Honda HRS536 VK, Owner'S Manual

Page 1: ...PRINTED IN U S A Printed on Recycled Paper Rotary Mower HRS536C 1997 2007 American Honda Motor Co Inc All Rights Reserved OWNER S MANUAL MANUEL DE L UTILISATEUR BEDIENUNGSANLEITUNG MANUAL DE EXPLICACIONES GEBRIUKSAANWIJZING MANUALE DELL UTENT C2 HRS536C ...

Page 2: ...serves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission SAFETY MESSAGES Pay special attention to statements preceded by the following words Each message tells you what the hazard is what can happen and what you can do to avoid or reduce injury DAMAGE PREVENTION MESSAGES You will also s...

Page 3: ... 2 COMPONENT IDENTIFICATION 7 3 CONTROLS 9 4 PRE OPERATION CHECKS 11 5 OPERATION 17 6 TRANSPORTING STORAGE 27 7 MAINTENANCE 32 8 TROUBLESHOOTING 42 9 SPECIFICATIONS 44 10 ASSEMBLY 46 11 ADDITIONAL INFORMATION 47 CONTENTS 2 E ...

Page 4: ...emove all objects which may be thrown by the machine Gasoline is highly flammable Store fuel in containers specifically designed for this purpose Refuel outdoors only and do not smoke while refuelling Add fuel before starting the engine Never remove the cap of the fuel tank or add gasoline while the engine is running or when the engine is hot If gasoline is spilled do not attempt to start the engi...

Page 5: ...hanging direction on slopes Do not mow excessively steep slopes Use extreme caution when reversing or pulling the lawn mower toward you Stop the blade s if the lawn mower has to be tilted for transporting when crossing surfaces other than grass and when transporting the lawn mower to and from the area to be mowed Never operate the lawn mower with defective guards or shields or without safety devic...

Page 6: ...ower Before refuelling the lawn mower Before removing the grass catcher side discharge adapter or mulching plug Reduce the throttle setting during engine shut down and turn the fuel valve off at the conclusion of mowing Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Never store the equipment with gasoline in the tank inside a building where fumes may rea...

Page 7: ...or pets are in the operating area Keep hands and feet away from the mower deck Pull off the spark plug cap before carrying out maintenance work 1 Permissible sound power level according to Directive 2000 14 EC 2 Conformity mark according to the EEC 89 392 modified Directive 3 Nominal power in kilowatt 4 Recommended engine speed in rpm 5 Weight in kilograms 6 Year of manufacture 7 Serial number 8 M...

Page 8: ...opelled push HRS536CSD Self propelled single speed DRIVE CLUTCH LEVER CSD ONLY HANDLEBAR FLYWHEEL BRAKE LEVER RECOIL STARTER GRIP REAR CUTTING HEIGHT ADJUSTMENT LEVER FRONT CUTTING HEIGHT ADJUSTMENT LEVERS MUFFLER DISCHARGE GUARD OIL FILLER CAP ENGINE SERIAL NUMBER A LABEL B LABEL ...

Page 9: ...ering parts and when making technical or warranty inquiries Frame serial number MZB__ ______________ Engine serial number GJAE ______________ THROTTLE LEVER HANDLEBAR LOCKING KNOB 2 AIR CLEANER CARBURETOR SPARK PLUG CAP FUEL VALVE MOWER DECK FUEL TANK CAP FRAME SERIAL NUMBER 2 COMPONENT IDENTIFICATION 8 E ...

Page 10: ...the carburetor The fuel valve must be ON to start and operate the mower The fuel valve should be kept OFF when the mower is not in use Throttle Lever CHOKE For starting a cold engine FAST For restarting a warm engine and for mowing SLOW For idling the engine OFF ON FUEL VALVE CHOKE FAST SLOW 3 CONTROLS E 9 ...

Page 11: ...he rear wheels The drive clutch lever should only be engaged after the engine has been started Cutting Height Adjustment Levers There are six approximate settings 25 87 mm The adjusters move back to lower and forward to raise the mower deck For the best overall lawn finish each wheel should be adjusted to the same position 25 mm 37 mm 50 mm 66 mm 75 mm 87 mm REAR ADJUSTMENT LEVER FRONT ADJUSTMENT ...

Page 12: ...thers Look for things like stones sticks bones and wire Remove them from the mowing area People and Pets People and animals near the mowing area can move into your path or into a position where they could be struck by thrown objects Clear the area of people and pets especially children Their safety is your responsibility Lawn Check the length and condition of the grass so you will know what cuttin...

Page 13: ...lade can break causing blade pieces to be thrown from the mower When a blade needs sharpening or replacement take the lawn mower to an authorized Honda servicing dealer Or if you have a torque wrench you can remove and install the blade yourself see pages 40 Check that the blade bolts are tight see page 40 BLADE BLADE BOLTS WARNING A worn cracked or damaged blade can break and pieces of the damage...

Page 14: ...pstick without screwing it into the filler neck Check the oil level shown on the dipstick 3 If the oil level is low add the recommended oil see page 35 to reach the upper limit mark on the dipstick Do not overfill 4 After checking the engine oil level screw in the filler cap dipstick securely FILLER CAP DIPSTICK FILLER CAP DIPSTICK UPPER LIMIT LOWER LIMIT 4 PRE OPERATION CHECKS E 13 ...

Page 15: ...Remove the tank cap 1 and check the fuel level Refill the tank if the fuel level is low Refuel carefully to avoid spilling fuel Do not overfill there should be no fuel in the filler neck 2 After refueling tighten the fuel tank cap securely Fuel Recommendations Use unleaded gasoline with an octane rating of 86 or higher This engine is designed to operate on unleaded gasoline Unleaded gasoline produ...

Page 16: ... Side Discharge The mower can be used to mulch or side discharge grass clippings To mulch make sure the side discharge chute is not installed and the side door on the mower deck is fully closed To discharge the clippings from the side door stop the engine lift the side door up and install the side discharge chute as shown COVER PAPER FILTER AIR CLEANER HOUSING SIDE DOOR SIDE DISCHARGE CHUTE 4 PRE ...

Page 17: ...hest setting is 90 mm Each position increments about 13 mm To adjust cutting height pull each adjustment lever toward the wheel and move it into another notch If you are not sure what cutting height to select start with a high setting and check the appearance of the lawn after mowing a small area Then readjust cutting height if necessary ADJUSTMENT LEVERS ADJUSTMENT LEVERS 4 PRE OPERATION CHECKS 1...

Page 18: ...ing or operating the engine in an enclosed area such as a garage Your mower s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death STARTING THE ENGINE The blade turns when you operate the starter It is easiest to start the engine in a clear or mowed area where the blade can turn freely 1 Turn the fuel valve to the ON position 2 Mov...

Page 19: ...Return the starter grip gently Keep your hands and feet away from the mower deck at all times when starting and running the engine Continue to hold the flywheel brake lever against the handlebar the engine will stop if you release the lever 4 If the CHOKE position was used during starting move the throttle lever away from the CHOKE position as soon as the engine warms up enough to run smoothly Set...

Page 20: ...t When you need to leave the mower for any reason always turn the engine OFF by releasing the flywheel brake lever Flywheel Brake Lever The lever must be pulled backward against the handlebar to start the engine The blade starts to rotate when the lever is pushed forward against the handlebar and the recoil starter grip is pulled Continue to hold the lever against the handlebar to keep the engine ...

Page 21: ...ever before starting the engine If the drive clutch is engaged the mower will move forward when you operate the starter Operate the drive clutch lever with a quick and complete motion so the drive clutch is either fully engaged or released Hold the drive clutch lever against the handlebar during self propelled mowing This will help to extend the service life of the clutch mechanism DRIVE CLUTCH LE...

Page 22: ...le lever to the SLOW position 2 Release the drive clutch lever SD 3 Release the flywheel brake lever 4 When the mower is not in use turn the fuel valve to OFF FUEL VALVE OFF SLOW DRIVE CLUTCH LEVER SD FLYWHEEL BRAKE LEVER 5 OPERATION E 21 ...

Page 23: ...r Slopes Mow across slopes not up and down Avoid steep slopes more than 20 and be careful when changing direction Mowing on a slope when the grass is damp or wet could cause you to slip fall and lose control of the mower WARNING The blade is sharp and spins at high speed A spinning blade can cut you severely and can amputate fingers and toes Wear protective footwear Keep your hands and feet away f...

Page 24: ...ft and or break the mower deck or other components Vibration usually indicates serious trouble The Distributor s Limited Warranty does not cover parts damaged by accident or collision Gravel and Loose Objects Gravel loose stones and landscaping material can be picked up by the mower and thrown many feet with enough force to cause serious personal injury and or property damage The best way to preve...

Page 25: ...losely you ll see that most grass has stems and leaves If you cut off the leaves you ll scalp the lawn Let the grass recover between mowings Your mower will work better and your lawn will look better If your grass gets too tall cut it once at the highest cutting height setting then mow again in 2 or 3 days Don t take off more than one third of total grass height in any one mowing or brown patches ...

Page 26: ...lso wet grass clippings will clog the mower deck and collect in clumps on the lawn Always wait for wet grass to dry before mowing Fallen Leaves When equipped with the optional grass bag your mower can be used to pick up fallen leaves for disposal If using the mower to bag large amounts of fallen leaves and not for mowing set the cutting height adjustment levers so the front of the mower deck is on...

Page 27: ...s where you can use counterclockwise mowing patterns Side Discharge Mowing Where possible use the same mowing pattern recommended for mulching If the lawn has an irregular shape or many obstacles divide it into sections where clippings will be discharged away from uncut areas This will prevent clippings from piling up in the path of the mower Bagging Requires optional grass bag kit Use a clockwise...

Page 28: ...ove the grass bag LOADING AND UNLOADING If a suitable loading ramp is not available two people should lift the mower on and off the transport vehicle while holding the mower level Position the mower so all four wheels are on the bed of the transport vehicle Tie the mower down with rope or straps and block the wheels Keep the tie down rope or straps away from the controls adjustment levers cables a...

Page 29: ...ng a garden hose or pressure washing equipment to clean the mower deck be careful to avoid getting water into controls and cables or anywhere near the engine air cleaner or muffler opening Before washing the underside of the mower deck be sure the fuel valve is in the OFF position Disconnect the spark plug cap Rest the mower on its right side so the carburetor side is up This will help to prevent ...

Page 30: ...ributor s Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose or you can avoid fuel deterioration problems by draining the fuel tank and carburetor Adding fuel stabilizer to extend fuel storage life When adding a fuel stabil...

Page 31: ...veral times to distribute the oil in the cylinder Reinstall the spark plug Pull the starter rope slowly until resistance is felt then return the starter grip gently This closes the valves so moisture cannot enter Handlebar Folding Remove the grass bag if installed Loosen the handlebar locking knobs Press the handlebar struts to release the locating pins then swing the handlebar forward Don t allow...

Page 32: ... Tilting can cause fuel or oil leakage The handlebar can be folded for compact storage see page 30 With the engine and exhaust system cool cover the mower to keep out dust A hot engine and exhaust system can ignite or melt some materials Do not use sheet plastic as a dust cover A nonporous cover will trap moisture around the mower promoting rust and corrosion REMOVAL FROM STORAGE Check your mower ...

Page 33: ...rmally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your mower under severe conditions such as sustained high load or high temperature operation or use in unusually wet or dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use WARNING Improper mainte...

Page 34: ...un the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Remember that an authorized Honda servicing dealer kn...

Page 35: ...ery 50 hours every 100 hours every 150 hours See page Perform at every indicated interval Blade condition and blade bolt tightness Check O 12 Engine oil Check O 35 Change O O 1 35 Air Cleaner Check O 37 Clean O 1 37 Replace O 1 Spark plug Clean adjust O 38 Replace O Spark arrester optional equipment Clean inspect O 48 Idle speed Check adjust O 2 Flywheel brake operation Inspect O Flywheel brake pa...

Page 36: ...ill drain through the filler neck Allow the oil to drain completely Please dispose of used motor oil and the containers in a manner that is compatible with the environment We suggest you take it in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash pour it on the ground or down a drain 4 Fill with the recommended oil Do not overfill me...

Page 37: ...cause engine damage d Screw in the filler cap dipstick securely Engine Oil Recommendations Oil is a major factor affecting performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range The SAE oil viscosity and service classificat...

Page 38: ...he filter 2 Clean the filter by tapping the filter several times on a hard surface to remove dirt or blowing compressed air not exceeding 207 kPa through the filter from the inside Never try to brush off dirt brushing will force dirt into the fibers 3 Wipe dirt from the inside of the air cleaner housing and cover using a moist rag Be careful to prevent dirt from entering the air duct that leads to...

Page 39: ...the plug replace it if the electrodes are worn or if the insulator is cracked or chipped Clean plug completely if you are going to reuse it 3 Set the gap to 0 7 0 8 mm 4 After the plug seats tighten it as follows to seat the washer Old plug 1 8 to 1 4 turn New plug 1 2 turn NOTICE A loose spark plug can overheat and damage the engine Overtightening the spark plug can damage the threads in the cyli...

Page 40: ...rheat and result in serious engine damage For use at low altitudes have an authorized Honda servicing dealer return the carburetor to original factory specifications Fuel Recommendations Use unleaded gasoline with a pump octane rating of 86 or higher This engine is certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system l...

Page 41: ...the right side carburetor side up 2 Remove the two blade bolts with a 14 mm socket Use a wooden block to prevent the blade from turning when removing the bolts Remove the blade from the blade holder 3 Installation Clean around the blade holder Install the blade using the bolts and special washers exactly concave side of the special washers toward the blade as shown The blade bolts and washers are ...

Page 42: ...n the blade bolts before you use the mower If the blade bolts are overtightened they could break If the blade bolts are not tightened enough they could loosen or come out In either case it would be possible for the blade to fly off while you are operating the mower 7 MAINTENANCE E 41 ...

Page 43: ... to shop manual Fuel filter clogged carburetor malfunction ignition malfunction valves stuck etc Replace or repair faulty components as necessary Loss of Power Possible Cause Correction 1 Check throttle position Throttle not set to FAST Move throttle to FAST p 19 2 Check grass height Grass too tall to cut Raise cutting height p 10 cut narrower swath p 24 or cut more frequently 3 Check under mower ...

Page 44: ...heck that the throttle lever is in the FAST position Engine speed is too slow to cut well Move throttle lever to the FAST position p 19 2 Reduce forward speed Mower is moving too fast for lawn conditions Release the drive clutch lever SD and push slower SD PD 3 Check cutting height adjustment levers Adjustment levers set at different positions Set all levers at the same cutting height position p 1...

Page 45: ...e 25 mm 37 mm 50 mm 66 mm 75 mm 87 mm Fuel Tank Capacity 1 1 l Engine Oil Capacity 0 55 l ENGINE DESIGN AND PERFORMANCE Engine Model GCV160 Engine Type 4 stroke overhead cam single cylinder air cooled Displacement 160 cc Bore and Stroke 64 x 50 mm Compression Ratio 8 5 1 Ignition System Transistorized magneto Maximum Horsepower 4 1 kW at 3 600 rpm Maximum Torque 11 0 N m at 2 500 rpm TRANSMISSION ...

Page 46: ...ed 2800 2900 rpm See shop manual Throttle Cable Adjust for proper choke operation and maximum governed speed See shop manual TUNEUP Spark Plug Gap 0 028 0 031 in 0 7 0 8 mm See page 38 Idle Speed 1 700 150 rpm See page 39 Valve Clearance cold Intake 0 15 0 02 mm Exhaust 0 20 0 02 mm See shop manual Other Specifications No other adjustments needed Sound power level according to 2000 14 EC Directive...

Page 47: ...l the flywheel brake lever back then pull the starter grip toward the starter rope loop Release the lever then press the rope into the loop Connect the spark plug cap Add Oil The mower is shipped WITHOUT OIL in the engine Refer to page 37 for what kind of oil to use and how to correctly add oil to the engine Add Fuel See page 14 for instructions on how to add fuel Before Use All operators of the m...

Page 48: ...taining up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system If you...

Page 49: ... be serviced every 100 hours to keep it functioning as designed 1 Allow the engine to cool then remove the bolts from the muffler shield Remove the muffler shield 2 Loosen the two set screws and remove the spark arrester 3 Check for carbon deposits on the spark arrester and the exhaust port Brush carbon deposits away Be careful to avoid damaging the spark arrester screen 4 Installation is the reve...

Page 50: ...PRINTED IN U S A Printed on Recycled Paper Rotary Mower HRS536C 1997 2007 American Honda Motor Co Inc All Rights Reserved OWNER S MANUAL MANUEL DE L UTILISATEUR BEDIENUNGSANLEITUNG MANUAL DE EXPLICACIONES GEBRIUKSAANWIJZING MANUALE DELL UTENT C2 HRS536C ...