Honda HRU196K1, Owner'S Manual & Service Record Booklet

Page 1: ...d Booklet HRU19K1 HRU19M1 HRU197K1 HRU197M1 HRU196K1 HRU196M1 HRU216K2 HRU216M2 Read and understand this Owners Manual before operating your Honda mower and ensure that you have identified the information applicable to your particular model mower ...

Page 2: ... messages is to help prevent damage to your lawn mower other property or the environment Do not use this lawn mower except for mowing lawns Illustrations in this manual are for instructional purposes only and may not be exact representations All information contained in this manual is based on the latest product information available at the time of publication Honda Australia Motorcycle and Power ...

Page 3: ...ting Height Adjustment Lever 12 Shift Lever 13 Front Guard 14 5 PRE OPERATION CHECKS 15 ARE YOU READY TO MOW 15 CHECK YOUR LAWN 15 CHECK YOUR MOWER 16 Blades 16 Engine Oil Level 19 Fuel 20 Air Cleaner 21 Grass Bag 21 Cutting Height 23 6 OPERATION 24 MOWING PRECAUTIONS 24 STARTING THE ENGINE 24 Throttle Lever 25 Blade Control Lever 27 Drive Clutch Lever 28 Shift Lever 29 STOPPING THE ENGINE 30 ...

Page 4: ...NANCE 42 MAINTENANCE SAFETY 43 MAINTENANCE SCHEDULE 44 ENGINE MAINTENANCE 45 Engine Oil Change 45 Engine Oil Recommendations 46 Air Cleaner Service 47 Spark Plug Service 48 Carburettor Modification for Altitude operation 50 Fuel Recommendations 50 BLADE REMOVAL INSTALLATION 51 GRASS BAG CLEANING REPLACEMENT 56 9 TROUBLESHOOTING 57 10 SPECIFICATIONS 59 11 OPERATOR SAFETY FEATURES 62 12 SET UP INSTR...

Page 5: ...nt of valves cleaning of carburettor fuel strainer and air filter Normal replacement of service items including but not limited to spark plug air filter and cutting blades Deterioration of any item due to normal use fair wear and exposure unless due to a defect in material or workmanship Any work or adjustment performed by persons other than Authorised Honda Lawnmower Dealers nor damage resulting ...

Page 6: ...ifically 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 petrol while the engine is running or when the engine is hot If petrol is spilled do not attempt to start the engine but move the mower away from the area of spillage and avoid creating any source of ignition until the petrol vap...

Page 7: ...r pick up or carry a lawn mower while the engine is running Stop the engine and disconnect the spark plug cap Before clearing a blockage or unclogging the mower Before checking cleaning or working on the mower After striking a foreign object Inspect the mower for damage and make repairs before restarting and operating the mower If the mower starts to vibrate abnormally check immediately Stop the e...

Page 8: ...7 3 COMPONENT IDENTIFICATION HRU216M2 K2 SHOWN HRU197K1 M1 ...

Page 9: ...rame and engine numbers and serial codes and date of purchase in the space below You will need this information when ordering parts and when making technical or warranty inquiries Frame Serial Number Engine Serial Number Date of Purchase 21 Models only ...

Page 10: ... 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 NOTE Fuel Valve may vary in appearance depending on engine model Throttle Lever CHOKE For starting a cold engine Not for HRU19K1 or HRU19M1 HIGH For restarting a warm engine and for mowing LOW For idling the engine ...

Page 11: ...ade control system The blades will not turn unless the blade control button is pushed in conjunction with the blade control lever being pushed forward NOTE Engine will Stop in this position on models fitted with Fly Wheel Brake Depress Blade Control Button before pushing the Lever Forward or Blades will not rotate ...

Page 12: ...Drive Clutch Lever 21 Models Only The drive clutch lever engages push forward and disengages release the transmission that drives the rear wheels The drive clutch lever should only be engaged after the engine has been started ...

Page 13: ... with one lever The cutting heights listed are approximate The actual height of cut grass will vary with lawn and soil conditions Move the adjuster forward to lower and back to raise the cutter housing NOTE The 19 models have the Height Adjustment Lever on the left hand side so the above figures will be reversed ...

Page 14: ... Lever 21 Models Only The shift lever selects and controls the self propelled drive speed For mowing thick grass or manoeuvring in small areas For intermediate self propelled mowing speed For maximum self propelled transport speed ...

Page 15: ...se the front guard when lifting the lawn mower the front guard can also be utilised to tie down lawnmower for transportation Do not step on the front guard Have the front guard replaced by an authorised Honda service dealer whenever it is deformed NOTICE ...

Page 16: ...otential hazard to you and others Look for things like stones sticks bones and wire Remove them from the mowing area PEOPLE 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 especially children and pets Their safety is your responsibility LAWN Check the length and condition of the grass so y...

Page 17: ...gloves to protect your hands from the cutter blades 1 Stop the engine and turn the fuel valve to the OFF position 2 Disconnect the spark plug cap from the spark plug see page 48 3 Remove the grass bag if installed 4 Tilt the mower to the right so the carburettor side is up This will help to prevent fuel leakage oil contamination of the air cleaner and hard starting NOTE Remember Fuel Valve may app...

Page 18: ... Check that the blade setting bolts and the blade disc holder bolt are tight see page 51 Never operate the mower with worn damaged split or dented blades A piece of blade which breaks off and is thrown outwards can cause serious bodily injuries Two Blades Models Four Blade Models ...

Page 19: ...t cracked or otherwise damaged must be replaced A worn or damaged blade can break causing blade pieces to be thrown from the mower When a blade needs sharpening or replacement take the lawn mower to an authorised Honda servicing dealer Uneven or incorrect sharpening can cause imbalance and vibration If you have a torque wrench and the other correct tools you can remove and install the blades yours...

Page 20: ...e dipstick clean 3 Insert the dipstick without screwing it into the filler neck Remove it and check the oil level shown on the dipstick 4 If the oil level is low add the recommended oil see page 46 to reach the upper limit mark on the dipstick Do not overfill 5 After checking the engine oil level screw in the oil filler cap dipstick securely NOTE OIL FILLER CAP DIPSTICK MAY VARY IN APPEARANCE DEPE...

Page 21: ...ower inside a building where petrol fumes may reach flames or sparks Keep petrol away from appliances with pilot lights barbecues electric appliances etc NOTICE Fuel can damage paint and some plastic Be careful not to spill fuel when filling your fuel tank Damage caused by spilled fuel is not covered under warranty Remove the fuel filler cap and check the fuel level Refill the tank if the fuel lev...

Page 22: ...mpty the grass bag before it becomes filled to the limit of its capacity Bagging performance will diminish after the bag becomes about 90 filled Also the bag is easier to empty when not packed full Inspection Inspect the grass bag before use Check for holes tears and excessive wear The grass bag will wear during normal use and will eventually require replacement See page 56 NOTE Under heavy mowing...

Page 23: ...n place Removal 1 Raise the discharge guard grasp the grass bag handle and remove the grass bag 2 Release the discharge guard 3 When the grass bag is clear of the discharge guard you can lift the grass bag through the handlebars or remove it from the rear of the mower below the handlebar NOTE GRASS BAG DESIGN MAY VARY DEPENDENT ON MODEL BUT ATTACHMENT PROCEDURE REMAINS THE SAME FOR ALL MODELS ...

Page 24: ...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 NOTE All 19 models have the height adjuster lever on the left hand side of the Cutter Housing NOTE 19 model shown Remember heights are reversed compared to other mod...

Page 25: ...me familiar with how this mower works and practice in a safe area until you build up your skills For your safety avoid starting 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 1 Turn the fuel valve to the ON position NOTE Fuel Valve m...

Page 26: ...N continued 2 Move the throttle lever to the proper starting position COLD ENGINE Move the throttle lever to the CHOKE position NOT APPLICABLE TO HRU19 Models WARM ENGINE Move the throttle lever to the HIGH position ...

Page 27: ...d feet away from the cutter housing at all times when starting and running the engine NOTE HRU196M1 and all 21 Models Do not engage the Blade Control Lever or Drive Control Lever during starting All Other Models Engage the Blade Control Lever during starting 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 t...

Page 28: ...ed with Fly Wheel Brake Blade Control Lever HRU196M1 and all 21 Models To prevent stalling always put the throttle lever in the fast position before engaging the blade control lever To start blade rotation press the button on top of the blade control lever then push the lever forward quickly and hold it against the handlebar All other models There is no Button to press simply engage the lever Rele...

Page 29: ... lever 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 NOTE Do not e...

Page 30: ...tle lever The throttle lever must remain in the HIGH position for good mowing performance Otherwise cut quality suffers The speed must only be changed with the mower stationary release the clutch lever before changing gears For maximum mowing performance use 1st and 2nd gears for mowing and 3rd gear for transporting Always disengage blades when transporting mower To avoid incomplete gear engagemen...

Page 31: ... the blade control lever NOTE On models equipped with Fly Wheel Brake Engine will stop automatically For models not equipped with Fly Wheel Brake 2 Move the throttle lever to the STOP position 3 When the mower is not in use turn the fuel valve to the OFF position as shown on Page 9 ...

Page 32: ...with your foot Use the handlebar to control mower The blades are sharp and spin 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 from the cutter housing while the engine is running Stop the engine before performing any adjustment inspection or maintenance Slopes Mow across slopes not up and down Avoid steep...

Page 33: ...nd the crankshaft and or break the cutter housing or other components Vibration usually indicates damage to the mower or debris caught in the blades A worn cracked or damaged blade can break and pieces of the damaged blade can become dangerous projectiles Thrown objects can cause serious injury Inspect the blades regularly and do not operate the mower with a worn or damaged blade The Warranty does...

Page 34: ...h move the mower slower or raise the cutting height Consult a local nursery or lawn and garden centre for cutting height recommendations and advice about specific types of grasses and growing conditions in your area If you look closely 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 mowing Your mower will work better and...

Page 35: ...len Leaves When equipped with the 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 lever at highest setting If you want to mulch fallen leaves into your lawn don t let the leaf cover get too deep before you begin For best results start mulching while grass still shows...

Page 36: ...equipment design and the direction in which the blades rotate cause these mowing patterns to give the best results Bagging Use a clockwise mowing pattern This will give the best bagging performance leaving the least amount of clippings on the lawn NOTE If your mower is fitted with a Mulching Plug mowing in a Counter Clockwise direction will give the best result ...

Page 37: ...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 and the carburettor The handlebar can be folded so the mower will take up less space see page 40 STORAGE PREPARA...

Page 38: ...ner or muffler opening To wash the underside of the cutter deck attach a garden hose to the fitting on the cutter deck see below and turn water on Start engine engage blades and allow it to run at normal operating speed for several minutes This should be done in an area where the water and debris can run onto grass or a dirt surface Do not flush the water or debris into the storm water system 1 Af...

Page 39: ...illed the fuel tank NOTE Your Honda mower can operate on blended fuel containing a maximum of 10 Ethanol However fuel containing Ethanol may deteriorate quicker than non blended fuel The Warranty does not cover fuel system damage or engine performance problems resulting from the use of blended fuels or neglected storage preparation You can avoid fuel deterioration problems by draining the fuel tan...

Page 40: ...spills immediately 3 Engine Oil Change the engine oil see page 45 Engine Cylinder 1 Remove the spark plug see pages 48 2 Pour 5 10cc One Teaspoon of clean engine oil into the cylinder 3 Pull the starter grip several times to distribute the oil in the cylinder Reinstall the spark plug 4 Pull the starter grip slowly until resistance is felt then return the starter grip gently This closes the valves ...

Page 41: ...uts to release them from the locating grooves then swing the handlebar forward with the drive clutch lever held by your hand Don t allow the cables and air cleaner hose to be bent or pinched 4 Loosely install the two handlebar locking knobs Handlebar Setting Squeeze the drive clutch lever and raise the handlebar in place in the reverse order of handlebar folding taking care that the cables and air...

Page 42: ...ce the mower with its wheels on a level surface Tilting can cause fuel or oil leakage The handlebar can be folded for compact storage see page 40 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 plastic sheet as a dust cover A nonporous cover will trap moisture around the mower promoting rust and c...

Page 43: ...commendations and schedules in this owner s manual To help you properly care for your mower the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified...

Page 44: ...poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read and understand the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explos...

Page 45: ...vicing dealer unless you have the proper tools and are mechanically proficient Refer to the Honda workshop manual for service procedures 3 Change engine oil every 25 hours when used under heavy load or in high ambient temperatures 4 For commercial use log hours of operation to determine proper maintenance intervals Flywheel Brake Shoes Check 2 ...

Page 46: ...l drain through the filler neck Allow the oil to drain completely Please dispose of used motor oil and containers in a manner that is compatible with the environment NOTE Do not throw waste oil or containers in the trash or pour oil on the ground or down a drain We suggest you take it in a sealed container to your local recycling centre or service station for reclamation 4 Fill with the recommende...

Page 47: ...t transferred to the air cleaner housing and air cleaner NOTICE Running the engine with a low oil level can cause severe engine damage d Screw the oil filler cap dipstick securely Engine Oil Recommendations Oil is a major factor affecting performance and service life Use 4 stroke motor oil that meets or exceeds the requirements for API service classification SG or higher or equivalent Always check...

Page 48: ...16M2 are equipped with a Snorkel to help prevent dust entry Ensure the hose is properly attached and is in good condition at all times 1 Unscrew and remove the two air cleaner nuts then remove the air cleaner cover 2 Remove the filter elements from the air cleaner housing and remove the foam filter element from the paper filter element 3 Inspect the filter elements for holes or tears and replace t...

Page 49: ...o prevent dirt from entering the air duct that leads to the carburettor 6 Reinstall the filters and cover and where used tighten the air cleaner nuts securely Spark Plug Service Recommended spark plug GXV160 BPR5ES NGK or W16EPR U DENSO GCV160 GSV190 BPR6ES NGK NOTICE An incorrect spark plug can cause engine damage For good performance the spark plug must be properly gapped and free of deposits 1 ...

Page 50: ... Correct the gap if necessary by bending the side electrode 6 Install the spark plug carefully by hand to avoid cross threading 7 After the spark plug seats tighten with a spark plug wrench to compress the washer If reinstalling the old spark plug tighten to turn after the spark plug seats If installing a new spark plug tighten turn after the spark plug seats NOTICE A loose spark plug can overheat...

Page 51: ...y cause the engine to overheat and result in serious engine damage For use at low altitude have your servicing dealer return the carburettor to original factory specifications Fuel Recommendations Use unleaded petrol with a pump octane rating of 86 or higher This engine is certified to operate on unleaded petrol Unleaded petrol produces fewer engine and spark plug deposits and extends exhaust syst...

Page 52: ...by trained staff at an authorised Honda servicing dealer If you are replacing the blades use Honda genuine replacement blades or equivalent Removal 1 Turn the fuel valve to the OFF position 2 Disconnect the spark plug cap and tilt the mower to the right side so the carburettor side is facing up 3 Hold the blade disc firmly by inserting a suitable screwdriver through the blade disc to prevent it fr...

Page 53: ... washers blades blade disc removed 4 Remove the blade setting bolts blades spring washers blade washers and self lock nuts from the blade disc NOTE Do not mix up the Blade Setting Bolts and the Blade Holder Bolts NOTE DO NOT REMOVE CENTRE BOLT ON MODELS FITTED WITH BLADE BRAKE ...

Page 54: ...g bolt as described below 3 Tighten the self lock nuts with a torque wrench Prevent the blade disc from turning when tightening the self lock nuts tighten the self lock nuts to the specified torque The blade setting bolts are specially designed for the mower When you replace them use only Honda genuine parts Otherwise the blade may detach from the mower and cause serious injury Self lock nuts tigh...

Page 55: ...54 8 MAINTENANCE continued 4 Install the blade blade disc washers and blade disc holder bolts 5 Hold the blade disc firmly and install the blade disc holder bolts ...

Page 56: ...es contact the housing consult an authorised Honda servicing dealer A bent blade can be the cause of serious personal injury or accident If you don t have a torque wrench have an authorised Honda servicing dealer tighten the blade setting bolts and the blade disc holder bolt before you use the mower If the blade setting bolts and the blade disc holder bolt are over tightened they could break If th...

Page 57: ... completely before use a wet bag will clog quickly Grass Bag Replacement Replace a worn or damaged bag with a Honda genuine bag or its equivalent Bag Removal Unclip the plastic edges of the bag from the frame Remove the bag from the frame Bag Installation Insert the frame into the new bag Clip the plastic edges to the frame a shown ...

Page 58: ...ised Honda servicing dealer or refer to shop manual Fuel filter clogged carburettor 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 HIGH Move throttle to HIGH page 25 2 Check grass height Grass too tall to cut Raise cutting height page 23 cut narrower swath page ...

Page 59: ...n 7 Check that the throttle lever is in the HIGH position Engine speed is too slow to cut well Move throttle lever to the HIGH position page 25 8 Reduce forward speed Mower is moving too fast for lawn conditions Select a slower speed or release the drive clutch lever and push mower 9 Check cutting height adjustment levers Adjustment lever is set at incorrect positions Set lever at the correct heig...

Page 60: ...ITIES NOTE Overall height and wheel base are measured with cutting height set at 28mm third position from the bottom Model HRU216M2 HRU216K2 HRU196M1 HRU196K1 HRU197M1 Overall Length 1695mm 1540mm Overall Width 570mm 505mm Overall Height 1050mm 1025mm Dry Weight 53 0kg 44 0kg 40 0kg 36 0kg Wheel Base 25mm 565mm Tread Front 700mm 440mm Rear 500mm 458mm Cutting Width 530mm 470mm Grass Bag Cap 70ℓ 70...

Page 61: ...ENGINE DESIGN AND PERFORMANCE Model HRU216M2 HRU216K2 HRU196M1 HRU196K1 Engine Model GXV160H2 Engine Type 4 stroke overhead valve single cylinder Displacement 163cm Bore and Stroke 68 x 45mm Compression Ratio 8 0 0 2 Ignition System Transistor type magneto ignition Fuel Unleaded petrol with a pump octane rating of 86 or higher Engine Oil SAE 10W 30 API SG or higher 0 65 ℓ Engine Oil Capacity Spark...

Page 62: ...imum Engine Speed 3 100 0 rpm 150 rpm Idle Speed 1 700 150 rpm Valve Clearance cold Intake 0 15 0 02mm Exhaust 0 20 0 02mm Model HRU19M1 HRU19K1 Engine Model GCV160A0 Engine Type 4 stroke overhead valve single cylinder Displacement 160cm Bore and Stroke 64 x 50mm Compression Ratio 8 5 1 Ignition System Transistor type magneto ignition Fuel Unleaded petrol with a pump octane rating of 86 or higher ...

Page 63: ...n Operation Remote Control Number of Speeds 3 Speeds Lubrication System Oil Bath Splash Lubricant Hypoid Gear Oil SAE 90 Oil Capacity 0 2 ℓ Ground Speed 1st 0 8 m sec 2nd 1 1 m sec 3rd 1 4 m sec OPERATOR SAFETY FEATURES All Models MODEL HRU216 M2 HRU216 K2 HRU196 M1 HRU196 K1 HRU197 M1 HRU197 K1 HRU19 M1 HRU19 K1 FLYWHEEL BRAKE N N N Y Y Y Y Y BLADE CONTROL Y Y Y N N N N N AUTO STOP N N N Y Y Y Y ...

Page 64: ...lebar into the normal position Tighten the grip handle joints securely 2 Check that the rope guide is installed correctly and that the locking nut is tight 3 Ensure all cable ties are fitted correctly and that operating cables are correctly routed and not binding Refer Page 64 4 On Models fitted with a Snorkel check that the air cleaner hose is firmly connected to the air cleaner cover and throttl...

Page 65: ...ner hose with the cable ties as shown below Secure the cables with the cable ties as shown below 6 Fill Engine with appropriate Engine Oil Page 46 7 Fill Fuel tank with fresh Unleaded Petrol Page 20 12 Start and Run Engine 13 Confirm Operation of all controls and Levers ...

Page 66: ...r Service Record Record further services here Here is an easy way to keep track of the hours your Honda lawnmower has done Record how many hours you get from a tank of fuel then simply record the number of tanks used TANKS X HOURS per TANK TOTAL HOURS USE ...

Page 67: ...66 Part Number GS001 2010 ...