Small Engines (Lawn Mowers, etc.): Honda HR215KHMA wont start, tall fescue grass, amp fuse

Question
QUESTION: Honda HR215KHMA / MZAM-6282989 / GXV140 Engine

My very first lawnmower ran consistently for 7 years with reasonable maintenance - e.g. stabilizer with fuel, oil change, washing, WD40, etc.

Last week, it stopped after cutting about 1200 sq ft of 5" high tall fescue grass at maximum 3" height setting.

It would not start using the electric starter, so I used the manual pull starter and it ran for another 5 minutes, then stopped again. This time the electric nor manual start could get it going. I let it 'rest' for a 5 minutes, the tried the electric start again. It would start but the engine would not turn over. So, back to manual pull start and the mower would run for 2 minutes then stop again. After this the both the electric and manual start would start it, but it would stop as soon as it started.

Now, the mower does not start at all. The electric starter would click and whirr, but the engine would not turn over over. The manual starter does not work as the pull starter cord cant be fully pulled back - only pulls out 2 feet. The flywheel seems to be stuck or something is blocking the camshaft inside. I tried manually rewinding the flywheel, but it only goes about 1.5 turns, then gets stuck. Thus, even manually it cant be started.

Strangely, When the mower is turned on its right side, the flywheel can be turned/rotated all the way. I did not attempt to start it in this position though.

I also removed the cylinder head cover (with the OHV marking) to check if there is any broken rocker arm, but saw nothing broken at all.  

Note that the 1 amp fuse is newly replaced, the fuel is fresh, oil is filled to recommended level, fuel line is open, starter key is always set to ON position during attempts to start the mower.

I am quite handy with very little knowledge of small engines and would like to repair this myself. Based on the info, please advise if this is DIY repairable, and what I need to do, or if this unfortunately requires professional expertise.

Thanks in advance for your help.

Eric

ANSWER: Hello Eric:

You can View a Breakdown/IPL of the Mower/Engine at this Site Addy, http://hayward.arinet.com/scripts/EmpartISAPI.dll?MF&app=ASP&lang=EN&TF=Mainfram and Select the Catalog American Honda. With the Spark Plug Removed, is there Compression to Blow your Finger Off the Plug Hole? If the Connecting Rod has Not Broken, then Check the Valve Clearances. I Do Not Use the Setting Called for by the OEMs. I have Found that the Following Works Best. Remove the Valve Cover (on the Dead Cylinder for Twin Cylinder Engines). Set the Cylinder you are Setting the Valves on to Top Dead Center (Both Rocker Arms will have Play in them when the Engine is at TDC) When Setting the Valve Clearance. Now Loosen the Valve Adjuster Locks and Set the Intake Valve Clearance to .004in -.006in and the Exhaust to .008in - .010in. I have had Better Performance Out of the Mowers and Less Burnt Valves Using these Settings. If the Valve Clearances are Good, then Check for Spark at the Plug. If the Plug is Not Firing, then Check the Coil/Igniter/Magneto. Hope this Helps. I am Here if You Require More Assistance. Let me Know What Happens, Please. Thanks.

Good Luck

Respectfully

John

PS: I am Allowed to Answer 10 Questions a Day. If you See I am Maxxed Out, then Try Submitting your Question at or Just After 9pm EST (US). My New Day Starts then. Thanks.

Respectfully

John

---------- FOLLOW-UP ----------

QUESTION: Honda HR215KHMA / MZAM-6282989 / GXV140 Engine

Hello John,

The engine turned, but not successfully. Here's what I did: I installed a new/fresh spark plug and charged the battery overnight using its adapter/transformer. The flywheel would have to be turned
counter-clockwise for it to rotate clockwise to start and run.

I then used the electric starter and the HR215KHMA started with 'authoritative' power.

However, the flywheel/motor would turn over, but would immediately seiZe with a loud 'clank' sound as if metal was blocking the camshaft/crankshaft inside.

Sometimes, when started, the flywheel/motor would turn over, but the engine would NOT run by itself. The sound is 'flimsy' as if the piston is NOT moving/pumping at all. It would stop when I turn the starter key to OFF position, else it just keeps on turning without actually running by itself.

There seems to be something out of place in the crankshaft/camshaft area when the flywheel would not turn as if something is blocking what is attached to it.

I do not know if this is really the case, but that's how it felt when the flywheel turned over and immediately stopped, OR if it turned continuously BUT the engine would not run by itself.  

If something needs to be replaced inside the engine, I am ready to be guided. HELP!!!!

Again, your insights will be greatly appreciated.



Eric

Answer
Hello Again Eric:

From this Last Description, it Sounds like the Connecting Rod has Broken from the Piston. This is an Internal Repair and Most Times the Crankshaft Must be Replaced with the Connecting Rod. For this Type of Damage, I Suggest a Short Block Assembly. Hope this Helps. I am Here if You Require More Assistance. Let me Know What Happens, Please. Thanks.

Good Luck

Respectfully

John