HRD536C Hrd536cki HRD536C2

HRD536C - HRD536CK1 - HRD536C2
INDEX
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.3 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1 General safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.2 Service rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.3 Serial number location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.4 Maintenance standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.5 Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.6 Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.8 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.1 Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.2 Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3.4 Throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 3.5 Drive clutch cable (S type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.6 Rotostop cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.7 Shift cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3.8 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.9 carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.10 Governor adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.11 Fuel tank / Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3.12 Fuel line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3.13 Spark arrester (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.14 Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 BLADE / ROTOSTOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.1 How the rotostop works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.2 Blade brake clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4.3 Inspecting the Rotostop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 4.4 Blade sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ENGINE REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 34 5.1 Engine removal : ~ 8132520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 5.2 Engine installation : ~ 8132520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 5.3 Engine installation : 8132521 ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 7.1 Recoil starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 8. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8.1 Air cleaner / carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8.2 Control base / Governor arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 8.3 Fan cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 FLYWHEEL / IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 9.1 Flywheel / Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 CAM PULLEY / CRANKSHAFT / PISTON / CYLINDER BARREL . . . . 49 10.1 Cam pulley / Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 10.2 Oil pan / Crankshaft / Cylinder barrel. . . . . . . . . . . . . . . . . . . . . . . . 52 10.3 Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 10.4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 10.5 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 10.6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 10.7 Valve seat reconditionning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 FRONT WHEEL / REAR WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 11.1 Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 11.2 Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 REAR DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 12.1 Transmission HXE / SXE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 12.2 Transmission TXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 HANDLE / CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 13.1 Upper handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 13.2 Handle / Cutter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 13.3 Control lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 13.4 Wire / Harness routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 DISCHARGE GUARD / GRASS BAG . . . . . . . . . . . . . . . . . . . . . . . . . . 82 14.1 Discharge guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 14.2 Grass bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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2.
9. 10.
3.
11.
12.
13.
14.
4.
5.
6. 7.
HRD536C - HRD536CK1 - HRD536C2 - SPECIFICATIONS

1. SPECIFICATIONS
1.1 General specifications
MODELS TYPES DIMENSIONS AND WEIGHT Grass bag capacity Dry weight Curb weight FRAME Cutting width Cutting heights adjustment Wheel diameter Blade Step Height Front Rear Width Thickness Air lift Type Number of gears Drive system Clutch Shift control Lubricant Oil capacity Blade stopping system Drive wheel Driving speed (at 2900 rpm) Differential Fuel consumption Sound pressure level at operators ears (according to Directive EEC/81/1051) Sound power level (in accordance with Directives 84/538/EEC and 87/252/EEC) Guaranteed sound pawer level (According to 2000/14/EC directive) Vibration test (according to EN1033, ENV25349/1993, ENV28041/1993, ISO5347/1987 & ISO5348/1987) m/s 1st: 0.7 - 2nd: 1.2 0 - 1.4 HRD536C SXE Units l kg kg mm mm mm mm mm mm Mechanical pinion 2 Dog clutch Grease: Shell Co Darina D 85 g Hydrostatic Continuous V-belt Relief valve Honda HST oil 140 cc Rotostop Rear 1st: 0.77 2nd: 1.17 3nd: 1.44 One-way clutch 0.58 85 100 5.5 3.3 100 4.2 0 - 1.4 1st: 0.77 2nd: 1.17 3nd: 1.44 Cone clutch Manual remote control 15W30 Oil - API: SD/SF 190 - 200 cc Relief valve Honda HST oil 140 cc Cone clutch 15W30 Oil API: SD/SF 190 - 200 cc HXE HXE 80 41.9 47.9 42.6 48.5 530 7 15 ~ 77 200 200 90 2.7 25 Bevel gear 3 Hydrostatic Continuous Bevel gear 3 41.9 47.9 42.6 48.5 41.9 47.9 HRD536CK1 TXE HXE HRD536C2 TXE
Transmission
l/h dB (A) dB (A) dB (A) m/s2
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General specifications
MODELS TYPES ENGINE Model Type Displacement Bore x stroke Maximum power Maximum torque Operating speed Compression ratio Cooling system Ignition system Ignition timing Spark plug carburettor Air cleaner Governor Lubrication Oil capacity Recommended oil Starting system Stopping system Recommended fuel Fuel tank capacity l l SAE 10W30 Recoil starter Grouding of primary circuit Gasoline, regular or premium, preferably lead-free 1.1 cm3 (cc) mm kW/rpm Nm / rpm tr.min-1 (rpm) Units GCV160 4-stroke, overhead camshaft, vertical one cylinder 160 64 x 50 4.1 / 3600 11 / 2500 2900 + 0 100
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HRD536C SXE HXE HXE
HRD536CK1 TXE HXE
HRD536C2 TXE
8.5 : 1 Forced air Transistorized magneto 20 BTDC BPR6ES (NGK) Horizontal, butterfly valve type Dry element (paper) Centrifugal mechanical governor Forced splash type 0.55 SAE 10W40 - 15W30 - 20W50 API : SF/SG

1.2 Dimensional drawings
HRD536C MODELS A mm B mm C mm D mm E mm SXE HXE HRD536CK1 HXE 1575 574 1018 476 512 625 TXE HRD536C2 HXE TXE
F mm
The dimensions are measured using the following parameters:

Cutting height Adjustment of handle height 30 mm Support adjustable in intermediate position
F A
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1.3 Wiring diagrams
Bk [1] Black Engine stop switch Spark plug Ignition coil Engine block
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Bl
[2] [3] [4]
[1]
[2] [4]
[3]
HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

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 is well ventilated. Never run the engine in a closed area. The exhaust contains carbon monoxide gas. Petrol is extremely flammable and is explosive under certain conditions. Do not smoke 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. 1. Use genuine Honda or Honda recommended parts and lubricants. Parts that do not meet Hondas 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 and tighten to the specified torque diagonally, unless a particular sequence is specified. 5. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 6. After reassembly, check all parts for proper installation and operation.
2.2 Service rules
[2]
7. Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening 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 not interchangeable with nonmetric fasteners. The use of incorrect tools and fasteners will damage the mower. 9. Follow the instructions represented by these symbols when they are used:
GREASE
: Apply grease
S.TOOL
: Special tool
OIL
: Apply oil
2.3 Serial number location

The engine serial number is stamped on the crankcase. Refer to this number when ordering parts or making technical inquiries. [1] ENGINE SERIAL NUMBER [2] FRAME SERIAL NUMBER
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2.4 Maintenance standards
PART
Idle speed Engine Maximum speed Cylinder compression (at 600 rpm) Main jet Pilot screw opening Float level Gap Valve clearance (cold) Valves Stem O.D. Guide I.D. Spring free length Valve seat width Skirt O.D. Piston-to-cylinder clearance Piston pin bore I.D. Piston pin O.D. Thickness Piston ring Side clearance End gap Cylinder Connecting rod Sleeve I.D. Small end I.D. Big end I.D. Big end oil clearance Big end axial clearance Main journal O.D. Crankshaft Cylinder barrel Oil pan Cam pulley Rocker arm Ignition coil Blade brake clutch Axial clearance Crank pin O.D. Main journal I.D. Main journal I.D. Cam height Cam pulley I.D. (bearing) Cam pulley shaft O.D. Rocker arm I.D. Rocker arm shaft O.D. Rocker arm shaft bearing I.D. Primary coil resistance Secondary coil resistance Air gap Brake lining thickness Clutch lining thickness Clutch return spring free lenght PTO side Flywheel side IN EX IN EX IN/EX IN/EX IN/EX
-8-
ITEM
HRD536C - HRD536CK1 HRD536C2
STANDARD
1700 150 rpm 2000 150 rpm 2800 ~ 2900 rpm 0.49 Mpa - 5.0 kg/cm2 #65 1 turn out 9.2 mm 0.7 - 0.8 mm 0.15 0.04 mm 0.20 0.04 mm 5.480 mm 5.440 mm 5.500 mm 34 mm 0.7 mm 63.969 mm 0.031 - 0.070 mm 13.002 mm 13 mm 1.5 mm 2.5 mm 0.015 - 0.045 mm 0.20 - 0.35 mm 0.30 - 0.45 mm 0.15 - 0.35 mm 64 mm 13.005 mm 26.02 mm 0.040 - 0.063 mm 0.1 - 0.4 mm 27.993 mm 25.393 mm 0.15 - 0.75 mm 25.98 mm 25.420 mm 28.020 mm 37.394 mm 10.027 mm 9.987 mm 6 mm 5.990 mm 6 mm 1.0 - 1.2 10.6 - 12.8 k 0.2 - 0.6 mm -
SERVICE LIMIT
5.318 mm 5.275 mm 5.572 mm 32.5 mm 1.8 mm 63.829 mm 0.12 mm 13.048 mm 12.954 mm 1.37 mm 2.37 mm 0.15 mm 1 mm 1 mm 1 mm 64.165 mm 13.07 mm 26.066 mm 0.12 mm 0.8 mm 27.933 mm 25.333 mm 1 mm 25.92 mm 25.466 mm 28.066 mm 37.369 mm 10.075 mm 9.920 mm 6.043 mm 5.953 mm 6.043 mm 2.0 mm 2.0 mm 65 mm
carburettor Spark plug
Cylinder head Piston
Top/Second Oil Top/Second/Oil Top Second Oil

2.5 Torque values
Specific torque values

TIGHTENING TORQUE N.m 12 12 12 20 10 75 8.5 8.5 10 3 12 8 12 12 55 55 24 kgf.m 1.2 1.2 1.2 2 1 7.5 0.9 0.9 1 0.3 1.2 0.8 1.2 1.2 5.6 5.6 2.4
Standard torque values

TIGHTENING TORQUE N.m 4 5 9 9 10 12 24 27 35 40 55 60 kgf.m 0.4 0.5 0.9 0.9 1 1.2 2.4 2.8 3.6 4.1 5.5 6.1
ITEM Cylinder head cover screw Oil pan screw Connecting rod screw Spark plug Governor arm nut Ecrou de volant Air cleaner case screw Recoil starter nut Muffler screw Fuel valve bracket screw Fan cover stud bolt Valve adjusting lock nut Breather cover bolt Governor holder screw Blade screw Blade holder screw Front wheel adjuster center screw
THREAD DIA. X PITCH M6 x 1.0 M6 x 1.0 (CT) M7 x 1.0 M14 x 1.25 M6 x 1.0 M14 x 1.5 M6 x 1.0 (CT) M6 x 1.0 M6 x 1.0 (CT) M5 x 0.8 M6 x 1.0 M5 x 0.5 M6 x 1.0 M6 x 1.0 M10 x 1.25 M10 x 1.25 M8 x 1.25
ITEM 5 mm screw 5 mm screw/nut 6 mm screw 6 mm screw (small head type) 6 mm screw/nut 6 mm flange screw/nut 8 mm screw/nut 8 mm flange screw/nut 10 mm screw/nut 10 mm flange screw/nut 12 mm screw/nut 12 mm flange screw/nut
NOTE:Use standard torque values for fasteners that are not listed in this table. (CT): Tapping screw
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2.6 Special tools
TOOL NAME [1] [2] [3] Float level gauge Valve adjustment wrench B Valve seat cutter, 45 - 27.2 Cutter holder Digital multimeter Cleaning brush TOOL NUMBER 07401-0010000 07708-0030400 07780-0010200 07781-VA2-0100 or 07981-VA2-0101 KS-AHM-33-003 or commercially available 07998-VA2-0100 APPLICATION Float level inspection Valve clearance adjustment
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Valve seat reconditioning (IN/EX) Valve seat reconditioning Electrical parts testing Combustion chamber cleaning
[1]
[2]
[3]
[4] [5] [6]
[4]
[5]
[6]

2.7 Troubleshooting
b. Hard starting
1 Check fuel level in the tank. Sufficient fuel 2 Check that fuel reaches the carburettor by loosening the drain screw. Fuel arrives to carburettor 3 Remove the spark plug and check for wet or fouled electrodes. Dry 4 Check the carburettor pilot jet and nozzle for blockage. Normal 5 Check the choke and/or throttle cable adjustment. Normal 6 Perform spark plug (p.13). Poor performance at high speed Good spark Abnormale compression No spark of weak spark Follow ignition system troubleshooting (ch. 2.7c). Check for carbon deposits in the combustion 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. Abnormal Adjust throttle cable. Abnormal Disassemble and clean the carburettor. Wet Clean electrodes and restart, taking care that the choke is not closed too much. If flooding is severe, check the carburettor float level. No fuel arriving to the carburettor Check the fuel line and fuel filter for clogging. No fuel in tank Fill with fuel and start again.
Engine
a. General symptom and possible causes

CARBURETTOR FLOAT CHAMBER contains stale gasoline Drain old fuel. Fill tank with fresh gasoline ch. 8.1 FUEL FILTER clogged Check : ch. 3.11 and 8.3 CARBURETTOR malfunction Readjust: ch. 3.9 Disassemble and inspect: ch. 8.1 Hard starting IGNITION SYSTEM malfunction Troubleshooting: ch. 2.7c IGNITION COIL AIR GAP out of adjustment 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 or damaged Disassemble and inspect: ch. 10.4 Correct: ch. 10.7 Engine lacks power CYLINDER, PISTON or PISTON RING worn 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 Engine will not rev sufficiently
Poor performance at low speed
7 Check cylinder compression. Normal compression
8 Install the spark plug and restart the engine.
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c. Ignition system
1 Perform spark plug test. Plug gap = 0.7-0.8 mm 2 Check again with a new spark plug. 3 Check again with a new spark plug cap. No spark 4 Disconnect the black wire from the engine stop switch and recheck. Spark Faulty engine stop switch or combination switch. Replace the engine stop switch or combination switch. Faulty ignition coil. Replace the ignition coil. Blade does not stop turning when ROTOSTOP lever released. No spark Faulty spark plug. Install a new spark plug. Faulty spark plug cap. Install a new spark plug cap. Faulty spark plug cap.
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c. Blade
Blade does not rotate when ROTOSTOP lever is grasped. Blade stops turning when beginning to mow; engine still running. ROTOSTOP CABLE out of adjustment. Adjust: ch. 3.6 ROTOSTOP CABLE too loose. Adjust: ch. 3.6 CLUTCH LINING worn. Check: ch. 4.1 BLADE BRAKE CLUTCH ASSEMBLY faulty. Replace: ch. 4.1 ROTOSTOP CABLE too tight. Adjust: ch. 3.6 BRAKE LINING worn. Check: ch. 4.1
No spark
Spark
No spark
Frame
d. Transmission (S type)
Gears are not changed. DRIVE CLUTCH CABLE out of adjustment. Adjust: ch. 3.5 DRIVE BELT worn or damage. Replace: ch. 12.1 TENSION SPRING comes off or damage. Replace: ch. 12.1 TRANSMISSION malfunction. Replace : ch. 12.1 CLUTCH RETURN SPRING damage. Replace: ch. 12.1 SHIFT CABLE out of adjustment. Adjust: ch. 3.7 TRANSMISSION malfunction. Replace: ch. 12.1
a. Drive clutch (except H type)

Mower does not advance when the drive clutch lever is grasped.
e. HST (hydrostatic) transmission (H type)

Driving speed too slow. Mower does not advance. SHIFT CABLE out of adjustment. Adjust: ch. 3.7 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 HST TRANSMISSION faulty. Replace: ch. 12.1 CONTROL ARM is restricted with dust between the case and control arm. Clean HST RETURN SPRING is broken. Replace: ch. 12.1
Mower does not stop when the drive clutch lever is released.
b. Throttle control
Engine speed is too low or too high. Engine speed is unstable. THROTTLE CABLE out of adjustment. Adjust: ch. 3.4 GOVERNOR out of adjustment. Adjust: ch. 3.10
Mower does not stop and can not be pulled.

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.
[1]
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 with fuel. 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 the spark plug to the cylinder head cover bolt. 3. Pull the recoil starter and check to see if sparks jump across the electrodes.
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2.8 Maintenance schedule
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Maintenance to be performed at every indicated month or operating hour interval, whichever comes first Engine oil
Regular service period (2) Check level Change Check
Each use
First month or 20 h
Every 3 months or 50 h
Every 6 months or 100 h
Every year or 300 h
See ch. 3.1 3.1 3.3
Air cleaner
Clean Replace (filter)
(1) (1)
3.3 8.1 14.2 2.5 3.2 6 3.6 (2) 4.2 3.7 3.4 (2) 3.8 12.1d (2) (2) 12.1d 3.11 3.12
Grass bag Blade screw tightness and blade condition Spark plug Spark arrester Rotostop cable Rotostop Shift cable Throttle cable Valve clearance Drive belt
Check - Clean Check (replace if necessary) Check - Clean - Adjust Clean Check - Adjust Check Check - Adjust Check - Adjust Inspect - Adjust Check Replace
Fuel filter and fuel tank Fuel line
Clean Check Every 2 years (replace if necessary)
(1) Service more frequently when used in dusty areas. (2) For professional commercial use, log hours of operation to determine proper maintenance intervals.
HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

3. MAINTENANCE
3.1 Oil
CAUTION: Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil; keep out of reach of children. NOTE: Dispose of used engine oil in a manner that is compatible with the environment. We suggest that it be taken ina sealed container to your local waste disposal site, or service station for disposal. Do not throw it in the trash or pour it on the ground, down sewers or drains.
a. Engine oil level check 1. Make sure that the mower is level. 2. Remove the engine oil dipstick and wipe it clean.
10W 20W
3. Fully insert the dipstick, then remove it to check the oil level.
20W 30W 40W
[4]
4. If the oil level is near or below the lower level mark on the dipstick, fill to upper level mark with the recommended oil.
Recommended engine oil Use Honda 4-stroke oil Service classification: SF, SG Viscosity: SAE 10W30
20W40 20W50 15W40 15W50
[5]
10W40 10W30 -30 -20 -10 0 10 20 30 40C
[6]
-20 0 20 40 60 80 100F
[1] [2] [3] [4] [5] [6]
OIL FILLER CAP / DIPSTICK UPPER LEVEL LOWER LEVEL SINGLE GRADE MULTIGRADE AMBIENT TEMPERATURE
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b. Engine oil change
- 16 -
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 the carburettor. 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 and drain 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 l
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 after the mower has run. Wait until the hydrostatic transmission has cooled down before checking the hydrostatic transmission oil level. CAUTION:

Be careful not to allow dust or other foreign materials to enter the hydrostatic transmission. Clean the surrounding area before checking the transmission oil level. Use only Honda hydrostatic transmission oil, when topping up or changing the hydrostatic transmission oil.
Recommended oil HST Honda oil

3.2 Spark plug
If the engine has been running, the engine will be very hot. Allow it to cool before proceeding. 1. Remove the spark plug cap. 2. Clean any dirt from around spark plug. 3. Remove the spark plug using the spark plug wrench.
[1]
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 by bending the side electrode.
Spark plug gap Recommended spark plug 0.7 - 0.8 mm BPR6ES (NGK)
0.7 - 0.8 mm
7. Make sure the sealing washer is in good condition. Thread the spark plug in by hand to prevent cross-threading. 8. Once the spark plug is seated, tighten with a spark plug wrench to compress the washer. TIGHTENING TORQUE: 20 N.m NOTE: When installing a new spark plug, tighten 1/2 turn after the spark plug seat to compress the washer. When reinstalling used spark plug, tighten 1/8 - 1/4 turn after the spark plug seats to compress the washer. CAUTION:

The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and may damage the engine. Never use a spark plug with an improper heat range. [1] WIRE BRUSH
- 17 -

3.3 Air cleaner
- 18 -
Never clean the air cleaner elements using gas or flammable solvents; this could cause a fire or an explosion. CAUTION:
Never run the engine without the air cleaner. Rapid engine wear will result from contaminants, 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.
[1] [2]
[5] [4]
[3]
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. Damaged elements will allow dirt to enter the system. Always clean the air cleaner case and air passages before installing clean elements. [1] [2] [3] [4] [5] LATCH TABS (2) COVER AIR CLEANER ELEMENT AIR DUCT AIR CLEANER CASE

3.4 Throttle cable
[1] [3]
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 mm clearance [3]) and the choke should be fully open. 5. If adjustment is necessary, loosen the throttle cable lock nuts [8] and adjust the cable [7] as required. 6. Move the throttle lever to CHOKE position and verify that the choke arm [9] is fully raised (choke fully closed) by pushing it with your finger. 7. After throttle cable/linkage adjustment, make sure that the maximum engine speed is within the specified range. If any adjustment is necessary, adjust the speed using the lock nuts [8] at the handle.
Maximum engine speed 2800 to 2900 rpm
[2]
[6] [4] [5]
[1] CHOKE ARM [2] THROTTLE ARM [3] CLEARANCE

[7]
Lever clearance
0 - 1 mm
[8]
[4] [5] [6] [7] [8] [9]
CONTROL ARM SPRING GOVERNOR THROTTLE CABLE LOCK NUTS CHOKE ARM
[9]
- 19 -

3.5 Drive clutch cable (S type)
[1]
[3]
- 20 -
NOTE: Before making any cable tension adjustements, always check that the cables are corrected routed. a. S type 1. Stop the engine and disconnect the spark plug cap. 2. Measure clearance [1] at the tip of the lever [2].
Lever clearance
[2]
[4]
5 - 15 mm
3. If adjustment is necessary, loosen the lock nuts [3] and adjust as required. 4. Retighten the lock nuts securely. [1] [2] [3] [4] CLEARANCE DRIVE CLUTCH LEVER LOCK NUTS DRIVE CLUTCH CABLE
[5]
b. TXE type
[3]
1. The drive clutch lever [1] should only have between 1 and 5 mm clearance. 2. Adjustments can be made with the nuts [2].
Lever clearance 1 - 5 mm
SXE
HXE
[6]
3.6 Rotostop cable

SXE - HXE type: ~ 8132520 1. Stop the engine and disconnect the spark plug cap.
[6]
2. Measure clearance [5] at the tip of the lever with the button pushed in.
Lever clearance 20 - 30 mm
[6]
[6]
3. If adjustment is necessary, loosen the lock nuts [6] and adjust as required. 4. Retighten the lock nuts securely.

[1]
[4]
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] and the 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]
[1-1]
1,5-3 mm
[1-2]
0.5 to 1 mm
0,5-1 m
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
[2]
NOTE: If the measurements specified above cannot be achieved by adjustment, please refer to chapter , Inspecting the Rotostop (See ch. 4.3).
[2]
A poorly adjusted cable can be dangerous. if the cable is too taut, the blade might not stop and the cable could snap.
TXE
HXE
If the cable is too slack, the clutch might slip and the brake and the clutch could clash.
[3]
[3]
- 21 -

3.7 Shift cable
SXE type
[1]
- 22 -
[A]
1. Stop the engine and remove the spark plug cap. 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 the shift 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 engages 1st and 2nd gear. Readjust if necessary. HXE type 1. Stop the engine and remove the spark plug cap.
[4] [3]
ST O P
[2]
[1]
[1]
ST
O P
2. Make sure that the cables routing properly and cable bands are set in the place correctly (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).
[2]
5. Tighten the lock nuts securely. 6. Verify the highest speed and ensure that it falls within the range specified below:
Maximum engine speed 2900 + 0 100
[6]
from 0 to 1.35 - 1.4 m/s
TXE type
[1] [2]
1. Stop the engine and remove the spark plug cap. 2. The shift lever [6] must be in ligne with the 1 mark on the case when it is pulled to its maximum rearward position. 3. All three of the shift levers positions must correspond to the three positions of the transmissions 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 lever engages. Readjust if necessary. [1] SHIFT CABLE [2] LOCK NUTS [3] SHIFT ARM [4] TRANSMISSION [5] CLEARANCE
2
1
[7]

3.8 Valve clearance
NOTE: Valve clearance inspection and adjustment must be performed with the engine cold. 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 head cover 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 the cam 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] on the rocker arm.
Standard valve clearance IN: 0.15 0.04 mm EX: 0.20 0.04 mm
[2]
[1] [2]
[3]
[2] [1] [2]
[5]
[8]
S .T OOL
[4]
[7]
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. TIGHTENING TORQUE: 8 N.m 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] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] CYLINDER HEAD COVER CORNER FLANGE BOLTS, 6 x 12 mm (4) CAM PULLEY ALIGNMENT MARKS CYLINDER HEAD COVER MATING SURFACE VALVE ADJUSTING LOCK NUT
S.TOOL
[9]
[6]
[10] [7]
[12]
[11]
VALVE ADJUSTING WRENCH B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07708-0030400 VALVE ADJUSTING SCREW FEELER GAUGE VALVE STEM TO INCREASE VALVE CLEARANCE, SCREW OUT. TO DECREASE VALVE CLEARANCE, SCREW IN.
- 23 -

3.9 Carburettor
[1]
- 24 -
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 the highest idle rpm. The correct setting will usually be obtained at approximately the following 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 the carburettor throttle valve fully [3]. 3. While holding the carburettor throttle valve [3] fully open, turn the governor arm shaft clockwise fully [6] and tighten the governor arm nut to the specified torque. TIGHTENING TORQUE: 10 N.m 4. Check to see whether the governor arm and the carburettor throttle valve operate smoothly. 5. Start the engine and allow it to warm it up to the normal operating temperature. Move the control lever to the maximum engine speed position and check the maximum engine speed.
Maximum speed (no load) 2900 + 0 100
[2]
tr.min -1 (rpm)
6. Adjustment is made at the governor spring installation position [7] of the control lever.
[4]
[3] [7] [6] [5]

10
[1] [2] [3] [4] [5] [6] [7]
PILOT SCREW THROTTLE STOP SCREW CARBURETTOR THROTTLE VALVE GOVERNOR ARM GOVERNOR ARM NUT GOVERNOR ARM SHAFT GOVERNOR SPRING INSTALLATION POSITION

3.11 Fuel tank / Fuel filter
[1]
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].
[3]
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

[2]
Check 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. 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] [2] [3] [4] FAN COVER FUEL TUBE FUEL VALVE FUEL FILTER
[2]
[4]
[3] [2]
- 25 -

3.13 Spark arrester
The engine and exhaust system renain hot for a while after stopping.
[1] [2] [4] [3]
- 26 -
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 before servicing the spark arrester. 1. Remove the 3 flange screws [4] from the muffler protector [5] and remove the muffler protector. 2. Remove the tapping screws [1] from the spark arrester [3] and remove the spark arrester from the muffler [2]. 3. Check for carbon deposits around the exhaust port and spark arrester. Clean if necessary. 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 of removal. [1] [2] [3] [4] [5] [6] SELF-TAPPING SCREW, 4 x 6 mm MUFFLER SPARK ARRESTER FLANGE NUT, 6 mm (3) MUFFLER PROTECTOR WIRE BRUSH
[5]
[6]

3.14 Blade
The 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 or placing your hands near the cutter housing. Wear heavy gloves to protect your hands when handling the blade.
[2] [1]
1. Move the throttle lever to STOP position and turn the fuel shut-off valve, drain the carburettor. 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 if necessary. TIGHTENING TORQUE: 55 N.m 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 blade pieces can cause serious injury. Replace worn or damaged blades. Use genuine Honda replacement blades. [1] [2] [3] [4] [5] NORMAL DULL CUTTING EDGE BENT EXCESSIVE WEAR CRACKED
[3]
[4]
[5]
- 27 -
HRD536C - HRD536CK1 - HRD536C2 - BLADE / ROTOSTOP

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.
- 28 -
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 edge of the lining. 5. The blade starts to rotate. b. Rotostop lever released (right-hand section of the drawing)
[1] [5]
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]. At the 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.
[2] [3] [4] [4] [6]
[1] [2] [3] [4] [5] [6] [7] [8]
CLUTCH CONTROL PLATE BRAKE ANCHOR PLATE LINING CLUTCH SPRING CLUTCH CONE BLADE HOLDER ROTOSTOP LEVER ENGAGED ROTOSTOP LEVER RELEASED
[7]
[8]

4.2 Blade brake clutch (BBC)
a.
[1]
Disassembly / Reassembly HRD536CK1: ~ 8132520
[2]
[3]
[4]
22
[6] [5]
[11] [11] - 1 [10] [9] [8]
[7]
55
[11] - 2
Do not turn the mower upside down. 1. Stop the engine and disconnect the spark plug 2. 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 by loosening 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 to facilitate Rotostop installation. [2] ROTOSTOP CABLE ADJUSTMENT: ch. 3.6 DISASSEMBLY: 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 TIGHTENING TORQUE: 22 N.m [5] BLADE HOLDER SCREW DISASSEMBLY/REASSEMBLY: Loosen or tighten the blade holder screw with holding the flywheel lever with a strap wrench. [6] BLADE INSPECTION: ch. 3.14 SHARPENING: ch. 4.4 [7] BLADE SCREW (2) DISASSEMBLY/REASSEMBLY: Use a wood en block to prevent the blade from turning. TIGHTENING TORQUE: 55 N.m [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 a screw driver as shown. INSPECTION: ch. 4.2b. [11]-1 RETURN SPRING [11]-2 COLLAR b. Inspection
- 29 -

BBC bottom plate Measure the lining thickness.
Service limit [1] Clutch lining thickness: 2.0 mm [2] Brake lining thickness: 2.0 mm
- 30 -
[1]
Replace the bottom plate if the lining thickness is below the service limit.
[2]
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
[A]

c. Models HRD536C1 / HRD536C2: 8132521 ~
Do not turn the lawnmower over.
[21] [1] [18]
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.
[2] [3]
10 10 10 10
[17] [16] [15] [14] [13] [20] [19] [12] [11] [10] [9] [8] [7]
55 14
NOTE: Before working on the Rotostop, remove the Rotostop return spring [17] using needle-nose pliers. [1] CABLE BRACKET [2] FIXING SCREW, 14 mm M6 (1)
TIGHTENING TORQUE: 10 N.m WRENCH SIZE: 10 mm WRENCH SIZE: 10 mm WRENCH SIZE: 14 mm
[3] FIXING SCREW, 20 mm M6 (1)

TIGHTENING TORQUE: 10 N.m [4] BLADE SCREW, 20 mm M10 (2) TIGHTENING TORQUE: 55 N.m [5] SPRING WASHER, 10 mm (2) [6] BLADE
[11]
"up"
[10] [9]
REASSEMBLY: Fit the washer with the OUT mark facing outwards. INSPECTION: ch. 3.14 SHARPENING: ch. 4.4
[7] BLADE HOLDER SCREW, 25 mm M10 TIGHTENING TORQUE: 55 N.m [8] LOWER BALL BEARING, 6204 [9] BLADE HOLDER [10] CLUTCH SPRING [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] CLUTCH LINING WRENCH SIZE: 14 mm
[6] [5]
REASSEMBLY: Fit the spring with the UP mark facing the engine. INSPECTION: See ch. 4.2b
CLUTCH CONE SPRING LOCK BRACKET CONTROL SYSTEM RETURN SPRING BRAKE ANCHOR PLATE STEEL BALLS (3) ROTOSTOP RETURN SPRING
55 14
[4]
"out"
REMOVAL/REASSEMBLY: Use needle-nose pliers.

CLUTCH CABLE CLUTCH CONTROL PLATE UPPER BALL BEARING KEY
- 31 -

4.3 Inspecting the Rotostop
0,5-1 m m
[2]
0,5 mm
- 32 -
If the steps described below show that the clutch or brake is worn, the clutch lining and spring 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
[1]
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 greater than:
[3]
Distance
0.5 mm
> 1 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 greater than:
Distance 1 mm
[4]

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 or placing your hands near the cutter housing.
[1]
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 blade screws and blade. 3. Inspect the blade for signs of wear or damage. A blade that is worn out, bent, cracked or 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 restore straight, 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 to develop during mower operation. Grind or file the upper surface of the blade only. The cutting edge must be even with the lower surface of the blade. Taper the blade profile, with the maximum amount of material removed at the blade tip and no 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 symmetry and 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 be 0.1 - 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 heavy end until good balance is achieved. NOTE: An unbalanced blade will cause abnormal vibration and may eventually damage the mower. 7. Install the blade. TIGHTENING TORQUE: 55 N.m [1] DULL CUTTING EDGE [2] CORRECT SHARPENING [3] TAPER [4] INCORRECT SHARPENING [5] STEP [6] SHARPEN AT ORIGINAL ANGLE
[2]
[3] [4]
[5]
[6]
- 33 -
HRD536C - HRD536CK1 - HRD536C2 - ENGINE REMOVAL / INSTALLATION

[4] [6] [5] [3]
- 34 -
5.
ENGINE REMOVAL / INSTALLATION
5.1 Engine removal: ~ 8132520

Gasoline is highly flammable and explosive. If ignited, gasoline can burn you severely. When draining gasoline: Drain gasoline into an appropriate container. Keep sparks and flames away and do not smoke. Wipe up spills immediately.
[10]
1. Drain the gasoline from the carburettor and fuel tank into an appropriate container.
[7]
[11]
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 the control arm 5. Remove the screw [3] and the washer [4] and remove the collar [6] and drive cover [5].
[9]
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 the hole in the transmission bracket [9]. Insert a screwdriver or rod into the holes and pivot the transmission to remove the drive 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 cutter housing.
[8]
[12] [13]
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 on the crankshaft. Connect the throttle cable [16] to the throttle arm, then secure the cable holder with screw [15]. Adjust the throttle cable after engine installation (ch. 3.4).
[11] [15] 0-1 mm [16]
[10]
[3] [4] [6] [14]
FLANGE SCREW, 6 x 70 mm WASHER, 6 mm COLLAR, 10 x 53 mm ENGINE MOUNTING SCREWS, 8 x 60 mm (3)
HRD536C - HRD536CK1 - HRD536C2 - ENGINE REMOVAL / INSTALLATION

5.3 Engine installation: 8132521 ~
When you refit the engine, make sure you dont lose or forget the studs [7]. [1] [2] [3] [4] LEFT-HAND GUARD RETURN SPRING CUTTER HOUSING COVER ENGINE FIXING SCREW, 8 x 60mm (4)
TIGHTENING TORQUE: 22 N.m
22 10
[6] [9]
22 10
WRENCH SIZE: 12 mm
[11]
[10]
[7] [8]
[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)
TIGHTENING TORQUE: 22 N.m WRENCH SIZE: 10 mm WRENCH SIZE: 10 mm
[11] WASHER HEAD SCREW, 14 mm M6 (1)

TIGHTENING TORQUE: 22 N.m
[5] [4]
22 12
- 35 -
HRD536C - HRD536CK1 - HRD536C2 - MUFFLER

6. MUFFLER
a. Removal / Installation
- 36 -
[2]
[3]
[1]
[4]
The engine and muffler become very hot during operation and they remain hot for a while after operation. Be sure that muffler removal/installation is performed uten the engine is cold. [1] MUFFLER PROTECTOR [2] SPARK ARRESTER INSTALLATION: Install after removing the carbon from the screen with a wire brush. [3] SELF-TAPPING SCREW, 4 x 6 mm [4] MUFFLER GASKET Do not reuse. [5] MUFFLER INSTALLATION: Install after removing the carbon deposits from the muffler using a plastic hammer. Do not tap on the muffler seal flange and do not damage the part. If the seal flange is dented or damaged, replace the muffler. Check the cylinder barrel exhaust port for damage. [5]-1 MUFFLER SEAL FLANGE [5]-2 EXHAUST PORT [6] FLANGE SCREW, 6 x 79 mm (2) TIGHTENING TORQUE: 12 N.m [7] FLANGE SCREW, 6 x 12 mm (3)
[6]
12
[5]
[5] - 1
[7] [5] - 2
HRD536C - HRD536CK1 - HRD536C2 - RECOIL STARTER

[1]
8,5
7.
RECOIL STARTER
7.1 Recoil starter

[2]
NOTE: Replace the starter rope if it is frayed or worn out. Do not disassemble the recoil starter [2] assembly. [1] FLANGE NUT, 6 mm (3) TIGHTENING TORQUE: 8.5 N.m [2] RECOIL STARTER ASSEMBLY
- 37 -
HRD536C - HRD536CK1 - HRD536C2 - RECOIL STARTER

[3]
- 38 -
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 and remove the starter rope. 4. When the starter rope has broken or the starter reel has rewound, align the rope hole [6] in the starter case [4] with the rope hole in the starter reel [3] by turning the starter reel 5 turns in the direction of the arrow.
Starter rope length 2.3 m 3 mm
[1]
[2] [4]
Starter rope diameter
[6]
5. Pass the starter rope [5] through the starter grip and make the slip knot [7] at the end of the rope as shown. 6. Pass another end of the starter rope through the rope hole in the starter case and through the rope hole in the starter reel [3] and make the untieable knot at the rope end. 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] [2] [3] [4] [5] [6] [7] [8] STARTER GRIP BAND STARTER REEL STARTER CASE STARTER ROPE ALIGN THE HOLES SLIP KNOT RACHETS
[5]
[1]
[8]
[7]
HRD536C - HRD536CK1 - HRD536C2 - FUEL SYSTEM

[1] [2] [3]
8.
FUEL SYSTEM
8.1 Air cleaner / carburettor

[4]
Before removal, completely drain the carburettor. 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. 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 REMOVAL/INSTALLATION: ch. 8.2 [3] BREATHER COVER [4] CHOKE ROD REMOVAL/INSTALLATION: ch. 8.2 [5] FUEL TUBE [6] TUBE CLIP, B8 [7] CARBURETTOR GASKET Do not reuse. [8] CARBURETTOR DISASSEMBLY/REASSEMBLY: ch. 8.1c INSPECTION: ch. 8.1c ADJUSTMENT: ch. 8.1c [9] AIR CLEANER COVER [10] FLANGE SCREW, 6 x 14 mm TIGHTENING TORQUE: 10 N.m
[5]
[6] [10]
10
[7]
[8] [9]
- 39 -

[18] [17] [16] [15]
[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 air cleaner 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.
- 40 -
[11]
[14] [13] [12]

10
Governor rod / Throttle return spring / Choke rod Removal 1. 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 throttle lever [5]. 4. Install the insulator gasket, carburettor insulator, air guide, carburettor, carburettor gasket, 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
[1] [7] [6]
[2]
[3]
[5]
[4]

[2] [3] [4]
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. NOTE: Clean the outside of the carburettor before disassembly.
[1]
[12]
[5] [5] - 1 [5] - 2 [5] - 3
[11] [5] - 4 [11] - 1 [6]
[7] [10]
[8]
[1] CARBURETTOR BODY REASSEMBLY: Clean internal passages and orifices with compressed air before installation. [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
[7] [9]
- 41 -
- 42 -
Place the carburettor in the position as shown and measure the distance between the top of the float and the carburettor body when the float just touches the seat without compressing the valve spring. [1]
S.TOOL
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 float height.
S .T OOL
[1]

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 TIGHTENING TORQUE: 10 N.m [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 TIGHTENING TORQUE: 3 N.m [10] COLLAR [11] FUEL TUBE REASSEMBLY: Inspect for cracks or deterioration before installation and replace if necessary (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
[2]
[1] [18] [19] [17] [4]

10
[3] [20] [21] [22]
[5] [16] [6]
[7] [15] [8] [14] [10] [11] [12] [9]

3
[13]
8.3 Fan cover - 43 -

a. Removal / Installation 1. Before disassembly, completely drain the fuel tank and fuel line.
- 44 -
[1] [2]
[2] - 1
2. Remove the recoil starter (ch. 7.1). 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] FUEL TANK CAP REASSEMBLY: Make sure that the air vent hole is clean and unclogged. Blow with compressed air if necessary. [2] FAN COVER/FUEL TANK FUEL CAPACITY: 1.1 l CLEANING: ch. 3.11 INSTALLATION: Wash with solvent to remove the sediment and dry thoroughly before installing. Check whether the spark plug wire and the stop switch wire are securely set in the groove in the 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 blow with compressed air. [4] FUEL TUBE, 5.3 x 100 mm REASSEMBLY: Inspect for cracks or deterioration before installation and replace if necessary. [5] TUBE CLIP, B10 (2) [6] FAN COVER COLLAR (3)
[2] - 2
[3] [4]
[6]
[5]
HRD536C - HRD536CK1 - HRD536C2 - FLYWHEEL / IGNITION COIL

9. FLYWHEEL / IGNITION COIL
9.1 Flywheel / Ignition coil a. Disassembly / Reassembly
[2]
52
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 TIGHTENING TORQUE: 52 N.m [3] SIDE PLATE [4] FLANGE SCREW, 6 x 12 mm TIGHTENING TORQUE: 12 N.m [5] FLANGE SCREW, 6 x 14 mm TIGHTENING TORQUE: 12 N.m [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 key remains 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. 47 ADJUSTMENT: p. 48 [14] FAN COVER STUD BOLT (3) TIGHTENING TORQUE: 12 N.m [15] FLANGE SCREW, 6 x 20 mm TIGHTENING TORQUE: 12 N.m
[1]
[3]
12
[14]
[15]
12
[4]
12
[13]
[12]
[5]
12
[6]
[11]
[7]
[10] [9]
[8] [5]
- 45 -

14 mm special nut / flywheel
[4]
- 46 -
Removal 1. Remove the ignition coil. 2. While holding the flywheel with a strap wrench [1], remove the nut [2]. CAUTION:
[1]
[2]
[5]
[3]
Do not loosen the nut by setting a screw driver or equivalent tool on the fan blade or projection [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 the magnetic parts of the flywheel. NOTE: Do not position the flywheel puller at any parts other than under the magnetic parts [4]. Set a rag [7] or equivalent cloth between the flywheel and the puller. 5. Tighten the flywheel puller and remove the flywheel. CAUTION:
[6]
Do not hit the flywheel with a hammer. [1] [2] [3] [4] [5] [6]
S.TOOL
[7] [4]
STRAP WRENCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available SPECIAL NUT, 14 mm PROJECTIONS MAGNETICS PARTS PULLER MARK
S.TOOL
FLYWHEEL PULLER 6-inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available [7] RAG

a. Installation CAUTION:
[1]
52
Remove all of dirt, oil, grease and other foreign material from the tapered part before installation. 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 specified torque. TIGHTENING TORQUE: 52 N.m b. Inspection Ignition coil
[2]
Primary side Measure the resistance of the primary coil [3] by attaching one ohmmeter lead to the ignition coils primary terminal while touching the other test lead to the iron core.
Primary side resistance 1.0 - 1.2
Secondary side Attach a tester lead between the spark plug cap and iron core and measure the resistance of the secondary coil [4].
[3]
[4]
Secondary side resistance
10.6 - 12.8
[1] SPECIAL NUT, 14 mm [2] S.TOOL STRAP WRENCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available [3] PRIMARY COIL [4] SECONDARY COIL
- 47 -

Engine stop switch To perform this test, use a multimeter set in ohmmeter position.
Digital multimeter display NO CONTINUITY CONTINUITY O 1 0 Analog multimeter needle Does not moves Moves (to the end)
- 48 -
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.
[1]
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 the flywheel. Both gaps should be adjusted simultaneously. 3. Push the ignition coil [2] firmly toward the flywheel [4] and tighten the bolts.
[3]
[2]
Specified clearance
0.2 - 0.6 mm
NOTE: Avoid the magnetic part of the flywheel when adjusting. [1] [2] [3] [4] PLUNGER IGNITION COIL FEELER GAUGE FLYWHEEL
[2]
0.2 - 0.6 mm
0.2 - 0.6 mm
[4]
HRD536C - HRD536CK1 - HRD536C2 - CAM PULLEY / CRANKSHAFT / PISTON / CYLINDER BARREL

[2] [1]
12
10. CAM PULLEY / CRANKSHAFT / PISTON / CYLINDER BARREL

10.1 Cam pulley / Rocker arm
a. Removal / Installation [1] CYLINDER HEAD COVER REMOVAL/INSTALLATION: ch. 3.8 [2] FLANGE SCREW, 6 x 12 mm (4) TIGHTENING TORQUE: 12 N.m [3] VALVE ADJUSTMENT SCREW (2) ADJUSTMENT: ch. 3.8 [4] VALVE ADJUSTMENT LOCK NUT (2) TIGHTENING TORQUE: 8 N.m [5] ROCKER ARM SHAFT (2) INSPECTION: ch. 10.6 INSTALLATION: ch. 3.8 [6] INTAKE ROCKER ARM INSPECTION: ch. 10.6 [7] TIMING BELT [8] CAM PULLEY SHAFT INSPECTION: ch. 10.6 [9] O-RING, 6.8 x 1.9 mm Do not reuse. [10] CAM PULLEY Decompressor weight INSPECTION: ch. 10.6 INSTALLATION: ch. 10.2 Take care not to drop the cam pulley. [11] EXHAUST ROCKER ARM INSPECTION: ch. 10.6
OIL
[3] [11]
OIL
OIL
OIL
[4]
[10]
OIL
[5]
[6]
OIL
[7] [8] [9]
- 49 -

[10]
[1] [2]
- 50 -
Cam pulley
[4] [2]
Decompressor weight inspection: Before installing, inspect for worn and weakened springs and check that the compressor weight moves smoothly. a. Installation 1. Set so that the crankshaft key groove (PTO side) [10] faces up as shown (piston must be 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 cover mating 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.
[3]
[6]
[2]
[7]
[5]
[9]
[1] [2] [3] [4] [5] [6] [7] [8] [9] [10]
[8]
WEIGHT RETURN SPRING CAM PULLEY DECOMPRESSOR WEIGHT ALIGNMENT MARKS CRANKSHAFT KEY GROOVE Flywheel side CYLINDER HEAD COVER MATING SURFACE TIMING BELT O-RING, 6.8 x 1.9 mm CAM PULLEY SHAFT VIEW FROM PTO SIDE

Rocker arm shaft Installation Install the rocker arm shaft [2] from the side opposite the cam pulley [1] as shown.
[1]
Cylinder head cover Installation 1. Clean the mating surfaces of the cylinder head cover and the cylinder barrel using a degreasing agent or a clean shop rag. 2. Apply liquid gasket compound [3] (Three Bond 1207 or equivalent) to the cylinder head cover, specifically to the inner wall of the groove and bolt hole (see the part shown) 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 the engine. [1] [2] [3] [4] CAM PULLEY ROCKER ARM SHAFT LIQUID GASKET APPLICATION AREA CYLINDER COVER VIEWED FROM BACK SIDE
[2]
[4]
[3]
- 51 -

10.2 Oil pan / Crankshaft / Cylinder barrel
GR E A S E
- 52 -
a. Removal / Installation Remove the cam pulley and rocker arm (ch. 10.1).
[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 pan with the oil seal. [2] OIL PAN ASSEMBLY DISASSEMBLY/REASSEMBLY: ch. 10.2 INSPECTION: ch. 10.6 REMOVAL: p. 53 [3] DOWEL PIN, 8 x 20 mm (2) [4] TIMING BELT SPECIFIED BELT: 84HU7 G-200 INSTALLATION: Check that the belt is not worn or cracked. Do not bend or twist the belt. [5] CYLINDER BARREL INSPECTION: ch. 10.6 INSTALLATION: p. 54 [6] OIL SEAL, 25.4 x 62 x 6 mm [7] PISTON ASSEMBLY DISASSEMBLY/REASSEMBLY: ch. 10.3 INSPECTION: ch. 10.6 INSTALLATION: p. 55 [8] OIL DIPPER [9] CONNECTING ROD CAP INSTALLATION: p. 56 [10] CONNECTING ROD BOLT (2) TIGHTENING TORQUE: 12 N.m [11] CRANKSHAFT INSPECTION: ch. 10.6 INSTALLATION: Be careful not to damage the oil seal. Cover the grooves with adhesive type 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 TIGHTENING TORQUE: 12 N.m
[2]
[13]
12
[3] [4] [12] [5]

OIL
[11]
OIL
[10]
OIL
[9]
GR E A S E
[8]
[7]
[6]

Oil pan
[1]
[2]
Removal Insert a screwdriver or equivalent tool into the recess [1] as shown and remove the oil pan from the cylinder barrel. Piston assembly / Connecting rod cap Installation
[3]
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 pin hole and the longer side of the connecting rod big end [3] are at the right side (the piston must be at the top dead center of the compression stroke). CAUTION:
[7]
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 the connecting rod to the crank pin. 5. Apply oil to the connecting rod cap bearing.
[8]
[4] [5] [6]
6. Install so that the projection [5] by the oil dipper [4] and the projection of the connecting rod [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: TIGHTENING TORQUE: 12 N.m Thrust washer [7] Installation 1. Install the timing belt [8] on the timing belt pulley. 2. Note the installation direction. [1] [2] [3] [4] [5] [6] [7] [8] RECESS MODEL MARK CONNECTING ROD WITH THE LONG END OIL DIPPER PROJECTIONS CONNECTING ROD TRUST WASHER TIMING BELT
- 53 -

Cylinder barrel / 6 x 25 mm flange bolt
[1] [2]
- 54 -
Installation 1. Align the y mark [3] on the cylinder barrel [4] with the , [2] mark on the crankshaft [1]. 2. Install the cam pulley (p. 50). 3. Clean the mating surfaces of the cylinder barrel [4] and the oil pan using a degreasing agent or a clean shop rag. 4. Set the two 8 x 20 mm dowel pins on the cylinder barrel. 5. Apply a bead ( 1.5-2.0 mm) of the liquid gasket compound (Three Bond 1207 or equivalent) 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 numbered sequence. TIGHTENING TORQUE: 12 N.m 8. Wait for approximately 20 minutes after assembly before filling oil and starting the engine. [1] CRANKSHAFT [2] , MARK [3] y MARK [4] CYLINDER BARREL [5] LIQUID GASKET APPLICATION AREA
[4]
[3]

[1] - 1 [1] [1] - 1 [1] - 2
120 120 120
10.3 Piston
a. Disassembly / Reassembly [1] PISTON RINGS INSPECTION: ch. 10.6 REASSEMBLY: 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 INSPECTION: ch. 10.6 [4] PISTON PIN INSPECTION: ch. 10.6 [5] CONNECTING ROD INSPECTION: ch. 10.6 [6] PISTON PIN CLIP (2) REASSEMBLY: Install by setting one end of the clip in the piston groove, holding the other end 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
[2]
R
[1] - 3
[1] - 2
[1] - 3
[3]
[6] [6] - 1 [4]
OIL
[6] - 2
OIL
[5]
- 55 -

[1] [2]
- 56 -
Piston / Connecting rod Reassembly 1. Apply oil to the piston pin [2], piston pin hole and the connecting rod small end.
[3] [4]
2. Set the piston [1] so that the , of the FW , mark [4] stamped at the back of the piston points down. 3. Set the connecting rod [6] in the piston so that the model mark y [7] by the piston pin hole 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).
[7]
FW
[6]
[5]
[1] [2] [3] [4] [5] [6] [7]
PISTON PISTON PIN PISTON PIN CLIP (2) FW , MARK CONNECTING ROD WITH THE LARGE END CONNECTING ROD MODEL MARK y

10.4 Valves
OIL
a. Disassembly / Reassembly Remove the oil pan, crankshaft and cylinder barrel (ch. 10.2).
[2]
[1]
[3]
[7]
[4]
[1] VALVE SPRING RETAINER (2) DISASSEMBLY: Push down and slide the retainer to the side, so the valve stem slips through the hole at the side of the retainer. CAUTION: Do not remove the valve spring retainer while the piston is installed, as the valves will drop into the cylinder. [2] VALVE SPRING (2) INSPECTION: ch. 10.6 [3] SPARK PLUG INSPECTION/CLEANING: ch. 3.2 Standard 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 mm EX: 24 mm Be 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 INSPECTION: ch. 10.6
[6]
OIL
[5]
- 57 -

Cylinder barrel Combustion chamber cleaning
S.TOOL
- 58 -
[2]
1. Prepare a cylinder of thick paper or equivalent material [1], having a large enough diameter so as to fit against the inner wall of the cylinder, and then insert it into the cylinder. 2. Attach the cleaning brush (special tool) [2] to an electric drill [3] and clean the combustion chamber. CAUTION:
[1]
Be sure to insert a tube of thick paper into the cylinder to protect the inner wall of the cylinder during cleaning of the combustion chamber. Do not press the cleaning brush strongly against the combustion chamber. [1] THICK PAPER OR EQUIVALENT [2] S.TOOL CLEANING BRUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07998-VA20100 [3] S.TOOL ELECTRIC DRILL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available
[3]

[3] [2] [1] [14] [15] [6]
OIL
[4]
10.5 Governor
a. Disassembly / Reassembly
[5]
[7]
12
[13]
[8]
[12] [11] [9] - 1
[9] - 3
[9] [9] - 1 [10]
[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 the slides moves smoothly. [6] GOVERNOR HOLDER CLIP REASSEMBLY: Insert firmly into the shaft groove. [7] SCREW, 6 x 14 mm (2) TIGHTENING TORQUE: 12 N.m [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 and move 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 INSPECTION: ch. 10.6 [11] O-RING, 14.7 x 2.2 mm [12] EXTENSION LOCK WASHER [13] GASKET [14] OIL FILLER CAP [15] OIL FILLER EXTENSION
[9] - 2
[9] - 3
- 59 -

10.6 Inspection
[2]
- 60 -
Cam pulley cam height

[1] Standard 37.394 mm Service limit 37.369 mm
[1]
Cam pulley I.D. (bearing)

Cam pulley shaft O.D.

[3]
[4]
Rocker arm I.D.

Rocker arm shaft bearing I.D.

Rocker arm shaft O.D.

Rocker arm-to-rocker arm shaft clearance

[5]
[6]
Rocker arm shaft bearing-to-rocker arm shaft clearance

[5] Standard 0.010 - 0.058 mm Service limit 0.07 mm
Cylinder I.D. Measure and record the cylinder I.D. at three levels in both the X axis (perpendicular to crankshaft) and the Y axis (parallel to crankshaft). Take the maximum reading to determine cylinder wear and taper.

Piston skirt O.D.
[2]
[1]
Measure and record the piston O.D. at a point 10 mm from the bottom of the skirt and 90 to the piston pin bore.
10 mm
Piston-to-cylinder clearance
[1] Standard 0.031 - 0.070 mm Service limit 0.120 mm
Piston ring width

[2] Top/Second Oil Standard 1.5 mm 2.5 mm Service limit 1.37 mm 2.37 mm
[4]
[3]
Piston ring side clearance

[3] Top/Second/Oil Standard 0.015 - 0.045 mm Service limit 0.150 mm
Piston ring end gap

[4] Top Second Oil Standard 0.20 - 0.35 mm 0.30 - 0.45 mm 0.15 - 0.35 mm Service limit 1.0 mm 1.0 mm 1.0 mm
NOTE: Use the top of the piston to position the ring horizontally in the cylinder.
[5]
[6]
Piston pin O.D.

Piston pin bore I.D.

- 61 -

[1]
[2]
- 62 -
Connecting rod small end I.D.

Connecting rod big end I.D.

Crankshaft main journal O.D.

[5] [3]
[6]
[3] PTO side [4] Flywheel side [5]
Standard 27.993 mm 25.393 mm
Service limit 27.933 mm 25.333 mm
[4]
Crankshaft main journal O.D.

Connecting rod big end axial clearance 1. Measure the clearances with a feeler gauge.
[7]
[9] [8]
12
[7]
Standard 0.1 - 0.4 mm
Service limit 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 the specified torque. NOTE: Place the plastigauge axially. Tighten the two bolts equally while holding the crankshaft to keep it from turning. 3. Remove the connecting rod cap and measure the plastigauge with the scale [10].
[10]
[9]
[11]
4. If the clearance exceeds the service limit, replace the connecting rod and recheck the clearance. [8] CONNECTING ROD BOLT (2) TIGHTENING TORQUE: 12 N.m [10] PLASTIGAUGE SCALE [11] PLASTIGAUGE

Cylinder barrel main journal I.D.
[1]
[2]
[1]
Standard 25.420 mm
Oil pan main journal I.D.

Crankshaft axial clearance 1. Measure the crankshaft axial runout before removing the oil pan, crankshaft and piston.
[3]
[3]
[4]
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.
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.
[5]
[7]
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.
[5] IN EX Standard 5.48 mm 5.44 mm Service limit 5.318 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.
[6]
[7]
Standard 5.50 mm
Replace the cylinder barrel if they are over service limit.
- 63 -

Valve seat width
- 64 -
NO
1. Thoroughly clean the combustion chambers and valve seats to remove carbon deposits (ch. 10.4). 2. Apply a light coat of Prussian Blue compound or erasable felt-tipped marker ink to the valve faces [1]. 3. Insert the valves and then lift them and snap them closed against their seats several times. Be sure that the valve does not rotate on the seat. The transferred marking compound will show any area of the seat that is not concentric. 4. Measure the valve seat width.
Standard 0.7 mm Service limit 1.8 mm
OK [1]
5. If the valve seat width is under the standard, or over the service limit, or if the valve seat is too high [3] / low [2], recondition the valve seat (ch. 10.7).
NO
[2]
[3]

10.7 Valve seat reconditionning
S.TOOL
[3]
[1]
[2]
S.TOOL
1. Thoroughly clean the combustion chambers and valve seats to remove carbon deposits (ch. 10.4). 2. Apply a light coat of Prussian Blue compound or erasable felt-tipped marker ink to the valve faces [1]. 3. Insert the valves and then lift them and snap them closed against their seats several times. Be sure the valve does not rotate on the seat. The transferred marking compound 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 concentric seat. NOTE: Follow the instructions of the valve seat cutter manufacturers instructions. Turn the cutter clokwise never counter clokwise. continue to turn the cutter as you lift it from the valve seat. Valve seat width
Standard 0.7 mm Service limit 1.8 mm
[4]
0.7 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 several times. Be sure the valves does not rotate on the seat. The seating surface, as shown by 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 the cylinder barrel before assembly. 7. Check valve clearance after assembly (ch. 3.8). [1] VALVE FACE [2] S.TOOL VALVE SEAT CUTTER, 45, 27.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07780-0010200 [3] S.TOOL CUTTER HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07981-VA20100 or 07981-VA20101 [4] TUBE, 4 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available
- 65 -
HRD536C - HRD536CK1 - HRD536C2 - FRONT WHEELS / REAR WHEELS

11. FRONT WHEELS / REAR WHEELS
11.1 Front wheels
a. Disassembly / Reassembly Wear heavy gloves to protect your hands when servicing near the blade.
[2]
- 66 -
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 upside down.
[3]
[1] ADJUSTING CENTER SCREW, 8 mm (2)

TIGHTENING TORQUE: 24 N.m WRENCH SIZE: 13 mm
[4]
[2] [3] [4] [5]

25
COLLAR, 12 x 8 x 7 mm (2) ADJUSTER GRIP (2) FRONT ADJUSTER LEVER (2) FLANGE NUT, 8mm (2)
[5] [1]
[6]
[6] [7] [8] [9]
FRONT WHEEL ASSEMBLY (2) WHEEL BEARING (4) FRONT WHEEL CAP (2) WHEEL FLANGE SCREW, 8 x 12 mm (2)
[7] [13] [12]

GR E A S E
[11]
[10] [10] - 1 [9]
[10] WHEEL WASHER (2) REASSEMBLY: Install the washer as shown. [10]-1 WHEEL SIDE [11] FRONT ADJUSTER ARM (2) [12] GREASE WASHER, 42 x 8.5 mm (2) [13] WASHER, 8 mm (2)
24
[8]
HRD536C - HRD536CK1 - HRD536C2 - FRONT WHEELS / REAR WHEELS

11.2 Rear wheels
[2] [1] [3] [4]
Wear heavy gloves to protect your hands when servicing near the blade. 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 the machine 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) TIGHTENING TORQUE: 24 N.m [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 inserting the rear adjuster arm.
[26]
[5] [6]
[7] [8] [25] [23] [24] [22] [21] [9] [10] [11] [12] [20] [13]
[14] [14] - 1 [19] [19] - 1
[18]
24
[17]
[16] [15]
12. REAR DRIVE SYSTEM

- 67 -
HRD536C - HRD536CK1 - HRD536C2 - REAR DRIVE SYSTEM

12.1 Transmission HXE / SXE
[1] [2] [3]
- 68 -
a. Removal Wear heavy gloves to protect your hands when servicing near the blade. 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 aligns with the hole in the transmission bracket [7]. Insert a screwdriver or rod into the holes and pivot the transmission to remove the drive belt from the drive pulley [6]. 5. Tilt the mower so that the carburettor is facing upward.
[5]
[4]
[6]
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 rear wheel [8], wheel washer and thrust washer on both sides. 7. Remove the snap ring, pinion gear collar, pinion gear, ratchet key and ratchet spring from the axle shaft. 8. Remove the 5 x 12 mm pan screw, washer and wheel cover [10].
[7]
[8]
[1] [2] [3] [4] [5] [6] [7] [8] [9] [10]
[9]
FLANGE SCREW, 6 x 32 mm WASHER COLLAR DRIVE COLLAR WOODRUFF KEY DRIVE PULLEY TRANSMISSION BRACKET REAR WHEEL WHEEL CAP WHEEL COVER
[10]

[1] [2]
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].
[3] [4]
11. Remove the screws [8] and rear axle holder [3] and remove the transmission assembly [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 the transmission. [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] TENSION SPRING REAR ADJUSTER ARM (RIGHT) AXLE HOLDER (2) HYDROSTATIC TRANSMISSION ASSEMBLY SHIFT CABLE DRIVE CLUTCH CABLE LOCK WASHER Never re-use SCREW, M6 x 12 mm (4) REAR ADJUSTER ARM (LEFT) WASHER (2) SNAP RING, 22 mm (2) SHIFT CABLE SPRING TENSIONER PLATE AXLE SHAFT GROOVE
[13] [12] [6] [7] [11] [8] [10] [9] [5]
[14]
- 69 -

12.2 Transmission TXE
a. Removal
[2] [3] [4] [7] [5] [6]
- 70 -
Wear heavy gloves to protect your hands when servicing near the blade. [1] [2] [3] [4] [5] [6] [7] TRANSMISSION PULLEY PIN, SPLIT, 5 x 35 mm ARM, CLUTCH NUT SELF LOCK, M5 WASHER, 5 mm SPRING RETURN (CLUTCH)
[1]
[9]
[8]
1. Remove the spark plug cap.

[11]
2. Drain the gasoline from the carburettor tank, as well as the engine oil (ch. 3.9 and 3.11). 3. Remove the belt guard. 4. Remove the blade (ch. 4). 5. Remove the Rotostop assembly (ch. 4). 6. Disconnect the drive belts tension spring [8] using a pair of tongue & groove pliers [9]. 7. Remove the drive belt by removing the driving pulley from the engines output shaft.
2
[10]
[4]
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].

[4]
[1]
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 ( 5 mmpin driver), - Unscrew the cable retaining screw [3] from the transmission. TIGHTENING TORQUE: 5 N.m - Unhook the cable from the selector arm [4].
[2]
[3]
b. Reassembly
28,5 mm
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.
[5]
2. Make a loop with a piece of string [6] and hook it onto the transmissions adjuster arm.
[6]
3. On the blade side, pry using a metal rod and pressing against the blade housing for leverage, 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 -

[1] [2] [3]
24
- 72 -
c. Disassembly / Reassembly
[4] - 2 [4] [4] - 1
[10]
[9]
[5]
[8]
[7] [6]
30
[11]
[12] [13] [13] - 2
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 [9] TRANSMISSION BRACKET [10] FLANGE, M8 x 16 mm (2) TIGHTENING TORQUE: 24 N.m 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) TIGHTENING TORQUE: 12 N.m [15] TRANSMISSION ASSEMBLY REASSEMBLY: Replace as an assembly if necessary. [16] HST RETURN SPRING [17] BUMPER RUBBER [18] TRANSMISSION BRACKET d. Transmission installation 1.
[18] [14]
12
[13] - 1
[17]
[15]
[16]

[11] [12]
GR E A S E
[1]
2. 3. 4. 5. 6.
7.
[3] [2] [10] [2] [4]
Connect the drive clutch cable [3] and shift cable [2] to the transmission. Do not secure the drive clutch cable to the cable stay. Install the spring tensioner plate [10] in the cutter housing and connect the spring [11] to the plate. Cover the groove at the ends of the axle shaft with thin transparent tape to prevent seal damage during assembly. Apply grease to the inside of the adjuster bushings and install the rear adjuster arms [7]-[12]. 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. 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 the transmission bracket. Insert a screwdriver or rod into the holes, pivot the transmission, and install the drive belt over the pulley. 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] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] HST ASSEMBLY SHIFT CABLE DRIVE CLUTCH CABLE SPECIAL WASHER SCREW, M6 x 12 mm (4) AXLE HOLDER (2) LEFT REAR ADJUSTER ARM SNAP RING, 22 mm (2) WASHER (2) SPRING TENSIONER PLATE TENSION SPRING RIGHT REAR ADJUSTER ARM
[9] [8] [7] [6]
[5]
- 73 -

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.
[1] [2]
22
- 74 -
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 from the 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.
[3]
9. Reassemble parts in reverse order of disassembly. Following adjustment: - Rotostop cable (ch. 3.6). f.
[4]
Oil seal replacement / Oil change
CAUTION: Be careful to prevent dust or other foreign bodies from entering the hydrostatic transmission. 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 them and 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 seals during [4] assembly. [1] ROTOSTOP CABLE [2] STOP SCREW TIGHTENING TORQUE: 22 N.m [3] RETURN SPRING REASSEMBLY: ch. 4.1 [4] OIL SEAL, 13 x 22 x 3 mm (3)

[1] [2] [3]
Empty air CAUTION:

[6]
[4] [5]
[7]
[9] [10]
[8]
Be careful to prevent dust or other foreign bodies from entering the hydrostatic transmission. 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.
[12]
[11]
[1] COVER [2] SEAL [3] SCREW, 5 x 12 mm TIGHTENING TORQUE: 7 N.m [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 -
HRD536C - HRD536CK1 - HRD536C2 - HANDLE / CONTROL LEVERS

[1] [21] [4] [5]
GR E A S E
- 76 -
[2]
[3]
13. HANDLE / CONTROL LEVERS

13.1 Upper handle
a. Disassembly / Reassembly SXE / TXE type [1] WASHER [2] BUSH (2) [3] DRIVE CLUTCH LEVER 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 interfering with the Rotostop lever. [14] DRIVE CLUTCH CABLE 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
[6] [20]
[7] [8] [9]
[19] [10] [17] [18] [11] [12] [13]
[16] [14]
[15]
[10]
[14] [15]
[16]

[1] [20] [2] [3] [4] [5]
[6]
GR E A S E
[7] [19] [8] [9] [18] [10] [17] [11] [12] [16]
[13] [14]
[15]
[14] [11]
[1] WASHER [2] BUSH (2) [3] DRIVE CLUTCH LEVER 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 interfering with the Rotostop lever. [18] JOINT ROD [19] COLLAR [20] ROTOSTOP LEVER RETURN SPRING REASSEMBLY: Hook the spring as shown.
[16]
- 77 -

13.2 Handle / Cutter housing
[2] [1]
- 78 -
[3]
[4]
[11] [6] [7]
[5]
[8] [9] [10]
[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)

[1] [2] [3] [4] [5]
GR E A S E
13.3 Control lever

a. Disassembly / Reassembly [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] [27] [28] [29] [30] [31] [32] [33] [34] [35] SXE type CONTROL COVER SHIFT LEVER COLLAR STOPPER PLATE THROTTLE LEVER SPRING SEAT SPRING THROTTLE CABLE TAPPING SCREW, 5 x 12 mm (2) SCREW, 6 x 10 mm SHIFT CABLE PLAIN WASHER, 10 mm SHIFT LEVER SPRING PLAIN WASHER, 6 mm FLANGE NUT, 6 mm HXE type SHIFT LEVER ARM SHIFT LEVER SPRING STOPPER PLATE A CONTROL COVER THROTTLE LEVER Apply grease SPRING HANDLE SPRING SEAT THROTTLE CABLE CONTROL COVER SCREW, 5 x 12 mm STOPPER PLATE B SCREW, 6 x 10 mm SPRING SPRING SEAT SHIFT LEVER JOINT PIN SHIFT CABLE PLAIN WASHER, 6 mm LOCK PIN, 6 mm CENTER LEVER SPRING SHIFT LEVER
[15] [14]
[13] [12]
[6]
[11] [10] [9] [8]

[20] [16] [17] [18] [19] [34] [33] [32] [31] [30] [29] [28] [27] [26] [25] [24] [23] [35] [26] [18] [35] [17]
[7]
[20]
GR E A S E
[21]
[22]
- 79 -

[8]
TXE type
- 80 -
[7] [5] [6]

[1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] THROTTLE LEVER SPRING, 15 mm SPRING SEAT THROTTLE CABLE COLLAR, 10 / 6.5 x 11 mm WASHER SPRING, 17.5 / 11.5 mm CASE SHIFT LEVER SUPPORT SHIFT CABLE TAPPING SCREW, 12 x 5 mm FLANGE NUT, 6 mm LOCK PIN LOCK PIN, 5.5 x 18 mm SCREW, 6 x 10 mm
[12]
[14]
[13]
[9]
[1]
[10]
[15] [11]
[3] [2]
[4]

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 [4] SELF-TAPPING SCREW, 6 x 12 mm [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
[1] [2]
[10] [9] [8] [2]
[7]
[6]
[5]
[4]
25
[3]
r > 50 mm
12 0
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 radius of less than 50 mm [13]. Tighter radius bends may cause the cable to kink and prevent it from sliding freely in its sheath.
[11]
0 25
Cables should be placed so that they form a loop [12] at the handle attachment point. [14] ROTOSTOP CABLE [15] CLUTCH CABLE
[13]
0
[12]
[7]
[14]
[15]
30
- 81 -
HRD536C - HRD536CK1 - HRD536C2 - DISCHARGE GUARD / GRASS BAG

[1]
- 82 -
14. DISCHARGE GUARD / GRASS BAG

[2] [3]
14.1 Discharge guard

[4]
[1] STOPPER WASHER (2) Never re-use [2] DISCHARGE GUARD SHAFT [3] GUARD RETURN SPRING [4] DISCHARGE GUARD Change if worn or cracked
HRD536C [7]
HRD536C
[6]
14.2 Grass bag

a. Assembly
[5] [6]
[7]
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] [6] [7] [8] [9] GRASS BAG FRAME PLASTIC EDGES FLANGE SCREW, 6 x 12 mm (3) (HRD536CK1 / HRD536C2) SCROLL GUIDE (HRD536CK1 / HRD536C2)
HRD536CK1 [7]
HRD536CK1
[6]
[9] [6] [8]
[5]
[7]
NOTE: HRD536C: Scroll guide is welded to the frame [6] HRD536CK1 / HRD536C2: Scroll guide [9] is mounted on the cutter housing.
HRD536C - HRD536CK1 - HRD536C2
SHOP MANUAL
3
HRD536C - HRD536CK1 HRD536C2

42 VF0 F51 L 106 1102 - 1
PREFACE
This manual covers the construction, function and servicing procedures of Honda HRD536C, 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 are based 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 notice and without incurring any obligation. No part of this publication may be reproduced without written permission.
Honda Europe Power Equipment S.A. Communication department
-1-

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HRD536C - HRD536CK1 - HRD536C2

HRD536C - HRD536CK1 - HRD536C2 - SPECIFICATIONS

l/h dB (A) dB (A) dB (A) m/s2

HRD536C - HRD536CK1 - HRD536C2 - SPECIFICATIONS

HRD536C SXE HXE HXE

HRD536CK1 TXE HXE

HRD536C - HRD536CK1 - HRD536C2 - SPECIFICATIONS

The dimensions are measured using the following parameters:

HRD536C - HRD536CK1 - HRD536C2 - SPECIFICATIONS

[2] [3] [4]

HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

2.2 Service rules

2.3 Serial number location

HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

carburettor Spark plug

Cylinder head Piston

Top/Second Oil Top/Second/Oil Top Second Oil

HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

Specific torque values

Standard torque values

HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

[4] [5] [6]

HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

a. General symptom and possible causes

Poor performance at low speed

7 Check cylinder compression. Normal compression

8 Install the spark plug and restart the engine.

HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

a. Drive clutch (except H type)

e. HST (hydrostatic) transmission (H type)

Mower does not stop and can not be pulled.

HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

0.49 Mpa at 600 rpm

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

HRD536C - HRD536CK1 - HRD536C2 - SERVICE INFORMATION

Regular service period (2) Check level Change Check

Every 6 months or 100 h

Every year or 300 h

See ch. 3.1 3.1 3.3

Clean Replace (filter)

Fuel filter and fuel tank Fuel line

Clean Check Every 2 years (replace if necessary)

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

20W40 20W50 15W40 15W50

10W40 10W30 -30 -20 -10 0 10 20 30 40C

[1] [2] [3] [4] [5] [6]

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

[6] [4] [5]

[1] CHOKE ARM [2] THROTTLE ARM [3] CLEARANCE

[4] [5] [6] [7] [8] [9]

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

3.6 Rotostop cable

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

from 0 to 1.35 - 1.4 m/s

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

[2] [1] [2]

HRD536C - HRD536CK1 - HRD536C2 - MAINTENANCE

3.10 Governor adjustment

[3] [7] [6] [5]