YEAR/MODEL ANNÉE/MODÈLE. GCV160LA0 R3A JAN Engine # 13. SERVICE BULLETIN "File Under Engine SAFETY RECALL

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1 BULLETIN DE SERVICE YEAR/MODEL ANNÉE/MODÈLE DATE OF ISSUE DATE EN VIGUEUR BULLETIN NUMBER NUMÉRO DU BULLETIN GCV160LA0 R3A JAN Engine # 13 SERVICE BULLETIN "File Under Engine SAFETY RECALL GCV160LA0 R3A ENGINE STOP SWITCH INSTALLED ON COLUMBIA (VD39E) LAWN MOWERS SYMPTOM: Honda Canada Inc. has initiated a safety recall of certain Honda GCV160LA0 R3A general purpose engines installed on Columbia, YardMan, Troy-Bilt and Cub Cadet lawn mowers. This recall only applies to the GCV160LA0 R3A (electric start) engines. Due to a manufacturing defect, the engine stop switch may become inoperative allowing the lawn mower engine to continue to run after the blade control lever is released. Because the blade continues to rotate, this poses a potential safety hazard to the operator or a bystander. The affected Serial numbers will not appear in Owner Information Inquiry. If a unit is presented for repair within the serial number range shown below, please contact Techline for confirmation that it is affected AFFECTED UNITS: The affected engine is used on various electric start walk behind lawn mowers. When determining affected units, refer to the Honda engine model and serial number range listed below. Mower Brand Lawn Mower Engine Model Model/Type Columbia 12ALD33Q897 GCV160LA0 R3A YardMan 12AEB12Q501 GCV160LA0 R3A Troy-Bilt 12ALD37Q563 GCV160LA0 R3A Cub Cadet 12ARD23Q596 GCV160LA0 R3A ENGINE SERIAL NUMBER RANGE GCV160LA0R3A GJARA thru GJARA Honda Canada Inc. All Rights Reserved Page 1 of 9

2 CORRECTIVE ACTION: Countermeasure flywheel brake and stop switch assemblies are available to correct this condition. These parts can be identified by the presence of a manufacturing code applied to the side of the stop switch. A new flywheel brake assembly must be installed on all affected units following the repair procedure starting on page 3. Units in Inventory: Affected units in warehouses will be repaired prior to shipment. The repaired engines can be identified by the following: Punch mark next to the engine serial number Registered Units: Registered owners of affected Columbia, YardMan, Troy-Bilt and Cub Cadet lawn mowers will be directly notified and asked to arrange to have the flywheel brake assembly replaced. A sample customer letter will be provided when it is available. Page 2 of 6

3 Repair Procedure Remove the Fan Cover/Fuel Tank 1. Disconnect the spark plug cap and turn the fuel valve to the OFF position. 2. Pull the blade control lever against the handlebar and hold it in position with a strap or rope. This will allow you to turn the flywheel to align the flywheel puller marks. 3. Remove the three 6 mm flange nuts and remove the recoil starter. 4. Remove the fuel cap and lift the fan cover/fuel tank off the studs and drain the fuel into an approved gasoline container. 5. Carefully disconnect the fuel hose from the fuel valve and remove the fan cover/fuel tank. Page 3 of 6

4 Remove the Flywheel 1. Position the flywheel holder P/N 07APB- Z28A100 on the flywheel and remove the 14 mm special nut as shown. The flywheel holder can be ordered through normal ordering routes. 2. Turn the flywheel so the PULLER mark and magnets are in the position shown. 3. Using a commercially available 6-inch puller, place the jaws under the PULLER marks. Place a shop towel between the puller and the flywheel to prevent damage to the ring gear. Make sure the puller jaw does not touch or interfere with the ignition coil. Remove the coil if necessary. 4. Tighten the flywheel puller and lightly tap the end of the puller with a brass hammer to remove the flywheel. 5. Release the blade control lever from the handlebar and disconnect the flywheel brake cable from the brake assembly. Page 4 of 6

5 Remove the Flywheel Brake Assembly 1. Remove the three 6 x 12 mm bolts and lift the wire clamp to gain access to the switch wires. 2. Remove the 6 x 14 mm bolt and 6 x 23 mm bolt from the brake assembly. Lift the flywheel brake assembly away from the engine. 3. Note the orientation of the black and red wires from the connectors and disconnect them from the stop switch. Install New Flywheel Brake Assembly 1. Install the new flywheel brake assembly and the remaining components in the reverse order of removal. Pay attention to the following: Verify the orientation of the red and black wire connector to the stop switch Make sure the Woodruff key is in place Make sure the wiring is properly routed before installing the wire clamp Tighten the flywheel nut to the specified torque TORQUE: 52 N m (38 ft lb) If the ignition coil was removed, adjust the coil to the specified air gap COIL AIR GAP: 0.2 ~ 0.5 mm (0.008 ~ in) 2. After installation is complete, start the lawn mower using the electric starter and confirm the engine quickly stops when the blade control lever is released from the handlebar. 3. Place a punch mark on the engine next to the serial number as shown, indicating the repair is complete. Page 5 of 6

6 SPECIAL TOOL: This service bulletin shows the following special tool: Tool Number 07APB-Z28A100 Description Flywheel holder PARTS INFORMATION: Order parts through your normal parts ordering procedures. Part Number Description Qty Z0L-824 Flywheel brake assembly 1 WARRANTY INFORMATION: VIN Information Honda Engine Model/Type GCV160LA0 R3A Engine Serial Number Range GJARA thru GJARA Be sure the warranty claim contains the following information: Failed Part Number: Z0L-824 Labour Operation Number 6141G5 Description Install a new flywheel brake assembly Flat Rate Time 0.4 hrs Defect Code: 7DD Symptom Code:J51 A long claim form will be required. Tech-line will provide will provide additional claiming instructions during VIN confirmation. Page 6 of 6