crwdns2936637:0crwdne2936637:0 crwdns2853008:0crwdne2853008:0 crwdns2861143:0crwdne2861143:0

Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement

crwdns2915892:0crwdne2915892:0

This guide shows how to remove and replace the cast aluminum flywheel key on the Honda HRS216K6 lawn mower.

Drain the fuel from the fuel tank before you begin this procedure. Any fuel remaining in the tank will spill out. Be ready to contain any spillage.

You may need a blowtorch to help heat up and loosen the flywheel.

crwdns2942213:0crwdne2942213:0

  1. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Disconnect the spark plug: crwdns2935265:01crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Disconnect the spark plug: crwdns2935265:01crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Before you begin, make sure the engine is switched off and cool to the touch.

    • Grab the plastic housing at the end of the spark plug wire and pull firmly to disconnect it.

    crwdns2913378:0crwdne2913378:0

  2. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Restrict fuel flow: crwdns2935265:02crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Turn the fuel cutoff valve to the off position to restrict fuel flow during disassembly.

    • Turn the fuel cutoff valve clockwise so the handle becomes vertical.

    crwdns2913378:0crwdne2913378:0

  3. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Disconnect the fuel tank: crwdns2935265:03crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Disconnect the fuel tank: crwdns2935265:03crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Disconnect the fuel tank: crwdns2935265:03crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Use needle nose pliers to compress and slide the tube clamp away from the cutoff valve's fitting.

    crwdns2913378:0crwdne2913378:0

  4. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:04crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:04crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Residual fuel may leak out of this hose. Be ready to catch any spillage.

    • Disconnect the fuel line from the cutoff valve.

    crwdns2913378:0crwdne2913378:0

  5. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Disconnect the brake cable: crwdns2935265:05crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Use needle nose pliers to squeeze the two locking tabs on the brake cable latch.

    crwdns2913378:0crwdne2913378:0

  7. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:06crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:06crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:06crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Pull to unlatch the cable sheath.

    • Pull the brake cable away from the motor.

    crwdns2913378:0crwdne2913378:0

  8. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:07crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:07crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:07crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Push the cable towards the cable anchor to give it enough slack to be removed.

    • Remove the brake cable from the motor.

    crwdns2913378:0crwdne2913378:0

  9. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Disconnect the pull start cord: crwdns2935265:08crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Disconnect the pull start cord: crwdns2935265:08crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Disconnect the pull start cord: crwdns2935265:08crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Pull the pull start cord out of the small opening on the handle post and remove it.

    crwdns2913378:0crwdne2913378:0

  10. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Remove the fan cover: crwdns2935265:09crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Remove the three 10 mm nuts securing the fan cover.

    crwdns2913378:0crwdne2913378:0

  11. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:010crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:010crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove the fan cover.

    • The fuel tank is connected to the fan cover. They will both come out as one unit.

    crwdns2913378:0crwdne2913378:0

  12. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Remove the cooling fan: crwdns2935265:011crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Remove the 19 mm nut securing the flywheel and cooling fan to the motor.

    crwdns2913378:0crwdne2913378:0

  13. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:012crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement: crwdns2935265:012crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove the washer on top of the cooling fan.

    • Remove the cooling fan.

    crwdns2913378:0crwdne2913378:0

  14. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Loosen the flywheel: crwdns2935265:013crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Loosen the flywheel: crwdns2935265:013crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Caution: The flywheel may come loose at any time during this step, potentially sending itself and the puller into the air. Before you begin this step, be sure to wear PPE.

    • Use a universal puller to loosen the flywheel from the tapered pressure fit on the end of the crankshaft.

    • Attach the universal puller arms underneath the denoted "puller" sections on the flywheel.

    • Use a wrench to torque down the puller to slowly loosen the flywheel.

    • This may take a lot of force.

    • If the flywheel seems to become stuck after significant pressure is applied with the universal puller, use a blowtorch to slowly apply heat where the flywheel contacts the crankshaft.

    • The flywheel will "pop" off the crankshaft once loose.

    crwdns2913378:0crwdne2913378:0

  15. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Remove the flywheel: crwdns2935265:014crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Remove the flywheel: crwdns2935265:014crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Remove the flywheel: crwdns2935265:014crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Remove the flywheel.

    • If the flywheel became deformed at all during the last step, it will need to be replaced before reinstallation.

    • During reassembly, make sure to align the flywheel with the flywheel key.

    crwdns2913378:0crwdne2913378:0

  16. Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Remove the flywheel key: crwdns2935265:015crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Honda Lawn Mower HRS216K6 PKAA Flywheel Key Replacement, Remove the flywheel key: crwdns2935265:015crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Use needle nose pliers to remove the flywheel key from its slot in the crankshaft.

    • During reinstallation, make sure the key is fully seated in the slot. Otherwise the flywheel will not fit correctly.

    crwdns2913378:0crwdne2913378:0
crwdns2915888:0crwdne2915888:0

To reassemble your device, follow these instructions in reverse order.

crwdns2935229:02crwdne2935229:0

crwdns2862417:0crwdne2862417:0

crwdns2935291:0crwdnd2935291:01crwdnd2935291:0crwdne2935291:0

Carsten Frauenheim

crwdns2935283:003/10/20crwdne2935283:0

115,225 crwdns2915208:0crwdne2915208:0

crwdns2935297:0339crwdne2935297:0

crwdns2918514:0crwdne2918514:0: 40

crwdns2935301:037crwdne2935301:0

crwdns2915084:0crwdne2915084:0

iFixit crwdns2935289:0iFixitcrwdne2935289:0

Staff

crwdns2931471:0136crwdne2931471:0

crwdns2935297:017,420crwdne2935297:0

crwdns2944067:00crwdne2944067:0

crwdns2917038:0crwdne2917038:0

crwdns2936625:0crwdne2936625:0:

crwdns2936751:024crwdne2936751:0 0

crwdns2936753:07crwdne2936753:0 18

crwdns2936753:030crwdne2936753:0 83

crwdns2942667:0crwdne2942667:0 2,392