IR O
D UT
A A
CONNECTING ROD SMALL END I.D. INSPECTION
M NO
13.005 mm (0.5120 in) 13.07 mm (0.515 in)
.- O
.A US
IS O
S N
CONNECTING ROD BIG END I.D. INSPECTION

A IÓ

IR UC
26.02 mm (1.024 in) 26.066 mm (1.0262 in)

D B
A RI
M ST
DI
CRANKSHAFT MAIN JOURNAL O.D. INSPECTION

20 U
FLYWHEEL SIDE

20 O S
27.993 mm 27.933 mm
PTO Side
(1.1021 in) (1.0997 in) PTO SIDE
25.393 mm 25.333 mm
1- ID
Flywheel side
(0.9997 in) (0.9974 in)
-0 HIB
03 O
PR
10-17
TIMING GEAR INSPECTION (K9) TIMING GEAR SLOT

The plastic timing gear is separate from the crankshaft in the K9
.A O
version.
.
IS D
Inspect the timing gear for excess wear, damage, or cracks and
S ZA
replace if necessary. Always replace the timing belt when
replacing the gear.
A RI
Make sure the timing gear boss fits completely into the slot in
the crankshaft.
IR O
D UT
TIMING GEAR
A A
CRANK PIN O.D. INSPECTION
M NO
25.98 mm (1.023 in) 25.92 mm (1.020 in)
.- O
.A US
IS O
S N
A IÓ
CONNECTING ROD BIG END AXIAL CLEARANCE

INSPECTION
IR UC
Measure the clearances with a feeler gauge.

D B
0.1 ~ 0.4 mm 0.8 mm

A RI
(0.004 ~ 0.016 in) (0.031 in)

M ST
DI
20 U
CONNECTING ROD BIG END OIL CLEARANCE

20 O S
INSPECTION
1. Wipe oil off the crank pin and connecting rod bearing CONNECTING
mating surface. ROD BIG END
1- ID
2. Place the plastigage on the crank pin. Set the connecting

rod and cap, and tighten the connecting rod bolts to the
-0 HIB
specified torque.
03 O
Place the plastigage axially.

PR
Tighten the two bolts equally while holding the crankshaft

to keep it from turning.
10-18
3. Remove the connecting rod cap and measure the

plastigage with the scale on the plastigage package to
.A O
PLASTIGAGE
determine the oil clearance. SCALE
.
IS D
Standard oil clearance Service limit
S ZA
0.040 ~ 0.063 mm 0.12 mm
(0.0016 ~ 0.0025 in) (0.005 in)
A RI
4. If the clearance exceeds the service limit, measure the
connecting rod I.D. and crankpin O.D. and replace the
IR O
worn parts as necessary. Recheck the big end oil PLASTIGAGE
clearance.
D UT
A A
CYLINDER BLOCK MAIN JOURNAL I.D.
INSPECTION
M NO
25.420 mm (1.0008 in) 25.466 mm (1.0026 in)
.- O
Inspect the bearing surface for scoring or damage. If the bearing
surface is worn or damaged, the cylinder block and
.A US
crankshaft will require replacement.
IS O
S N
OIL PAN MAIN JOURNAL I.D. INSPECTION

A IÓ

IR UC
28.020 mm (1.1031 in) 28.066 mm (1.1050 in)

Inspect the bearing surface for scoring or damage. If the bearing
surface is worn or damaged, the oil pan and crankshaft will
D B
require replacement.
A RI
M ST
DI
CRANKSHAFT AXIAL CLEARANCE INSPECTION

20 U
Measure the crankshaft axial play before removing the oil pan,
20 O S
crankshaft, and piston.

0.15 ~ 0.75 mm 1.0 mm
1- ID
(0.006 ~ 0.030 in) (0.04 in)

-0 HIB
If the axle clearance is too great, inspect the oil pan, cylinder
block, and timing gear thrust washer for wear and replace as
necessary.
03 O
PR
10-19
VALVE SPRING FREE LENGTH INSPECTION

Measure the free length of the valve springs.
.A O
.
IS D
30.5 mm (1.20 in) 29.0 mm (1.14 in)
S ZA
Replace the springs if they are shorter than the service limit.
A RI
IR O
D UT
A A
VALVE FACE/STEM O.D. INSPECTION
Inspect each valve face for pitting or wear irregularities. Inspect
M NO
each valve stem for bending or abnormal stem wear. Replace
the valve if necessary.
Measure and record each valve stem.
.- O
.A US
IN 5.48 mm (0.216 in) 5.318 mm (0.2094 in)
EX 5.44 mm (0.214 in)
IS O 5.275 mm (0.2077 in) VALVE FACE
Replace the valves if their O.D. is smaller than the service limit.
S N
VALVE GUIDE I.D. INSPECTION

A IÓ
Measure and record each valve guide I.D.

IR UC

5.50 mm (0.217 in) 5.572 mm (0.2194 in)
D B
Replace the cylinder block if they are over the service limit.
A RI
M ST
DI
VALVE SEAT WIDTH INSPECTION

20 U
1. Measure the valve seat width.

20 O S

0.70 mm (0.028 in) 1.8 mm (0.07 in)
VALVE SEAT
1- ID
2. Recondition the valve seat (page 10-10) if any of the TOO LOW
following are true:
-0 HIB
• Valve seat width is under or over the standard

• Valve seat is too high or low
03 O
• Valve seat is pitted or damaged

VALVE SEAT
PR
TOO HIGH
10-20
11. HANDLE PIPE/CABLES/SMART DRIVE
1. HANDLE PIPE REPLACEMENT . . . . . . . .11-1 4. HANDLE LOCKING KNOB . . . . . . . . . . . .11-6
.A O
2. HANDLE STAY/DISCHARGE GUARD . . .11-3 5. SMART DRIVE CABLE . . . . . . . . . . . . . . .11-7
.
IS D
3. HANDLE GRIP REMOVAL/ 6. SMART DRIVE DISASSEMBLY AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . .11-5 INSPECTION . . . . . . . . . . . . . . . . . . . . . .11-19
S ZA
A RI
1. HANDLE PIPE REPLACEMENT
IR O
1. Cut the three cable ties securing the brake cable and Smart Drive cable to the handle pipe. Fully loosen the
D UT
Smart Drive cable adjuster (P. 3-10).
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.
A A
3. Remove the flywheel brake lever from the handle pipe, then from the lever stop.
M NO
4. Remove the lock pin; then remove the lever stop from the handle pipe.
5. Remove the four 4 mm self-tapping screws and the upper and lower clutch grips. Carefully remove the
multi-position adjuster and spring.
.- O
6. Unsnap and remove the upper and lower bracket covers.
7. Remove the 5 x 37 mm roller pin, the four 4 mm self-tapping screws, and the upper and lower grip brackets.
.A US
UPPER BRACKET COVER
UPPER CLUTCH GRIP
HANDLE GRIP (2)
IS O
UPPER GRIP BRACKET
S N
MULTI-POSITION
LOWER GRIP BRACKET ADJUSTER
A IÓ
LOWER BRACKET COVER SPRING

IR UC
5 x 37 mm
LOWER CLUTCH GRIP ROLLER PIN
SMART DRIVE CABLE

D B
4 mm SELF TAPPING SCREW (8) REMOVAL/

A RI
INSTALLATION: (P. 11-7)

M ST
LEVER STOP
LOCK PIN
DI
ROPE GUIDE FLYWHEEL

20 U
BRAKE LEVER
20 O S
6 x 45 mm
FLYWHEEL BRAKE FLANGE BOLT
CONTROL CABLE
HANDLE PIPE CABLE TIE (3)
1- ID
6 mm PLAIN WASHER
6 mm LOCKING NUT
-0 HIB
8. Remove the Smart Drive cable from the lower grip bracket and then from the handle pipe assembly.
9. Remove the two special bolts, nylon washers, and the handle assembly from the handle stays.
03 O
10. Drive out the two 2 x 12 mm roll pins and remove the handle lock assemblies.
PR
11. Remove the 6 mm locking nut and the rope guide.
11-1
HANDLE PIPE/CABLES/SMART DRIVE HRR216VKA
.A O
.
IS D
ROPE GUIDE
S ZA
6 mm LOCKING NUT
A RI
IR O
D UT
A A
HEIGHT
M NO
HANDLE STAY (2) ADJUSTING
REPLACEMENT: P. 11-3 SPRING (2)
NYLON WASHER (2)
SPECIAL BOLT (2)
.- O
8 mm PIN (2)
.A US
2 x 12 mm ROLL PIN (2)
HEIGHT
ADJUSTING HANDLE LOCKING KNOB (2)
IS O
COLLAR (2) INSTALLATION: (P. 11-6)
S N
A IÓ
12. Install the handle pipe in the reverse order of its removal.
13. Readjust the Smart Drive cable (P. 3-10).
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
11-2
HRR216VKA HANDLE PIPE/CABLES/SMART DRIVE
2. HANDLE STAY/DISCHARGE GUARD
.A O
REMOVAL/INSTALLATION GUARD
.
IS D
1. Pry the push nut off the discharge guard shaft. RETURN
SPRING (2)
S ZA
The shaft on the K9 model is crimped at the end. Use
a small hacksaw to cut the end off the shaft. Install a DISCHARGE GUARD
new shaft using a push nut; it is not necessary to
A RI
crimp the end of the replacement shaft.
PUSH NUT
IR O
2. Remove the discharge guard shaft, the left and right
guard return springs, and the discharge guard.
D UT
K9 MODEL
Be careful when removing the discharge guard shaft.
The guard return springs are under tension and can
A A
fly out and injure someone.
M NO
.- O
.A US
.
3. To replace the grass bag plate, remove the three

IS O
grass bag plate bolts.
S N
A IÓ
IR UC
GRASS BAG
PLATE BOLT (3)
D B
A RI
M ST
DI
4. Release the handlebar locking knobs and allow the

20 U
handle pipe assembly to rest on the floor. NYLON WASHER (2)

20 O S
5. Remove the two special bolts and nylon washers, HANDLE PIPE
and remove the handle pipe assembly from the ASSEMBLY
handle stays.
1- ID
-0 HIB
SPECIAL
BOLT (2)
03 O
HANDLE STAY HANDLE LOCKING

(left side shown) KNOB (2)
PR
11-3
6. Remove the rear scroll (P. 4-7).

7. Move the rear adjusting lever all the way forward.
.A O
8. Remove the three 8 mm flange nuts and the left
.
IS D
handle stay.
S ZA
REAR
ADJUSTING
LEVER
A RI
8 mm
FLANGE LEFT
NUT (3) HANDLE
IR O
STAY
D UT
.
A A
9. Remove the three 8 mm flange nuts and the right 8 mm
RIGHT FLANGE
handle stay.
M NO
HANDLE NUT (3)
STAY
.- O
.A US
IS O
S N
.
A IÓ
10. Installation is the reverse of removal.

LEFT SPRING RIGHT SPRING
IR UC
The left and right discharge guard return springs are

different. Position the springs so the hooks lead to
the underside of the spring.
D B
A RI
.
M ST
Apply pressure to hold the springs in place when

installing the discharge guard shaft.
DI
11. After installation, raise the discharge guard and

confirm it moves freely and closes by spring force.
20 U
20 O S
1- ID
-0 HIB
.
03 O
PR
11-4
3. HANDLE GRIP REMOVAL/INSTALLATION
.A O
1. Remove the following, depending on the grip that
.
IS D
needs replacement: HANDLE 45 ~ 50 mm SMART DRIVE
GRIP (2)
S ZA
• Smart Drive cable (P. 11-7) (1.75 ~ 2.0 in) CONTROL
• Flywheel brake cable (P. 11-1)
A RI
• 6 mm locking pin and rope guide (P. 11-1)
2. Remove the handle pipe from the handle stays
IR O
(P. 11-1).
D UT
3. Remove the old grip(s). ™
CONTROL
4. Lubricate the inside of the handle grip with soapy
A A
water.
5. Slide the grip onto the handle pipe.
M NO
MULTI-POSITION
The grip should be 45 ~ 50 mm from the Smart Drive ADJUSTER
control as shown.
6. Reassemble the handle pipe and install the handle
.- O
pipe to the handle stays.
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
11-5
4. HANDLE LOCKING KNOB
.A O
REMOVAL
.
IS D
1/16” DRIFT PUNCH
1. Drive the 2 x 12 mm roll pin out with a 1/16” drift punch.
S ZA
2. Separate the parts as shown.
A RI
HANDLE
LOCKING
IR O
KNOB
D UT
2 x 12 mm
A A
ROLL PIN
M NO
.
INSTALLATION LOWER
1. Insert the height adjusting collar into the lower MOUNTING
8 mm PIN HOLE
.- O
mounting hole in the handle so that the flat part is
resting against the handle.
.A US
2. Slide the spring over the 8 mm pin.
3. Insert the pin into the collar and push it through until HEIGHT HANDLE
ADJUSTING LOCKING
you can see the hole in the pin on the other side. KNOB
IS O
SPRING
4. Install the handle locking knob onto the top of the pin
and line up the holes on the pin and the knob.
S N
HEIGHT
ADJUSTING
A IÓ
COLLAR 2 x 12 mm
ROLL PIN
.
IR UC
5. Insert the 1/16” drift punch from the bottom to keep

the two holes aligned.
D B
6. From the top side, start the 2 x 12 mm roll pin and

A RI
gently tap it in until it is flush with the knob.

1/16” DRIFT PUNCH
M ST
2 x 12 mm
ROLL PIN
DI
20 U
HANDLE LOCKING KNOB

20 O S
1- ID
-0 HIB
03 O
PR
11-6
5. SMART DRIVE CABLE
.A O
K5, K6
.
IS D
LOCK NUT
REMOVAL
S ZA
1. Drain the fuel tank.
LOOSEN
2. Drain the engine oil.
A RI
3. Fully loosen the Smart Drive cable adjuster.
IR O
4. Cut the cable tie securing the flywheel brake control TIGHTEN
cable to the Smart Drive cable.
D UT
ADJUSTER
A A
M NO
.- O
.A US
. IS O
5. Remove the four 4 mm self-tapping screws and the
UPPER CLUTCH GRIP
upper and lower clutch grips. Carefully remove the
S N
UPPER BRACKET COVER

6. Remove the upper and lower bracket covers.
A IÓ
7. Remove the four 4 mm self-tapping screws and the UPPER GRIP BRACKET
upper and lower grip brackets.
IR UC
8. Remove the 5 x 37 mm roller pin. 5 x 37 mm SPRING
9. Remove the cable from the lower grip bracket. ROLLER PIN
D B
MULTI-POSITION
4 mm ADJUSTER
A RI
SELF-TAPPING
SCREW (8)
M ST
DI
20 U
LOWER LOWER
20 O S
LOWER CLUTCH BRACKET GRIP

GRIP COVER BRACKET
1- ID
-0 HIB
03 O
PR
11-7
.A O
CABLE
bench vise. LOCKS
.
IS D
11. Remove the belt cover and drive belt (P. 4-2). CABLE
HOLDER
S ZA
12. Rotate the transmission 180° as shown.
13. Using pliers, pinch the Smart Drive cable locks, pull on
the cable, and remove it from the cable holder.
A RI
14. Lift the Smart Drive cable wire through the slot in the
cable holder and remove the cable end from the
IR O
transmission control arm.
D UT
15. Remove the Smart Drive cable from the lawn mower.
.
A A
INSTALLATION SNAP
CABLE HOLDER CUTTER
SLOT
M NO
FITTING HOUSING
1. Route the Smart Drive cable down through the hole in
HOLE
the cutter housing. SMART
2. Attach the Smart Drive cable end on the transmission DRIVE
CABLE
.- O
control arm.
WIRE
3. Align the Smart Drive cable wire with the cable holder
.A US
slot and install the snap fitting into the cable bracket.
4. Reinstall the belt tensioner spring and drive belt SMART
(P. 4-3). DRIVE
IS O
CABLE
END
S N
A IÓ
TRANSMISSION
CONTROL ARM
IR UC
5. If installing a new Smart Drive cable, fully loosen the

D B
cable adjuster before installing the new Smart Drive

HANDLE
A RI
cable. PIPE
6. Route the upper end of the Smart Drive cable through SLOT
M ST
the hole in the handle pipe until it's visible in the slot in CABLE
the top of the handle pipe. END
DI
SMART
DRIVE
CABLE
20 U
20 O S
1- ID
-0 HIB
03 O
PR
11-8
7. Install a screwdriver between the mower deck and the

transmission control arm. SCREWDRIVER
.A O
8. Remove the mower from the vise and set in its normal
.
IS D
operating position.
S ZA
A RI
IR O
D UT
TRANSMISSION
CONTROL ARM
.
A A
9. Connect the upper end of the Smart Drive cable to
M NO
the lower grip bracket.
.- O
.A US
SMART
DRIVE
CABLE LOWER
GRIP
IS O
BRACKET
.
S N
10. Fit the upper and lower grip brackets together

4 mm SELF-TAPPING LOWER GRIP
A IÓ
around the handle pipe slot and secure with the four
SCREW (4) BRACKET
4 mm self-tapping screws. The grip brackets will seat
IR UC
together when properly assembled.

D B
A RI
HANDLE
M ST
PIPE SLOT
Viewed from above UPPER GRIP BRACKET

DI
the handle pipe.
.
20 U
11. Insert the 5 x 37 mm roller pin through the Smart

SMART DRIVE UPPER GRIP BRACKET
20 O S
Drive cable end, and center the pin in the upper and CABLE END
lower grip bracket slots.
1- ID
-0 HIB
03 O
5 x 37 mm LOWER GRIP
Viewed from under
PR
ROLLER PIN BRACKET

the handle pipe.
11-9
12. Grease the inside pin grooves of the upper and lower UPPER BRACKET GRIP BRACKET (2)
bracket covers. COVER
.A O
5 x 37 mm
13. Snap the upper and lower bracket covers together with ROLLER PIN
.
IS D
the roller pin located in the pin groove. Make sure the
adjuster slots are located toward the rear of the mower.
S ZA

A RI
IR O
INSIDE PIN
D UT
GROOVES
A A
LOWER BRACKET
COVER
M NO
.

14. Grease both sides of the clutch grip guides. Insert
LOWER
the multi-position adjuster and spring in the track of the
CLUTCH GRIP
.- O
lower clutch grip and place the assembly over the inner BOTH SIDES OF GUIDES
bracket cover.
.A US
IS O
S N
A IÓ
ADJUSTER
SLOTS
IR UC
D B
A RI
SPRING
M ST
MULTI-POSITION
ADJUSTER
.
DI
15. Place the upper clutch grip over the adjuster

UPPER CLUTCH GRIP
assembly and secure to the lower clutch grip with the
20 U
four 4 mm self-tapping screws.

20 O S
16. Rotate the Smart Drive control and confirm that the
lower end of the Smart Drive cable moves the
17. Install the belt cover (P. 4-3).
1- ID
18. Install new cable ties securing the Smart Drive cable to
-0 HIB
the handle stay and handle pipe.

LOWER CLUTCH GRIP
20. Start and test the Smart Drive operation.
03 O
4 mm
PR
SELF-TAPPING Viewed from under

SCREW (4) the handle pipe.
.
11-10
K7
LOCK NUT
.A O
REMOVAL
.
IS D
LOOSEN
S ZA
3. Fully loosen the Smart Drive cable adjuster. TIGHTEN
A RI
4. Cut the cable tie securing the flywheel brake control
IR O
D UT
ADJUSTER
A A
M NO
.- O
.
.A US
UPPER CLUTCH GRIP
IS O
UPPER BRACKET COVER
S N
UPPER GRIP BRACKET
A IÓ
8. Remove the 5 x 37 mm roller pin. SPRING

5 x 37 mm
IR UC
MULTI-POSITION
4 mm ADJUSTER
SELF-TAPPI
D B
NG SCREW
A RI
M ST
DI
LOWER LOWER
COVER BRACKET
20 U
GRIP
20 O S
.
1- ID
-0 HIB
03 O
PR
11-11
CABLE
.A O
HOLDER
bench vise.
.
IS D
11. Remove the belt cover and drive belt (P. 4-4).
S ZA
12. Rotate the transmission 180° as shown.
the cable, and remove it from the cable holder.
A RI
14. Lift the Smart Drive cable wire through the slot in the
cable holder and remove the cable end from the
IR O
transmission control arm. CABLE
D UT
15. Remove the Smart Drive cable from the lawn mower. LOCKS
.
A A
INSTALLATION SNAP
CABLE HOLDER
SLOT
M NO
1. Route the Smart Drive cable down through the hole in FITTING
the cutter housing. SMART
2. Attach the Smart Drive cable end on the transmission DRIVE
CABLE
.- O
control arm.
WIRE
3. Align the Smart Drive cable wire with the cable holder
.A US
slot and install the snap fitting into the cable bracket.
4. Reinstall the belt tensioner spring and drive belt SMART
(P. 4-5). DRIVE
IS O
CABLE
END
S N
TRANSMISSION
CONTROL ARM
A IÓ
CUTTER
HOUSING
HOLE
IR UC
5. If installing a new Smart Drive cable, fully loosen the

D B
cable adjuster before installing the new Smart Drive HANDLE

PIPE
A RI
cable.
SLOT
6. Route the upper end of the Smart Drive cable through CABLE
M ST
the hole in the handle pipe until it's visible in the slot in END
the top of the handle pipe.
DI
SMART
DRIVE
CABLE
20 U
.
20 O S
1- ID
-0 HIB
03 O
PR
11-12
7. Install a screwdriver between the mower deck and the

transmission control arm. SCREWDRIVER
.A O
8. Remove the mower from the vise and set in its normal
.
IS D
operating position.
S ZA
A RI
TRANSMISSION
CONTROL ARM
IR O
D UT
A A
.
M NO
.- O
.A US
SMART
DRIVE
CABLE LOWER
IS O
GRIP
BRACKET
S N
.

A IÓ

around the handle pipe slot and secure with the four 4
SCREW (4) BRACKET
mm self-tapping screws. The grip brackets will seat
IR UC

D B
A RI
M ST
HANDLE
PIPE SLOT
Viewed from above

DI
UPPER GRIP BRACKET

the handle pipe.
20 U

20 O S

1- ID
-0 HIB
03 O
PR
Viewed from under ROLLER PIN BRACKET

the handle pipe.
11-13
.A O
5 x 37 mm
.
IS D
S ZA

A RI
IR O
INSIDE PIN
D UT
GROOVES
A A
LOWER BRACKET
COVER
M NO
.

LOWER
CLUTCH GRIP
.- O
bracket cover.
.A US
IS O
S N
A IÓ
ADJUSTER
SLOTS
IR UC
D B
A RI
SPRING
M ST
MULTI-POSITION
ADJUSTER
.
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
11-14
15. Place the upper clutch grip over the adjuster assembly
and secure to the lower clutch grip with the four 4 mm
.A O
self-tapping screws. UPPER CLUTCH GRIP
.
IS D
S ZA
17. Install the belt cover (P. 4-5).
A RI
18. Install new cable ties securing the Smart Drive cable to
the handle stay and handle pipe.
IR O
D UT
20. Start and test the Smart Drive operation.
LOWER CLUTCH GRIP
A A
4 mm
Viewed from under
M NO
SELF-TAPPING
.
(K8 and K9 versions)
.- O
REMOVAL
.A US
3. Fully loosen the Smart Drive cable adjuster.
IS O
4. Cut the cable tie securing the flywheel brake control LOCK NUT
S N
LOOSEN
A IÓ
TIGHTEN
IR UC
ADJUSTER
D B
A RI
M ST
DI
.
20 U
20 O S
1- ID
-0 HIB
03 O
PR
11-15

UPPER CLUTCH GRIP
.A O
multi-position adjuster and spring. UPPER BRACKET COVER
.
IS D
S ZA
UPPER GRIP BRACKET
8. Remove the 5 x 37 mm roller pin. 5 x 37 mm SPRING
A RI
MULTI-POSITION
IR O
ADJUSTER
D UT
A A
4 mm
M NO
SELF-
TAPPING
SCREW (8)
LOWER LOWER
.- O
GRIP COVER BRACKET
.A US
.
10. Put a protective pad around the upper handle pipe. CONTROL ARM
Tip the mower up and secure the upper handle pipe in a DRIVE CLUTCH
IS O
CABLE
bench vise.
S N
11. Remove the rear scroll (P. 4-7).

12. Push the transmission as shown and remove the Smart
A IÓ
CABLE
Drive cable from the control arm. HOLDER
IR UC
CABLE
the cable, and remove it from the cable holder. LOCKS
14. Remove the Smart Drive cable from the lawn mower.
D B
A RI
.
M ST
INSTALLATION SMART
CONTROL ARM DRIVE
DI
If installing a new Smart Drive cable, fully loosen the cable CABLE
adjuster before installing the new Smart Drive cable. END SNAP
FITTING
1. Route the Smart Drive cable down through the hole in
20 U
the cutter housing.

20 O S
SMART
2. Attach the Smart Drive cable end on the control arm. DRIVE
3. Push the transmission as shown, align the Smart Drive CABLE
WIRE
cable wire with the cable holder slot, and install the
1- ID
snap fitting into the cable bracket.

CABLE
HOLDER
-0 HIB
SLOT
03 O
PR
11-16
4. Route the upper end of the Smart Drive cable through

the hole in the handle pipe until it's visible in the slot in HANDLE
.A O
the top of the handle pipe. PIPE
SLOT
.
IS D
CABLE
S ZA
END
SMART
A RI
DRIVE
CABLE
IR O
.
D UT
A A
M NO
SMART
.- O
DRIVE
CABLE LOWER
.A US
GRIP
BRACKET
.

IS O
around the handle pipe slot and secure with the four 4
SCREW (4) BRACKET
mm self-tapping screws. The grip brackets will seat
S N

A IÓ
IR UC
HANDLE
D B
PIPE SLOT
A RI
Viewed from above UPPER GRIP BRACKET

the handle pipe.
M ST
.
DI

20 U
20 O S
1- ID
-0 HIB
Viewed from under ROLLER PIN BRACKET
the handle pipe.
03 O
.
PR
11-17
.A O
5 x 37 mm
.
IS D
S ZA
A RI

IR O
INSIDE PIN
D UT
GROOVES
A A
LOWER BRACKET
COVER
M NO
.

LOWER
CLUTCH GRIP
.- O
bracket cover.
.A US
IS O
S N
A IÓ
ADJUSTER
SLOTS
IR UC
D B
A RI
SPRING
M ST
MULTI-POSITION
ADJUSTER
.
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
11-18
11. Place the upper clutch grip over the adjuster

assembly and secure to the lower clutch grip with
.A O
the four 4 mm self-tapping screws. UPPER CLUTCH GRIP
.
IS D
S ZA
13. Install the belt cover (K8 P. 4-6) or rear scroll
A RI
(K9 P. 4-7).
14. Install new cable ties securing the Smart Drive
IR O
cable to the handle stay and handle pipe.
D UT
16. Start and test the Smart Drive operation. LOWER CLUTCH GRIP
A A
4 mm
Viewed from under
M NO
SELF-TAPPING
.- O
.A US
6. SMART DRIVE DISASSEMBLY AND INSPECTION
1. Confirm the rubber grips do not contact the Smart
IS O
Drive handle. Any contact will likely prevent the 45 ~ 50 mm 45 ~ 50 mm
(1.75 ~ 2.0 in) (1.75 ~ 2.0 in)
control from releasing properly.
S N
2. Loosen the Smart Drive cable adjuster completely

A IÓ
(P. 3-10).
IR UC
CONTROL
D B
A RI
HANDLE SMART DRIVE RUBBER

M ST
GRIP (2) HANDLE GRIP (2)

.
DI
3. Remove the 4 mm screws and separate the upper UPPER

and lower grips and multi-position adjuster and CLUTCH
20 U
spring. GRIP
20 O S
Viewed from under

the handle pipe.
LOWER
CLUTCH
1- ID
GRIP
-0 HIB
4 mm
SELF-TAPPING
SCREW (4) Multi-position adjuster and
spring
03 O
PR
11-19
4. Separate the upper and lower bracket covers.

UPPER BRACKET COVER 5 x 37 mm ROLLER PIN
Thoroughly clean the inside of the bracket
.A O
covers and inner bracket. Verify the pin and
cable move smoothly.
.
IS D
5. Slide the roller pin back and forth to confirm the
pin and cable move smoothly. If the cable binds,
S ZA
replace it.
6. Apply grease to the inside of the bracket covers
A RI
and reinstall. Be sure to align the roller pin with
the bracket cover grooves.
IR O
INSIDE PIN
D UT
GROOVES
A A
LOWER BRACKET
COVER
M NO
.

7. Grease both sides of the clutch grip guides. LOWER
8. Insert the multi-position adjuster and spring in CLUTCH GRIP
.- O
the track of the lower clutch grip. BOTH SIDES OF GUIDES
.A US
9. Place the assembly over the inner bracket cover.
IS O
ADJUSTER
SLOTS
S N
A IÓ
Multi-position adjuster
IR UC
and spring
D B
.
A RI
10. Place the upper grip over the cover assembly

UPPER CLUTCH GRIP
and secure to the lower clutch grip with the four
M ST
4 mm self-tapping screws. Rotate the Smart

Drive grip and confirm that it rotates smoothly Viewed from under
the handle pipe.
DI
and the cable moves at the transmission.

11. Go to the Smart Drive CABLE ADJUSTMENT
procedure (P. 3-10).
20 U
20 O S
1- ID
LOWER CLUTCH GRIP

4 mm
-0 HIB
SELF-TAPPING
SCREW (4)
03 O
PR
11-20
12. CLIP DIRECTOR/MOWER DECK/WHEELS
1. CLIP DIRECTOR (K9 ONLY) . . . . . . . . . . 12-1 3. WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
.A O
2. MOWER DECK . . . . . . . . . . . . . . . . . . . . 12-2
.
IS D
S ZA
1. CLIP DIRECTOR (K9 ONLY)
A RI
REMOVAL/INSTALLATION [1]
IR O
D UT
1. Move the Clip Director lever to the BAG position.
[2]
A A
2. Turn the fuel valve OFF and tilt the mower on its
right side with the gas filler cap up. [3]
M NO
[2]
3. Remove the three 6 x 10 mm flange bolts [1], two [1]
.- O
6 x 8 mm shoulder bolts [2], and one shoulder
screw [3], and then remove the rear scroll.
.A US
Shown with blades
removed for clarity.
IS O [1]
4. Remove the 5 x 16 mm self-tapping screw.

S N
5. Remove the two 6 mm cap nuts and special bolts.

A IÓ
6. Lift the Clip Director lever and shutter cover

assembly away from the mower deck.
IR UC
If you remove the handle from the cover, be 5 x 16 mm

careful. The handle is spring loaded and tends to SELF-TAPPING
D B
pop apart when removed. SCREW

A RI
7. Remove the Clip Director door through the back of

the deck.
M ST
8. Installation is done in the reverse order of removal.

Pay attention to the following:
DI
• Be sure the Clip Director is fully open (BAG

position) when installing the rear scroll.
20 U
20 O S
• Align the lower Clip Director hinge pin with the 6 mm CAP NUTS
hole in the scroll.
1- ID
• Use a long flat blade screwdriver and a piece of

-0 HIB
tape to hold the upper special nut in place while

installing the shoulder screw [3] in the center of
the rear scroll.
03 O
• Make sure the Clip Director shutter door pivot

PR
point aligns with the hole in the rear scroll when

assembling.
12-1
CLIP DIRECTOR/MOWER DECK/WHEELS HRR216VKA
2. MOWER DECK
.A O
K5 thru K7
.
IS D
S ZA
SCROLL PLATE
A RI
MULCHING PLUG
GUIDE PLATE
IR O
D UT
A A
SPRING (2)
M NO
HINGE PLATE (2)
GROMMETS
.- O
REAR
DOOR
.A US
PUSH NUT
IS O
SHIELD
SHAFT
DOOR SHAFT
S N
6 mm
A IÓ
NYLON
LOCK
NUT
IR UC
REAR
SHIELD
COVER
D B
PUSH NUT
8 mm FLAT
A RI
WASHER (2) 5/16-24 x 1" BELT COVER

FLANGE BOLT (4)
M ST
8 mm
FRONT
FLANGE
SCROLL 6 x 10 mm
DI
NUT (2)
FLANGE BOLT (5)
REAR SCROLL
20 U
20 O S
1- ID
-0 HIB
03 O
PR
12-2
HRR216VKA CLIP DIRECTOR/MOWER DECK/WHEELS
K8 VERSION
.A O
.
IS D
S ZA
A RI
IR O
D UT
A A
M NO
.- O
.A US
IS O
S N
Reference Reference
Description Quantity Description Quantity
A IÓ
# #
2 Belt cover 1 16 Right guard return spring 1
IR UC
3 Cutter housing 1 17 Left guard return spring 1

4 Rear shield 1 19 Flange bolt (5/16-24X1") 4
D B
5 Front scroll 1 21 Push nut (7.94 mm) 1

A RI
6 Rear scroll 1 22 Nylon locknut (8 mm) 1

M ST
7 Rear shield shaft 1 23 Plain washer (5/16) 2

8 Scroll plate 1 24 Flange nut (8 mm) 2
DI
9 Guide plate 1 25 Flange bolt (6 x 10) 7

10 Roto-Stop® cover 1 26 Push nut (3.96 mm) 1
20 U
12 Plug grommet 2 28 Pan bolt (6 x 12) 1

20 O S
13 Mulching plug 1 29 Mulching plug stopper 1

14 Discharge guard 1 30 Grass bag plate 1
15 Discharge guard shaft 1 31 Grass bag plate bolt 3
1- ID
32 Flange nut (6 mm) 3

-0 HIB
03 O
PR
12-3
K9 VERSION
.A O
.
IS D
S ZA
A RI
IR O
D UT
A A
M NO
.- O
.A US
IS O
S N
Reference Reference
A IÓ
Description Quantity Description Quantity

# #
IR UC
2 Special nut (6 x 7) 4 20 Scroll ramp 1

3 Cutter housing 1 21 Left guard return spring 1
4 Rear shield 1 22 Grass bag plate 1
D B
5 Front scroll 1 23 Scroll bolt 2

A RI
6 Rear scroll 1 24 Special bolt (6 x 12.5) 3

7 Rear shield shaft (405 mm) 1 25 Grass bag plate bolt 3
M ST
8 Roto-Stop cover 1 26 Flange bolt (5/16-24X1) 4

9 Cable grommet 1 27 Flat round push nut (3.96 mm) 1
DI
11 Plug grommet 1 28 Push nut (7.94 mm) 1

12 Shutter cover 1 29 Flange cap nut (6 mm) 2
20 U
13 Shutter 1 30 Nylon lock nut (6 mm) 1

20 O S
14 Shutter lever 2 31 Plain washer (5/16) 2

15 Lock lever 1 32 Tapping screw (5 x 16 mm) 1
16 Lever spring 1 33 Flange nut (6 mm) 2
1- ID
17 Discharge guard 1 34 Flange nut (8 mm) 2

18 Discharge guard shaft 1 35 Plain washer (6 mm) 1
-0 HIB
19 Right guard return spring 1 36 Flange bolt (6 x 10) 3

03 O
PR
12-4
HRR216VKA CLIP DIRECTOR/MOWER DECK/WHEELS
3. WHEELS
.A O
REAR WHEEL
.
IS D
S ZA
Right Side Shown
WHEEL WASHER
REASSEMBLY:
A RI
BEARING (2) GRIP
IR O
WHEEL SIDE
D UT
ADJUSTER
PLATE
A A

13 x 27 x 1 mm THRUST WASHER
WHEEL
M NO
BOLT
BUSHING
Apply grease
inside bushing
ADJUSTER

.- O
PANEL
.A US
CIRCLIP 8 mm
KEY FLANGE
IS O NUT
PINION GEAR
COLLAR
COVER
S N
A IÓ
PINION GEAR (12 tooth)

SEAL
RETURN THRUST
IR UC
SPRING COLLAR
ADJUSTER
13 mm ARM
D B
THRUST
Install with the punch COLLAR WASHER
A RI
mark facing: 25 mm
Left – inside CIRCLIP
Right – outside
M ST
CIRCLIP
26 x 44 mm FLAT WASHER
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
12-5
FRONT WHEEL
.A O
Right Side Shown
ADJUSTER
.
IS D
BOLT
S ZA
GRIP
A RI
IR O
ADJUSTER PLATE
D UT
A A
ADJUSTER ARM
M NO
WHEEL BOLT
.- O
5/16 in WASHER
WHEEL WASHER
.A US
REASSEMBLY:
COLLAR
IS O
WHEEL SIDE ADJUSTER PANEL
S N
8mm FLANGE NUT

A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
12-6
13. TRANSMISSION
.A O
1. TRANSMISSION (K5 AND K6) . . . . . . . . 13-1 3. TRANSMISSION (K8, K9) . . . . . . . . . . . 13-13
2. TRANSMISSION (K7) . . . . . . . . . . . . . . . 13-7
.
IS D
S ZA
1. TRANSMISSION (K5 and K6)
A RI
REMOVAL
IR O
1. Drain the fuel tank and engine oil. SNAP
CABLE HOLDER
D UT
SLOT
2. Loosen the Smart Drive cable adjuster (P. 3-10). FITTING
3. Cut the cable ties attaching the flywheel brake cable
A A
and the Smart Drive cable to the handle pipe.
4. Set the height adjusting lever in the highest cutting
M NO
position.
5. Protect the upper handle pipe and tip the mower up and
SMART
secure the upper handle pipe in a bench vise.
.- O
DRIVE
6. Remove the belt cover, belt tension spring, and drive CABLE
.A US
END
belt (P. 4-2).
7. Rotate the transmission out slightly (not too far or you'll
kink the cable).
IS O
TRANSMISSION BELT TENSION
8. Use needle nose pliers to remove the snap fitting from CONTROL ARM SPRING
S N
the clutch cable holder, and disconnect the Smart Drive

cable end from the transmission control arm.
A IÓ
9. Remove the wheel bolt, wheel, wheel washer, and flat

IR UC
washer from each side.

D B
FLAT WASHER
A RI
M ST
WHEEL WASHER
INSTALLATION:
DI
WHEEL Install curved side

BOLT as shown:
20 U
20 O S
MOWER
DECK
1- ID
-0 HIB
03 O
PR
13-1
TRANSMISSION HRR216VKA
10. Remove the 13 mm circlip, pinion collar, pinion gear,

WHEEL COVER
and wheel cover from each side.
.A O
.
IS D
12-TOOTH
PINION
S ZA
GEAR
PINION
A RI
COLLAR
IR O
13 mm
D UT
CIRCLIP
A A
M NO
.
11. Remove the ratchet key and spring from each side.
RATCHET KEY
.- O
.A US
SPRING
IS O
S N

A IÓ
IR UC
.
D B
12. Remove the remaining collars, circlip, and washer

from each side as shown.
A RI
M ST
DI
WASHER
20 U
CIRCLIP
20 O S
COLLAR
COLLAR
1- ID
-0 HIB
03 O
PR
13-2
HRR216VKA TRANSMISSION
13. Remove the 22 mm circlip from each side, and slide ADJUSTER
them and the washers inward towards the transmission. ASSEMBLY
.A O
14. Remove the adjuster assembly from each side, taking
.
IS D
care not to damage the seals.
S ZA

WASHER
A RI
CIRCLIP
IR O
D UT
A A
M NO
.
15. Slide the transmission/axle to the right side, and

then rotate it until the left side can be removed from the 22 mm
mower deck. Remove the transmission from the mower CIRCLIP (2) 22 mm
.- O
deck. WASHER (2)
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
13-3
.A O
(K5 VERSION up to MZCG - 7819952)
.
IS D
10 mm FLANGE NUT
S ZA
DRIVEN PULLEY
A RI
BELT TENSION SPRING
IR O
BELT SPRING PLATE
6 mm
D UT
FLANGE NUT
A A
12.7 x 28.6 x 6.4 mm
OIL SEAL (2)
M NO
10 x 24 mm WASHER
6 x 14 mm 12 x 28.5 x 6.35 mm OIL SEAL
FLANGE
.- O
BOLT (2) RETURN SPRING
.A US
TRANSMISSION CONTROL ARM
TENSIONER 6 x 12 mm FLANGE BOLT (2)

ARM
IS O
WIRE HOLDER
S N
A IÓ
10 x 19 x 7 mm
OIL SEAL
IR UC
SMART DRIVE CABLE

D B
TRANSMISSION CASE REASSEMBLY:

A RI
INSTALLATION: Use SAE Be sure to use the correct Smart Drive

cable. The part number is printed on
10W-30 engine oil and fill to the the cable.
M ST
capacity shown. Steel pulley type: 54510-VL0-B00

The correct oil level should be CASE O-RING Plastic pulley type: 54510-VH7-L00
8 ~ 12 mm (0.3 ~ 0.5 in) from (15 mm longer than 54510-VL0-B00)
DI
the top of the transmission case

when it is upside down. REDUCTION
CAPACITY: 150 cc (5.0 oz) COVER
20 U
TOP OF 8 ~ 12 mm
CASE
20 O S
(0.3 ~ 0.5 in)

8.8 ~ 11.8 N•m (6.5 ~ 8.7 ft•lb)
1- ID
-0 HIB
03 O
PR
13-4
(K5 VERSION MZCG - 7819953 ~ 7999999)

(K6 VERSION MZCG - 8000001 ~ 8199999)
.A O
(K7 VERSION MZCG - 8200001 ~ 8282198)
.
IS D
S ZA
POLYMER PULLEY
A RI
INSTALLATION:
Use a 5 mm (3/15 in) drift punch to align the hole in the pulley with
the pinion shaft pin hole.
IR O
Rotate the pulley until the pin hole is parallel to the belt tension arm.
D UT
Press the spring pin into the pulley so that the pin is centered in the 5 x 35 mm SPRING PIN
pinion shaft. The end of the pin should be about 30 mm from the
outside edges of the pulley.
A A
6 x 14 mm 12.7 x 28.6 x 6.4 mm OIL SEAL
FLANGE BOLT (2) 6 mm FLANGE NUT
M NO
BELT TENSION ARM BELT TENSION SPRING
12.7 x 28.6 x 6.4 mm

OIL SEAL (2)
.- O
.A US
TENSION SPRING PLATE
IS O
S N
10 x 19 x 7 mm 6 x 14 mm
OIL SEAL
A IÓ
FLANGE BOLT (2)
RETURN SPRING
IR UC
TRANSMISSION CASE WIRE HOLDER

D B
INSTALLATION: Use SAE

A RI
10W-30 engine oil and fill to the PINION SHAFT

capacity shown.
M ST

8 ~ 12 mm (0.3 ~ 0.5 in) from SMART DRIVE CABLE
the top of the transmission case
DI
when it is upside down.

REASSEMBLY:
CAPACITY: 150 cc (5.0 oz) Be sure to use the correct Smart Drive
TOP OF 8 ~ 12 mm cable. The part number is printed on
20 U
CASE CASE O-RING the cable.

(0.3 ~ 0.5 in)
Steel pulley type: 54510-VL0-B00
20 O S
REDUCTION Plastic pulley type: 54510-VH7-L00

COVER (15 mm longer than 54510-VL0-B00)
1- ID

-0 HIB
8.8 ~ 11.8 N•m (6.5 ~ 8.7 ft•lb)

03 O
PR
13-5
INSTALLATION
22 mm
.A O
1. Install the transmission in the reverse order of removal. CIRCLIP (2) 22 mm
2. Position the 22 mm circlips and 22 mm washers on the WASHER (2)
.
IS D
transmission axle.
S ZA
3. Rotate the transmission so that the pulley is facing
toward the front of the mower, and install the
A RI
transmission in the mower.
IR O
D UT
A A
M NO
.
Pay attention to the following points:.

LEFT SIDE (CLOSEST
.- O
• Apply grease to the rear adjuster bushings and ratchet TO TRANSMISSION)
.A US
keys prior to assembly
• Make sure the punch mark on the pinion gear faces in
(toward the mower deck) on the left axle, and the
IS O
punch mark faces out (toward the wheel) on the right
axle. PUNCH MARK
INSIDE
S N
• Install the curved wheel washers as shown on

A IÓ
page 12-5.
IR UC
D B
A RI
M ST
RIGHT SIDE
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
PUNCH MARK
OUTSIDE
13-6
2. TRANSMISSION (K7)
.A O
(K7 VERSION MZCG - 8282199 and SUBSEQUENT)
.
IS D
REMOVAL
S ZA
1. Drain the fuel tank and engine oil. CABLE HOLDER
SLOT
1. Loosen the Smart Drive cable adjuster (P. 3-10).
A RI
SNAP
2. Cut the cable ties attaching the flywheel brake cable FITTING
IR O
and the Smart Drive cable to the handle pipe.
D UT
position.
4. Protect the upper handle pipe and tip the mower up and
A A
SMART
secure the upper handle pipe in a bench vise. DRIVE
M NO
5. Remove the belt cover, belt tension spring, and drive CABLE
END BELT
belt (P. 4-4). TENSION
SPRING
6. Rotate the transmission out slightly (not too far or you'll
.- O
kink the cable). TRANSMISSION
CONTROL ARM
.A US
7. Use needle nose pliers to remove the snap fitting from
the clutch cable holder, and disconnect the Smart Drive
cable end from the transmission control arm.
IS O
washer from each side. FLAT WASHER
S N
A IÓ
WHEEL
BOLT
IR UC
D B
A RI
M ST
WHEEL WASHER
.
DI
9. Remove the 13 mm circlip, pinion gear collar, pinion

RATCHET KEY
gear, ratchet key, and ratchet return spring from each
20 U
side.
RATCHET RETURN SPRING
20 O S
12-TOOTH
PINION GEAR
1- ID
-0 HIB
PINION
03 O
GEAR 13 mm
COLLAR
PR
CIRCLIP
13-7
10. Remove the pinion gear collars and wheel covers from
PINION WHEEL
each side. COVER
.A O
GEAR
COLLAR
.
IS D
S ZA
A RI
IR O
D UT
A A
.
M NO
11. Remove the remaining thrust collars and circlips
from each side.
THRUST
COLLAR
.- O
13 mm
.A US
WASHER
IS O
13 mm
S N
CIRCLIP
A IÓ
12. Remove the 22 mm circlip from each side, and slide

IR UC
ADJUSTER
them and the washers inward towards the transmission. ASSEMBLY
D B

A RI
WASHER
M ST
CIRCLIP
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
13-8
14. Remove the two 8 mm flange nuts and the left side
adjuster panel. 22 mm
.A O
CIRCLIP (2) 22 mm
15. Slide the transmission/axle to the right side, then WASHER (2)
.
IS D
rotate it until the left side can be removed from the
mower deck. Remove the transmission from the
S ZA
mower deck.
A RI
ADJUSTER
PANEL
IR O
(LEFT)
D UT
A A
M NO
8 mm
FLANGE
NUT(2)
.- O
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
13-9
.A O
(K7 VERSION MZCG - 8282199 and SUBSEQUENT)
.
IS D
POLYMER PULLEY
INSTALLATION:
S ZA
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.
A RI
Press the spring pin into the pulley so that the pin is centered in the 5 x 35 mm SPRING PIN
pinion shaft. The end of the pin should be about 30 mm from the
IR O
outside edges of the pulley.
D UT
6 x 14 mm 12.7 x 28.6 x 6.4 mm OIL SEAL
FLANGE BOLT (2) 6 mm FLANGE NUT
A A
BELT TENSION SPRING
BELT TENSION ARM
M NO
12.7 x 28.6 x 6.4 mm
.- O
OIL SEAL (2)
TENSION SPRING PLATE
.A US
10 x 19 x 7 mm TRANSMISSION CONTROL ARM
OIL SEAL
IS O
6 x 14 mm
FLANGE BOLT (2)
RETURN SPRING
S N
WIRE HOLDER
A IÓ
IR UC
TRANSMISSION CASE PINION SHAFT

D B

engine oil and fill to the capacity SMART DRIVE CABLE
A RI
shown.
M ST
10 ~ 12 mm (0.4 ~ 0.5 in) from the top

of the transmission case when it is
upside down.
DI
CAPACITY: 65 ~ 70 cc (2.2 ~ 2.4 oz) CASE O-RING

TOP OF 10 ~ 12 mm
CASE REDUCTION
(0.4 ~ 0.5 in)
20 U
COVER
20 O S

1- ID
8.8 ~ 11.8 N•m (6.5 ~ 8.7 ft-lb)

-0 HIB
03 O
PR
13-10
INSTALLATION 25 mm
CIRCLIP (2) 26 x 44 mm
.A O
1.Position the 25 mm circlips and 26 x 44 mm washers on
WASHER (2)
the transmission axle as shown.
.
IS D
2. Rotate the transmission so that the pulley is facing
S ZA
A RI
3. Install the left-side adjuster panel ("L" is on the left-side
and "R" is on the right-side.
IR O
D UT
ADJUSTER
PANEL
A A
8 mm
M NO
FLANGE
NUT(2)
.
4. Apply general-purpose grease to the inside of the
.- O
ADJUSTER ARM
rear adjuster bushings.
.A US
ADJUSTER
5. Slide the adjuster plate onto the right-hand (RH) PLATE
adjusting arm.
6. Install the right-hand adjuster assembly on the
IS O

right-side, taking care not to damage the seals. 26 x 44 mm
WASHER
S N
7. Slide a 26 x 44 mm washer onto the adjuster and

secure with s 25 mm circlip. 25 mm
A IÓ
CIRCLIP
IR UC
D B
A RI
8. Install a thrust collar and secure with a 13 mm

M ST
circlip.
THRUST
DI
COLLAR
13 mm
20 U
CIRCLIP
20 O S
1- ID
-0 HIB
03 O
PR
13-11
9. Install a pinion gear collar and wheel cover.

PINION WHEEL
COVER
.A O
GEAR
COLLAR
.
IS D
S ZA
A RI
IR O
D UT
A A
.
10. Apply general-purpose grease to the areas shown.
M NO
RATCHET KEY RATCHET RETURN SPRING
11. Install a ratchet return spring and ratchet key. PINION GEAR
(12 TOOTH)
12. Install a pinion gear, pinion collar, and 13 mm circlip.
.- O
Make sure the pinion gear is installed correctly for each
side as shown.
.A US
Install with the
punch mark facing:
IS O
Left – inside
Right – outside
S N

PINION
A IÓ
GEAR
13 mm
COLLAR
CIRCLIP
IR UC
13. Install a wheel washer, flat washer, wheel, and

D B
wheel bolt. FLAT WASHER

A RI
14. Repeat steps 4 -12 for the left side.

M ST
WHEEL
BOLT
DI
20 U
20 O S
WHEEL WASHER
REASSEMBLY:
1- ID
shown.
-0 HIB
WHEEL
SIDE
03 O
PR
13-12
15. Rotate the transmission out slightly to install the Smart CABLE HOLDER
Drive cable. SLOT
.A O
SNAP
16. Connect the Smart Drive cable end onto the FITTING
.
IS D
transmission control arm, and install the snap fitting into
S ZA
the clutch cable holder.
17. Install the drive belt, belt tension spring, and belt
cover (P. 4-5).
A RI
18. Adjust the Smart Drive cable (P. 3-10). SMART
IR O
DRIVE
19. Add fuel and engine oil. CABLE
BELT
D UT
END
20. Start the engine and a. TENSION
SPRING
A A
TRANSMISSION
CONTROL ARM
M NO
.- O
3. TRANSMISSION (K8, K9)
.A US
REMOVAL
IS O
2. Drain the fuel tank (P. 3-11) and engine oil (P. 3-7).
S N
3. Loosen the Smart Drive cable adjuster (P. 3-10). TRANSMISSION

CONTROL ARM
A IÓ

position.
IR UC
BELT
5. Protect the upper handle pipe and tip the mower up and TENSION
secure the upper handle pipe in a bench vise. SPRING
D B
6. Remove the rear scroll (P. 4-7). SMART

DRIVE
A RI
CABLE
7. Remove the blades and blade holder (P. 4-1).
8. Serial numbers MZCG-9506882 and later:
M ST
CABLE HOLDER
Remove the belt guide.
9. Lift the drive pulley off the crankshaft and separate the DRIVE BELT
DI
belt from the drive pulley.

Leave the belt attached to the transmission.
20 U
DRIVE PULLEY
BELT GUIDE
10. Push down on the transmission control arm as shown,
20 O S
and disconnect the Smart Drive cable from the

11. Remove the belt tension spring from the cable holder and the transmission control arm.
1- ID
-0 HIB
03 O
PR
13-13
washer from each side. FLAT WASHER
.A O
.
IS D
WHEEL
S ZA
BOLT
A RI
IR O
D UT
WHEEL WASHER
A A
13. Remove the 13 mm circlip, pinion gear collar, pinion
M NO
RATCHET KEY
gear, ratchet key, and ratchet return spring from each
side.
RATCHET RETURN SPRING
.- O
12-TOOTH
PINION GEAR
.A US
IS O
S N
PINION
GEAR
A IÓ
COLLAR 13 mm
CIRCLIP
IR UC
14. Remove the pinion gear collars and wheel covers from
PINION WHEEL
D B
each side. GEAR COVER

COLLAR
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
13-14
15. Remove the remaining thrust collars, 13 mm washers,

and circlips from each side. THRUST COLLAR
.A O
13 mm WASHER
.
IS D
S ZA
13 mm
CIRCLIP
A RI
IR O
D UT
A A
16. Remove the 25 mm circlip from each side, and slide ADJUSTER
them and the 26 x 44 mm washers inward toward the ASSEMBLY
M NO
transmission.
.- O
26 x 44 mm
.A US
WASHER
25 mm
CIRCLIP
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
13-15
18. Remove the two 8 mm flange nuts and the left side
adjuster panel. 22 mm
.A O
CIRCLIP (2)
19. Slide the transmission/axle to the right side, and then 22 mm
.
IS D
rotate it until the left side can be removed from the WASHER (2)
mower deck; remove the transmission.
S ZA
A RI
ADJUSTER
PANEL
IR O
(LEFT)
D UT
A A
M NO
8 mm
FLANGE
NUT(2)
.- O
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
13-16
.A O
(up to MZCG-9506881)
.
IS D
S ZA
DRIVEN PULLEY HALVES
REMOVAL
A RI
Hold the pinion shaft with a wrench,
and then remove the 10 mm flange 10 mm FLANGE NUT
nut. 39 N•m (29 ft•lb)
IR O
INSTALLATION:
Align the pulley pins opposite each
D UT
other so that they fit into the small
holes of the other pulley half.
A A
M NO
PINS
.- O
10 x 24 mm WASHER
.A US
12.7 x 22.2 x 6.4 mm
OIL SEAL (2) 12.7 x 28.6 x 6.4 mm 6 x 12 mm
OIL SEAL
IS O FLANGE BOLT (2)
BELT GUIDE RETURN SPRING

INSPECTION: P. 2-14
S N
A IÓ
PINION SHAFT
IR UC
D B
A RI
M ST
DI
20 U
CASE O-RING CABLE HOLDER

20 O S
TRANSMISSION CASE
shown.
The correct oil level should be SMART DRIVE CABLE
1- ID
18 ~ 20 mm (0.71 ~ 0.79 in) from the ADJUSTMENT: P. 3-10

top of the transmission case when it is REDUCTION
upside down. COVER
-0 HIB
CAPACITY: 65 cc (2.2 oz) 6 x 12 mm FLANGE BOLT (4)

TOP OF 18 ~ 20 mm
CASE 8.8 ~ 11.8 N•m (6.5 ~ 8.7 ft•lb)
(0.71 ~ 0.79 in)
03 O

PR
13-17
(MZCG-9506882 and later)
.A O
.
IS D
DRIVEN PULLEY HALVES
S ZA
REMOVAL
Hold the pinion shaft with a wrench,
and then remove the 10 mm flange 10 mm FLANGE NUT
nut.
A RI
39 N•m (29 ft•lb)
INSTALLATION:
Align the pulley pins opposite each
other so that they fit into the small
IR O
holes of the other pulley half.
D UT
A A
M NO
PINS
10 x 24 mm WASHER
.- O
12.7 x 22.2 x 6.4 mm
OIL SEAL (2) 6 x 12 mm
FLANGE BOLT (2)
.A US
12.7 x 28.6 x 6.4 mm
OIL SEAL
IS O RETURN SPRING
BELT GUIDE
S N
PINION SHAFT
A IÓ
IR UC
D B
A RI
M ST
DI
CASE O-RING CABLE HOLDER

TRANSMISSION CASE
20 U

20 O S

shown.
The correct oil level should be SELECT DRIVE CLUTCH CABLE
18 ~ 20mm (0.71 ~ 0.79 in) from the
top of the transmission case when it is REDUCTION
COVER
1- ID
upside down.
CAPACITY: 65 cc (2.2 oz) 6 x 12 mm FLANGE BOLT (4)
TOP OF 18 ~ 20 mm
-0 HIB
CASE 8.8 ~ 11.8 N•m (6.5 ~ 8.7 ft•lb)

(0.71 ~ 0.79 in)
03 O
PR
13-18
INSTALLATION
25 mm
1. Position the 25 mm circlips and 26 x 44 mm washers on CIRCLIP (2)
.A O
the transmission axle as shown.
26 x 44 mm
.
IS D
2. Rotate the transmission so that the pulley is facing WASHER (2)
S ZA
A RI
3. Install the left-side adjuster panel (“L” is on the left-side
ADJUSTER
and “R” is on the right-side). PANEL
IR O
(LEFT)
D UT
A A
M NO
8 mm
FLANGE
NUT(2)
.- O
4. Apply general-purpose grease to the inside of the rear ADJUSTER ARM
.A US
adjuster bushings.
ADJUSTER
5. Slide the adjuster plate onto the right-hand (RH) PLATE
adjusting arm.
IS O
6. Install the right-hand adjuster assembly on the
right-side, taking care not to damage the seals. 26 x 44 mm
S N

WASHER
7. Slide a 26 x 44 mm washer onto the adjuster and
A IÓ
secure with a 25 mm circlip. 25 mm

CIRCLIP
IR UC
D B
A RI
M ST
DI
8. Install a thrust collar and 13 mm washer, and secure

20 U
with a 13 mm circlip.
20 O S
THRUST
COLLAR
13 mm
1- ID
WASHER
-0 HIB
03 O
13 mm
CIRCLIP
PR
13-19
9. Install a pinion gear collar and wheel cover.

PINION WHEEL
GEAR COVER
.A O
COLLAR
.
IS D
S ZA
A RI
IR O
D UT
A A
10. Apply general-purpose grease to the areas shown.
M NO
RATCHET KEY RATCHET RETURN SPRING
11. Install a ratchet return spring and ratchet key. 12-TOOTH
PINION GEAR
12. Install a pinion gear, pinion collar, and 13 mm circlip.
.- O
Make sure the pinion gear is installed correctly for each
side as shown.
.A US
Install with the punch
mark facing:
IS O
Left – inside
Right – outside
S N
PINION
A IÓ
GEAR 13 mm
COLLAR
 CIRCLIP
IR UC
13. Install a wheel washer, flat washer, wheel, and wheel

D B
bolt. FLAT WASHER

A RI
14. Repeat steps 4 -13 for the left side.

M ST
WHEEL
BOLT
DI
20 U
20 O S
WHEEL WASHER
REASSEMBLY:
1- ID
shown.
-0 HIB
WHEEL
SIDE
03 O
PR
13-20
15. Install the return spring. TRANSMISSION

CONTROL ARM
.A O
16. Push down on the control arm, and install the Smart
Drive cable end onto the transmission control arm.
.
IS D
17. Position the belt on the drive pulley and install the drive BELT
S ZA
TENSION
pulley on the crankshaft. SPRING
18. Serial numbers MZCG-9506882 and later: SMART
A RI
DRIVE
Reinstall the belt guide. CABLE
19. Install the rear scroll (P. 4-7).
IR O
20. Install the blade holder and blades (P. 4-1). CABLE HOLDER
D UT
21. Reconnect the spark plug cap. DRIVE BELT
22. Add fuel and engine oil.
A A
23. Start the engine and adjust the Smart Drive cable DRIVE PULLEY BELT GUIDE
M NO
(P. 3-10).
.- O
.A US
IS O
S N
A IÓ
IR UC
D B
A RI
M ST
DI
20 U
20 O S
1- ID
-0 HIB
03 O
PR
13-21
13-22
PR
TRANSMISSION
03 O
-0 HIB
1- ID
20 O S
20 U
DI
M ST
A RI
D B
NOTES
IR UC
A IÓ
S N
IS O
.A US
.- O
M NO
A A
D UT
IR O
A RI
S ZA
HRR216VKA
IS D
.A O
.
INDEX
A Evaporative emission control system . . . . . . . . . . . . . . 8-27
Air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 F
Air gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Fan cover removal/installation . . . . . . . . . . . . . . . . 8-24,8-25
.A O
B Filter, air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Blade holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Flywheel
.
IS D
Blades Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . 9-1,9-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
S ZA
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Flywheel brake inspection . . . . . . . . . . . . . . . . . . . . . . . 3-12
A RI
Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Fuel cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Torque spec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
IR O
Breather tube installation . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Fuel tank and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Fuel tank removal/installation . . . . . . . . . . . . . . . . 8-24,8-25
D UT
C Fuel tube
Cam pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Carburetor Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
A A
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Fuel valve disassembly/reassembly . . . . . . . . . . . . . . . 8-22
Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . . . . 8-5
G
M NO
Float level height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Governor
Choke control assembly. . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . . 10-13
Choke control system Max speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . 3-17
.- O
K5~K7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Governor arm disassembly/reassembly . . . . . . . . . . . . 8-21
K8~K9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Grass bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
.A US
Clip Director removal/installation . . . . . . . . . . . . . . . . . . 12-1 Guard, discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Combustion chamber cleaning . . . . . . . . . . . . . . . . . . 10-10 H
Commercially available tools . . . . . . . . . . . . . . . . . . . . . . 2-6 Handle grip removal/installation. . . . . . . . . . . . . . . . . . . 11-5
IS O
Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Handle locking knob . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Connecting rod Handle pipe replacement. . . . . . . . . . . . . . . . . . . . . . . . 11-1
S N
Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Handle stay removal/installation . . . . . . . . . . . . . . . . . . 11-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
A IÓ
Oil clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 I

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
IR UC
Crankshaft inspection . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Idle speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Crankshaft runout check . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Ignition coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Cylinder barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Inspection
D B
Cylinder block inspection . . . . . . . . . . . . . . . . . . . . . . . 10-19 Cam pulley height . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

Cylinder block/oil pan assembly. . . . . . . . . . . . . . . . . . . 10-6 Cam pulley I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
A RI
Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Cam pulley shaft O.D.. . . . . . . . . . . . . . . . . . . . . . . . 10-14

Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . 10-17,10-18
D
M ST
Crankshaft main journal . . . . . . . . . . . . . . . . . . . . . . 10-17

Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2,12-3,12-4 Cylinder block main journal. . . . . . . . . . . . . . . . . . . . 10-19
Decompressor weight . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Decompressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
DI
Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Oil pan main journal . . . . . . . . . . . . . . . . . . . . . . . . . 10-19

Discharge guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 Piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Drive belt
20 U
Piston ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

K5-K6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Piston-to-cylinder clearance . . . . . . . . . . . . . . . . . . . 10-15
20 O S
K7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Rocker arm shaft clearance . . . . . . . . . . . . . . . . . . . 10-15

K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
K9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Timing gear (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Drive system troubleshooting. . . . . . . . . . . . . . . . . 2-7~2-17 Valve face/stem O.D. . . . . . . . . . . . . . . . . . . . . . . . . 10-20
1- ID
E Valve guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20

Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Valve seat width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
-0 HIB
Emission control system . . . . . . . . . . . . . . . . . . . . . . . . 8-27 M

Engine Maintenance
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
03 O
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
PR
Mower deck . . . . . . . . . . . . . . . . . . . . . . . . . .12-2,12-3,12-4

Stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20,9-5 Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
O T
Oil Thermowax
.A O
Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
.
IS D
Oil leak, transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Throttle return spring . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
S ZA
Oil pan removal/installation . . . . . . . . . . . . . . . . . . . . . . 10-4 Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Timing gear inspection (K9) . . . . . . . . . . . . . . . . . . . . 10-18
P Tools
A RI
Pinion gear lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Commercially available. . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Piston Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
IR O
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Transmission
D UT
Cylinder clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Disassembly/reassembly . . . . . . . . 13-4,13-5,13-10,13-17
Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . . . 10-7 Installation . . . . . . . . . . . . . . . . . . . . . . . 13-6,13-11,13-19
Piston ring inspection . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Oil leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
A A
R Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1,13-7,13-13
Troubleshooting
M NO
Rear discharge guard . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Rear scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7,12-1 Drive system. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7~2-17
Rear scroll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Rear shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Tune-up specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
.- O
Rear wheel lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 V
Recoil starter
.A US
Valve
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Clearance adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Starter rope replacement . . . . . . . . . . . . . . . . . . . . . . . 7-2 Disassembly/reassembly . . . . . . . . . . . . . . . . . . . . . . 10-9
Removal, rear scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Seat reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
IS O
Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Rocker arm inspection . . . . . . . . . . . . . . . . . . . . . . . . 10-15 V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Rocker arm shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
S N
Vibration troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 2-19

S
A IÓ
W
Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-i Wheels
Schedule, maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
IR UC
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Scroll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7,12-1 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Scroll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
D B
Service rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

A RI
Smart Drive
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
M ST
Cable installation . . . . . . . . . . . . . . . . . . 11-8,11-12,11-16

Cable removal . . . . . . . . . . . . . . . . . . . . 11-7,11-11,11-15
Disassembly/inspection . . . . . . . . . . . . . . . . . . . . . . 11-19
DI
Spark arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Spark plug
Inspection/cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
20 U
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
20 O S
Specifications
Dimensions, weight, capacities . . . . . . . . . . . . . . . . . . 1-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1- ID
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2,2-3,8-5
-0 HIB
Tune-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Stop switch inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
03 O
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A Few Words About Safety

Failure to properly follow instructions and

Follow the procedures and precautions in this

Important Safety Precautions

help eliminate several potential hazards:

• Use only a nonflammable solvent, not gasoline, to clean parts.

• Safety Labels – on the mower.

CAUTION. CLIP DIRECTOR/MOWER DECK/

These signal words mean: WHEELS

American Honda Motor Co., Inc.

LAWN MOWER K VERSION IDENTIFICATION

8199999 9999999 GJAEA to GJAPA

2009 CARB/EPA regulation

gray (running change after first

K7 MZCG – 8200001 thru • Maximum cutting height increased

8399999 from 3.25 to 4 inches

K8 MZCG – 8400001 thru • New square Auto Choke System™

• Grass bag frame and mount

• Deep rear discharge door

VERSION FRAME SERIAL NUMBERS ENGINE SERIAL NUMBERS IDENTIFIERS/FEATURES/CHANGES

– New fan cover studs (collars

Fuel tank capacity 0.93 L (0.25 US gal)

Engine model GCV160A

Displacement 160 cc (9.8 cu in)

Compression ratio 8.5 : 1

Ignition system Transistorized magneto ignition

Ignition timing 20° B.T.D.C.

Lubrication system Splash type

Starting system Recoil starter

Carburetor Horizontal-type, butterfly valve

Air cleaner Dry (paper) type

620 mm (24.4 in)

* Dimensions measured with the cutting height set in the lowest

2. SYMBOLS USED IN THIS MANUAL

 A special tool is required to perform the procedure.

3. SERIAL NUMBER LOCATIONS

PART ITEM STANDARD VERSIONS

Maximum governed speed 2,950 ~ 3,100 rpm

Cylinder compression 490 kPa (5.0 kg/cm2, 71 psi) at 600 rpm

Main jet #70

Main jet #68

Pilot screw opening N/A

Main jet #68

PART ITEM STANDARD SERVICE LIMIT

Cylinder 64.000 ~ 64.015 mm (2.5197 ~ 2.5203 in)

Small end I.D. 13.005 mm (0.5120 in) 13.07 mm (0.515 in)

Crankshaft Flywheel side 25.393 mm (0.9997 in) 25.333 mm (0.9974 in)

Main journal I.D. 25.420 mm (1.0008 in) 25.466 mm (1.0026 in)

Resistance Primary coil 1.0 ~ 1.2 Ω -----------------------------------

Oil pan bolt M6 x 1.0 (ST) 12 1.2 8.7

Recoil starter nut M6 x 1.0 8.5 0.85 6.1

Valve adjusting lock nut M5 x 0.5 special 8 0.8 5.8

(ST) Indicates a self-tapping bolt.

5 mm 4.9 0.5 3.6

Bolt and nut 8 mm 21 2.1 15

Flange bolt and nut 8 mm 26 2.7 20

3 Flywheel holder 07APB-Z28A100 Flywheel removal

ZERO MIN MAX RANGE HOLD H

and Equipment program catalog for a complete tool listing.

7. DRIVE SYSTEM TROUBLESHOOTING

K5 thru K7 SERVICE BULLETIN #94 =>

1. Inspect the drive belt, transmission input shaft, Smart

3. Verify the transmission control arm moves when rotating