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1. The tractor is equipped with switches and relays preventing inadvertent starting of the tractor engine or opera tion if the operator leaves the tractor seat The tractor engine should not start if the following occurs engage parking brake e Operator in the tractor seat shift lever in NEUTRAL and the PTO clutch lever in the ON position e Operator in the tractor seat PTO clutch lever in the OFF position and the shift lever in a position other than NEUTRAL e Operator not in the seat when starting the engine The seat switch should kill the en gine if the operator is not in the seat or leaves the seat when the PTO clutch is engaged or the tractor is in gear YARD amp GARDEN TRACTORS Fig HN1 4 Exploded view of steering gear assembly 1 Cover 10 Washer 2 Nut 11 Nut 3 Steering wheel 12 Bushing 4 Washer 13 Washer 5 Bushing 14 Sector gear 6 Steering shaft 15 Steering arm 7 Bushing 16 Washer 8 Steering plate 17 Steering gear 9 Gear holder Refer to the wiring schematics at end of this section ENGINE MAINTENANCE The engine is equipped with a dry air filter that should be cleaned and in spected after every 50 hours of opera tion SERVICE MANUAL Fig HN1 5 To bleed cooling system open air bleed screw S and proceed as de scribed in text Remove the foam and paper air filter elements from the air filter housing Wash the foam element in a mild deter gent an
2. B L Black Blue B Y Black Yellow W B White Black R B Red Black R W Red White Off R G Red Green On G B Green Black t Start G W Green White G R Green Red Battery Combination G L Green Blue switch G Y Green Yellow G O Green Orange L B Blue Black Y B Yellow Black Y G Yellow Green Starter Ignition coil Regulator rectifier Fig HN1 34 Wiring schematic 220
3. Remove regulator rectifier bracket as sembly from the engine Separate the wiring from the engine Remove the cooling fan Remove the PTO clutch as described in the PTO CLUTCH section Detach the PTO ca ble from the brackets Remove the engine mounting bolts and nuts Lift the engine and move it forward to separate the engine from the drive shaft and remove it from the trac tor Reverse the removal procedure to in stall engine Tighten front engine re taining nuts to 35 40 N m 26 29 ft lb OVERHAUL Engine make and model are listed in specifications table at the beginning of this section Refer to the appropriate Honda engine section in this manual for service information on the engine and associated accessories FUEL SYSTEM Refer to ENGINE and ELECTRICAL SYSTEM sections for fuel system re lated components not covered here FUEL FILTER MAINTENANCE A fuel filter is located in the fuel line between the fuel tank and the fuel pump The fuel filter is visible through a hole in the rear hitch plate Inspect the fuel filter annually or af ter every 100 hours of operation Re place the filter ifit is dirty or damaged FUEL PUMP The fuel pump is located on a bracket below the fuel tank Testing Before testing the fuel pump be sure the fuel filter and fuel line are in good condition and the fuel flow to the pump is unimpeded Connect a suitable pressure gauge to the fuel pump output port Turn the ig n
4. lb and outer nut 6 to 90 110 N m 67 80 ft lb During final assembly stake the outer nut 6 into the slot in the transaxle case Tighten the input shaft housing 83 Fig HN1 19 cap screws to 20 24 N m 15 17 ft lb Tighten the transaxle case cap screws to 8 14 N m 6 10 Tighten the axle shaft to rear wheel nut to 550 65 N m 40 47 ft lb Tighten the neutral switch to 16 20 N m 12 15 ft Ib Gear Shimming Procedure Input shaft gear and bevel gear con tact pattern and backlash must be checked if the input shaft 9 Fig HN1 19 input shaft bearing bevel gear gear shaft 6 Fig HN1 21 shims or transaxle cases have been re placed or changed Coat the input bevel gear 9 Fig HN1 19 with Prussian Blue or other suitable compound Make a trial as sembly by installing the input shaft as sembly and the mainshaft and bevel gear assembly in the transaxle cases using the original pinion shaft shim 10 Fig HN1 19 and mainshaft shim 1 Fig HN1 21 Assemble the case halves Rotate the input shaft in the normal direction then remove the shaft and check the contact pattern on the input gear teeth Contact area should be cen tered on the tooth surface Ifthe contact area is toward the outer edge of tooth install a thinner shim 10 Fig HN1 19 If contact area is to ward base of tooth install a thicker shim 10 After correctly adjusting the bevel gear teeth contact reassemble the transaxle
5. Check the bevel gear back lash Attach a hose clamp or other device to the mainshaft to provide a reading point Position a dial indicator on the mainshaft Fig HN1 23 Prevent the input shaft from turning using the clutch or other device Gently rotate the mainshaft back and forth while observ ing the dial indicator reading Backlash should be 0 016 0 026 mm 0 0006 0 0010 in If backlash is insuf ficient decrease the thickness of the mainshaft shim 1 Fig HN21 If backlash is excessive increase the shim s thickness PTO BELT ADJUSTMENT Adjust belt tension by turning the tension knob at front of tractor Belt tension is correct when the mark on the 216 WIP oR ENH Seal Bracket Bearing housing Gasket Bearing Outer nut Inner nut Bearing 21 Fig HN1 19 Exploded view of transaxle pinion shaft assembly and left axle shaft 9 10 11 12 13 14 YARD amp GARDEN TRACTORS Pinion shaft 15 Bearing Shim 16 Washer Transaxle case 17 Bearing half 18 Gasket Bearing 19 Transaxle Washer case Axle shaft half left 20 Oil seal 21 Oil seal 22 Fill plug 23 O ring 24 Dowel 25 Bearing 26 Bearing Fig HN1 20 Exploded view of transaxle Also refer to Fig HN1 19 and HN1 21 a Awy NAM Countershaft driven gear Countershaft Washer Mainshaft and change shaft assembly Washer Bearing Bearing 8 9 10 11 12 13 14
6. compressing the clutch pack remove the three nuts 23 Fig HN1 8 Slowly unscrew the spring compressor tool and disassemble the clutch pack The thickness of the clutch facing on the disc 12 Fig HN1 8 should be 5 9 6 1 mm 0 232 0 240 in Replace the clutch disc if worn to a thickness of 4 5 mm 0 177 in or less The spring 20 free length should be 58 2 mm 2 29 in Replace the spring if the free length is less than 56 2 mm 2 21 in Replace the clutch damper rubber 25 if damaged When reassembling the clutch refer to Fig HN1 8 Align the spring end with one of the three threaded studs on the pressure plate Fig HN1 11 In stall the clutch disc 12 Fig HN1 8 with the splined hub s long side toward the lifter plate 11 Tighten the nuts 23 and 10 Fig HN1 8 to 10 13 N m 88 115 in lb Tighten the screw 19 to 24 30 N m 18 22 ft lb Make certain the dust plate 4 is mounted on the clutch plate 2 and that the clutch plate studs are through the dust plate holes Honda 10 1mm 0 4 0 004 in Clevis pin Lower adjusting bolt Fig HN1 13 Adjust locknut on upper end of damper until there is 10 mm 0 4 in clearance between bottom of nut and the clevis pin If removed reinstall the clutch rod end Fig HN1 12 so the top of rod end is 37 39 mm 1 46 1 53 in above the stop plate Adjust the upper nut to ob tain the desired height and tighten the jam nut
7. in the N notch of the shifter console Move the shift lever to each gear posi tion on the console and check that the proper gear is engaged in transaxle Tighten the shift rod jam nuts REMOVAL AND INSTALLATION To remove the shift linkage remove the shift lever knob 1 Fig HN1 18 seat and rear fenders Remove the pivot bolt 11 and withdraw the shift lever 6 Remove the snap rings 2 and 3 and thrust washer 4 Pull the clutch roller 7 and bearing 5 off the shift le ver Detach the shift rod 17 from the shifter arm 16 Remove the clamp bolt 18 and withdraw the shift lever shaft 12 from the shifter arm 16 Inspect all parts for wear or damage and replace when necessary When installing the shift linkage align the punch marks on the shift le ver shaft 12 and shifter arm 16 Ad just the linkage as previously described Brake cam arm Brake drum Lock nut T Adjuster Spring sleeve PET Parking brake cable Pale S amp S oo ovocod Punch mark ce on Fig HN1 15 The end of the parking brake cable must align with the punch mark on the spring sleeve when the parking brake is engaged Refer to text Fig HN1 16 If brake wear indicator N is near wear limit point P replace brake shoes TRANSAXLE The tractor is equipped with a five speed transaxle The transaxle also provides a reverse gear A drum brake is attached to the transaxle mainshaft and
8. is located in a compartment on the right side of the transaxle Refer to previous sections for service information on brake and clutch assemblies LUBRICATION The transaxle oil level should be checked annually or after every 100 hours of operation The transaxle oil should be level with the bottom edge of the fill cap opening located at the rear SERVICE MANUAL Fig HN1 17 Exploded view of brake assembly 1 Screw 5 Brake shoes 2 Washer 6 Cam 3 Brake drum 7 Stud 4 Brake spring 8 Backing plate of the transaxle Be sure the machine is on a level surface when checking the oil level Oil capacity is 2 9 liters 3 1 qt Recommended oil is SAE 10W 40 en gine oil REMOVAL AND INSTALLATION Raise and support the rear of the tractor Remove the left and right wheels Remove drive shaft and drive clutch Disconnect shift rod from transaxle shift lever Disconnect all interfering electrical wires Remove the fuel pump Discon nect brake rod from the brake lever 9 Parking brake 11 Brake arm rod 12 Bolt 10 Brake rod 13 Seal of shift linkage Knob Snap ring Snap ring Thrust washer Ball bearing Shift lever Clutch roller Snap ring Sleeve Spring Bolt Change lever shaft 13 Thrust washer 14 Bushings 15 Bracket 16 Shifter arm 17 Shift rod 18 Clamp bolt 19 Transaxle shifter shaft Hm NESOCDIABMNRONE Support the transaxle and remove transaxle moun
9. 1 7 at the rear end of the clutch ca ble to obtain the desired cable free play Hold the shift lever all the way to ward the seat Adjust position of the stopper bolt 1 Fig HN1 8 so the end of the clutch rod lightly contacts the head of the stopper bolt INSPECTION To check the clutch s condition place the gearshift lever in the second speed slot Raise the seat and remove inspec tion hole cover The indicator mark on YARD amp GARDEN TRACTORS Shift Adjusting nuts Clutch arm amp 0 5 1 0 mm 0 02 0 04 in Fig HN1 7 Turn adjusting nuts at end of clutch cable to adjust cable free play Refer to text o __ R AG 20 G 7 ae Pe 22 2495 96 Fig HN1 8 Exploded view of drive clutch assembly 10 Lifter plate 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 mwne OCOAIAN Stop bolt Clutch plate Bolt Dust seal plate Clutch rod Bearing locknut Ramp Ball retainer Rear clutch housing Nut Clutch disc Pressure plate Special washer Bearing Bearing Collar Washer Cap screw Spring Clutch setting spring Clutch cover Nut Damper hub Damper Drive shaft SERVICE MANUAL Red mark Aligning marks Fig HN1 9 Measure the distance D be tween lifter plate and pressure plate to de termine clutch disc thickness Fig HN1 10 Exploded view of spring loaded clutch pack with special
10. 15 16 Bearing Setscrew Shifter arm Transaxle case right Oil seal Oil seal Oil seal Neutral switch Shifter shaft 17 18 19 20 21 22 Oil seal Bearing Washer 25 mm Axle shaft right Washer 20 mm Bearing SERVICE MANUAL Fig HN1 21 Exploded view of transaxle mainshaft and change shaft 1 Shim 2 Main 5 gear 37T 3 Main 4 gear 28T 4 Main 3 gear 21T 5 Main 2 gear 16T 6 Mainshaft amp bevel pinion gear 7 Belleville washer 8 Countershaft drive gear 9 Thrust washer 10 Change 5 gear 32T 11 Spacer 2 mm 12 Change 4 gear 41T 13 Change 3 gear 48T 14 Change 2 gear 53T 15 Change 1 gear 56T 16 Neutral positioner 17 Reverse chain 18 Reverse gear 19 Spacer 1 mm 20 Detent spring 3 21 Detent ball 3 22 Spring pin 2 23 Key holder 24 Change shaft Fig HN1 22 Exploded view of differential assembly 1 Washer 6 Side gear 2 2 Bearing 7 Spring pin 3 Ring gear 8 Shim washer 4 Differential case 9 Pinion gear 2 5 Thrust washer 2 10 Pinion shaft Dial indicator Mainshaft shim Fig HN1 23 Use a dial indicator to mea sure bevel gear backlash Refer to text Belt tension adjusting knob Tension arm Tension indicator Alignment mark Fig HN1 24 Turn belt tension adjusting knob to adjust PTO belt tension Refer to text idler bracket aligns with the mark on the tension b
11. 18 down Push down on the friction disc hub so it contacts the pulley bearing Fig HN1 27 Measure the height H of the friction disc hub above the back face of the clutch bracket Install shim thickness based on hub height above the bracket face as specified in the fol lowing table Hub Height Shim Thickness Over 6 00 mm 0005 1 10 mm 0 236 in 0 043 in 5 90 6 00 mm 0 0c cease 1 20 mm 0 232 0 236 in 0 047 in 5 80 5 90 mm eee eens 1 30 mm 0 228 0 232 in 0 051 in 5 70 5 80 MM ee eee eee 1 40 mm 0 224 0 228 in 0 055 in 5 60 5 70 MM 2 cece e eee 1 50 mm 0 220 0 224 in 0 059 in Under 5 60 mm 8 1 60 mm 0 220 in 0 062 in After assembly measure the clear ance between the side plate Fig HN1 25 and friction disc then measure the clearance between the friction disc and clutch plate Add the clearances to gether Total clearance should be 0 6 mm 0 024 in Rotate the adjusting screw to obtain the specified clearance Adjust the PTO control cable as de scribed in the previous section With the engine stopped move the PTO con trol lever to the engaged position Mea sure the gap between the brake pad on the brake disc 5 Fig HN1 26 and the back face of the bracket 12 The gap should be 1 5 2 3 mm 0 060 0 090 in If the gap is not correct repeat ad justments ELECTRICAL SYSTEM Engine related electrical compo nents s
12. SERVICE MANUAL HONDA Honda CONDENSED SPECIFICATIONS Models Engine Make Model Number of cylinders Bore Stroke Displacement Power Rating Slow Idle High Speed No Load Crankcase Capacity Transaxle Capacity Coolant Capacity HT3813 HT4213 Honda GX360 2 58 mm 2 28 in 68 mm 2 68 in 359 cc 21 9 cu in 9 7 kW 13 hp 1300 rpm 3300 rpm 1 4 L 1 5 qt 2 9 L 3 1 qt 1 35 L 1 4 qt If installing new filter check oil level after running engine for a few minutes Fig HN1 1 Exploded view of front axle assembly 1 Spindle left 4 Tie rod 2 Bushing 5 Washer 3 Axle main member 6 Bolt 7 Steering lever 8 Drag link 9 Bolt 10 Snap ring 11 Spindle right NOTE Honda special tools may be required for some proce dures and are indicated in the text Read the text completely before attempting procedure FRONT AXLE AND STEERING SYSTEM MAINTENANCE Lubricate the steering spindles an nually or after 100 hours of operation Inject multipurpose grease into the grease fittings at the axle s outer ends Clean the grease fittings before and af ter lubrication FRONT WHEELS AND BEARINGS Each front wheel is supported by two sealed ball bearings not requiring peri odic lubrication Replace the bearings if they are loose or do not spin smoothly Tighten the bearing retaining nut to 55 65 N m 40 47 ft lb Secure the nut with a cot ter pin TIE ROD AND
13. TOE IN The tie rod 4 Fig HN1 1 is equipped with threaded ends at each end Replace the tie rod if the ends are damaged The recommended front wheel toe in is 6 14 mm 0 24 0 55 in Measure the 209 a Fig HN1 2 Measure distance A and B at front and rear of front wheels to deter mine front wheel toe in distance A Fig HN1 2 between the front of the front wheels at hub height and the distance B between the rear of the front wheels The front distance A should be smaller than the rear dis tance B To adjust toe in loosen the locknut at each tie rod end and rotate the tie rod NOTE Left tie rod end and nut have left hand threads STEERING SPINDLES REMOVAL AND INSTALLATION To remove the steering spindle raise and support the front of the tractor Re move the front wheel Disconnect tie rod end from spindle To remove the left spindle 1 Fig HN1 1 remove the clamp bolt 6 and detach the steering arm 7 from the spindle Slide spindle out of the axle When installing the steering lever align the punch mark on the spindle end with the punch mark on the steer ing arm Fig HN1 3 To remove the right spindle 11 Fig HN1 1 detach the snap ring 10 and slide the spindle out of the axle AXLE MAIN MEMBER REMOVAL AND INSTALLATION The complete front axle assembly may be removed as a unit To remove the axle main member 3 Fig HN1 1 raise and suppo
14. To determine if the clutch damper is functioning properly remove the damper and suspend a 3 5 kg 7 7 lb weight from the bolt end of damper Af ter fully compressing the damper mea sure the time required for the weight to fully extend the damper A normally functioning damper should extend in 3 4 4 3 seconds on Models HT3813KO or 2 7 3 4 seconds on Models HT3813K1 and HT4213 Al lowable limit is 3 2 4 5 seconds on Models HT3813K0 or 2 4 3 8 seconds on Models HT3813K1 and HT4213 Before installing the damper adjust the bolt position at the damper s lower end The end of the adjusting bolt should be 25 27 mm 0 98 1 06 in from the upper end of slot in the damper bracket Tighten jam nut to hold the bolt s position Install the damper Move the shift le ver to NEUTRAL Thread the lower locknut Fig HN1 13 onto the damper as far as it will go toward the damper body Compress then release the damper Be sure the lower adjusting bolt is seated against the flat pin in the damper bracket Fig FN1 13 Turn the damper upper locknut so it is 9 11 mm 0 35 0 43 in above the clevis pin Fig HN1 13 Hold the up per nut so it cannot turn then rotate the lower nut so the clevis pin is forced up against the upper nut BRAKE The tractor is equipped with a drum brake located in the transaxle case The brake drum is mounted on the transaxle countershaft 213 Honda The brake may be actuated either with the clutch
15. as necessary so the total A plus B clearance is 0 6 mm 0 02 in The PTO operating lever free play should be 1 3 mm 0 04 0 1 in mea sured at the lever s outer end To adjust free play raise the hood and rotate ad justing nuts at the end of the clutch ca ble housing Tighten the nuts and recheck free plhaOVERHAUL Before removing the PTO clutch dis connect the negative battery cable Re move the hood radiator fan and mower drive belt Disconnect the PTO clutch cable 4 Fig HN1 26 Detach the clutch return spring 2 Fig HN1 26 Unscrew the retain ing screw 24 and remove the fan hub 22 and clutch assembly from the en 217 Honda gine crankshaft Remove the nuts from the special bolts 3 and remove the brake disc 5 ball retainer 9 and ball control plate 7 Unscrew the nuts and bolts securing the clutch components Separate the drive pulley 18 and clutch compo nents 12 17 The standard brake disc 5 lining thickness is 7 0 mm 0 28 in Replace the brake disc if the lining is less than 5 0 mm 0 20 in Standard friction disc 18 lining thickness is 6 0 mm 0 24 in Replace the brake disc if the lining is less than 3 0 mm 0 12 in The brake and friction discs must be replaced as a set Do not replace one without replac ing the other To determine the correct shim thick ness 11 Fig HN1 26 assemble the components 12 20 Place the assem bly on a bench with the pulley
16. brake pedal or the park ing brake lever The clutch brake pedal actuates both the clutch and brake When the parking brake lever is en gaged an indicator lamp lights If the parking brake is engaged when the transmission is shifted into gear a warning buzzer sounds ADJUSTMENT Depressing the brake pedal disen gages the drive clutch and applies the brake Brake pedal rod must be ad justed so there is no clearance Fig HN1 14 between the end of operating rod and the front end of the brake pedal slot when the brake pedal is released To adjust loosen the jam nuts 2 and turn the brake rod 4 to remove any clearance When new brake shoes are installed turn the cam plate rod adjusting nut 6 Fig HN1 14 so there is a slight clearance between the rod end and the bottom end of the slot in the cam arm plate 5 when the brake pedal is re leased To check for proper parking brake ca ble adjustment pull the parking brake lever up until the ratchet locks The end of the parking brake cable should be aligned with the punch mark on the spring sleeve Fig HN1 15 To adjust loosen the cable adjuster locknut and turn the adjuster as required OVERHAUL To check brake shoe wear depress the brake pedal and note position of the brake wear indicator N Fig HN1 16 located near the brake assembly on the transaxle If the indicator is near the wear limit point P replate the brake shoes To remove the brake shoes remo
17. d water solution Rinse in clean water and allow to air dry After the foam element is dry soak it in clean engine oil Squeeze out excess oil Paper element may be cleaned by di recting low pressure compressed air stream from inside the filter toward the outside Replace the paper element if it can not be cleaned satisfactorily or if it is damaged The engine oil level should be checked prior to operating engine Check the oil level with the oil cap not screwed in but just touching the open ing s threads Oil should be changed after the first 20 hours of engine operation and after every 100 hours thereafter Change the oil filter after every 300 hours of opera tion or after two years Use oil meeting the latest API service classification Use SAE 10W 30 or 10W 40 oil use SAE 10W 40 if the tem perature is above 90 F 32 C Crankcase capacity is 1 4 liters 1 5 qt REMOVAL AND INSTALLATION Raise the hood and disconnect the battery cables Disconnect the head light wiring connector and remove bolt from the ground lead Remove the hood hinge bolts and remove the hood Drain the coolant Detach the radia tor hoses and remove the radiator Loosen the PTO belt tension knob and remove the mower drive belt Detach the engine ground cable from the front frame crossmember Discon nect the throttle cable Disconnect the fuel hoses Disconnect the wiring from the start ing motor charge coil and ignition coil
18. ent balls 21 and springs 20 when separating the gear selector 23 and sliding gear shaft 24 NOTE Ring gear 3 Fig HN1 22 retaining screws have left hand threads To disassemble the differential re move the bearings 2 Fig HN1 22 from the differential case 4 Unscrew the ring gear screws left hand threads and separate the ring gear 3 from the case Drive out the spring pin 7 and remove the pinion shaft 10 side gears 6 and pinion gears 9 and thrust washers 5 and 8 Inspect all parts for damage and re place when necessary Install new oil seals and gaskets when assembling When reassembling transaxle note the following If input shaft 9 Fig HN1 19 input shaft bearing bevel gear main shaft 6 Fig HN1 21 shims or transaxle cases were replaced refer to the following section for the shimming procedure Washers 11 Fig HN1 21 are 2mm 0 080 in thick and the washer 19 is 1 mm 0 039 in thick Install a Belleville washer 7 so the cup side is toward the gear 6 Install countershaft drive gear 8 so the extended hub is toward end of sliding gear shaft 24 Install the countershaft driven gear 1 Fig HN1 20 so the extended hub is facing away from the countershaft gear teeth Tighten the ring gear 3 Fig HN1 22 retaining screws left hand threads to 45 55 N m 33 40 ft lb 215 Honda Tighten the inner pinion gear nut 7 Fig HN1 19 to 70 80 N m 52 58 ft
19. in text Refer to test table Fig HN1 32 for 6 a a a oo a test values 1 Green Yellow I 4 Green 2 Green White 5 Green Red 3 Green Yellow II 6 White Black Starter relay harness Fig HN1 32 Diode test table Refer to Fig HN1 31 for terminal identification yale Fuse box LIA S A A d Rear wire Relay bracket 7 Control relay Main wire harness Fig HN1 33 Electrical system relays are mounted on the relay bracket located next to the battery should read infinity except in the three tests where 1 200 ohms should be found FUSES A 20 amp main fuse Fig HN1 33 protects the electrical system Three 5 amp fuses are also used to protect some circuits The fuses are located on a bracket adjacent to the battery WIRING DIAGRAM The wiring schematic for the tractor is shown in Fig HN1 34 219 Honda YARD amp GARDEN TRACTORS Diagram Key iy Connectors Ground Frame ground umo ja 4 Connection f No connection W B G R G Diode GIY G W PTO G Y e W B z clutch G B switch Headlight R W switch R W Parking brake switch Neutral switch Headlight Fuel pump Seat switch G L Parking G Y brake lamp Thermo switch G L Overheat G W alert lamp Color Code B Black w White R Red G Green L Blue Y Yellow Charging Br Brown coil Gr Gray Dg Dark green B W_ Black White B R Black Red
20. ition switch ON but do not start the engine Fuel pump pressure should be 6 9 14 2 kPa 1 0 2 0 psi Direct a hose from pump output port into a container Turn the ignition switch ON but do not start the engine Fuel pump volume should be at least 350 cc 11 8 oz during one minute of operation COOLING SYSTEM Cooling components on the engine such as the water pump and thermo Honda stat are covered in the appropriate Honda engine section at rear of this manual MAINTENANCE Maintain the coolant level between the reservoir tank s MIN and MAX marks The recommended coolant is a 50 50 mixture of clean water and per manent antifreeze Periodically clean debris from the ra diator screen Periodically inspect cool ant hoses between the radiator and engine water pump Replace damaged hoses WARNING Coolant in the sys tem is pressurized Remove the pressure cap only when engine is cold Change the coolant at least every two years Flush the cooling system at least every three years Coolant system ca pacity is approximately 1 35 liters 1 4 qt CHANGE COOLANT Remove the engine s pressure cap C Fig HN1 5 Drain coolant by open ing radiator drain valve WARNING Coolant in the radia tor is pressurized Remove pres sure cap only when the engine is cold Empty the reservoir tank Close the radiator drain valve Open the air bleed screw S Fig HN1 5 Refill with a 50 50 mixture of clean wa
21. o test table Fig HN1 30 for test values Tester lead Ti T2 T3 T4 T5 T1 A B E T2 C C y Ta c JaA c n G T4 D E D T B A A A Fig HN1 30 Regulator rectifier test table Refer to Fig HN1 28 for terminal identifica tion A Infinity B 0 2k 5k ohms C 0 5k 20k ohms D 1k 50k ohms E 0 5k 10k ohms To test the diode disconnect wire con nector from diode and use an ohmmeter set on Rx1 Refer to Fig HN1 31 In three separate tests connect the positive ohmmeter lead to terminal 2 and the negative lead to terminal 1 the positive ohmmeter lead to terminal 4 and the negative lead to terminal 3 the positive ohmmeter lead to terminal 6 and the negative lead to terminal 5 In the foregoing tests the ohmmeter should read 1 200 ohms Fig HN1 32 Connect the ohmmeter to all other terminal combinations Ohmmeter Honda Fig HN1 28 Drawing showing wiring har ness routing 1 Headlight switch 8 Charge coil 2 Fuse box 9 Rear wire harness 3 Main wire harness 10 Fuel pump 4 Ground cable 11 Neutral switch 5 Regulator rectifier 12 Parking brake switch 6 Thermoswitch 13 Seat switch 7 Starter motor 14 Combination switch 1 3 3 X 1 2 3 4 5 6 1 1 200 o0 oo oo o0 2 e ee e o0 3 co o0 1 200 o0 o0 2 4 6 4 o Fig HN1 31 Connect ohmmeter to diode 5 o0 00 1 200 terminals and refer to diode test procedure
22. racket Fig HN1 24 REMOVAL AND INSTALLATION To remove the PTO belt lower the mower deck Loosen the belt tension knob Raise the idler pulley and remove the belt from pulleys and mower deck Open the hood and detach the belt guide Open the upper radiator shroud and remove the belt from the top by routing it past the radiator Install the belt by reversing the re moval procedure Position the belt guide 3 6 mm 0 12 0 18 in from pul ley Adjust belt tension as described in previous section Honda E P Clutch plate c os Friction disc Blk Clutch side plate amp 5 Clearances Lock nut Adjusting bolt O Fig HN1 25 Use a feeler gauge to mea sure the PTO clutch plate clearances A and B Refer to text PTO CLUTCH A cable actuated disc clutch is at tached to the end of the engine crank shaft A switch prevents the engine starting if the PTO operating lever is in the engaged position ADJUSTMENT To adjust the PTO clutch open the hood and move the PTO clutch lever to the OFF position Using a feeler gauge measure the clearance A Fig HN1 25 between the clutch plate and friction disc and clearance B between the friction disc and the clutch side plate Add the two measured clearances together Loosen the locknut and turn the adjusting bolt
23. rt the front of the trac tor Disconnect the drag link s 8 outer end Support the axle main member and remove the axle retaining bolt 9 Lower the axle main member from the mainframe pivot point and roll the axle out from under the tractor When installing the axle main mem ber tighten the axle retaining bolt to 45 55 N m 33 40 ft lb 210 Punch marks KY Punch marks Spindle Fig HN1 3 Align punch marks on steering lever and spindle during assembly STEERING GEAR OVERHAUL To remove the steering shaft and gear assembly remove the cover 1 Fig HN1 4 and nut 2 Remove the steering wheel 3 and flat washer 4 Disconnect the drag link end and steering arm 15 Remove the cap screws retaining the steering plate 8 Remove the three cap screws retaining the steering gear holder 17 Remove the nut 11 and pull the steering shaft 6 out of the tractor Remove the gear 9 and washer 10 Remove the steering gear 14 and washers 13 and 16 Replace the bush ings 5 7 and 12 as required Reverse the removal procedure for reassembly Make certain the front wheels are straight ahead the larger opening in the steering wheel is toward the top and the steering gears are meshed in the center of the gear 14 during reassembly Tighten the three bolts retaining the steering gear holder 17 to 23 30 N m 17 22 ft lb and nuts 2 and 11 to 45 54 N m 33 40 ft Ib SAFETY INTERLOCK SYSTEM
24. spring compressor tool 07960 75000A Nut Washer Special tool Special tool 11 Lifter plate 12 Clutch dise 13 Pressure plate 20 Spring 22 Clutch cover Owe the clutch lever should be between the two notches on the clutch housing Fig HN1 9 If the indicator mark is past the red notch on the clutch housing clutch disc must be replaced Measure the distance D between the lifter plate and pressure plate The permissible range is 4 5 6 1 mm 0 18 0 24 in If the measurement is less than 4 5 mm 0 18 in clutch disc is excessively worn If distance is more than 6 1 mm 0 24 in clutch is out of adjustment OVERHAUL Remove the seat and rear fenders Remove the drive shaft Disconnect all clutch linkage Remove three screws retaining the damper hub 24 Fig HN1 8 and re move the hub Remove the cap screw 19 and washer 18 Remove the three nuts 10 and slide the clutch assembly off the transaxle input shaft Use a spanner wrench or special tool 07916 3710100 to remove the left hand thread bearing locknut 6 Use special Spring end Threaded stud O Fig HN1 11 Align end of clutch spring with threaded stud prior to assembly Fig HN1 12 Adjust upper nut so clutch rod end height A is between 37 39 mm 1 45 1 53 in spring compressor tool 07960 750000A or other suitable tool to compress the spring 20 in clutch pack Fig HN1 10 With the tool
25. sure the clutch is not worn exces sively before attempting clutch adjust ment See INSPECTION section With the shift lever in the second gear slot measure the lever free play between the side of the lever and the closed end of the slot The permissible range for lever free play is 3 12 mm 0 12 0 47 in desired free play is 7 8 mm 0 27 0 31 in Adjust the shift lever free play by al tering length of clutch rod 2 Fig HN1 6 Turn the adjusting nut 1 clockwise to increase free play or coun terclockwise to decrease free play NOTE Shift lever free play af fects clutch engagement time 212 Spring 13 Bushing 2 14 Clutch arm shaft 15 Stopper arm 16 Spring Change arm bracket Bushing 2 Washer 2 Less free play will slow the clutch engagement time more free play will make the clutch en gage faster Start the engine and shift the trans mission into first gear Note the clutch engagement time it should be less than one second If necessary adjust shift le ver free play to obtain desired clutch engagement action If proper clutch en gagement cannot be obtained by adjust ing the shift lever free play within the permissible range the clutch may be faulty Clutch cable free play should be 0 5 1 0 mm 0 02 0 04 in To adjust re move the seat and rear fenders Shift the transmission into second gear Push the clutch arm towards the shift lever and hold it there Adjust the nuts Fig HN
26. ter and per manent antifreeze Pour coolant into the fill hole until air free coolant runs out of bleed screw hole then reinstall the bleed screw Position the pressure cap on the filler neck but do not tighten the cap Run the engine until the upper radiator hose becomes warm Stop the engine and add coolant through the filler neck as needed Install and tighten the pres sure cap Fill the reservoir tank with coolant to proper level Run the engine while monitoring the engine temperature to be sure the engine does not overheat Allow the engine to cool and recheck the coolant level HOSE ROUTING The left radiator hose connects to the thermostat housing The right radiator hose connects to a spigot on the right side of the cylinder block Bypass hose attaches to a spigot at the right rear of 211 Honda Fig HN1 6 Exploded view of clutch linkage Adjust clutch rod 2 length by turning nuts 1 at rod end 1 Adjusting nuts 2 Clutch rod 3 Clutch cable 4 Damper arm 5 Damper 6 Adjustment bolt 7 Damper spring 8 Clutch arm the cylinder block and connects to the thermostat housing CLUTCH The clutch is a disc that is actuated by linkage connected to the shift lever and clutch brake pedal The clutch is disengaged when the shift lever is moved to another slot or the brake is applied A hydraulic cylinder damper attached to the clutch linkage regulates clutch engagement speed ADJUSTMENT Be
27. ting bolts Lower the transaxle assembly out of the frame and pull the transaxle from the tractor Reinstall by reversing the removal procedure Tighten transaxle retaining screws to 24 30 N m 18 22 ft lb Refill transaxle with oil as described in the LUBRICATION paragraph Ad just brake clutch and shift linkage as previously described OVERHAUL Remove the drain screw and drain the oil from the transaxle Remove the Fig HN1 18 Exploded view Honda brake assembly Unscrew and remove the input shaft bearing housing 8 Fig HN1 19 Break or bend back the staked area of nut 6 Using Honda tool 07916 7500000 unscrew the nut 6 and remove the input shaft 9 The old nut should be discarded If bearing 8 must be removed use Honda tool 07916 7500000 to unscrew the nut 7 Remove seal 1 and drive or press out the bearing 5 Unscrew and separate the transaxle case halves 11 and 19 Remove the left axle shaft 14 bearings and seals as needed from the left housing 19 Remove the countershaft gear 1 Fig HN1 20 and shaft 2 differ ential assembly 23 and mainshaft and sliding gear shaft as an assembly 4 from the right hou Remove the setscrew 9 from the shift arm 10 and pull the shift shaft 16 out of the housing Re move bearings and seals from the hous ing as needed Separate the gears from the mainshaft 6 Fig HN1 21 and slid ing gear shaft 24 Be careful not to lose the det
28. uch as the starter are covered in the appropriate Honda engine sec tion at the rear of this manual 218 a Fig HN1 26 Exploded view of PTO clutch REGULATOR RECTIFIER The regulator rectifier is attached to a bracket on the left side of the engine and can be identified by the fins on the body Fig HN1 28 To test the unit connect an ohmme ter to the terminals of the regulator rec tifier Fig HN1 29 as indicated in the chart in Fig HN1 30 Replace the regu lator rectifier if the specified values are not obtained DIODE The tractor is equipped with a six terminal diode in the fuel control circuit The diode is located below the PTO control lever YARD amp GARDEN TRACTORS 4 5 amp i ZS JE g g 1 Spring bracket 10 Key 18 Pulley 2 Spring 11 Shim 19 Bearing 3 Special bolt 12 Clutch cover 20 Snap ring 4 PTO cable 13 Side plate 21 Key 5 Brake disc 14 Friction disc 22 Fan hub 6 Spacer 15 Clutch plate 23 Washer 7 Ball control plate 16 Spring seat 24 Screw 8 Adjusting bolt 17 Spring 25 Fan 9 Ball retainer Friction disc Pulley bearing Fig HN1 27 Measure clutch disc hub height H to determine adjusting shim thickness Refer to text SERVICE MANUAL T4 T5 T1 T3 T2 Fig HN1 29 Connect ohmmeter to regula tor rectifier terminals and refer to regula tor rectifier test procedure in text Refer t
29. ve the seat rear fender and wire protector Raise the tractor s right side so the transaxle oil will not flow out Remove the screw 1 Fig HN1 17 washer 2 and brake drum 3 Remove the brake spring 4 and shoes 5 Brake lining thickness wear limit is 2 35 mm 0 093 in Ifthe brake cam 6 is removed reinstall the cam in the brake arm 11 so the punch marks on the cam and arm are aligned Adjust the brake linkage as previ ously described SHIFT CONTROL LINKAGE ADJUSTMENT The operator gearshift lever and transaxle gear selector arm must be 214 No clearance YARD amp GARDEN TRACTORS ND 3 Fig HN1 14 Adjust brake rod 4 so there rod and front end of brake pedal slot P 4 O is no clearance between the end of the brake 1 Brake pedal 4 Brake rod 7 Cam arm 2 Jam nuts 5 Cam plate 8 Brake drum 3 Clutch cable 6 Adjusting nut 9 Parking brake lever synchronized for proper gear selection Loosen jam nuts on the rod and rotate the rod end to adjust the rod length NOTE Rear jam nut has left hand threads The punch marks P Fig HN1 18 on the shift lever shaft 12 and shifter arm 16 must be aligned Move the shift lever to NEUTRAL Check the punch mark on the transaxle shifter shaft 19 aligns with the index mark cast in the top of the transaxle case Adjust the shift rod 17 length so the shift lever 6 is centered

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