Honda Rear Tine Tiller Frc800K1A P T O Change Fork Replacement Repair Guide

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Honda Rear Tine Tiller FRC800K1A Safety Precautions
2 steps
Outer Belt Cover
2 steps
Honda Rear Tine Tiller FRC800K1A Transmission Pulley Bolt Release
1 step
V-Belt
2 steps
Inner Belt Cover
12 steps
Rotary Tines
4 steps
Transmission
26 steps
Shift Holder Assembly
10 steps
P.T.O. Change Fork
5 steps

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Introduction

Drain the oil from the transmission before beginning this process.

Take plenty of additional reference photos during the transmission opening procedure in case internal components shift. Reference official Honda service documentation for more detailed schematics.

Review all reassembly tips before attempting transmission reassembly. Follow proper torque specifications for transmission case bolts. Use HondaBond 4, ThreeBond 1216 or an equivalent liquid gasket for reapplication.

After completing this procedure, refill the transmission with 5.3 quarts of SAE 10W-30 oil.

What you need

Step 1

              Disconnect the spark plug wire

Before you begin the repair, disconnect the spark plug wire.
Firmly grip the base of the connector and pull it away from the spark plug to disconnect it.

Before you begin the repair, disconnect the spark plug wire.

Firmly grip the base of the connector and pull it away from the spark plug to disconnect it.

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Step 2

              Turn off the fuel valve

Flip the fuel valve switch to the off position.

Flip the fuel valve switch to the off position.

Step 3

              Remove outer belt cover

Use a 14 mm socket to remove the bolt securing the outer belt cover.

Use a 14 mm socket to remove the bolt securing the outer belt cover.

Step 4

Tilt the outer belt cover down and pull it off of the lip on the inner belt cover to remove it.

Tilt the outer belt cover down and pull it off of the lip on the inner belt cover to remove it.

Step 5

              Loosen the transmission pulley bolt

This step may require two people.
Pull the tine engagement lever to put belt tension on the transmission pulley.
With the belt taut, use a 12 mm socket to loosen the transmission pulley bolt without fully removing it.
The pulley will rotate with the bolt and the bolt will not be able to be removed if belt tension is not applied.

This step may require two people.

Pull the tine engagement lever to put belt tension on the transmission pulley.

With the belt taut, use a 12 mm socket to loosen the transmission pulley bolt without fully removing it.

The pulley will rotate with the bolt and the bolt will not be able to be removed if belt tension is not applied.

Step 6

              Remove the V-belt

Push the V-belt towards the transmission pulley to release tension.
Slip the V-belt off of the groove in the pulley.

Push the V-belt towards the transmission pulley to release tension.

Slip the V-belt off of the groove in the pulley.

Step 7

Pull the V-belt down and out of the way of the two-prong belt guide.
Push the V-belt around and off of the motor pulley to remove.

Pull the V-belt down and out of the way of the two-prong belt guide.

Push the V-belt around and off of the motor pulley to remove.

Step 8

              Remove the belt guides

Use a 12 mm socket to remove the two bolts securing the belt guides to the inner belt cover.
Use a 10 mm socket to remove the bolt securing the inner belt cover to the frame.

Use a 12 mm socket to remove the two bolts securing the belt guides to the inner belt cover.

Use a 10 mm socket to remove the bolt securing the inner belt cover to the frame.

Step 9

              Lower the guard

Use a 14 mm socket to loosen the two bolts securing the guard to the frame.
These bolts have corresponding 14 mm nuts on their opposite ends. You will need to keep the bolts steady with a wrench or socket for the nuts to become loose.
Remove both nuts, but do not remove the bolts yet.

Use a 14 mm socket to loosen the two bolts securing the guard to the frame.

These bolts have corresponding 14 mm nuts on their opposite ends. You will need to keep the bolts steady with a wrench or socket for the nuts to become loose.

Remove both nuts, but do not remove the bolts yet.

Step 10

Remove the frontmost guard bolt.

Remove the frontmost guard bolt.

Step 11

Grab the guard and lower it to the ground, pivoting it on the rear guard bolt.

Grab the guard and lower it to the ground, pivoting it on the rear guard bolt.

Step 12

              Remove the pulley bolts

Use a 12 mm socket to remove the motor and transmission pulley bolts.
Hold the pulleys steady to more easily remove the bolts.

Use a 12 mm socket to remove the motor and transmission pulley bolts.

Hold the pulleys steady to more easily remove the bolts.

Step 13

              Remove the motor pulley

Remove the motor pulley.
Keep track of the key—which may fall out on its own—and keep it with the motor pulley.

Remove the motor pulley.

Keep track of the key—which may fall out on its own—and keep it with the motor pulley.

Step 14

              Remove the transmission pulley

Pull the transmission pulley straight off of the splined shaft to remove.

Pull the transmission pulley straight off of the splined shaft to remove.

Step 15

              Remove the tensioner pulley

Use snap ring pliers to remove the snap ring securing the tensioner pulley to its shaft.

Use snap ring pliers to remove the snap ring securing the tensioner pulley to its shaft.

Step 16

Remove the tensioner pulley.

Remove the tensioner pulley.

Step 17

              Remove the wire clips

Use needle nose pliers to remove the three wire clips securing various cables to the back of the inner belt cover.

Use needle nose pliers to remove the three wire clips securing various cables to the back of the inner belt cover.

Step 18

Use a 12 mm socket to remove the two remaining inner belt cover bolts behind the transmission pulley.

Use a 12 mm socket to remove the two remaining inner belt cover bolts behind the transmission pulley.

Step 19

              Remove the inner belt cover

Pull the inner belt cover clear of the motor and transmission shafts.
Remove the inner belt cover.

Pull the inner belt cover clear of the motor and transmission shafts.

Remove the inner belt cover.

Step 20

              Remove the side tine guards

Use a 12 mm socket and wrench to remove the six sets of side guard bolts and nuts, three on each side.

Use a 12 mm socket and wrench to remove the six sets of side guard bolts and nuts, three on each side.

Step 21

Slide the side guard off of the curved main guard to remove.
Repeat the same process on the opposite side.

Slide the side guard off of the curved main guard to remove.

Repeat the same process on the opposite side.

Step 22

              Remove the rotary tine

Use a 14 mm socket to remove the two rotary tine retaining bolts.
Repeat the same process on the opposite rotary tine.

Use a 14 mm socket to remove the two rotary tine retaining bolts.

Repeat the same process on the opposite rotary tine.

Step 23

Slide the rotary tine off its axle to remove it.
Repeat the same process on the opposite rotary tine.

Slide the rotary tine off its axle to remove it.

Step 24

              Remove the drag bar

Use a 14 mm socket to remove the bolt holding the drag bar in place.
Remove the drag bar.

Use a 14 mm socket to remove the bolt holding the drag bar in place.

Remove the drag bar.

Step 25

              Remove the cable guide

Use a Phillips #1 screwdriver to remove the cable guide screw.

Use a Phillips #1 screwdriver to remove the cable guide screw.

Step 26

Pull the cable guide’s metal clip out of the shifter frame.
Unwind the cables from the cable guide.
Remove the cable guide.

Pull the cable guide’s metal clip out of the shifter frame.

Unwind the cables from the cable guide.

Remove the cable guide.

Step 27

              Remove the cable clips

Use needle nose pliers to remove the cable clips.

Use needle nose pliers to remove the cable clips.

Step 28

              Remove the tensioner spring

Lift up on the tensioner pulley arm to loosen the tension on the tensioner spring.

Lift up on the tensioner pulley arm to loosen the tension on the tensioner spring.

Step 29

Remove the top of the tensioner spring from the end of the clutch cable.

Remove the top of the tensioner spring from the end of the clutch cable.

Step 30

Remove the bottom side of the tensioner spring from the tensioner arm.
Remove the tensioner spring.

Remove the bottom side of the tensioner spring from the tensioner arm.

Remove the tensioner spring.

Step 31

              Remove the clutch cable

Pull up on the clutch cable to remove it from its slot.

Pull up on the clutch cable to remove it from its slot.

Step 32

Use a Phillips #1 screwdriver to remove the cable guide screw.
Remove the cable from the cable guide.

Remove the cable from the cable guide.

Step 33

Use needle nose pliers to remove the cable clip.

Use needle nose pliers to remove the cable clip.

Step 34

              Remove change lever extension

Use needle nose pliers to straighten the change lever pin.
Pull the pin straight out to remove.

Use needle nose pliers to straighten the change lever pin.

Pull the pin straight out to remove.

Step 35

Slide the change lever extension off its base to remove.

Slide the change lever extension off its base to remove.

Step 36

              Remove the shift linkage mounting bracket

Remove the three shift linkage mounting bracket bolts and nuts:
Two 12 mm bolts and nuts
One 14 mm nut
This nut is holding the tensioner pulley arm assembly to the bracket. It may fall away once you remove this nut.

Remove the three shift linkage mounting bracket bolts and nuts:

Two 12 mm bolts and nuts

One 14 mm nut

This nut is holding the tensioner pulley arm assembly to the bracket. It may fall away once you remove this nut.

Step 37

Pull the shift linkage mounting bracket away from the frame.
If it hasn’t already come off, the tensioner pulley arm assembly may fall away once you remove the mounting bracket.

Pull the shift linkage mounting bracket away from the frame.

If it hasn’t already come off, the tensioner pulley arm assembly may fall away once you remove the mounting bracket.

Step 38

Pivot the shift lever out and away from the shift gate to remove it.

Pivot the shift lever out and away from the shift gate to remove it.

Step 39

              Remove the shift gate

Use a 14 mm socket to remove the two shift gate through-bolts.

Use a 14 mm socket to remove the two shift gate through-bolts.

Step 40

Lift the shift gate off of the transmission to remove it.

Lift the shift gate off of the transmission to remove it.

Step 41

              Remove the shifting arms

Use a 10 mm socket to remove the rotary change shifting arm bolt.
Remove the rotary change shifting arm.

Use a 10 mm socket to remove the rotary change shifting arm bolt.

Remove the rotary change shifting arm.

Step 42

Use a 10 mm socket to remove the two remaining shifting arm bolts.
Remove the two remaining shifting arms.

Use a 10 mm socket to remove the two remaining shifting arm bolts.

Remove the two remaining shifting arms.

Step 43

              Remove the handle

Use a 14 mm socket to remove the front handle bolt.
Use a 14 mm socket to remove the shouldered handle angle selection bolt.

Use a 14 mm socket to remove the front handle bolt.

Use a 14 mm socket to remove the shouldered handle angle selection bolt.

Step 44

Grab and rotate the handle off of the frame towards the motor.
Be careful not to snag, bend, or rip any cables as they are all still attached to the handle.
Set the handle near the motor.

Grab and rotate the handle off of the frame towards the motor.

Be careful not to snag, bend, or rip any cables as they are all still attached to the handle.

Set the handle near the motor.

Step 45

              Remove the blade guard

Use a 17 mm socket to remove the three frontside blade guard bolts.
Use a 14 mm socket to remove the four backside blade guard bolts.

Use a 17 mm socket to remove the three frontside blade guard bolts.

Use a 14 mm socket to remove the four backside blade guard bolts.

Step 46

Rotate the blade guard up and off of the transmission to remove it.

Rotate the blade guard up and off of the transmission to remove it.

Step 47

              Separate the transmission from the frame

The motor may fall away from the transmission during this step if it is not properly supported. Take care to ensure both the transmission and motor are supported.
Use a 14 mm socket to remove the two frame bolts.

The motor may fall away from the transmission during this step if it is not properly supported. Take care to ensure both the transmission and motor are supported.

Use a 14 mm socket to remove the two frame bolts.

Step 48

The transmission and motor are both very heavy. This may require two people.
Consider supporting the transmission with jack stands so you can easily remove the wheels in the coming steps.
While supporting both sides, roll the transmission away from the motor and frame.

The transmission and motor are both very heavy. This may require two people.

Consider supporting the transmission with jack stands so you can easily remove the wheels in the coming steps.

While supporting both sides, roll the transmission away from the motor and frame.

Step 49

              Remove the wheels

Remove the wheels.
Make sure the transmission is supported such that there isn’t too much pressure on the now-exposed axles.

Remove the wheels.

Make sure the transmission is supported such that there isn’t too much pressure on the now-exposed axles.

Step 50

              Support the transmission

Support the transmission with jack stands so the seam between the two halves is level with the work surface.
Orient the transmission such that the right half of the case is facing up. This is the side containing the shift holder assembly.

Support the transmission with jack stands so the seam between the two halves is level with the work surface.

Orient the transmission such that the right half of the case is facing up. This is the side containing the shift holder assembly.

Step 51

              Separate the two halves of the case

Remove the thirty-two transmission case fasteners:
Thirty 12 mm bolts and nuts
Two 14 mm bolts and nuts
Reinstallation tip: Install five to eight 12 mm transmission case bolts equidistant around the circumference of the two halves of the case to tighten the two halves together. Once the two halves are mated, reinstall the rest of the 12 mm and the two 14 mm transmission case bolts in a criss-cross pattern.
Torque all transmission case bolts to 16 ft-lb (22 Nm). Re-torque all transmission case bolts after five hours. Wipe off any excess liquid gasket that squeezes out after you start tightening the two halves together.

Remove the thirty-two transmission case fasteners:

Thirty 12 mm bolts and nuts

Two 14 mm bolts and nuts

Reinstallation tip: Install five to eight 12 mm transmission case bolts equidistant around the circumference of the two halves of the case to tighten the two halves together. Once the two halves are mated, reinstall the rest of the 12 mm and the two 14 mm transmission case bolts in a criss-cross pattern.

Torque all transmission case bolts to 16 ft-lb (22 Nm). Re-torque all transmission case bolts after five hours. Wipe off any excess liquid gasket that squeezes out after you start tightening the two halves together.

Step 52

Use a 12 mm socket to remove the three bolts securing the shift holder to the right transmission case.

Use a 12 mm socket to remove the three bolts securing the shift holder to the right transmission case.

Step 53

Use a sharp blade to cut away any gasket material around the shift holder assembly.
Always cut away from yourself and others.

Use a sharp blade to cut away any gasket material around the shift holder assembly.

Always cut away from yourself and others.

Step 54

Insert a large flathead screwdriver in between the two halves of the transmission case to pry them apart and break the gasket seal.
This may require a lot of force.

Insert a large flathead screwdriver in between the two halves of the transmission case to pry them apart and break the gasket seal.

This may require a lot of force.

Step 55

Work the flathead screwdriver around the transmission to create a small gap along the entire perimeter of the case.

Work the flathead screwdriver around the transmission to create a small gap along the entire perimeter of the case.

Step 56

After the top case is removed, the transmission gearing becomes exposed and has a tendency to move around. If gears, bearings, or washers fall out of their positioning, you will need to consult official Honda schematics to ensure proper reinstallation.
Use a mallet to lightly tap on the base of the shift holder assembly as you pry up the transmission case.
When removing the right half of the transmission case, make sure that the shift holder assembly is not coming up with the case as it is being pried up.
Reinstallation tip: If any of the bearings fall out of the right transmission case when installing it onto the left transmission case, install them onto their corresponding shaft on the left transmission case instead.

After the top case is removed, the transmission gearing becomes exposed and has a tendency to move around. If gears, bearings, or washers fall out of their positioning, you will need to consult official Honda schematics to ensure proper reinstallation.

Use a mallet to lightly tap on the base of the shift holder assembly as you pry up the transmission case.

When removing the right half of the transmission case, make sure that the shift holder assembly is not coming up with the case as it is being pried up.

Reinstallation tip: If any of the bearings fall out of the right transmission case when installing it onto the left transmission case, install them onto their corresponding shaft on the left transmission case instead. 

Step 57

Lightly tap on the tine shaft while prying up on the case to make removal easier.
Ensure the rotary chain stays seated in the bottom half of the transmission case.

Lightly tap on the tine shaft while prying up on the case to make removal easier.

Ensure the rotary chain stays seated in the bottom half of the transmission case.

Step 58

Slowly pull up to work the top case away from the bottom case.
Make sure no internal components come out with the top case. However, there are bearings installed in the top case that may stay with the bottom half of the case.
Completely remove the top half of the transmission case. You may have to “walk” the top half of the case off of the shafts it is slotted through.
Reinstallation tip: Scrape off old gasket before putting the transmission back together. Use a Scotch-Brite pad to remove any stubborn gasket from all mating surfaces, and do a final cleaning with isopropyl alcohol.
Be extra cautious to not let any old gasket fall into the transmission case oil basin, as debris could potentially harm future performance.
Reinstallation tip: When reapplying liquid gasket to the transmission case, run a 2-4 mm bead along all gasket mating surfaces on both the left and right transmission cases. Use HondaBond 4, ThreeBond 1216, or an equivalent liquid gasket. Reassemble both transmission halves within 10 minutes of applying the liquid gasket.
Reinstallation tip: If necessary, use a mallet to lightly tap the right transmission case until mostly flush with the left transmission case when putting the two halves back together.

Slowly pull up to work the top case away from the bottom case.

Make sure no internal components come out with the top case. However, there are bearings installed in the top case that may stay with the bottom half of the case.

Completely remove the top half of the transmission case. You may have to “walk” the top half of the case off of the shafts it is slotted through.

Reinstallation tip: Scrape off old gasket before putting the transmission back together. Use a Scotch-Brite pad to remove any stubborn gasket from all mating surfaces, and do a final cleaning with isopropyl alcohol.

Be extra cautious to not let any old gasket fall into the transmission case oil basin, as debris could potentially harm future performance.

Reinstallation tip: When reapplying liquid gasket to the transmission case, run a 2-4 mm bead along all gasket mating surfaces on both the left and right transmission cases. Use HondaBond 4, ThreeBond 1216, or an equivalent liquid gasket. Reassemble both transmission halves within 10 minutes of applying the liquid gasket.

Reinstallation tip: If necessary, use a mallet to lightly tap the right transmission case until mostly flush with the left transmission case when putting the two halves back together.

Step 59

              Remove the shift holder assembly

Slowly pull the shift holder assembly away from the transmission gearing to unseat the shift forks.
Lift the assembly out and away from the rest of the transmission to remove.
Some gears are supported by the shift forks, so they may shift during removal.
Reinstallation tip: Ensure the three shift forks line up with each of their corresponding gear shift slots.

Slowly pull the shift holder assembly away from the transmission gearing to unseat the shift forks.

Lift the assembly out and away from the rest of the transmission to remove.

Some gears are supported by the shift forks, so they may shift during removal.

Reinstallation tip: Ensure the three shift forks line up with each of their corresponding gear shift slots.

Step 60

              Secure the shift holder assembly

Support the shift holder assembly securely in a padded vise.
To avoid marring the shift holder components or housing, use a vise with plastic jaw covers or use a soft towel.

Support the shift holder assembly securely in a padded vise.

To avoid marring the shift holder components or housing, use a vise with plastic jaw covers or use a soft towel.

Step 61

              Remove the shift holder spring

Use a 2.5 mm punch to partially remove the shift holder spring pin.
Leave the spring pin in the shift holder. It only needs to be pushed down enough so the spring can be removed.

Use a 2.5 mm punch to partially remove the shift holder spring pin.

Leave the spring pin in the shift holder. It only needs to be pushed down enough so the spring can be removed.

Step 62

Use needle nose pliers to remove the spring from the shift holder housing.
There is a #10 ball bearing securing the P.T.O. change fork in place. It is located between the retention spring and the change fork.
Reinstallation Tip: Each change fork is separated by two #10 steel ball bearings. If any ball bearings fall out of the shift holder assembly, ensure there are two between the PTO change fork and the middle change fork and one between the PTO change fork and the spring in the shift shaft holder passage.

Use needle nose pliers to remove the spring from the shift holder housing.

There is a #10 ball bearing securing the P.T.O. change fork in place. It is located between the retention spring and the change fork.

Reinstallation Tip: Each change fork is separated by two #10 steel ball bearings. If any ball bearings fall out of the shift holder assembly, ensure there are two between the PTO change fork and the middle change fork and one between the PTO change fork and the spring in the shift shaft holder passage.

Step 63

              Remove the P.T.O. change fork

With the retention spring removed and the ball bearing out of the way, pull the P.T.O. change fork directly out of the shift holder assembly to remove.

With the retention spring removed and the ball bearing out of the way, pull the P.T.O. change fork directly out of the shift holder assembly to remove.

Step 64

              Remove change fork oil seals

Use a pick tool to remove the oil seal from the empty P.T.O. change fork passage.
Repeat for each removed change fork.
Use a pick tool to remove the large oval o-ring from the shaft holder assembly.

Use a pick tool to remove the oil seal from the empty P.T.O. change fork passage.

Repeat for each removed change fork.

Use a pick tool to remove the large oval o-ring from the shaft holder assembly.

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

Refill the transmission with 5.3 quarts of SAE 10W-30 oil.

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                    Carsten Frauenheim

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