HRD536C_HRD536CKI_HRD536C2

INDEX

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2. SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 General safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.2 Service rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.3 Serial number location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.4 Maintenance standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.5 Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.6 Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.8 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1 Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.2 Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.4 Throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193.5 Drive clutch cable (S type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.6 Rotostop cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.7 Shift cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.8 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.9 carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.10 Governor adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.11 Fuel tank / Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.12 Fuel line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.13 Spark arrester (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.14 Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4. BLADE / ROTOSTOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.1 How the rotostop works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.2 Blade brake clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.3 Inspecting the Rotostop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324.4 Blade sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5. ENGINE REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.1 Engine removal : ~ 8132520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.2 Engine installation : ~ 8132520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.3 Engine installation : 8132521 ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6. MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7. RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.1 Recoil starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

8. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8.1 Air cleaner / carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398.2 Control base / Governor arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438.3 Fan cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

9. FLYWHEEL / IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9.1 Flywheel / Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

10. CAM PULLEY / CRANKSHAFT / PISTON / CYLINDER BARREL . . . . 49

10.1 Cam pulley / Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4910.2 Oil pan / Crankshaft / Cylinder barrel. . . . . . . . . . . . . . . . . . . . . . . . 5210.3 Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5510.4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5710.5 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5910.6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6010.7 Valve seat reconditionning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

11. FRONT WHEEL / REAR WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

11.1 Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6611.2 Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

12. REAR DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

12.1 Transmission HXE / SXE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6812.2 Transmission TXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

13. HANDLE / CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

13.1 Upper handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7613.2 Handle / Cutter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7813.3 Control lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7913.4 Wire / Harness routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

14. DISCHARGE GUARD / GRASS BAG . . . . . . . . . . . . . . . . . . . . . . . . . . 82

14.1 Discharge guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8214.2 Grass bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

- 2 -HRD536C - HRD536CK1 - HRD536C2

1. SPECIFICATIONS

1.1 General specifications

MODELS HRD536C HRD536CK1 HRD536C2

TYPES SXE HXE HXE TXE HXE TXE

DIMENSIONS AND WEIGHT Units

Grass bag capacity 80

Dry weight kg 41.9 42.6 41.9 42.6 41.9

Curb weight kg 47.9 48.5 47.9 48.5 47.9

FRAME

Cutting width mm 530

Cutting heights adjustmentStep 7

Height mm 15 ~ 77

Wheel diameterFront mm 200

Rear mm 200

Blade

Width mm 90

Thickness mm 2.7

Air lift 25

Transmission

Type Mechanical pinion Hydrostatic Bevel gear Hydrostatic Bevel gear

Number of gears 2 Continuous 3 Continuous 3

Drive system V-belt

Clutch Dog clutch Relief valve Cone clutch Relief valve Cone clutch

Shift control Manual remote control

LubricantGrease: Shell Co

Darina “D”Honda HST oil 15W30 Oil - API: SD/SF Honda HST oil

15W30 OilAPI: SD/SF

Oil capacity 85 g 140 cc 190 - 200 cc 140 cc 190 - 200 cc

Blade stopping system Rotostop

Drive wheel Rear

Driving speed (at 2900 rpm) m/s 1st: 0.7 - 2nd: 1.2 0 - 1.41st: 0.77 -2nd: 1.17 -3nd: 1.44

0 - 1.41st: 0.77 -2nd: 1.17 -3nd: 1.44

Differential One-way clutch

Fuel consumption /h 0.58

Sound pressure level at operator’s ears (according to DirectiveEEC/81/1051)

dB (A) 85

Sound power level (in accordance with Directives 84/538/EECand 87/252/EEC)

dB (A) 100 -

Guaranteed sound pawer level (According to 2000/14/ECdirective)

dB (A) - 100

Vibration test (according to EN1033, ENV25349/1993,ENV28041/1993, ISO5347/1987 & ISO5348/1987) m/s2 5.5 3.3 4.2

- 3 -

HRD536C - HRD536CK1 - HRD536C2 - SPECIFICATIONS

General specifications

MODELS HRD536C HRD536CK1 HRD536C2

TYPES SXE HXE HXE TXE HXE TXE

ENGINE Units

Model GCV160

Type 4-stroke, overhead camshaft, vertical one cylinder

Displacement cm3 (cc) 160

Bore x stroke mm 64 x 50

Maximum power kW/rpm 4.1 / 3600

Maximum torque Nm / rpm 11 / 2500

Operating speed tr.min-1 (rpm) 2900

Compression ratio 8.5 : 1

Cooling system Forced air

Ignition system Transistorized magneto

Ignition timing 20° BTDC

Spark plug BPR6ES (NGK)

carburettor Horizontal, butterfly valve type

Air cleaner Dry element (paper)

Governor Centrifugal mechanical governor

Lubrication Forced splash type

Oil capacity 0.55

Recommended oil SAE 10W30SAE 10W40 - 15W30 - 20W50

API : SF/SG

Starting system Recoil starter

Stopping system Grouding of primary circuit

Recommended fuel Gasoline, regular or premium, preferably lead-free

Fuel tank capacity 1.1

- 4 -HRD536C - HRD536CK1 - HRD536C2 - SPECIFICATIONS

+ 0- 100

1.2 Dimensional drawings

HRD536C HRD536CK1 HRD536C2

MODELS SXE HXE HXE TXE HXE TXE

A mm 1575

B mm 574

C mm 1018

D mm 476

E mm 512

F mm 625

The dimensions are measured using the following parameters:

Cutting height 30 mm

Adjustment of handle height Support adjustable in intermediate position

- 5 -

HRD536C - HRD536CK1 - HRD536C2 - SPECIFICATIONS

A

C

D

F

BE

1.3 Wiring diagrams

Bk Black

[1] Engine stop switch

[2] Spark plug

[3] Ignition coil

[4] Engine block

- 6 -HRD536C - HRD536CK1 - HRD536C2 - SPECIFICATIONS

[1] [2] [3]

[4]

B l

2. SERVICE INFORMATION

2.1 General safety

Stop the engine and remove the spark plug cap before servicing the engine.

If the engine must be running to perform certain operations, make sure the area iswell ventilated. Never run the engine in a closed area. The exhaust contains carbonmonoxide gas.

Petrol is extremely flammable and is explosive under certain conditions. Do notsmoke and keep all open flames and sparks away from your working area.

CAUTION:

• Keep away from rotating of hot parts and high voltage wires when the engine is running.

2.2 Service rules

1. Use genuine Honda or Honda recommended parts and lubricants. Parts that do notmeet Honda’s design specifications may damage the mower.

2. Use the special tools designed for the product.

3. Install new gaskets, O-rings, etc. when reassembling.

4. When tightening bolts or nuts, begin with larger-diameter or inner bolts first andtighten to the specified torque diagonally, unless a particular sequence is specified.

5. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfacesbefore reassembly.

6. After reassembly, check all parts for proper installation and operation.

7. Many screws used in this machine are self-tapping. Be aware that cross-threading orovertightening these screws will strip the threads and ruin the hole.

8. Use only metric tools when servicing the mower. Metric bolts, nuts and screws are notinterchangeable with nonmetric fasteners. The use of incorrect tools and fastenerswill damage the mower.

9. Follow the instructions represented by these symbols when they are used:

: Apply grease : Special tool : Apply oil

2.3 Serial number location

The engine serial number is stamped on the crankcase. Refer to this number when orderingparts or making technical inquiries.

[1] ENGINE SERIAL NUMBER

[2] FRAME SERIAL NUMBER

- 7 -

HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

[2]

GREASE S.TOOL OIL

2.4 Maintenance standards

PART ITEM STANDARD SERVICE LIMIT

EngineIdle speed

HRD536C - HRD536CK1HRD536C2

1700 ± 150 rpm2000 ± 150 rpm

-

Maximum speed 2800 ~ 2900 rpm -Cylinder compression (at 600 rpm) 0.49 Mpa - 5.0 kg/cm2 -

carburettorMain jet #65 -Pilot screw opening 1 turn out -Float level 9.2 mm -

Spark plug Gap 0.7 - 0.8 mm -

Valves

Valve clearance (cold)IN 0.15 ± 0.04 mm -EX 0.20 ± 0.04 mm -

Stem O.D.IN 5.480 mm 5.318 mmEX 5.440 mm 5.275 mm

Guide I.D. IN/EX 5.500 mm 5.572 mmSpring free length IN/EX 34 mm 32.5 mm

Cylinder head Valve seat width IN/EX 0.7 mm 1.8 mm

Piston

Skirt O.D. 63.969 mm 63.829 mmPiston-to-cylinder clearance 0.031 - 0.070 mm 0.12 mmPiston pin bore I.D. 13.002 mm 13.048 mmPiston pin O.D. 13 mm 12.954 mm

Piston ring

ThicknessTop/Second 1.5 mm 1.37 mmOil 2.5 mm 2.37 mm

Side clearance Top/Second/Oil 0.015 - 0.045 mm 0.15 mm

End gapTop 0.20 - 0.35 mm 1 mmSecond 0.30 - 0.45 mm 1 mmOil 0.15 - 0.35 mm 1 mm

Cylinder Sleeve I.D. 64 mm 64.165 mm

Connecting rod

Small end I.D. 13.005 mm 13.07 mmBig end I.D. 26.02 mm 26.066 mmBig end oil clearance 0.040 - 0.063 mm 0.12 mmBig end axial clearance 0.1 - 0.4 mm 0.8 mm

CrankshaftMain journal O.D.

PTO side 27.993 mm 27.933 mmFlywheel side 25.393 mm 25.333 mm

Axial clearance 0.15 - 0.75 mm 1 mmCrank pin O.D. 25.98 mm 25.92 mm

Cylinder barrel Main journal I.D. 25.420 mm 25.466 mmOil pan Main journal I.D. 28.020 mm 28.066 mm

Cam pulleyCam height 37.394 mm 37.369 mmCam pulley I.D. (bearing) 10.027 mm 10.075 mmCam pulley shaft O.D. 9.987 mm 9.920 mm

Rocker armRocker arm I.D. 6 mm 6.043 mmRocker arm shaft O.D. 5.990 mm 5.953 mmRocker arm shaft bearing I.D. 6 mm 6.043 mm

Ignition coilPrimary coil resistance 1.0 - 1.2 Ω -Secondary coil resistance 10.6 - 12.8 k Ω -Air gap 0.2 - 0.6 mm -

Blade brake clutchBrake lining thickness - 2.0 mmClutch lining thickness - 2.0 mmClutch return spring free lenght - 65 mm

- 8 -HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

2.5 Torque values

Specific torque values

ITEMTHREAD

DIA. X PITCH

TIGHTENINGTORQUE

N.m kgf.m

Cylinder head cover screw M6 x 1.0 12 1.2

Oil pan screw M6 x 1.0 (CT) 12 1.2

Connecting rod screw M7 x 1.0 12 1.2

Spark plug M14 x 1.25 20 2

Governor arm nut M6 x 1.0 10 1

Ecrou de volant M14 x 1.5 75 7.5

Air cleaner case screw M6 x 1.0 (CT) 8.5 0.9

Recoil starter nut M6 x 1.0 8.5 0.9

Muffler screw M6 x 1.0 (CT) 10 1

Fuel valve bracket screw M5 x 0.8 3 0.3

Fan cover stud bolt M6 x 1.0 12 1.2

Valve adjusting lock nut M5 x 0.5 8 0.8

Breather cover bolt M6 x 1.0 12 1.2

Governor holder screw M6 x 1.0 12 1.2

Blade screw M10 x 1.25 55 5.6

Blade holder screw M10 x 1.25 55 5.6

Front wheel adjuster center screw M8 x 1.25 24 2.4

NOTE:Use standard torque values for fasteners that are not listed in this table.

(CT): Tapping screw

• Standard torque values

ITEMTIGHTENING TORQUE

N.m kgf.m

5 mm screw 4 0.4

5 mm screw/nut 5 0.5

6 mm screw 9 0.9

6 mm screw (small head type) 9 0.9

6 mm screw/nut 10 1

6 mm flange screw/nut 12 1.2







- 9 -


2.6 Special tools

TOOL NAME TOOL NUMBER APPLICATION

[1] Float level gauge 07401-0010000 Float level inspection

[2] Valve adjustment wrench B 07708-0030400 Valve clearance adjustment

[3] Valve seat cutter, 45° - Ø 27.2 07780-0010200 Valve seat reconditioning (IN/EX)

[4] Cutter holder07781-VA2-0100 or

07981-VA2-0101Valve seat reconditioning

[5] Digital multimeterKS-AHM-33-003 or

commercially availableElectrical parts testing

[6] Cleaning brush 07998-VA2-0100 Combustion chamber cleaning


[1] [2] [3]

[4]

[5]

[6]

2.7 Troubleshooting

Engine

a. General symptom and possible causes

CARBURETTOR FLOAT CHAMBERcontains stale gasoline Drain old fuel. Filltank with fresh gasoline

ch. 8.1

FUEL FILTER clogged

Check : ch. 3.11 and 8.3

CARBURETTOR malfunction

Readjust: ch. 3.9Disassemble and inspect: ch. 8.1

Engine will not revsufficiently

Hard starting IGNITION SYSTEM malfunction

Troubleshooting: ch. 2.7c

IGNITION COIL AIR GAP out ofadjustment

Readjust: ch. 9.1

SPARK PLUG faulty

Check: ch. 3.2

GOVERNOR out of adjustment

Readjust: ch. 3.10

VALVE CLEARANCE incorrect

Readjust: ch. 3.8

VALVE or VALVE SEAT worn ordamaged

Poor performance athigh speed

Disassemble and inspect: ch. 10.4Correct: ch. 10.7

Engine lacks powerCYLINDER, PISTON or PISTON RINGworn

Poor performance at lowspeed

Disassemble and inspect:ch. 10.2 and 10.3

AIR CLEANER restricted

Clean : ch. 3.3

SPARK ARRESTER restricted

Clean or replace: ch. 3.13

b. Hard starting

1Check fuel level in the tank. Fill with fuel and start again.

2Check that fuel reaches thecarburettor by loosening thedrain screw.

Check the fuel line and fuel filterfor clogging.

3Remove the spark plug andcheck for wet or fouledelectrodes.

Clean electrodes and restart,taking care that the choke is notclosed too much. If flooding is severe, check the

carburettor float level.

4Check the carburettor pilot jetand nozzle for blockage.

Disassemble and clean thecarburettor.

5Check the choke and/or throttlecable adjustment.

Adjust throttle cable.

6 Perform spark plug (p.13).Follow ignition system

troubleshooting (ch. 2.7c).

7Check cylinder compression.

Check for carbon deposits in thecombustion chamber.Check that the valve clearance is

correct.Check for defective cylinder head

gasket, valves or valve seats.Check that the cylinder head is

correctly tightened.Check for worn piston rings,

piston or cylinder.

8 Install the spark plug and restartthe engine.

- 11 -


Fuel arrives to carburettor

Normal

Normal

Good spark

Normal compression

No fuel in tank

No fuel arriving tothe carburettor

Wet

Abnormal

No spark of weak spark

Sufficient fuel

Abnormal

Abnormalecompression

Dry

c. Ignition system

1 Perform spark plug test.Plug gap = 0.7-0.8 mm

Faulty spark plug. Install a newspark plug.

2Check again with a new spark plug.Faulty spark plug cap. Install a

new spark plug cap.

3Check again with a new spark plugcap.

Faulty spark plug cap.

4Disconnect the black wire from theengine stop switch and recheck.

Faulty engine stop switch orcombination switch. Replace theengine stop switch orcombination switch.

Faulty ignition coil. Replace theignition coil.

Frame

a. Drive clutch (except H type)

Mower does not advance when thedrive clutch lever is grasped.

DRIVE CLUTCH CABLE out ofadjustment.

Adjust: ch. 3.5

DRIVE BELT worn or damage.

Replace: ch. 12.1

TENSION SPRING comes off ordamage.

Replace: ch. 12.1

TRANSMISSION malfunction.

Replace : ch. 12.1

Mower does not stop when the driveclutch lever is released.

CLUTCH RETURN SPRING damage.

Replace: ch. 12.1

b. Throttle control

Engine speed is too low or too high. THROTTLE CABLE out of adjustment.

Adjust: ch. 3.4

Engine speed is unstable. GOVERNOR out of adjustment.

Adjust: ch. 3.10

c. Blade

Blade does not rotate whenROTOSTOP lever is grasped.

ROTOSTOP CABLE out ofadjustment.

Adjust: ch. 3.6

Blade stops turning when beginningto mow; engine still running.

ROTOSTOP CABLE too loose.

Adjust: ch. 3.6

CLUTCH LINING worn.

Check: ch. 4.1

BLADE BRAKE CLUTCHASSEMBLY faulty.

Replace: ch. 4.1

ROTOSTOP CABLE too tight.

Adjust: ch. 3.6

Blade does not stop turning whenROTOSTOP lever released.

BRAKE LINING worn.

Check: ch. 4.1

d. Transmission (S type)

Gears are not changed.SHIFT CABLE out ofadjustment.

Adjust: ch. 3.7

TRANSMISSION malfunction.

Replace: ch. 12.1

e. HST (hydrostatic) transmission (H type)

Driving speed too slow. SHIFT CABLE out of adjustment.

Adjust: ch. 3.7

Mower does not advance. DRIVE BELT comes out or is broken.

Replace: ch. 12.1

TENSION SPRING comes off or damage.

Replace: ch. 12.1

SHIFT CABLE is broken.

Replace: ch. 13.1

Mower does not stop and can not bepulled.

HST TRANSMISSION faulty.

Replace: ch. 12.1

CONTROL ARM is restricted with dustbetween the case and control arm.

Clean

HST RETURN SPRING is broken.

Replace: ch. 12.1

- 12 -HRD536C - HRD536CK1 - HRD536C2

No spark

No spark

No spark

No spark

Spark

Spark

- SERVICE INFORMATION

• Cylinder compression check

1. Remove the spark plug cap and spark plug.

2. Install a compression gauge [1] in the spark plug hole.

3. Crank the engine using the recoil starter until stable compression is obtained.

Cylinder compression 0.49 Mpa at 600 rpm

[1] COMPRESSION GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available

• Spark plug test

Never hold the spark plug lead with wet hands while performing this test.

Make sure that no fuel has been spilled on the engine and that the plug is not wet withfuel.

To avoid fire hazards, keep sparks away from the plug hole.

1. Disconnect the spark plug cap and remove the spark plug.

2. Attach the removed spark plug to the plug cap. Ground the negative (-) terminal of thespark plug to the cylinder head cover bolt.

3. Pull the recoil starter and check to see if sparks jump across the electrodes.

- 13 -


[1]

2.8 Maintenance schedule

Maintenance to be performed at everyindicated month or operating hourinterval, whichever comes first

Regular service period (2) Each useFirst month

or 20 hEvery 3 months or

50 hEvery 6 months or

100 hEvery yearor 300 h See ch.

Engine oilCheck level 3.1

Change 3.1

Air cleaner

Check 3.3

Clean (1) 3.3

Replace (filter) (1) 8.1

Grass bag Check - Clean 14.2

Blade screw tightness and bladecondition Check (replace if necessary) 2.5

Spark plug Check - Clean - Adjust 3.2

Spark arrester Clean 6

Rotostop cable Check - Adjust 3.6

Rotostop Check (2) 4.2

Shift cable Check - Adjust 3.7

Throttle cable Check - Adjust 3.4

Valve clearance Inspect - Adjust (2) 3.8

Drive beltCheck 12.1d

Replace (2) 12.1d

Fuel filter and fuel tank Clean (2) 3.11

Fuel line Check Every 2 years (replace if necessary) 3.12

(1) Service more frequently when used in dusty areas.

(2) For professional commercial use, log hours of operation to determine proper maintenance intervals.


3. MAINTENANCE

3.1 Oil

CAUTION:

• Used engine oil may cause skin cancer if repeatedly left in contact with the skin forprolonged periods. Although this is unlikely unless you handle used oil on a daily basis, itis still advisable to thoroughly wash your hands with soap and water as soon as possibleafter handling used oil; keep out of reach of children.

NOTE: Dispose of used engine oil in a manner that is compatible with the environment. Wesuggest that it be taken ina sealed container to your local waste disposal site, or servicestation for disposal. Do not throw it in the trash or pour it on the ground, down sewers ordrains.

a. Engine oil level check

1. Make sure that the mower is level.

2. Remove the engine oil dipstick and wipe it clean.

3. Fully insert the dipstick, then remove it to check the oil level.

4. If the oil level is near or below the lower level mark on the dipstick, fill to upper levelmark with the recommended oil.

Recommended engine oilUse Honda 4-stroke oil

Service classification: SF, SGViscosity: SAE 10W30

[1] OIL FILLER CAP / DIPSTICK

[2] UPPER LEVEL

[3] LOWER LEVEL

[4] SINGLE GRADE

[5] MULTIGRADE

[6] AMBIENT TEMPERATURE

- 15 -

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

10W

20W

20W

30W

40W

20W40 20W50

15W40 15W50

10W40

10W30

-30 -20 -10 0 10 20 30 40°C

-20 0 20 40 60 80 100°F

[4]

[6]

[5]

b. Engine oil change

NOTE: Draining can be performed rapidly and completely when the engine is still warm.

1. Stop the engine and disconnect the spark plug cap.

2. Move the throttle lever to “STOP” position and turn the fuel shut-off valve, drain thecarburettor.

3. Tilt the mower rightward with the carburettor on the upper side as shown.

4. Place a suitable container under the oil filler tube.

5. Remove the oil filler cap and drain the oil.

6. When oil stops, raise the mower about 45° and wait 5-10 seconds, tilt the mower anddrain the oil.

7. Repeat Procedure 6. as appropriate until all oil is drainged.

8. Raise the mower and refill with recommended engine oil while checking the oil level.

Oil capacity 0.55

9. Tighten the oil filler cap securely.

c. Hydrostatic transmission oil (H type)

The hydrostatic transmission becomes very hot and remains hot for some time afterthe mower has run. Wait until the hydrostatic transmission has cooled down beforechecking the hydrostatic transmission oil level.

CAUTION:

• Be careful not to allow dust or other foreign materials to enter the hydrostatictransmission. Clean the surrounding area before checking the transmission oil level.

• Use only Honda hydrostatic transmission oil, when topping up or changing thehydrostatic transmission oil.

Recommended oil HST Honda oil

- 16 -HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

C

3.2 Spark plug

If the engine has been running, the engine will be very hot. Allow it to cool beforeproceeding.

1. Remove the spark plug cap.

2. Clean any dirt from around spark plug.

3. Remove the spark plug using the spark plug wrench.

4. Visually inspect the spark plug. Discard the plug if the insulator is cracked or chipped.

5. Remove carbon or other deposits with a stiff wire brush.

6. Measure the plug gap with a wire-type feeler gauge. If necessary, adjust the gap bybending the side electrode.

Spark plug gap 0.7 - 0.8 mm

Recommended spark plug BPR6ES (NGK)

7. Make sure the sealing washer is in good condition. Thread the spark plug in by hand toprevent cross-threading.

8. Once the spark plug is seated, tighten with a spark plug wrench to compress thewasher.

TIGHTENING TORQUE: 20 N.m

NOTE: When installing a new spark plug, tighten 1/2 turn after the spark plug seat tocompress the washer. When reinstalling used spark plug, tighten 1/8 - 1/4 turn after the sparkplug seats to compress the washer.

CAUTION:

• The spark plug must be securely tightened. An improperly tightened spark plug canbecome very hot and may damage the engine.

• Never use a spark plug with an improper heat range.

[1] WIRE BRUSH

- 17 -


0.7 - 0.8 mm

[1]

3.3 Air cleaner

Never clean the air cleaner elements using gas or flammable solvents; this couldcause a fire or an explosion.

CAUTION:

• Never run the engine without the air cleaner. Rapid engine wear will result fromcontaminants, such as dust and dirt being draw into the engine.

1. Press the latch tabs [1] on the top of the air cleaner cover and remove the cover [2].

2. Inspect the air filter [3] and replace if damaged.

3. Tap the filter several times on a hard surface to remove dirt or blow compressed air(not exceeding 2 kgf/cm2) through the filter from the clean side that faces the engine.

NOTE: Never try to brush of dirt; brushing will force dirt into the fibers.

4. Wipe dirt from the inside of the air cleaner cover and clean case [5] uping a moist rag.

NOTE: Be careful to prevent dirt from entering the air duct [4] that leads to the carburettor.

5. Reinstall the filter [3] and air cleaner cover [2].

CAUTION:

• Carefully check both elements for holes or tears and replace as required. Damagedelements will allow dirt to enter the system.

• Always clean the air cleaner case and air passages before installing clean elements.

[1] LATCH TABS (2)

[2] COVER

[3] AIR CLEANER ELEMENT

[4] AIR DUCT

[5] AIR CLEANER CASE


[3]

[2]

[1]

[4]

[5]

3.4 Throttle cable

a. Throttle cable / Linkage adjustment

1. Stop the engine and remove the spark plug cap.

2. Verify that the spring [5] of the governor [6] is well connected to the control arm [4].

3. Move the throttle lever to “FAST” position.

4. The throttle arm [2] should just come into contact with the choke arm [1] (0 - 1 mmclearance [3]) and the choke should be fully open.

5. If adjustment is necessary, loosen the throttle cable lock nuts [8] and adjust thecable [7] as required.

6. Move the throttle lever to “CHOKE” position and verify that the choke arm [9] is fullyraised (choke fully closed) by pushing it with your finger.

7. After throttle cable/linkage adjustment, make sure that the maximum engine speed iswithin the specified range. If any adjustment is necessary, adjust the speed using thelock nuts [8] at the handle.

Maximum engine speed 2800 to 2900 rpm

[1] CHOKE ARM

[2] THROTTLE ARM

[3] CLEARANCE

Lever clearance 0 - 1 mm

[4] CONTROL ARM

[5] SPRING

[6] GOVERNOR

[7] THROTTLE CABLE

[8] LOCK NUTS

[9] CHOKE ARM

- 19 -


[1]

[2]

[3]

[4] [5]

[6]

[7]

[8]

[9]

3.5 Drive clutch cable (S type)

NOTE: Before making any cable tension adjustements, always check that the cables arecorrected routed.

a. S type


2. Measure clearance [1] at the tip of the lever [2].


3. If adjustment is necessary, loosen the lock nuts [3] and adjust as required.

4. Retighten the lock nuts securely.

[1] CLEARANCE

[2] DRIVE CLUTCH LEVER

[3] LOCK NUTS

[4] DRIVE CLUTCH CABLE

b. TXE type

1. The drive clutch lever [1] should only have between 1 and 5 mm clearance.

2. Adjustments can be made with the nuts [2].


3.6 Rotostop cable

• SXE - HXE type: ~ 8132520


2. Measure clearance [5] at the tip of the lever with the button pushed in.


3. If adjustment is necessary, loosen the lock nuts [6] and adjust as required.

4. Retighten the lock nuts securely.


[5]

[6]

[6]

HXE

[2]

[1][3]

[4]

[3]

[6]

[6]

SXE

• HXE/TXE type: 8132521 ~

Do not turn the lawnmower over.

1. Switch the engine off and remove the spark plug cap.

2. Put the throttle to stop, close the fuel cock and drain the carburettor.

3. Put the lawnmower on its side so that the carburettor is facing upwards.

4. With the Rotostop lever released [1-1], measure the distance between the stop [2] andthe left-hand edge of the light.

Distance [1-1] 1.5 to 3 mm

5. With the Rotostop lever engaged [1-2], measure the distance between the stop [2]and the right-hand edge of the light.

Distance [1-2] 0.5 to 1 mm

6. If necessary, adjust the cable using the adjusting nuts [3].

7. Once the adjustment is complete, check the play on the Rotostop lever [4].

Play at lever 5 to 10 mm

NOTE: If the measurements specified above cannot be achieved by adjustment, pleaserefer to chapter , “Inspecting the Rotostop” (See ch. 4.3).

A poorly adjusted cable can be dangerous.

• if the cable is too taut, the blade might not stop and the cable could snap.

• If the cable is too slack, the clutch might slip and the brake and the clutch couldclash.

- 21 -


[4]

1,5-3 mm[1-1]

[2]

[1]

0,5-1 mm[1-2]

[2]

[3]

TXE

[3]

HXE

3.7 Shift cable

• SXE type


2. Loosen the lock nut [2] of the shift cable [1] completely.

3. Tilt the mower and set the transmission [4] in 2nd position move the shift arm [3]toward the cable stay.

4. Raise mower, set the shift lever to the centre of 2nd position mark [A] and tighten theshift cable lock nuts [2] securely.

5. Verify that the shift lever operates smoothly.

6. Install the spark plug cap and start the engine, and verify that the shift lever engages1st and 2nd gear. Readjust if necessary.

• HXE type


2. Make sure that the cables routing properly and cable bands are set in the placecorrectly (ch. 13.4).

3. Set the shift lever to the fastest position and loosen the lock nuts [2].

4. Turn the lock nuts to set the drive clutch lever clearance 1.5 - 6.5 mm).

5. Tighten the lock nuts securely.

6. Verify the highest speed and ensure that it falls within the range specified below:

Maximum engine speed2900

from 0 to 1.35 - 1.4 m/s

• TXE type


2. The shift lever [6] must be in ligne with the “1” mark on the case when it is pulled to itsmaximum rearward position.

3. All three of the shift lever’s positions must correspond to the three positions of thetransmission’s selector arm [7].

4. If adjustement is required, turn the adjustment nuts [2] accordingly.

NOTE: Install the spark plug cap and start the engine, and verify that the shift leverengages. Readjust if necessary.

[1] SHIFT CABLE

[2] LOCK NUTS

[3] SHIFT ARM

[4] TRANSMISSION

[5] CLEARANCE


[1]

[2]

S T OP

[4]

[1]

[3]

[A]

[1]

[2]

S T OP

[2]

[1]

[6]

3

1

[7]

2

+ 0- 100

3.8 Valve clearance

NOTE: Valve clearance inspection and adjustment must be performed with the enginecold.

1. Place the engine upright with the cylinder head cover [1] facing up.2. Remove the four 6 x 12 mm flange bolts [3].3. To remove the cylinder head cover [1], gently pry at each corner [2] of the head cover.

CAUTION:

• Do not remove the cylinder head cover with force. Forcing the cover may deform it.

• Replace the cylinder head cover if it is deformed.4. Set the piston at top dead center of the compression stroke (both valves fully closed).

The top dead center of the compression stroke is in the position where the cylinder headcover mating surface [6] is in line with the alignment marks [5] of the cam pulley [4].

CAUTION:

• If the exhaust side opens when the cylinder head cover mating surface is in line with thecam pulley alignment marks, turn the recoil starter again and align the marks.

5. Insert a feeler gauge [10] between the valve stem [11] and the adjusting screw [9] onthe rocker arm.

Standard valve clearanceIN: 0.15 ± 0.04 mm

EX: 0.20 ± 0.04 mm

6. If adjustment is necessary, proceed as follows:a. Hold the adjusting screw using the special tool [8] and loosen the lock nut [7].b. Turn the adjusting screw to obtain the specified intake and exhaust valve

clearance [12].c. Hold the adjusting screw using the special tool and tighten the lock nut.


7. Recheck valve clearance after tightening the lock nut.8. Apply a liquid gasket product (Three Bond 1207 or equivalent) to the cylinder head

cover installation surface and install the cylinder head cover (ch. 10.1).

[1] CYLINDER HEAD COVER[2] CORNER[3] FLANGE BOLTS, 6 x 12 mm (4)[4] CAM PULLEY[5] ALIGNMENT MARKS[6] CYLINDER HEAD COVER MATING SURFACE[7] VALVE ADJUSTING LOCK NUT[8]

VALVE ADJUSTING WRENCH B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07708-0030400[9] VALVE ADJUSTING SCREW

[10] FEELER GAUGE[11] VALVE STEM[12] TO INCREASE VALVE CLEARANCE, SCREW OUT.

TO DECREASE VALVE CLEARANCE, SCREW IN.

- 23 -


[4]

[5]

[6]

[1]

[2]

[2]

[2]

[3]

[1]

[2]

[8]

[7]

[10]

[9]

[12] [11]

[7]

S .T OOL

S.TOOL

3.9 Carburettor

a. Pilot screw adjustment

1. Start engine and allow it to warm up to normal operating temperature.

2. With the engine idling, turn the pilot screw [1] in or out to the setting that produces thehighest idle rpm. The correct setting will usually be obtained at approximately thefollowing number of turns out from the fully closed (lightly seated) position.

Pilot screw adjustment 2000 ± 150 rpm

b. Throttle stop screw adjustment

1. Start the engine and allow it to warm up to normal operating temperature.

2. With the engine idling, turn the throttle stop screw [2] to obtain the standard idle speed.

Standard idle speed 1 turn out

3.10 Governor adjustment

1. Loosen the nut [5] on the governor arm [4].

2. Push the governor arm toward the opposite side from the carburettor and open thecarburettor throttle valve fully [3].

3. While holding the carburettor throttle valve [3] fully open, turn the governor arm shaftclockwise fully [6] and tighten the governor arm nut to the specified torque.


4. Check to see whether the governor arm and the carburettor throttle valve operatesmoothly.

5. Start the engine and allow it to warm it up to the normal operating temperature. Movethe control lever to the maximum engine speed position and check the maximumengine speed.

Maximum speed (no load) 2900 tr.min -1 (rpm)

6. Adjustment is made at the governor spring installation position [7] of the control lever.

[1] PILOT SCREW

[2] THROTTLE STOP SCREW

[3] CARBURETTOR THROTTLE VALVE

[4] GOVERNOR ARM

[5] GOVERNOR ARM NUT

[6] GOVERNOR ARM SHAFT

[7] GOVERNOR SPRING INSTALLATION POSITION


[1]

[2]

[3]

[7]

[6] [5]

[4]

10

+ 0- 100

3.11 Fuel tank / Fuel filter

• Cleaning

Gasoline is highly flammable and explosive.You can be burnt or seriously injured when handling fuel.Keep heat, sparks and flame away.Handle fuel only outdoors.Wipe up spills immediately.

1. Turn the fuel valve to the “OFF” position [3] and drain the fuel into a suitable container.

2. Remove the recoil starter (ch. 7.1).

3. Disconnect the fuel tube [2] from the fuel valve [3].

4. Remove the fan cover [1].

5. Clean the fuel tank and check the filter [4] for tears.

6. Connect the fuel tube to the fan cover and install the fan cover.

7. Connect the fuel tube to the fuel valve [3]. After assembly, check for fuel leaks.

3.12 Fuel line

• Check


1. Check the fuel lines for deterioration, cracks or signs of leakage.

2. Drain the fuel into a suitable container.

3. Replace the fuel lines as necessary.

[1] FAN COVER

[2] FUEL TUBE

[3] FUEL VALVE

[4] FUEL FILTER

- 25 -


[1]

[2]

[3]

[4]

[2]

[3][2]

3.13 Spark arrester

The engine and exhaust system renain hot for a while after stopping.

A hot engine and exhaust system may cause burns and ignite flammable materials.

Avoid touching a hot engine or exhaust system. Allow the engine to cool beforeservicing the spark arrester.

1. Remove the 3 flange screws [4] from the muffler protector [5] and remove the mufflerprotector.

2. Remove the tapping screws [1] from the spark arrester [3] and remove the sparkarrester from the muffler [2].

3. Check for carbon deposits around the exhaust port and spark arrester. Clean ifnecessary.

4. Replace the spark arrester if there are any breaks or tears.

5. Install the spark arrester [3] and the muffler [2] protector in the reverse order ofremoval.

[1] SELF-TAPPING SCREW, 4 x 6 mm

[2] MUFFLER

[3] SPARK ARRESTER

[4] FLANGE NUT, 6 mm (3)

[5] MUFFLER PROTECTOR

[6] WIRE BRUSH


[1]

[2]

[3][4]

[5]

[6]

3.14 Blade

The blade will start spinning if the Rotostop lever is engaged while the engine isrunning.

Stop the engine and disconnect the spark plug cap before inspecting the blade orplacing your hands near the cutter housing.

Wear heavy gloves to protect your hands when handling the blade.

1. Move the throttle lever to “STOP” position and turn the fuel shut-off valve, drain thecarburettor.

2. Tilt the mower so that the carburettor is facing upward.

3. Check the tight ness of the blade screws and blade holder screw, retighten ifnecessary.


4. Inspect the blade for signs of wear or damage. A blade that is worn out, bent, cracked,or otherwised damaged, must be replaced. A dull blade can be sharpened (ch. 4.4).

Worn or damaged blade can break and throw pieces with great force. Thrown bladepieces can cause serious injury. Replace worn or damaged blades.

Use genuine Honda replacement blades.

[1] NORMAL

[2] DULL CUTTING EDGE

[3] BENT

[4] EXCESSIVE WEAR

[5] CRACKED

- 27 -


[1]

[2]

[3]

[4]

[5]

4. BLADE / ROTOSTOP

4.1 How the rotostop works: 8132521 ~

a. Rotostop lever engaged (left-hand section of the drawing)

1. The clutch control plate [1] pivots anti-clockwise.

2. The brake anchor plate [2] rises and moves away from the upper part of the lining [3].

3. The clutch spring [4] pushes the lining [3] (female cone) against the clutch cone [5](male cone).

4. The lining [3] then drives the blade holder [6] through detents located around the edgeof the lining.

5. The blade starts to rotate.

b. Rotostop lever released (right-hand section of the drawing)

1. The Rotostop return spring pivots the control plate [1] clockwise.

2. The brake anchor plate [2] drops and pushes against the upper part of the lining [3]. Atthe same time, the lining [3] is pushed downwards by the brake anchor plate [2],moving it away from the clutch cone [5].

3. The blade stops.

[1] CLUTCH CONTROL PLATE

[2] BRAKE ANCHOR PLATE

[3] LINING

[4] CLUTCH SPRING

[5] CLUTCH CONE

[6] BLADE HOLDER

[7] ROTOSTOP LEVER ENGAGED

[8] ROTOSTOP LEVER RELEASED

- 28 -HRD536C - HRD536CK1 - HRD536C2

[1]

[2]

[4]

[4]

[5]

[3]

[6]

[7] [8]

- BLADE / ROTOSTOP

4.2 Blade brake clutch (BBC)

a. Disassembly / Reassembly HRD536CK1: ~ 8132520

Do not turn the mower upside down.

1. Stop the engine and disconnect the spark plug2. Move the throttle lever to the “STOP” position and turn the fuel shut-off valve “OFF”,

drain the carburettor.3. Tilt the mower so the carburettor is facing upward.

NOTE: Before carrying out any operation on the Rotostop, release the Rotostop cable byloosening the lock nuts of the handle and removing the Rotostop return spring.

[1] WOODRUFF KEY

REASSEMBLY: Position the key on the engine shaft with a slight forward incline tofacilitate Rotostop installation.

[2] ROTOSTOP CABLE

ADJUSTMENT: ch. 3.6DISASSEMBLY: Remove the cable stay.REASSEMBLY: Connect the Rotostop cable before tightening the stop screw.

[3] BBC BOTTOM PLATE

INSPECTION: ch. 4.2b

[4] STOP SCREW


[5] BLADE HOLDER SCREW

DISASSEMBLY/REASSEMBLY: Loosen or tighten the blade holder screw with holdingthe flywheel lever with a strap wrench.

[6] BLADE

INSPECTION: ch. 3.14SHARPENING: ch. 4.4

[7] BLADE SCREW (2)

DISASSEMBLY/REASSEMBLY: Use a wood en block to prevent the blade from turning.


[8] LOCK WASHER (2)

REASSEMBLY: Install the lock washer with “OUT” mark facing out.

[9] SCREW, 6 x 14 mm[10] COLLAR[11] RETURN SPRING

REASSEMBLY: Hook one end to the BBC plate and the other end to the collar using ascrew driver as shown.INSPECTION: ch. 4.2b.

[11]-1 RETURN SPRING[11]-2 COLLAR

b. Inspection

- 29 -

HRD536C - HRD536CK1 - HRD536C2

[1]

[2]

[3] [4]

[5]

[6]

[7][8]

[9][10]

[11]

[11] - 1

[11] - 2

55

22

- BLADE / ROTOSTOP

• BBC bottom plate

Measure the lining thickness.

Service limit[1] Clutch lining thickness: 2.0 mm

[2] Brake lining thickness: 2.0 mm

Replace the bottom plate if the lining thickness is below the service limit.

• Clutch return spring

Measure the return spring free length.

Service limit [A] 65 mm

Replace the return spring if the free length is longer than the service limit.

[3] BRAKING AREA

[4] CLUTCH AREA

- 30 -HRD536C - HRD536CK1 - HRD536C2 - BLADE / ROTOSTOP

[2]

[1]

[A]

c. Models HRD536C1 / HRD536C2: 8132521 ~

Do not turn the lawnmower over.

1. Switch the engine off and remove the spark plug cap.

2. Put the throttle to stop, close the fuel cock and drain the carburettor.

3. Put the lawnmower on its side so that the carburettor is facing upwards.

NOTE: Before working on the Rotostop, remove the Rotostop return spring [17] usingneedle-nose pliers.

[1] CABLE BRACKET[2] FIXING SCREW, 14 mm M6 (1)

TIGHTENING TORQUE: 10 N.m WRENCH SIZE: 10 mm

[3] FIXING SCREW, 20 mm M6 (1)


[4] BLADE SCREW, 20 mm M10 (2)


[5] SPRING WASHER, 10 mm (2)

REASSEMBLY: Fit the washer with the “OUT” mark facing outwards.

[6] BLADE

INSPECTION: ch. 3.14SHARPENING: ch. 4.4

[7] BLADE HOLDER SCREW, 25 mm M10


[8] LOWER BALL BEARING, 6204[9] BLADE HOLDER

[10] CLUTCH SPRING

REASSEMBLY: Fit the spring with the “UP” mark facing the engine.[11] CLUTCH LINING

INSPECTION: See ch. 4.2b[12] CLUTCH CONE[13] SPRING LOCK BRACKET[14] CONTROL SYSTEM RETURN SPRING[15] BRAKE ANCHOR PLATE[16] STEEL BALLS (3)[17] ROTOSTOP RETURN SPRING

REMOVAL/REASSEMBLY: Use needle-nose pliers.[18] CLUTCH CABLE[19] CLUTCH CONTROL PLATE[20] UPPER BALL BEARING[21] KEY

- 31 -


"up"

"out"

[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8]

[9]

[9]

[10]

[10]

[11]

[11]

[12]

[13]

[14]

[15]

[16]

[18]

[17]

[19]

[21]

[20]

1010

10 10

14

14

55

55

- BLADE / ROTOSTOP

4.3 Inspecting the Rotostop

If the steps described below show that the clutch or brake is worn, the clutch lining andspring must be replaced.

1. Set the clutch cable to the engaged position.The distance between the light and the finger [1] should be between:

Distance 0.5 to 1 mm

2. Measuring the wear on the clutch:

Engage the Rotostop lever,The distance between the brake anchor plate [2] and the lining [3] should be greaterthan:

Distance ≥ 0.5 mm

3. Measuring the wear on the brake:

Engage the Rotostop lever.The distance between the finger [4] and the left-hand edge of the light must be greaterthan:

Distance ≥ 1 mm

- 32 -HRD536C - HRD536CK1 - HRD536C2 - BLADE / ROTOSTOP

> 1 mm

[4]

12

0,5 mm[2]

[3]

0,5-1 mm

[1]

4.4 Blade sharpening

1. Stop the engine and remove the spark plug cap to prevent accidental starting.

Blade will start spinning if the Rotostop lever is engaged while the engine is running.

Stop the engine and disconnect the spark plug cap before inspecting the blade orplacing your hands near the cutter housing.

Tilt the mower so the carburettor faces upward.

Wear heavy gloves to protect your hands when handling the blade.

2. Use a wooden block to prevent the blade from turning and remove the two bladescrews and blade.

3. Inspect the blade for signs of wear or damage. A blade that is worn out, bent, crackedor otherwise damaged must be replaced. A dull blade can be sharpened.

4. Grind or file the blade no more than is necessary to remove nicks and to restorestraight, sharp cutting edges that are even with the lower surface of the blade.

NOTE: Grinding or filing a step in the blade can create a weak point, causing cracks todevelop during mower operation.Grind or file the upper surface of the blade only. The cutting edge must be even with thelower surface of the blade.Taper the blade profile, with the maximum amount of material removed at the blade tip andno material removed at the inner end of the cutting surface.Maintain the original blade bevel angle (30° - 40°) while sharpening [6].Do not alter the angle.Remove equal amounts of material from both cutting edges to preserve blade symmetryand balance.

5. After sharpening, dress the cutting edges with a file, so they will not be razor-sharp.Razor-sharp edges will easily chip and will quickly become dull. The blade should be0.1 - 0.3 mm thick at the cutting edges.

6. Test blade balance by placing the clean, sharpened blade on a screw driver as shown.A balanced blade will stay horizontal. If one end of the blade tips, grind or file the heavyend until good balance is achieved.

NOTE: An unbalanced blade will cause abnormal vibration and may eventually damagethe mower.

7. Install the blade.


[1] DULL CUTTING EDGE

[2] CORRECT SHARPENING

[3] TAPER

[4] INCORRECT SHARPENING

[5] STEP

[6] SHARPEN AT ORIGINAL ANGLE

- 33 -

HRD536C - HRD536CK1 - HRD536C2 - BLADE / ROTOSTOP

[1]

[2]

[4]

[3]

[5]

[6]

5. ENGINE REMOVAL / INSTALLATION

5.1 Engine removal: ~ 8132520

Gasoline is highly flammable and explosive. If ignited, gasoline can burn youseverely.

When draining gasoline:

Drain gasoline into an appropriate container.

Keep sparks and flames away and do not smoke.

Wipe up spills immediately.

1. Drain the gasoline from the carburettor and fuel tank into an appropriate container.

2. Drain the engine oil (ch. 3.1).

3. Remove the blade and Rotostop (ch. 4).

4. Loosen the throttle cable holder screw and disconnect the throttle cable from thecontrol arm

5. Remove the screw [3] and the washer [4] and remove the collar [6] and drive cover [5].

6. Remove the two flange screws and the Rotostop cable stay [7] and [8].

7. Turn the driven pulley (transmission side) so that the hole in the pulley aligns with thehole in the transmission bracket [9].Insert a screwdriver or rod into the holes and pivot the transmission to remove thedrive belt from the pulley.Remove the drive pulley [11] and woodruff key [10] from the crankshaft.

8. Undo the knot on the recoil starter rope [12] at handle level to release it.

9. Remove the engine mounting screws [14], then remove the engine from the cutterhousing.

5.2 Engine installation: ~ 8132520

Install the engine in the reverse order of removal.

NOTE: Install the drive pulley [11] by aligning the key groove with the woodruf [10] key onthe crankshaft.Connect the throttle cable [16] to the throttle arm, then secure the cable holder withscrew [15]. Adjust the throttle cable after engine installation (ch. 3.4).

[3] FLANGE SCREW, 6 x 70 mm

[4] WASHER, 6 mm

[6] COLLAR, 10 x 53 mm

[14] ENGINE MOUNTING SCREWS, 8 x 60 mm (3)

- 34 -HRD536C - HRD536CK1 - HRD536C2

[3][4]

[5]

[6]

[8]

[7]

[9]

[10]

[11]

[12] [13]

0-1 mm

[11]

[15]

[16]

[10]

- ENGINE REMOVAL / INSTALLATION

5.3 Engine installation: 8132521 ~When you refit the engine, make sure you don’t lose or forget the studs [7].

[1] LEFT-HAND GUARD

[2] RETURN SPRING

[3] CUTTER HOUSING COVER

[4] ENGINE FIXING SCREW, 8 x 60mm (4)


[5] WASHER, 8 x 2 x 23mm (2)

[6] ENGINE

HRD536CK1: GCV160

[7] ENGINE MOUNTING STUD (4)

THICKNESS 3.5 mm

[8] ADIABATIC BUSH (4)

[9] ROTOSTOP CABLE BRACKET

[10] WASHER HEAD SCREW, 20 mm M6 (1)


[11] WASHER HEAD SCREW, 14 mm M6 (1)


- 35 -

HRD536C - HRD536CK1 - HRD536C2 - ENGINE REMOVAL / INSTALLATION

[6]

[9]

[10][11]

[7]

[8]

[5]

[4]

1010

2222

1222

6. MUFFLER

a. Removal / Installation

The engine and muffler become very hot during operation and they remain hot for awhile after operation. Be sure that muffler removal/installation is performed uten theengine is cold.

[1] MUFFLER PROTECTOR

[2] SPARK ARRESTER

INSTALLATION: Install after removing the carbon from the screen with a wire brush.


[4] MUFFLER GASKET

Do not reuse.

[5] MUFFLER

INSTALLATION: Install after removing the carbon deposits from the muffler using a plastichammer. Do not tap on the muffler seal flange and do not damage the part. If the seal flangeis dented or damaged, replace the muffler. Check the cylinder barrel exhaust port fordamage.

[5]-1 MUFFLER SEAL FLANGE

[5]-2 EXHAUST PORT

[6] FLANGE SCREW, 6 x 79 mm (2)



- 36 -HRD536C - HRD536CK1 - HRD536C2 - MUFFLER

[2]

[3]

[1]

[5]

[5] - 1

[5] - 2

[4]

[6]

[7]

12

7. RECOIL STARTER

7.1 Recoil starter


NOTE: Replace the starter rope if it is frayed or worn out. Do not disassemble the recoilstarter [2] assembly.

[1] FLANGE NUT, 6 mm (3)

TIGHTENING TORQUE: 8.5 N.m

[2] RECOIL STARTER ASSEMBLY

- 37 -

HRD536C - HRD536CK1 - HRD536C2 - RECOIL STARTER

[1]

[2]

8,5

b. Starter rope replacement

1. Pull the starter grip [1] fully (until the starter rope is pulled out fully).

2. To prevent the starter reel from rewinding, hold the starter reel [3] and starter case [4]with a band [2] or equivalent material as shown.

3. Untie the knot of the starter rope [5] at the starter grip side and the starter reel side andremove the starter rope.

4. When the starter rope has broken or the starter reel has rewound, align the ropehole [6] in the starter case [4] with the rope hole in the starter reel [3] by turning thestarter reel 5 turns in the direction of the arrow.

Starter rope length 2.3 m

Starter rope diameter 3 mm

5. Pass the starter rope [5] through the starter grip and make the slip knot [7] at the end ofthe rope as shown.

6. Pass another end of the starter rope through the rope hole in the starter case andthrough the rope hole in the starter reel [3] and make the untieable knot at the ropeend.

7. Wind the starter rope slowly on the starter reel.

8. Check the operation of the ratchets [8] by pulling the starter rope several times.

[1] STARTER GRIP

[2] BAND

[3] STARTER REEL

[4] STARTER CASE

[5] STARTER ROPE

[6] ALIGN THE HOLES

[7] SLIP KNOT

[8] RACHETS

- 38 -HRD536C - HRD536CK1 - HRD536C2 - RECOIL STARTER

[1]

[2]

[4]

[3]

[5]

[1]

[6]

[7][8]

8. FUEL SYSTEM

8.1 Air cleaner / carburettor


Before removal, completely drain the carburettor.

Gasoline is highly flammable and explosive. You can be burnt or seriously injuredwhen handling fuel. Keep heat, sparks and flame away. Handle fuel only outdoors.Wipe up spills immediately.

CAUTION:

• If these parts are left out, dirt will enter the intake system and damage the engine.

[1] GOVERNOR ROD

REMOVAL/INSTALLATION: ch. 8.2

[2] THROTTLE RETURN SPRING


[3] BREATHER COVER

[4] CHOKE ROD


[5] FUEL TUBE

[6] TUBE CLIP, B8

[7] CARBURETTOR GASKET

Do not reuse.

[8] CARBURETTOR

DISASSEMBLY/REASSEMBLY: ch. 8.1cINSPECTION: ch. 8.1cADJUSTMENT: ch. 8.1c

[9] AIR CLEANER COVER



- 39 -

HRD536C - HRD536CK1 - HRD536C2 - FUEL SYSTEM

[1] [2] [3]

[4]

[5]

[6]

[7]

[8]

[9]

[10] 10

[11] AIR CLEANER ELEMENT (PAPER ELEMENT)

CLEANING: ch. 3.3[12] FLANGE SCREW, 6 x 86 mm (2)

TIGHTENING TORQUE: 10 N.m[13] AIR CLEANER CASE

INSTALLATION: Before installation, clean inside the case with compressed air.[14] AIR CLEANER PACKING

Do not reuse.[15] BREATHER TUBE

INSTALLATION: Connect one end to the breather cover hole and the other end to the aircleaner case.

[16] INSULATOR PACKING

Do not reuse.[17] CARBURETTOR INSULATOR

INSTALLATION: blow out the passages with compressed air and install.[18] AIR GUIDE

INSTALLATION: Replace the gasket if it is damaged.

• Governor rod / Throttle return spring / Choke rod

Removal1. Unhook the throttle return spring [1].2. Remove the fuel tube.3. Remove the two 6 x 86 mm flange bolts and the 6 x 14 mm flange bolt from the air

cleaner case.4. Remove the air cleaner case, air cleaner gasket, carburettor gasket, air guide,

carburettor insulator and insulator gasket.5. Unhook the choke rod [3] and governor rod [2] from the carburettor.

Installation

1. Install the fuel tube on the carburettor.2. Set the choke rod [3] on the carburettor choke lever [4].3. Hook the governor rod [2] in the larger hole [6] in the carburettor throttle lever [5].

Hook the throttle return spring [1] in the smaller hole [7] in the carburettor throttlelever [5].

4. Install the insulator gasket, carburettor insulator, air guide, carburettor, carburettorgasket, air cleaner gasket and air cleaner case.

5. Install the two 6 x 86 mm flange bolts and 6 x 14 mm flange bolt.[1] THROTTLE RETURN SPRING[2] GOVERNOR ROD[3] CHOKE ROD[4] CARBURETTOR CHOKE LEVER[5] CARBURETTOR THROTTLE LEVER[6] LARGER HOLE[7] SMALLER HOLE

b. Disassembly / Reassembly

- 40 -HRD536C - HRD536CK1 - HRD536C2

[1] [2]

[3]

[4][5]

[6]

[7]

- FUEL SYSTEM

[11]

[12][13]

[14]

[15]

[16]

[17]

[18]

10


NOTE: Clean the outside of the carburettor before disassembly.

[1] CARBURETTOR BODY

REASSEMBLY: Clean internal passages and orifices with compressed air beforeinstallation.

[2] SCREW, 5 x 6 mm

[3] PILOT SCREW

ADJUSTMENT: ch. 3.9

[4] THROTTLE STOP SCREW

ADJUSTMENT: ch. 3.9

[5] FLOAT VALVE

REASSEMBLY: Check for worn float valve seat and float valve before installation.

[5]-1 VALVE SEAT

[5]-2 FLOAT VALVE

[5]-3 REPLACE

[5]-4 OK

[6] FLOAT PIN

[7] SET PACKING

[8] FLOAT CHAMBER

[9] MOUNTING BOLT

REASSEMBLY: After assembly, check for any sign of fuel leakage.

[10] FLOAT

REASSEMBLY: Check for smooth movement after installation.INSPECTION: ch. 8.1c

[11] MAIN JET

REASSEMBLY: Clean thoroughly with compressed air before installation.MAIN JET NUMBER: # 65

[11]-1 MAIN JET

[12] MAIN NOZZLE

REASSEMBLY: Clean thoroughly with compressed air before installation.

c. Inspection

• Float level height

- 41 -


[1]

[2][3]

[4]

[5]

[5] - 1

[5] - 2

[5] - 3

[5] - 4

[6]

[7]

[8]

[7]

[9]

[10]

[11]

[11] - 1

[12]

- FUEL SYSTEM

Place the carburettor in the position as shown and measure the distance between the top ofthe float and the carburettor body when the float just touches the seat without compressingthe valve spring.

[1]

FLOAT LEVEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07401-0010000

Standard float height 9.2 mm

If the height is off specification, replace the float and/or the float valve. Recheck the floatheight.

- 42 -HRD536C - HRD536CK1 - HRD536C2 - FUEL SYSTEM

S .T OOL

[1]

S.TOOL

8.2 Control base / Governor arm

a. Disassembly / Reassembly

Remove the air cleaner and carburettor (ch. 8.1).

[1] GOVERNOR ROD

[2] THROTTLE RETURN SPRING

REASSEMBLY: Hook the ends through the small holes in the governor arm and throttle.Install the spring with the long end on the carburettor.

[3] GOVERNOR ARM

REASSEMBLY: Adjust the governor (ch. 3.10).

[4] GOVERNOR ARM NUT


[5] GOVERNOR ARM BOLT

[6] THROTTLE CABLE

ADJUSTMENT: ch. 3.4

[7] CABLE HOLDER

[8] SCREW, 5 x 16 mm

[9] SCREW WASHER, 5 x 10 mm


[10] COLLAR

[11] FUEL TUBE

REASSEMBLY: Inspect for cracks or deterioration before installation and replace ifnecessary (ch. 3.12).

[12] TUBE CLIP, C9

[13] FUEL VALVE

[14] FUEL VALVE BRACKET

[15] LEVER SPRING

Move the spring so that the hook ends face downward.

[16] SCREW, 6 x 45 mm

[17] CONTROL BASE

With flywheel brake/solid wire cable type

[18] CHOKE ROD

[19] ENGINE STOP SWITCH

[20] WASHER, 4 mm

[21] SCREW WASHER, 4 x 12 mm

[22] GOVERNOR SPRING

8.3 Fan cover

- 43 -


[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8]

[9]

[10]

[11]

[12]

[13]

[14]

[15]

[16]

[17]

[18]

[19] [20] [21][22]

10

3

- FUEL SYSTEM


1. Before disassembly, completely drain the fuel tank and fuel line.

2. Remove the recoil starter (ch. 7.1).


[1] FUEL TANK CAP

REASSEMBLY: Make sure that the air vent hole is clean and unclogged. Blow withcompressed air if necessary.

[2] FAN COVER/FUEL TANK

FUEL CAPACITY: 1.1

CLEANING: ch. 3.11INSTALLATION: Wash with solvent to remove the sediment and dry thoroughly beforeinstalling.Check whether the spark plug wire and the stop switch wire are securely set in the groove inthe fan cover as shown.

[2]-1 STOP SWITCH WIRE

[2]-2 SPARK PLUG WIRE

[3] FUEL FILTER

REASSEMBLY: Make sure that the filter is unclogged. Clean with clean gasoline or blowwith compressed air.

[4] FUEL TUBE, 5.3 x 100 mm

REASSEMBLY: Inspect for cracks or deterioration before installation and replace ifnecessary.

[5] TUBE CLIP, B10 (2)

[6] FAN COVER COLLAR (3)

- 44 -HRD536C - HRD536CK1 - HRD536C2

[1]

[2]

[2] - 1

[2] - 2

[3]

[4]

[5]

[6]

- FUEL SYSTEM

9. FLYWHEEL / IGNITION COIL

9.1 Flywheel / Ignition coil


1. Remove the air cleaner and carburettor (ch. 8.1).

2. Remove the control bade and governor arm (ch. 8.2).

3. Remove the fan cover (ch. 8.3).

[1] FLYWHEEL

When disassembling and reassembling, be careful not to damage the fan blades.

[2] SPECIAL NUT, 14 mm


[3] SIDE PLATE





[6] STOP SWITCH WIRE

[7] CLIP A

[8] BREATHER COVER

[9] BREATHER COVER GASKET

Do not reuse.

[10] BREATHER VALVE

[11] SPECIAL WOODRUFF KEY, 25 x 18 mm

REASSEMBLY: When installing the flywheel, check to be sure that the woodruff keyremains in its slot on the crankshaft.

[12] SPARK PLUG WIRE

REASSEMBLY: Check for cracked or damaged insulation; replace if necessary.

[13] IGNITION COIL

INSPECTION: p. 47ADJUSTMENT: p. 48

[14] FAN COVER STUD BOLT (3)




- 45 -


[2]

[1]

[12]

[13]

[14][15]

[3]

[4]

[11]

[10]

[9]

[8]

[7]

[6]

[5]

[5]

12

12

52

1212

- FLYWHEEL / IGNITION COIL

• 14 mm special nut / flywheel

Removal

1. Remove the ignition coil.

2. While holding the flywheel with a strap wrench [1], remove the nut [2].

CAUTION:

• Do not loosen the nut by setting a screw driver or equivalent tool on the fan blade orprojection [3].

3. Set the magnetic parts [4] of the flywheel in the position shown.

4. Set the flywheel puller [6] on the flywheel; specifically, set at the part under themagnetic parts of the flywheel.

NOTE: Do not position the flywheel puller at any parts other than under the magneticparts [4]. Set a rag [7] or equivalent cloth between the flywheel and the puller.

5. Tighten the flywheel puller and remove the flywheel.

CAUTION:

• Do not hit the flywheel with a hammer.

[1]

STRAP WRENCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available


[3] PROJECTIONS

[4] MAGNETICS PARTS

[5] PULLER MARK

[6]

FLYWHEEL PULLER 6-inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available

[7] RAG

- 46 -HRD536C - HRD536CK1 - HRD536C2 - FLYWHEEL / IGNITION COIL

[1][2]

[3]

[4]

[5]

[4][7]

[6]

S.TOOL

S.TOOL

a. Installation

CAUTION:

• Remove all of dirt, oil, grease and other foreign material from the tapered part beforeinstallation.

• Be sure that the magnetic part is free of any metal parts and foreign material.

1. Be sure that the woodruff key is set in the key groove properly.

2. Install the flywheel.

3. Apply oil to the threads.

4. While holding the flywheel with a strap wrench [2], tighten the nut [1] to the specifiedtorque.


b. Inspection

• Ignition coil

Primary side

Measure the resistance of the primary coil [3] by attaching one ohmmeter lead to the ignitioncoil’s primary terminal while touching the other test lead to the iron core.

Primary side resistance 1.0 - 1.2 Ω

Secondary side

Attach a tester lead between the spark plug cap and iron core and measure the resistanceof the secondary coil [4].

Secondary side resistance 10.6 - 12.8 Ω


[2]

STRAP WRENCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available

[3] PRIMARY COIL

[4] SECONDARY COIL

- 47 -

HRD536C - HRD536CK1 - HRD536C2 - FLYWHEEL / IGNITION COIL

[2]

[1] 52

[3] [4]

S.TOOL

• Engine stop switch

To perform this test, use a multimeter set in ohmmeter position.

Digital multimeter display Analog multimeter needle

NO CONTINUITY ∞ Ω 1 Does not moves

CONTINUITY O Ω 0 Moves (to the end)

There should be continuity when the plunger [1] is pushed in.

There should be no continuity when the plunger [1] is released.

Replace the engine stop switch if correct continuity test results are not obtained.

c. Adjustment

• Ignition coil air gap

Adjustment is required only when the ignition coil [2] or the flywheel has been removed.

1. Loosen the ignition coil bolts.

2. Insert a long feeler gauge [3] of the proper thickness between the ignition coil and theflywheel.Both gaps should be adjusted simultaneously.

3. Push the ignition coil [2] firmly toward the flywheel [4] and tighten the bolts.

Specified clearance 0.2 - 0.6 mm

NOTE: Avoid the magnetic part of the flywheel when adjusting.

[1] PLUNGER

[2] IGNITION COIL

[3] FEELER GAUGE

[4] FLYWHEEL

- 48 -HRD536C - HRD536CK1 - HRD536C2 - FLYWHEEL / IGNITION COIL

[1]

[2]

[3]

0.2 - 0.6 mm 0.2 - 0.6 mm

[4]

[2]

10. CAM PULLEY / CRANKSHAFT / PISTON / CYLINDER BARREL

10.1 Cam pulley / Rocker arm


[1] CYLINDER HEAD COVER




[3] VALVE ADJUSTMENT SCREW (2)

ADJUSTMENT: ch. 3.8

[4] VALVE ADJUSTMENT LOCK NUT (2)


[5] ROCKER ARM SHAFT (2)

INSPECTION: ch. 10.6INSTALLATION: ch. 3.8

[6] INTAKE ROCKER ARM

INSPECTION: ch. 10.6

[7] TIMING BELT

[8] CAM PULLEY SHAFT


[9] O-RING, 6.8 x 1.9 mm

Do not reuse.

[10] CAM PULLEY

Decompressor weightINSPECTION: ch. 10.6INSTALLATION: ch. 10.2Take care not to drop the cam pulley.

[11] EXHAUST ROCKER ARM


- 49 -


OIL

OIL

[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8][9]

[10]

[11]

OIL

OILOIL

OIL

8

12

- CAM PULLEY / CRANKSHAFT / PISTON / CYLINDER BARREL

• Cam pulley

Decompressor weight inspection:

Before installing, inspect for worn and weakened springs and check that the compressorweight moves smoothly.

a. Installation

1. Set so that the crankshaft key groove (PTO side) [10] faces up as shown (piston mustbe at the top dead center of the compression stroke).

2. Set the cam pulley [2] on the timing belt [7] so that the cam pulley alignment marks [4]are in line with the cylinder head cover mating surface [6].

NOTE: Set the cam pulley on the timing pulley, being careful not to turn the crankshaft.

3. Apply oil to the 6.8 x 1.9 mm O-ring [8] and set it on the cam pulley shaft [9].

4. Install the cam pulley shaft on the cylinder barrel.

5. While holding the cam pulley alignment marks in line with the cylinder head covermating surface, check again to ensure that the crankshaft key groove [5] is facing up.

6. When the key groove is not facing up, repeat the procedure from the step 1.

[1] WEIGHT RETURN SPRING

[2] CAM PULLEY

[3] DECOMPRESSOR WEIGHT

[4] ALIGNMENT MARKS

[5] CRANKSHAFT KEY GROOVE

Flywheel side

[6] CYLINDER HEAD COVER MATING SURFACE

[7] TIMING BELT

[8] O-RING, 6.8 x 1.9 mm

[9] CAM PULLEY SHAFT

[10] VIEW FROM PTO SIDE

- 50 -HRD536C - HRD536CK1 - HRD536C2 - CAM PULLEY / CRANKSHAFT / PISTON / CYLINDER BARREL

[1][2]

[3]

[4]

[2]

[5]

[6]

[10]

[8]

[9]

[2] [7]

• Rocker arm shaft

Installation

Install the rocker arm shaft [2] from the side opposite the cam pulley [1] as shown.

• Cylinder head cover

Installation

1. Clean the mating surfaces of the cylinder head cover and the cylinder barrel using adegreasing agent or a clean shop rag.

2. Apply liquid gasket compound [3] (Three Bond 1207 or equivalent) to the cylinderhead cover, specifically to the inner wall of the groove and bolt hole (see the partshown) in the cylinder head cover.

NOTE: Assemble within 10 minutes after applying the liquid gasket compound.

3. Wait for approximately 20 minutes after assembly before filling oil and starting theengine.

[1] CAM PULLEY

[2] ROCKER ARM SHAFT

[3] LIQUID GASKET APPLICATION AREA

[4] CYLINDER COVER VIEWED FROM BACK SIDE

- 51 -

HRD536C - HRD536CK1 - HRD536C2 - CAM PULLEY / CRANKSHAFT / PISTON / CYLINDER BARREL

[1]

[2]

[3]

[4]

10.2 Oil pan / Crankshaft / Cylinder barrel


Remove the cam pulley and rocker arm (ch. 10.1).

[1] OIL SEAL, 28 x 41.25 x 6 mm

INSTALLATION: Be careful not to damage the lip of the oil seal when installing the oil panwith the oil seal.

[2] OIL PAN ASSEMBLY

DISASSEMBLY/REASSEMBLY: ch. 10.2INSPECTION: ch. 10.6REMOVAL: p. 53

[3] DOWEL PIN, 8 x 20 mm (2)

[4] TIMING BELT

SPECIFIED BELT: 84HU7 G-200INSTALLATION: Check that the belt is not worn or cracked. Do not bend or twist the belt.

[5] CYLINDER BARREL

INSPECTION: ch. 10.6INSTALLATION: p. 54

[6] OIL SEAL, 25.4 x 62 x 6 mm

[7] PISTON ASSEMBLY

DISASSEMBLY/REASSEMBLY: ch. 10.3INSPECTION: ch. 10.6INSTALLATION: p. 55

[8] OIL DIPPER

[9] CONNECTING ROD CAP

INSTALLATION: p. 56

[10] CONNECTING ROD BOLT (2)


[11] CRANKSHAFT

INSPECTION: ch. 10.6INSTALLATION: Be careful not to damage the oil seal. Cover the grooves with adhesivetype in order to protect the seals during reassembly.After installation, clean the crankshaft tapered surface.

[12] THRUST WASHER

INSTALLATION: p. 53

[13] SCREW, 6 x 25 mm (8)

INSTALLATION: p. 54


- 52 -HRD536C - HRD536CK1 - HRD536C2

[1]

[2]

[3]

[4]

[5]

[6][7]

[8]

[9]

[10]

[11]

[12]

[13]

OIL

OIL

OIL

GR E AS E

GR E AS E

12


• Oil pan

Removal

Insert a screwdriver or equivalent tool into the recess [1] as shown and remove the oil panfrom the cylinder barrel.

• Piston assembly / Connecting rod cap

Installation

1. Apply oil to the inner wall of the cylinder and to the outer surface of the piston.

2. Install the piston assembly in the cylinder so that the model mark [2] by the piston pinhole and the longer side of the connecting rod big end [3] are at the right side (thepiston must be at the top dead center of the compression stroke).

CAUTION:

• Be careful not to break the piston ring when installing the piston assembly in the cylinder.

3. Install the crankshaft in the cylinder barrel (p. 52).

4. Apply oil to the connecting rod big end bearing and the crank pin, then connect theconnecting rod to the crank pin.

5. Apply oil to the connecting rod cap bearing.

6. Install so that the projection [5] by the oil dipper [4] and the projection of the connectingrod [6] face the same direction.Note that the oil dipper must be at the right-hand side this time.

7. Tighten the connecting rod bolts to the specified torque:


• Thrust washer [7]

Installation

1. Install the timing belt [8] on the timing belt pulley.

2. Note the installation direction.

[1] RECESS

[2] MODEL MARK

[3] CONNECTING ROD WITH THE LONG END

[4] OIL DIPPER

[5] PROJECTIONS

[6] CONNECTING ROD

[7] TRUST WASHER

[8] TIMING BELT

- 53 -


[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8]

• Cylinder barrel / 6 x 25 mm flange bolt

Installation

1. Align the “” mark [3] on the cylinder barrel [4] with the “,” [2] mark on thecrankshaft [1].

2. Install the cam pulley (p. 50).

3. Clean the mating surfaces of the cylinder barrel [4] and the oil pan using a degreasingagent or a clean shop rag.

4. Set the two 8 x 20 mm dowel pins on the cylinder barrel.

5. Apply a bead (Ø 1.5-2.0 mm) of the liquid gasket compound (Three Bond 1207 orequivalent) to the cylinder, specifically to the mating surface with the oil pan [5].

6. Install the oil pan on the cylinder barrel.

NOTE: Assemble within 10 minutes after applying the liquid gasket.If it is hard to install the oil pan securely, assembly by turning the crankshaft a little.

7. Loosely tighten each bolt, then retighten to the specified torque in the numberedsequence.


8. Wait for approximately 20 minutes after assembly before filling oil and starting theengine.

[1] CRANKSHAFT

[2] “,” MARK

[3] “” MARK

[4] CYLINDER BARREL

[5] LIQUID GASKET APPLICATION AREA


[1]

[2]

[3][4]

10.3 Piston


[1] PISTON RINGS

INSPECTION: ch. 10.6REASSEMBLY: Install with the maker mark facing upward as shown.Do not interchange the top ring and the second ring.After assembly, check for smooth movement of the piston ring.Stagger the piston ring end gaps 120° apart. Do not align with the piston pin.

[1]-1 TOP RING (CHROME PLATED)

[1]-2 SECOND RING

[1]-3 OIL RING

[2] MAKER MARK

[3] PISTON


[4] PISTON PIN


[5] CONNECTING ROD


[6] PISTON PIN CLIP (2)

REASSEMBLY: Install by setting one end of the clip in the piston groove, holding the otherend with long-nose pliers, and by rotating the clip inward.Do not align the end gap of the clip with the cutout in the piston pin bore.

[6]-1 CLIP

[6]-2 CUTOUT

- 55 -


R120°

120°120°

[1] - 1

[1] - 2

[1] - 3

[1]

[1] - 1

[2]

[1] - 2

[1] - 3

[3]

[4]

[5]

[6]

[6] - 2

[6] - 1

OIL

OIL


• Piston / Connecting rod

Reassembly

1. Apply oil to the piston pin [2], piston pin hole and the connecting rod small end.

2. Set the piston [1] so that the “,” of the “FW,” mark [4] stamped at the back of thepiston points down.

3. Set the connecting rod [6] in the piston so that the model mark “” [7] by the piston pinhole and the longer side of the connecting rod large end [5] face to the right-hand side(“FW,” mark towards the flywheel side).

4. Apply oil to the piston pin [2] and install it in the piston.

5. Install two new piston pin clips [3].

6. Install the piston / connecting rod assembly in the cylinder barrel (ch. 10.2).

[1] PISTON

[2] PISTON PIN

[3] PISTON PIN CLIP (2)

[4] “FW,” MARK

[5] CONNECTING ROD WITH THE LARGE END

[6] CONNECTING ROD

[7] MODEL MARK “”


FW

[1] [2]

[3]

[4]

[5][6]

[7]

10.4 Valves


Remove the oil pan, crankshaft and cylinder barrel (ch. 10.2).

[1] VALVE SPRING RETAINER (2)

DISASSEMBLY: Push down and slide the retainer to the side, so the valve stem slipsthrough the hole at the side of the retainer.CAUTION:

Do not remove the valve spring retainer while the piston is installed, as the valves willŸdrop into the cylinder.

[2] VALVE SPRING (2)


[3] SPARK PLUG

INSPECTION/CLEANING: ch. 3.2Standard spark plug: BPR 6ES (NGK)

[4] CYLINDER BARREL

CLEANING: p. 54

[5] INTAKE VALVE

REASSEMBLY: Do not interchange with the exhaust valve.Valve head diameter:IN: 25 mmEX: 24 mmBe careful not to damage the valve stem seal when installing.INSPECTION: ch. 10.6

[6] EXHAUST VALVE

REASSEMBLY: Before installation, remove carbon deposits and inspect the valve.INSPECTION: ch. 10.6

[7] VALVE GUIDE


- 57 -


[1]

[2]

[3]

[4]

[5]

[6]

[7]

OIL

OIL


• Cylinder barrel

Combustion chamber cleaning

1. Prepare a cylinder of thick paper or equivalent material [1], having a large enoughdiameter so as to fit against the inner wall of the cylinder, and then insert it into thecylinder.

2. Attach the cleaning brush (special tool) [2] to an electric drill [3] and clean thecombustion chamber.

CAUTION:

• Be sure to insert a tube of thick paper into the cylinder to protect the inner wall of thecylinder during cleaning of the combustion chamber.

• Do not press the cleaning brush strongly against the combustion chamber.

[1] THICK PAPER OR EQUIVALENT

[2]

CLEANING BRUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07998-VA20100

[3]

ELECTRIC DRILL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available


[1]

[2]

[3]

S.TOOL

S.TOOL

S.TOOL

10.5 Governor


[1] GOVERNOR HOLDER SHAFT

[2] GOVERNOR SHAFT GROOVE

[3] GOVERNOR WEIGHT HOLDER ASSEMBLY

REASSEMBLY: Before installing, check for wear and damage of the gear.Check that the weights move freely.Be sure to install the governor weight before installing the crankshaft.

[4] THRUST WASHER, 6 mm

[5] GOVERNOR SLIDER

REASSEMBLY: Spread the governor weights to install the slider; then check to be sure theslides moves smoothly.

[6] GOVERNOR HOLDER CLIP

REASSEMBLY: Insert firmly into the shaft groove.

[7] SCREW, 6 x 14 mm (2)


[8] WASHER, 6 mm

REASSEMBLY: Install inside the case.

[9] GOVERNOR ARM SHAFT

REASSEMBLY: Install the lock pin immediately after installing the governor arm shaft andmove the shaft over against the governor slider.The lock pin must be installed with the straight side of the pin against the groove in the shaft.

[9]-1 GOVERNOR ARM SHAFT

[9]-2 GROOVE

[9]-3 LOCK PIN, 8 mm

[10] OIL PAN


[11] O-RING, 14.7 x 2.2 mm

[12] EXTENSION LOCK WASHER

[13] GASKET

[14] OIL FILLER CAP

[15] OIL FILLER EXTENSION

- 59 -


[1][2]

[3] [4]

[5]

[6]

[7]

[8]

[9] - 1

[9]

[10]

[11]

[12]

[13]

[14][15]

[9] - 2

[9] - 1

[9] - 3

[9] - 3

OIL

12


10.6 Inspection

• Cam pulley cam height

Standard Service limit

[1] 37.394 mm 37.369 mm

• Cam pulley I.D. (bearing)


[2] 10.027 mm 10.075 mm

• Cam pulley shaft O.D.


[3] 9.987 mm 9.920 mm

• Rocker arm I.D.


[4] 6.000 mm 6.043 mm

• Rocker arm shaft bearing I.D.


[4] 6.000 mm 6.043 mm

• Rocker arm shaft O.D.


[5] 5.990 mm 5.953 mm

• Rocker arm-to-rocker arm shaft clearance

• Rocker arm shaft bearing-to-rocker arm shaft clearance


[5] 0.010 - 0.058 mm 0.07 mm

• Cylinder I.D.

Measure and record the cylinder I.D. at three levels in both the “X” axis (perpendicular tocrankshaft) and the “Y” axis (parallel to crankshaft). Take the maximum reading todetermine cylinder wear and taper.


[6] 64.000 mm 64.165 mm


[1]

[2]

[3]

[4]

[5][6]

• Piston skirt O.D.

Measure and record the piston O.D. at a point 10 mm from the bottom of the skirt and 90° tothe piston pin bore.


[1] 63.969 mm 63.829 mm

• Piston-to-cylinder clearance


[1] 0.031 - 0.070 mm 0.120 mm

• Piston ring width

[2] Standard Service limit

Top/Second 1.5 mm 1.37 mm

Oil 2.5 mm 2.37 mm

• Piston ring side clearance


Top/Second/Oil 0.015 - 0.045 mm 0.150 mm

• Piston ring end gap


Top 0.20 - 0.35 mm 1.0 mm

Second 0.30 - 0.45 mm 1.0 mm

Oil 0.15 - 0.35 mm 1.0 mm

NOTE: Use the top of the piston to position the ring horizontally in the cylinder.

• Piston pin O.D.


[5] 13.000 mm 12.954 mm

• Piston pin bore I.D.


[6] 13.002 mm 13.048 mm

- 61 -


10 mm

[1]

[2]

[3]

[4]

[5] [6]


• Connecting rod small end I.D.


[1] 13.005 mm 13.070 mm

• Connecting rod big end I.D.


[2] 26.020 mm 26.066 mm

• Crankshaft main journal O.D.


PTO side [4] 27.993 mm 27.933 mm

Flywheel side [5] 25.393 mm 25.333 mm

• Crankshaft main journal O.D.


[6] 25.98 mm 25.92 mm

• Connecting rod big end axial clearance

1. Measure the clearances with a feeler gauge.


[7] 0.1 - 0.4 mm 0.8 mm

• Connecting rod big end oil clearance

1. Wipe oil off the crank pin and connecting rod bearing mating surface.

2. Place the plastigauge [11] on the crank pin.Set the connecting rod and cap and tighten the connecting rod bolts [8] to thespecified torque.

NOTE: Place the plastigauge axially. Tighten the two bolts equally while holding thecrankshaft to keep it from turning.

3. Remove the connecting rod cap and measure the plastigauge with the scale [10].


[9] 0.040 - 0.063 mm 0.12 mm

4. If the clearance exceeds the service limit, replace the connecting rod and recheck theclearance.

[8] CONNECTING ROD BOLT (2)


[10] PLASTIGAUGE SCALE

[11] PLASTIGAUGE


[1] [2]

[5]

[4]

[3] [6]

[7]

[8]

[9]

12

[10]

[11]

• Cylinder barrel main journal I.D.


[1] 25.420 mm 25.466 mm

• Oil pan main journal I.D.


[2] 28.020 mm 28.066 mm

• Crankshaft axial clearance

1. Measure the crankshaft axial runout before removing the oil pan, crankshaft andpiston.


[3] 0.15 - 0.75 mm 1.0 mm

Replace the crankshaft if the measurement is above the service limit.

2. Install the new crankshaft and recheck the axial clearance.If it exceeds the service limit, replace the oil pan and cylinder barrel.

• Valve spring free length

1. Measure the free length of the valve springs.


[4] 34.0 mm 32.5 mm

Replace the springs if they are shorter than the service limit.

• Valve face / Stem O.D.

1. Inspect each valve [6] for pitting or wear irregularities.

2. Inspect each valve stem for bending or abnormal stem wear.Replace the valve if necessary.

3. Measure and record each valve stem O.D.


IN 5.48 mm 5.318 mm

EX 5.44 mm 5.275 mm

Replace the valves if their O.D. is smaller than the service limit.

• Valve guide I.D.

1. Measure and record each valve guide I.D.


[7] 5.50 mm 5.572 mm

Replace the cylinder barrel if they are over service limit.

- 63 -


[1] [2]

[3][4]

[5]

[6]

[7]

• Valve seat width

1. Thoroughly clean the combustion chambers and valve seats to remove carbondeposits (ch. 10.4).

2. Apply a light coat of Prussian Blue compound or erasable felt-tipped marker ink to thevalve faces [1].

3. Insert the valves and then lift them and snap them closed against their seats severaltimes. Be sure that the valve does not rotate on the seat. The transferred markingcompound will show any area of the seat that is not concentric.

4. Measure the valve seat width.


0.7 mm 1.8 mm

5. If the valve seat width is under the standard, or over the service limit, or if the valveseat is too high [3] / low [2], recondition the valve seat (ch. 10.7).


[1]

NO

OK

NO

[2]

[3]

10.7 Valve seat reconditionning

1. Thoroughly clean the combustion chambers and valve seats to remove carbondeposits (ch. 10.4).

2. Apply a light coat of Prussian Blue compound or erasable felt-tipped marker ink to thevalve faces [1].

3. Insert the valves and then lift them and snap them closed against their seats severaltimes. Be sure the valve does not rotate on the seat. The transferred markingcompound will show any area of the seat that is not concentric.

4. Using a 45° cutter [2], remove enough material to produce a smooth and concentricseat.

NOTE: Follow the instructions of the valve seat cutter manufacturer’s instructions. Turnthe cutter clokwise never counter clokwise. continue to turn the cutter as you lift it from thevalve seat.

• Valve seat width


0.7 mm 1.8 mm

5. After resurfacing the seats, inspect for even valve seating.Apply Prussian Blue compound or erasable felt-tipped marker ink to the valve faces.Insert the valves and then lift them and snap them closed against their seats severaltimes. Be sure the valves does not rotate on the seat. The seating surface, as shownby the transferred marking compound, should have good contact all the way around.

6. Lap the valves into their seats, using a 4 mm tube as shown [4] and lapping compound(commercially available).

CAUTION:

• To avoid severe engine damage, be sure to remove all lapping compound from thecylinder barrel before assembly.

7. Check valve clearance after assembly (ch. 3.8).

[1] VALVE FACE

[2]

VALVE SEAT CUTTER, 45°, Ø 27.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07780-0010200

[3]

CUTTER HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07981-VA20100 or 07981-VA20101

[4] TUBE, 4 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available

- 65 -


[1]

[2]

[3]

S.TOOL

S.TOOL

0.7 mm

[4]

S.TOOL

S.TOOL

11. FRONT WHEELS / REAR WHEELS

11.1 Front wheels


Wear heavy gloves to protect your hands when servicing near the blade.

NOTE: The front wheels can be serviced with the engine on the cutter housing.

Place the mower on wooden blocks and support the housing securely. Do not turn upsidedown.

[1] ADJUSTING CENTER SCREW, 8 mm (2)


[2] COLLAR, 12 x 8 x 7 mm (2)

[3] ADJUSTER GRIP (2)

[4] FRONT ADJUSTER LEVER (2)

[5] FLANGE NUT, 8mm (2)


[6] FRONT WHEEL ASSEMBLY (2)

[7] WHEEL BEARING (4)

[8] FRONT WHEEL CAP (2)

[9] WHEEL FLANGE SCREW, 8 x 12 mm (2)


[10] WHEEL WASHER (2)

REASSEMBLY: Install the washer as shown.

[10]-1 WHEEL SIDE

[11] FRONT ADJUSTER ARM (2)

[12] WASHER, 42 x 8.5 mm (2)

[13] WASHER, 8 mm (2)

- 66 -HRD536C - HRD536CK1 - HRD536C2

[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8][9]

[10][11]

[12]

[13]

GR E AS E

[10] - 1

25

24

- FRONT WHEELS / REAR WHEELS

GREASE

11.2 Rear wheels



NOTE: The rear wheels can be serviced with the engine on the cutter housing.

Place the mower on wooden blocks and support the housing securely. Do not turn themachine upside down.

[1] SNAP RING, 22 mm (2)[2] PLAIN WASHER, 22 mm (2)[3] ADJUSTER GRIP (2)[4] REAR ADJUSTER LEVER (2)[5] REAR ADJUSTER ARM (2)

REASSEMBLY: Apply grease to the inside before installing.

[6] WHEEL COVER (2)[7] COLLAR (2)[8] WASHER, 5 mm (2)[9] PAN SCREW, 5 x 12 mm (2)

[10] RATCHET KEY (2)[11] SNAP RING (4)[12] RATCHET RETURN SPRING (2)[13] PINION GEAR COLLAR (2)[14] PINION GEAR (2)

REASSEMBLY: Install with punch mark facing: LEFT: inside. RIGHT: outside

[14]-1 PUNCH MARK[15] REAR WHEEL CAP (2)[16] WHEEL SCREW, 8 x 12 mm (2)


[17] REAR WHEEL ASSEMBLY (2)[18] WHEEL BEARING (4)[19] WHEEL WASHER (2)

REASSEMBLY: Install the washer as shown.

[19]-1 WHEEL SIDE[20] THRUST WASHER (2)[21] BUSHING (4)[22] SEAL (4)[23] WASHER PLAIN, 22 mm (2)[24] BOLT FLANGE, 6 x 12 mm (4)[25] AXLE HOLDER[26] AXLE SHAFT GROOVE

REASSEMBLY: Apply transparent tape over axle grooves to protect seal when insertingthe rear adjuster arm.

12. REAR DRIVE SYSTEM

- 67 -


[1]

[2]

[3]

[4]

[5]

[6]

[7] [8]

[9]

[10]

[11]

[12]

[13]

[14]

[15]

[16][17]

[18]

[19]

[20]

[21]

[22]

[23]

[24]

[25]

[26]

[19] - 1

[14] - 1

24

- FRONT WHEELS / REAR WHEELS

12.1 Transmission HXE / SXE

a. Removal


NOTE: The drive system can be serviced with the engine on the cutter housing.

1. Drain the fuel from the fuel tank and carburettor, and drain the engine oil.

2. Disconnect the drive clutch cable and shift cable (S type only) from the control lever.

3. Remove the screw [1], washer [2], collar [3] and drive cover [4].

4. Turn the driven pulley (transmission side) so that the hole in the driven pulley alignswith the hole in the transmission bracket [7]. Insert a screwdriver or rod into the holesand pivot the transmission to remove the drive belt from the drive pulley [6].

5. Tilt the mower so that the carburettor is facing upward.

NOTE: Rest the handle on a support to prevent damage to the recoil starter and fuel tank.

6. Pull off the rear wheel cap [9]. Remove the wheel screw, then remove the rearwheel [8], wheel washer and thrust washer on both sides.

7. Remove the snap ring, pinion gear collar, pinion gear, ratchet key and ratchet springfrom the axle shaft.

8. Remove the 5 x 12 mm pan screw, washer and wheel cover [10].


[2] WASHER

[3] COLLAR

[4] DRIVE COLLAR

[5] WOODRUFF KEY

[6] DRIVE PULLEY

[7] TRANSMISSION BRACKET

[8] REAR WHEEL

[9] WHEEL CAP

[10] WHEEL COVER

- 68 -HRD536C - HRD536CK1 - HRD536C2 - REAR DRIVE SYSTEM

[1]

[2]

[3]

[4]

[7]

[5]

[6]

[10]

[8]

[9]

9. Apply transparent tape over axle grooves [14] to protect seal during disassembly.

10. Remove the snap ring [11] and washer [10] from the inside of the rear adjuster arm [2].

11. Remove the screws [8] and rear axle holder [3] and remove the transmissionassembly [4].

12. Disconnect the drive clutch cable [6] from the cable stay on the transmission bracket.

13. Unhook the tension spring [1] from the transmission bracket and remove thetransmission.

[1] TENSION SPRING

[2] REAR ADJUSTER ARM (RIGHT)

[3] AXLE HOLDER (2)

[4] HYDROSTATIC TRANSMISSION ASSEMBLY

[5] SHIFT CABLE


[7] LOCK WASHER

Never re-use

[8] SCREW, M6 x 12 mm (4)

[9] REAR ADJUSTER ARM (LEFT)

[10] WASHER (2)

[11] SNAP RING, 22 mm (2)

[12] SHIFT CABLE

[13] SPRING TENSIONER PLATE

[14] AXLE SHAFT GROOVE

- 69 -

HRD536C - HRD536CK1 - HRD536C2[1]

[2]

[3]

[4]

[5][6]

[7]

[8]

[9][10]

[11]

[12]

[13]

[14]

- REAR DRIVE SYSTEM

12.2 Transmission TXE

a. Removal


[1] TRANSMISSION

[2] PULLEY

[3] PIN, SPLIT, 5 x 35 mm

[4] ARM, CLUTCH

[5] NUT SELF LOCK, M5

[6] WASHER, 5 mm

[7] SPRING RETURN (CLUTCH)

1. Remove the spark plug cap.

2. Drain the gasoline from the carburettor tank, as well as the engine oil (ch. 3.9 and3.11).

3. Remove the belt guard.

4. Remove the blade (ch. 4).

5. Remove the Rotostop assembly (ch. 4).

6. Disconnect the drive belt’s tension spring [8] using a pair of tongue & groove pliers [9].

7. Remove the drive belt by removing the driving pulley from the engine’s output shaft.

8. Remove the rear wheels and the cutting height adjustment mechanism (ch.11.2).

9. Remove the clutch cable [10]:

Release the cable from the adjustment nuts (side handle)Unclip the plastic end fitting using needle-nose pliers [11] (transmission)

NOTE: The split washer, into which the cable is clipped, is held in place by a single screw.

TIGHTENING TORQUE : 2 N.m

Unhook the cable from the clutch arm [4].


[3]

[4]

[2]

[1]

[5][6]

[7]

[8]

[9]

1

2

[10]

[11]

[4]

10. Remove the gear shift cable [1]:

- Release the cable at the adjustment nuts (side handle)- Unhook the cable from the handle shift lever (cotter pin [2])- Cut the cable clamps,- Remove the transmission with the cable,- Remove the driving pulley (Ø 5 mmpin driver),- Unscrew the cable retaining screw [3] from the transmission.


- Unhook the cable from the selector arm [4].

b. Reassembly

Reassembly the transmission by performing the above operations in reverse order.

NOTE:

• Pulley

Center the pin [5] on the input shaft (use the pin driver to measure).

• V-Belt

1. Replace the belt tension spring.

2. Make a loop with a piece of string [6] and hook it onto the transmission’s adjuster arm.

3. On the blade side, pry using a metal rod and pressing against the blade housing forleverage, to rotate the transmission forward and engage the belt.

4. Next, perform all necessary lever adjustments (ch. 2).

[5] PIN, SPLIT, 5 x 35 mm

- 71 -

HRD536C - HRD536CK1 - HRD536C2 - REAR DRIVE SYSTEM

[1]

[3]

[4]

5[2]

28,5 mm

[5][6]

c. Disassembly / Reassembly

• SXE type

[1] SELF-LOCKING NUT, 10 mm

TIGHTENING TORQUE: 30 N.m maximum

[2] WASHER, 10.2 x 20 x 3.5 mm

[3] WOODRUFF KEY

[4] DRIVEN PULLEY

REASSEMBLY: Install the pulley with the longer boss toward transmission side.

[4]-1 TRANSMISSION SIDE

[4]-2 SELF-LOCKING NUT SIDE

[5] CLUTCH RETURN SPRING

[6] TRANSMISSION ASSEMBLY

REASSEMBLY: Replace as an assembly if necessary.

[7] LOCK WASHER (CLUTCH CABLE)

Never re-use

[8] BUMPER RUBBER


[10] FLANGE, M8 x 16 mm (2)


• HXE type

[11] SELF-LOCKING NUT, 10 mm

TIGHTENING TORQUE: 30 N.m maximum

[12] WOODRUFF KEY

[13] DRIVEN PULLEY

REASSEMBLY: Install the pulley with the smaller boss toward transmission side.

[13]-1 TRANSMISSION SIDE

[13]-2 SELF-LOCKING NUT SIDE

[14] FLANGE SCREW, M6 x 16 mm (3)


[15] TRANSMISSION ASSEMBLY

REASSEMBLY: Replace as an assembly if necessary.

[16] HST RETURN SPRING

[17] BUMPER RUBBER


d. Transmission installation

1.

- 72 -HRD536C - HRD536CK1 - HRD536C2

[1] [2]

[3]

[4]

[4] - 2

[4] - 1

[5]

[6]

[7]

[8]

[9]

[10]24

[11] [12]

[13]

[14]

[15]

[16]

[17]

[18][13] - 1

[13] - 2

12

30

- REAR DRIVE SYSTEM

Connect the drive clutch cable [3] and shift cable [2] to the transmission. Do not securethe drive clutch cable to the cable stay.

2. Install the spring tensioner plate [10] in the cutter housing and connect the spring [11]to the plate.

3. Cover the groove at the ends of the axle shaft with thin transparent tape to preventseal damage during assembly.

4. Apply grease to the inside of the adjuster bushings and install the rear adjuster arms[7]-[12].

5. Install the washers [9] and snap rings [8] while pushing the adjuster toward inside.Place the axle shaft holders [6] and tighten the screws [5] securely.

6. Connect the tension spring to the transmission. Turn the transmission pulley(transmission side) so that the hole in the pulley aligns with the hole in thetransmission bracket. Insert a screwdriver or rod into the holes, pivot thetransmission, and install the drive belt over the pulley.

7. Connect the drive clutch [3] and shift cables [2] to the control lever.

8. Install the removed parts in the reverse order of removal.

Adjust following:- drive clutch cable (ch. 3.5),- shift cable (ch. 3.7).

[1] HST ASSEMBLY

[2] SHIFT CABLE


[4] SPECIAL WASHER

[5] SCREW, M6 x 12 mm (4)

[6] AXLE HOLDER (2)

[7] LEFT REAR ADJUSTER ARM

[8] SNAP RING, 22 mm (2)

[9] WASHER (2)

[10] SPRING TENSIONER PLATE

[11] TENSION SPRING

[12] RIGHT REAR ADJUSTER ARM

- 73 -


[1]

[2][3]

[4]

[5]

[6][7][8]

[9]

[10]

[11]

[2]

[12]

GR E AS E

e. Drive belt replacement

NOTE: It is advisable to disassemble the blade for safety reasons.

1. Drain the fuel from the fuel tank and carburettor, and drain the engine oil.

2. Disconnect the Rotostop cable [1] from the Rotostop lever.

3. Remove the 6 x 32 mm flange screw, washer, collar and drive cover.

4. Press on the pulley to pivot the transmission forwards, in order to release the belt fromthe pulley.

5. Disconnect the Rotostop cable (Rotostop side).

6. Disassemble the return spring [3].

7. Unscrew and remove the guide screw [2].

8. The belt can be removed.

9. Reassemble parts in reverse order of disassembly.

Following adjustment:- Rotostop cable (ch. 3.6).

f. Oil seal replacement / Oil change

CAUTION:

• Be careful to prevent dust or other foreign bodies from entering the hydrostatictransmission.

• Clean the pump shaft and the final shaft carefully before removing the oil seals.

• Be careful not to damage the oil seal support areas to avoid risks or leaking.

NOTE: Lubricate the oil seals well with hydrostatic transmission oil before installing themand check that the seal does not fold back after installation.After replacing the oil seals, the air contained in the hydrostatic transmission must be bled.

1. Cover the grooves of the final shaft with adhesive tape in order to protect the sealsduring [4] assembly.

[1] ROTOSTOP CABLE

[2] STOP SCREW


[3] RETURN SPRING

REASSEMBLY: ch. 4.1

[4] OIL SEAL, 13 x 22 x 3 mm (3)


[2]

[1]

[3]

22

[4]

• Empty air

CAUTION:

• Be careful to prevent dust or other foreign bodies from entering the hydrostatictransmission.

1. Remove the cover [1] and its seal [2].

2. Fill the hydrostatic transmission with oil to the lower level mark [5].3. Evacuate the air from the case by rotating [6] the hydrostatic transmission.4. Complete filling the transmission with oil until it reaches the upper level mark [4].5. Manually turn the final shaft [7] 5 to 10 times clockwise.6. Refill the transmission with oil until it reaches the lower level [5].7. Evacuate the air from the case by rotating the hydrostatic transmission.8. Complete filling the transmission with oil until it reaches the upper level mark [4], and

install the seal and the cover. Do not tighten the screws.9. Fit a nut and a lock nut [10] on the oil pump shaft [8], then turn it 10 to 15 times using a

wrench [9].10. Turn the control arm [12] in the direction of the arrow and install a (60-70 mm)

screw [11].11. Rotate the oil pump shaft [8] clockwise until the final shaft has rotated 10 to 15 times.12. Withdraw the screw [11].13. Repeat operations 1. through 5., then operations 3. and 4.14. Install the seal [2] and fasten the cover [1] temporarily.15. Repeat operations 9. to 11.16. Remove the nut and lock nut [10] from the oil pump shaft [8].17. Remove the cover and its seal, fill the hydrostatic transmission with oil until it reaches

the lower level mark [5].18. Evacuate the air from the case by rotating the hydrostatic transmission.19. Complete filling the transmission with oil until it reaches the upper level mark [4].20. Install the packing and the cover.

[1] COVER

[2] SEAL

[3] SCREW, 5 x 12 mm


[4] UPPER LEVEL

[5] LOWER LEVEL

[6] AIR

[7] FINAL SHAFT

[8] OIL PUMP SHAFT

[9] WRENCH

[10] NUTS

[11] FLANGE SCREW, 6 mm

[12] CONTROL ARM

- 75 -


[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8]

[10]

[9]

[11]

[12]

13. HANDLE / CONTROL LEVERS

13.1 Upper handle


• SXE / TXE type

[1] WASHER

[2] BUSH (2)


ADJUSTMENT: ch. 3.5

[4] ROTOSTOP LEVER

[5] RATCHET PUSH ROD

[6] LOCK WASHER, 6 mm

[7] HINGE PIN

[8] LOCKING LEVER

[9] ROTOSTOP CABLE ARM

[10] ROTOSTOP CABLE

ADJUSTMENT: ch. 3.6

[11] ROTOSTOP CABLE JOINT PIN

[12] HINGE PIN

[13] CLUTCH SPRING

REASSEMBLY: Hook to the drive clutch lever from inside as shown to avoid interferingwith the Rotostop lever.


ADJUSTMENT: ch. 3.5

[15] THROTTLE CABLE

ADJUSTMENT: ch. 3.4

[16] SHIFT CABLE

ADJUSTMENT: ch. 3.7

[17] HANDLE

[18] RATCHET RETURN SPRING

[19] JOINT ROD

[20] COLLAR

[21] ROTOSTOP LEVER RETURN SPRING

REASSEMBLY: Hook the spring as shown.

• HXE type

- 76 -HRD536C - HRD536CK1 - HRD536C2

[1] [2] [3]

[4][5]

[6][7]

[8]

[9]

[10]

[11]

[12]

[13]

[14]

[15]

[15]

[16]

[14]

[10]

[16]

[17] [18]

[19]

[20]

[21]

GR E AS E

- HANDLE / CONTROL LEVERS

[1] WASHER

[2] BUSH (2)


ADJUSTMENT: ch. 3.5

[4] ROTOSTOP LEVER

[5] RATCHET PUSH ROD

[6] LOCKWASHER (2)

[7] HINGE PIN

[8] LOCKING LEVER

[9] ROTOSTOP CABLE ARM

[10] ROTOSTOP CABLE JOINT PIN

[11] ROTOSTOP CABLE

[12] RATCHET RETURN SPRING

ADJUSTMENT: ch. 3.6

[13] HINGE PIN

[14] THROTTLE CABLE

ADJUSTMENT: ch. 3.5

[15] SHIFT CABLE

ADJUSTMENT: ch. 3.7

[16] HANDLE

[17] CLUTCH SPRING

REASSEMBLY: Hook to the drive clutch lever from inside as shown to avoid interferingwith the Rotostop lever.

[18] JOINT ROD

[19] COLLAR

[20] ROTOSTOP LEVER RETURN SPRING

REASSEMBLY: Hook the spring as shown.

- 77 -

HRD536C - HRD536CK1 - HRD536C2[1]

[3][2]

[4]

[5]

[6]

[7]

[8]

[9]

[10]

[11]

[12]

[13]

[14]

[15]

[16]

[16]

[17]

[18]

[19]

[20]

[11]

[14]

GR E AS E

- HANDLE / CONTROL LEVERS

13.2 Handle / Cutter housing


[1] RIGHT HANDLE SUPPORT

[2] HANDLE

[3] WIRE BAND (2)

REASSEMBLY: ch. 13.4

[4] HANDLE HOLDER SCREW (2)

[5] HANDLE JOINT KNOB (2)

[6] LEFT HANDLE SUPPORT

[7] SELF-LOCKING NUT, 8 mm (2)

[8] HANDLE SUPPORT COLLAR

[9] SCREW, 8 x 55 mm (2)

[10] SCREW, 8 x 25 mm (2)

[11] HANDLE COLLAR (2)

- 78 -HRD536C - HRD536CK1 - HRD536C2 - HANDLE / CONTROL LEVERS

[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8]

[9]

[10]

[11]

13.3 Control lever


• SXE type

[1] CONTROL COVER[2] SHIFT LEVER[3] COLLAR[4] STOPPER PLATE[5] THROTTLE LEVER[6] SPRING SEAT[7] SPRING[8] THROTTLE CABLE[9] TAPPING SCREW, 5 x 12 mm (2)

[10] SCREW, 6 x 10 mm[11] SHIFT CABLE[12] PLAIN WASHER, 10 mm[13] SHIFT LEVER SPRING[14] PLAIN WASHER, 6 mm[15] FLANGE NUT, 6 mm

• HXE type

[16] SHIFT LEVER ARM[17] SHIFT LEVER SPRING[18] STOPPER PLATE A[19] CONTROL COVER[20] THROTTLE LEVER

Apply grease

[21] SPRING[22] HANDLE[23] SPRING SEAT[24] THROTTLE CABLE[25] CONTROL COVER SCREW, 5 x 12 mm[26] STOPPER PLATE B[27] SCREW, 6 x 10 mm[28] SPRING[29] SPRING SEAT[30] SHIFT LEVER JOINT PIN[31] SHIFT CABLE[32] PLAIN WASHER, 6 mm[33] LOCK PIN, 6 mm[34] CENTER LEVER SPRING[35] SHIFT LEVER

- 79 -

HRD536C - HRD536CK1 - HRD536C2 - HANDLE / CONTROL LEVERS

[1] [2][3] [4]

[5]

[6]

[7]

[8]

[9]

[10]

[11]

[12]

[13]

[14]

[15]

GR E AS E

[16] [17][18]

[19]

[20]

[21][22]

[24]

[25][26]

[27][28]

[29]

[30]

[31]

[32]

[33]

[34][35]

[26]

[18]

[35]

[17]

[23]

GR E AS E

[20]

• TXE type

[1] THROTTLE LEVER

[2] SPRING, 15 mm

[3] SPRING SEAT

[4] THROTTLE CABLE

[5] COLLAR, 10 / 6.5 x 11 mm

[6] WASHER SPRING, 17.5 / 11.5 mm

[7] CASE

[8] SHIFT LEVER

[9] SUPPORT

[10] SHIFT CABLE

[11] TAPPING SCREW, 12 x 5 mm

[12] FLANGE NUT, 6 mm

[13] LOCK PIN

[14] LOCK PIN, 5.5 x 18 mm

[15] SCREW, 6 x 10 mm

- 80 -HRD536C - HRD536CK1 - HRD536C2 - HANDLE / CONTROL LEVERS

[7][8]

[11]

[1]

[2]

[3]

[4]

[5]

[6]

[15]

[9]

[13]

[14]

[12]

[10]

13.4 Wire / Harness routing

• SXE and HXE type

[1] RECOIL STARTER ROPE

Lenght: 2.30 m Diameter: 3 mm

[2] WIRE BAND (3)

Clamp all cables together

[3] CABLE CLAMP

Clamp throttle cable and rotostop cable to the cutter housing


[5] SHIFT CABLE

NOTE: Do not clamp on the cutter housing

[6] ROTOSTOP CABLE

[7] THROTTLE CABLE

[8] SPARK PLUG CABLE

[9] IGNITION COIL GROUND CABLE

[10] IGNITION COIL

• TXE type

Secure two cable clamps [11] to maintain the cable harness as shown.

Take special care when routing the shift cable. Bends in this cable should not have a radiusof less than 50 mm [13]. Tighter radius bends may cause the cable to kink and prevent itfrom sliding freely in its sheath.

Cables should be placed so that they form a loop [12] at the handle attachment point.

[14] ROTOSTOP CABLE

[15] CLUTCH CABLE

- 81 -

HRD536C - HRD536CK1 - HRD536C2 - HANDLE / CONTROL LEVERS

250

120

[1]

[2]

[2]

[3]

[4][5][6][7]

[8]

[9]

[10]

[11]

[7][14]

[15]

300

250

[12]

r > 50 mm

[13]

14. DISCHARGE GUARD / GRASS BAG

14.1 Discharge guard


[1] STOPPER WASHER (2)

Never re-use

[2] DISCHARGE GUARD SHAFT

[3] GUARD RETURN SPRING

[4] DISCHARGE GUARD

Change if worn or cracked

14.2 Grass bag

a. Assembly

NOTE: Before assembly, check the grass bag for fraying, tears or clogged mesh.

1. Insert the grass bag frame [6] into the grass bag [5] as shown.

2. Hook the plastic edges [7] of the grass bag onto the frame.

[5] GRASS BAG

[6] FRAME

[7] PLASTIC EDGES

[8] FLANGE SCREW, 6 x 12 mm (3) (HRD536CK1 / HRD536C2)

[9] SCROLL GUIDE (HRD536CK1 / HRD536C2)

NOTE:

HRD536C: Scroll guide is welded to the frame [6]HRD536CK1 / HRD536C2: Scroll guide [9] is mounted on the cutter housing.

- 82 -HRD536C - HRD536CK1 - HRD536C2 - DISCHARGE GUARD / GRASS BAG

[1][2]

[3]

[4]

[6]

[7]

[5]

HRD536C

[6]

[7]

[5][9]

[8]

HRD536CK1

[7]

[6]HRD536C

[7]

[6]HRD536CK1

PREFACE

This manual covers the construction, function and servicing procedures of HondaHRD536C, HRD536CK1 and HRD536C2 rotary mower.

Careful observance of these instructions will result in better, safer service work.

All information, illustrations, directions and specifications included in this publication arebased on the latest product information available at the time of approval for printing.Honda Europe Power Equipment S.A. reserves the right to make changes without noticeand without incurring any obligation.No part of this publication may be reproduced without written permission.

Honda Europe Power Equipment S.A.

Communication department

- 1 -


HRD536C - HRD536CK1 -HRD536C2

42 VF0 F51 L 106 1102 - 1

SHOP MANUAL

1

3

HRD536C_HRD536CKI_HRD536C2

Documents

Transcript of HRD536C_HRD536CKI_HRD536C2