Difficulty

Moderate

Steps

37

Time Required

                          1 - 3 hours

Sections

9

  • Honda Lawn Mower HRS216K6 PKAA Safety Precautions
  • 2 steps
  • Fan Cover and Fuel Tank
  • 8 steps
  • Cooling Fan
  • 2 steps
  • Flywheel
  • 2 steps
  • Flywheel Key
  • 1 step
  • Blade Assembly
  • 4 steps
  • Honda Lawn Mower HRS216K6 PKAA Engine Removal
  • 2 steps
  • Honda Lawn Mower HRS216K6 PKAA Oil Pan Removal
  • 7 steps
  • Crankshaft
  • 9 steps

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Introduction

Drain the fuel from the fuel tank before you begin this procedure. Any fuel remaining in the tank will spill out. Be ready to contain any spillage.

Drain the oil from the motor before you begin this procedure. Any engine oil remaining in the motor will spill out. Be ready to contain any spillage.

You will need to refill the engine oil after this procedure. The lawn mower requires up to 0.55 liters of SAE 10W-30 oil.

You will need to reapply liquid gasket after this procedure. Use ThreeBond 1216, Hondabond HT, or equivalent.

You may need a blowtorch to help heat up and loosen the flywheel.

What you need

Step 1

              Disconnect the spark plug
  • Before you begin, make sure the engine is switched off and cool to the touch.
  • Grab the plastic housing at the end of the spark plug wire and pull firmly to disconnect it.

Before you begin, make sure the engine is switched off and cool to the touch.

Grab the plastic housing at the end of the spark plug wire and pull firmly to disconnect it.

1024

Step 2

              Restrict fuel flow
  • Turn the fuel cutoff valve to the off position to restrict fuel flow during disassembly.
  • Turn the fuel cutoff valve clockwise so the handle becomes vertical.

Turn the fuel cutoff valve to the off position to restrict fuel flow during disassembly.

Turn the fuel cutoff valve clockwise so the handle becomes vertical.

Step 3

              Disconnect the fuel tank
  • Use needle nose pliers to compress and slide the tube clamp away from the cutoff valve’s fitting.

Use needle nose pliers to compress and slide the tube clamp away from the cutoff valve’s fitting.

Step 4

  • Residual fuel may leak out of this hose. Be ready to catch any spillage.
  • Disconnect the fuel line from the cutoff valve.

Residual fuel may leak out of this hose. Be ready to catch any spillage.

Disconnect the fuel line from the cutoff valve.

Step 5

              Disconnect the brake cable
  • Use needle nose pliers to squeeze the two locking tabs on the brake cable latch.

Use needle nose pliers to squeeze the two locking tabs on the brake cable latch.

Step 6

  • Pull to unlatch the cable sheath.
  • Pull the brake cable away from the motor.

Pull to unlatch the cable sheath.

Pull the brake cable away from the motor.

Step 7

  • Push the cable towards the cable anchor to give it enough slack to be removed.
  • Remove the brake cable from the motor.

Push the cable towards the cable anchor to give it enough slack to be removed.

Remove the brake cable from the motor.

Step 8

              Disconnect the pull start cord
  • Pull the pull start cord out of the small opening on the handle post and remove it.

Pull the pull start cord out of the small opening on the handle post and remove it.

Step 9

              Remove the fan cover
  • Remove the three 10 mm nuts securing the fan cover.

Remove the three 10 mm nuts securing the fan cover.

Step 10

  • Remove the fan cover.
  • The fuel tank is connected to the fan cover. They will both come out as one unit.

Remove the fan cover.

The fuel tank is connected to the fan cover. They will both come out as one unit.

Step 11

              Remove the cooling fan
  • Remove the 19 mm nut securing the flywheel and cooling fan to the motor.

Remove the 19 mm nut securing the flywheel and cooling fan to the motor.

Step 12

  • Remove the washer on top of the cooling fan.
  • Remove the cooling fan.

Remove the washer on top of the cooling fan.

Remove the cooling fan.

Step 13

              Loosen the flywheel
  • Caution: The flywheel may come loose at any time during this step, potentially sending itself and the puller into the air. Before you begin this step, be sure to wear PPE.
  • Use a universal puller to loosen the flywheel from the tapered pressure fit on the end of the crankshaft.
  • Attach the universal puller arms underneath the denoted “puller” sections on the flywheel.
  • Use a wrench to torque down the puller to slowly loosen the flywheel.
  • This may take a lot of force.
  • If the flywheel seems to become stuck after significant pressure is applied with the universal puller, use a blowtorch to slowly apply heat where the flywheel contacts the crankshaft.
  • The flywheel will “pop” off the crankshaft once loose.

Caution: The flywheel may come loose at any time during this step, potentially sending itself and the puller into the air. Before you begin this step, be sure to wear PPE.

Use a universal puller to loosen the flywheel from the tapered pressure fit on the end of the crankshaft.

Attach the universal puller arms underneath the denoted “puller” sections on the flywheel.

Use a wrench to torque down the puller to slowly loosen the flywheel.

This may take a lot of force.

If the flywheel seems to become stuck after significant pressure is applied with the universal puller, use a blowtorch to slowly apply heat where the flywheel contacts the crankshaft.

The flywheel will “pop” off the crankshaft once loose.

Step 14

              Remove the flywheel
  • Remove the flywheel.
  • If the flywheel became deformed at all during the last step, it will need to be replaced before reinstallation.
  • During reassembly, make sure to align the flywheel with the flywheel key.

Remove the flywheel.

If the flywheel became deformed at all during the last step, it will need to be replaced before reinstallation.

During reassembly, make sure to align the flywheel with the flywheel key.

Step 15

              Remove the flywheel key
  • Use needle nose pliers to remove the flywheel key from its slot in the crankshaft.
  • During reinstallation, make sure the key is fully seated in the slot. Otherwise the flywheel will not fit correctly.

Use needle nose pliers to remove the flywheel key from its slot in the crankshaft.

During reinstallation, make sure the key is fully seated in the slot. Otherwise the flywheel will not fit correctly.

Step 16

              Remove the blade
  • Loosen, but don’t remove, the shiny 14 mm blade holder bolt.
  • Remove the two matte 14 mm bolts securing the blade to the blade holder.

Loosen, but don’t remove, the shiny 14 mm blade holder bolt.

Remove the two matte 14 mm bolts securing the blade to the blade holder.

Step 17

  • Remove the blade.
  • If the blade is heavily used, it may be sharp in some areas. If this is the case, use gloves to remove it.

Remove the blade.

If the blade is heavily used, it may be sharp in some areas. If this is the case, use gloves to remove it.

Step 18

              Remove the blade holder
  • Fully remove the 14 mm bolt securing the blade holder to the crankshaft.

Fully remove the 14 mm bolt securing the blade holder to the crankshaft.

Step 19

  • Remove the blade holder.
  • If the blade holder is difficult to remove by hand, use a pry bar for more leverage.
  • The blade holder will come out with its accompanying shaft key.

Remove the blade holder.

If the blade holder is difficult to remove by hand, use a pry bar for more leverage.

The blade holder will come out with its accompanying shaft key.

Step 20

              Remove the motor
  • Remove the four 12 mm bolts securing the motor to the frame.
  • Once these bolts are removed, the engine will be free to fall off the mower frame. If you are removing the bolts while the mower is on its side, you may need another person to steady the motor.

Remove the four 12 mm bolts securing the motor to the frame.

Once these bolts are removed, the engine will be free to fall off the mower frame. If you are removing the bolts while the mower is on its side, you may need another person to steady the motor.

Step 21

  • Lift the engine off of the mower frame and remove it.

Lift the engine off of the mower frame and remove it.

Step 22

              Flip the motor over
  • Flip the motor over such that it’s resting on the three mounting posts for the fan cover.

Flip the motor over such that it’s resting on the three mounting posts for the fan cover.

Step 23

              Remove the governor arm
  • Loosen, but don’t remove, the 10 mm bolt securing the governor arm to the motor.

Loosen, but don’t remove, the 10 mm bolt securing the governor arm to the motor.

Step 24

  • Remove the governor arm from the mounting post.
  • Don’t completely remove the governor arm. It’s still connected to the motor with some springs.
  • Set the governor arm aside.

Remove the governor arm from the mounting post.

Don’t completely remove the governor arm. It’s still connected to the motor with some springs.

Set the governor arm aside.

Step 25

              Remove oil pan
  • Remove the eight 10 mm flange bolts securing the oil pan to the engine block.

Remove the eight 10 mm flange bolts securing the oil pan to the engine block.

Step 26

  • Loosen the oil pan by inserting a flathead screwdriver in the two recessed access points on either side of the engine block.

Loosen the oil pan by inserting a flathead screwdriver in the two recessed access points on either side of the engine block.

Step 27

  • Use a flathead screwdriver to pry the case apart.
  • Work your way around the entire mating surface to loosen the oil pan.
  • Any residual engine oil may start to leak out. Be ready to contain any spillage.

Use a flathead screwdriver to pry the case apart.

Work your way around the entire mating surface to loosen the oil pan.

Any residual engine oil may start to leak out. Be ready to contain any spillage.

Step 28

  • Lift the oil pan straight up and remove it.
  • Any residual engine oil may leak out. Be ready to contain any spillage.
  • Before reassembly, clean off old liquid gasket from the engine block mating surfaces thoroughly before applying new HondaBond or equivalent liquid gasket.
  • During reassembly, loosely tighten each flange bolt and then tighten center-out to 9 ft-lb (12 N-m).
  • Wait at least 20 minutes after reassembly before adding oil to the engine.

Lift the oil pan straight up and remove it.

Any residual engine oil may leak out. Be ready to contain any spillage.

Before reassembly, clean off old liquid gasket from the engine block mating surfaces thoroughly before applying new HondaBond or equivalent liquid gasket.

During reassembly, loosely tighten each flange bolt and then tighten center-out to 9 ft-lb (12 N-m).

Wait at least 20 minutes after reassembly before adding oil to the engine.

Step 29

              Position the piston
  • Rotate the crankshaft by hand to position the piston at top dead center (TDC) by aligning the two marks:
  • The arrow on the crankshaft
  • The seam on the cylinder block

Rotate the crankshaft by hand to position the piston at top dead center (TDC) by aligning the two marks:

The arrow on the crankshaft

The seam on the cylinder block

Step 30

              Remove the crankshaft
  • Remove the thrust washer.
  • Note the orientation of the washer—it only goes on one way.

Remove the thrust washer.

Note the orientation of the washer—it only goes on one way.

Step 31

  • Remove the two 10 mm bolts securing the end cap to the connecting rod.

Remove the two 10 mm bolts securing the end cap to the connecting rod.

Step 32

  • Remove the connecting rod end cap.

Remove the connecting rod end cap.

Step 33

  • Slip the timing belt off of the timing pulley on the crankshaft.

Slip the timing belt off of the timing pulley on the crankshaft.

Step 34

  • Pull the crankshaft directly up and out until it’s restricted by the timing belt.
  • This shouldn’t require much force—don’t stretch the timing belt.

Pull the crankshaft directly up and out until it’s restricted by the timing belt.

This shouldn’t require much force—don’t stretch the timing belt.

Step 35

  • Slip the timing belt around the counterweights on the crankshaft.
  • The other side of the timing belt is connected to the cam pulley inside of the cylinder head. It can slip off during this step. If it does, peer up into the cylinder head and reseat the timing belt on the cam pulley.

Slip the timing belt around the counterweights on the crankshaft.

The other side of the timing belt is connected to the cam pulley inside of the cylinder head. It can slip off during this step. If it does, peer up into the cylinder head and reseat the timing belt on the cam pulley.

Step 36

  • With the crankshaft free of the timing belt, remove it from the motor.

With the crankshaft free of the timing belt, remove it from the motor.

Step 37

              Remove the timing pulley
  • Remove the timing pulley from the crankshaft.

Remove the timing pulley from the crankshaft.

To reassemble your device, follow these instructions in reverse order.

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