Honda HS828 Problems: Don’t Let Your Legendary Snow Blower Die
The Honda HS828 track-drive snow blower is a legend in the world of outdoor power equipment. For decades, it has been revered for its robust construction, powerful engine, and unstoppable traction. Many of these machines, built between 1991 and 1998, are still in service today, a testament to their incredible engineering.
However, this legendary status presents a critical problem for owners. The very age that proves its durability also makes it a ticking time bomb for specific, predictable failures that can leave you stranded in the middle of a blizzard. The core challenge is no longer just clearing snow; it’s keeping this vintage beast from becoming an unreliable liability when you need it most.
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The Unyielding Legacy of the Honda HS828
Understanding the HS828’s reputation is key to appreciating the importance of its upkeep. Powered by the venerable Honda GX240 8-horsepower engine, this machine was built for commercial-grade work. Its track drive system provides superior grip on steep inclines and icy surfaces, a feature that wheeled models simply cannot match.
The hydrostatic transmission allows for seamless speed adjustments without stopping, and its 28-inch clearing width can handle serious snowfall with ease. Users consistently praise its ability to throw snow incredible distances, clearing paths in a fraction of the time required by lesser machines. Yet, for every story of its power, there’s a growing chorus of owners facing frustrating, age-related mechanical issues.
The Core Problem: Why Your HS828 Fails to Start or Run Smoothly
By far, the most common complaints surrounding an aging Honda HS828 revolve around the engine. You pull the starter cord, and nothing happens. Or, it sputters to life, only to run rough, surge, or die under load. The primary culprit is almost always the fuel system, which was not designed to cope with the realities of modern gasoline.
The Fuel System Culprit: Varnish and Clogs
Modern gasoline contains ethanol, which is hygroscopic, meaning it attracts and absorbs water. Over time, this ethanol-and-water mixture can phase-separate in the fuel tank, leading to corrosion. More critically, as fuel sits, it degrades and forms a sticky varnish that wreaks havoc on the delicate passages inside the carburetor.
The main jet and pilot jet in the HS828’s carburetor have incredibly small openings. It takes only a microscopic amount of this varnish to restrict fuel flow, leading to a lean running condition. This is the root cause of engine surging, where the engine RPMs fluctuate up and down uncontrollably. Eventually, these passages can become completely blocked, preventing the engine from starting at all.
Ignition System Woes: Spark and Electrical Faults
While less common than fuel issues, the ignition system is another potential point of failure. The spark plug is a simple maintenance item that can become fouled with carbon deposits over time, leading to a weak or non-existent spark. An old spark plug wire or cap can also degrade, preventing the electrical charge from reaching the plug.
The engine’s on/off switch is a simple kill switch that works by grounding out the ignition coil. After decades of exposure to moisture and vibration, the wiring to this switch can become frayed or the switch itself can fail. This can result in an intermittent no-spark condition that is often frustrating to diagnose.
Mastering the HS828: Proactive Solutions for Peak Performance
Transforming your HS828 from an unpredictable machine into a reliable workhorse requires proactive, not reactive, maintenance. Addressing the common failure points before they leave you stranded is the key to another decade of faithful service. The focus should be on revitalizing the fuel system and preemptively servicing other critical mechanical components.
Step-by-Step Carburetor Revitalization
Do not fear the carburetor. With basic tools and a can of carburetor cleaner, you can solve 90% of the HS828’s running issues. The process involves removing, disassembling, cleaning, and reinstalling the carburetor. Always work in a well-ventilated area and take pictures with your phone at each step to ensure you can reassemble everything correctly.
First, turn off the fuel valve and drain any remaining gasoline from the carburetor bowl via the drain screw. Carefully disconnect the fuel line, throttle linkage, and choke linkage. Remove the two nuts holding the carburetor to the engine studs and gently pull it free. On a clean workbench, remove the float bowl, float pin, float, and needle valve. Then, carefully unscrew the main jet and the pilot jet. Thoroughly spray all metal parts and all internal passages with carburetor cleaner, using the small straw to direct the spray into the jet orifices. After a thorough cleaning, reassemble in reverse order. For many, purchasing a high-quality aftermarket carburetor can be a faster and surprisingly affordable solution.
The Unseen Failure Point: Proactive Gearbox Maintenance
One of the most critical, and most overlooked, maintenance items on a track-drive HS828 is the right-side auger drive gearbox. This sealed unit contains grease that, after 20-30 years, becomes dry and caked, offering zero lubrication. This inevitably leads to catastrophic gear and bearing failure, an expensive and labor-intensive repair.
A little preventative maintenance can completely avoid this disaster. A common and highly effective modification is to install a grease fitting (zerk) on the gearbox housing. By drilling and tapping a small hole, you can inject fresh grease annually, forcing out the old, dried-up lubricant and ensuring the internal components remain protected. This is the kind of expert-level service that ensures longevity and helps you understand how to stop spinning parts from causing catastrophic damage before it happens.
Beyond the Engine: Tackling Drive and Auger Issues
The HS828’s legendary status is built on more than just its engine; its mechanical systems for traction and snow-clearing are equally robust. However, age and use take their toll. Addressing wear and tear on the track drive, auger housing, and control systems is essential for maintaining full functionality and preventing costly component failures.
Diagnosing and Fixing Track Drive Slippage
The track drive system gives the HS828 its incredible climbing ability, but it requires proper tension to function correctly. If the tracks are loose, they can slip under load, especially when climbing a grade or pushing into a heavy snowbank. Track tension is adjustable via bolts located at the rear of the track assembly.
Another common issue sourced from owner forums is the failure of the auger housing height adjustment mechanism. Users report that the foot pedal used to raise and lower the auger housing can fail to lock in place, causing the housing to pop back up to its highest transport position. This is typically caused by worn teeth on the locking quadrant or a weak or broken return spring. Cleaning the entire mechanism of built-up ice and grime and inspecting these components can often solve the problem.
| Problem Symptom | Likely Cause | Solution |
|---|---|---|
| Engine surges or hunts at steady RPM. | Clogged pilot jet in the carburetor. | Thoroughly clean the carburetor with a focus on the pilot jet, or replace the carburetor. |
| Engine will only run with the choke partially on. | Clogged main jet in the carburetor. | Clean the carburetor, ensuring the main jet and emulsion tube are clear of debris. |
| Recoil starter rope pulls with no resistance. | Sticking or worn pawls (dogs) in the recoil assembly. | Disassemble the recoil starter, clean the pawl mechanism, and lightly lubricate. |
| Machine pulls to one side during operation. | Uneven track tension or unevenly worn skid shoes. | Adjust track tension to be equal on both sides. Adjust or replace skid shoes. |
| Auger housing won’t stay locked in a lowered position. | Worn locking teeth or weak spring in the height-adjust pedal mechanism. | Clean the mechanism thoroughly. Inspect for wear and replace worn components. |
| Augers turn but the machine throws snow poorly. | Broken shear pin on the impeller (second stage). | Inspect and replace the impeller shear pin located behind the main auger gearbox. |
Shear Pin Strategy: The Unsung Hero of Auger Protection
The auger system is protected by shear pins, which are designed to break if the augers hit a solid object like a rock or a frozen newspaper. This sacrificial pin saves the expensive auger gearbox from being destroyed. Always have several spare shear pins on hand during the winter.
It’s crucial to use only the correct OEM-spec shear pins from Honda. Using a standard bolt that is harder than a shear pin will not protect the gearbox. If you find yourself replacing shear pins frequently, you are likely operating with the auger housing too low for the surface conditions. Adjust the skid shoes to raise the scraper bar slightly off the ground, especially on gravel or uneven driveways.
The Financial Equation: Repair, Replace, or Restore?
When faced with a significant repair, owners must weigh the costs. Is it worth putting hundreds of dollars into a 30-year-old machine? The answer often comes down to the machine’s overall condition and the owner’s mechanical aptitude. For those comfortable with performing their own repairs, keeping an HS828 running can be very cost-effective.
However, if you are paying for shop labor, the costs can quickly add up. A major gearbox or transmission repair could easily exceed the value of the machine. This is where you have to ask yourself a question similar to a home renovation project: is it worth it to invest heavily in this older foundation, or is it time for a full replacement? A well-maintained HS828 can still outperform many new, mid-tier snow blowers, making a strong case for thoughtful restoration.
Your Pre-Winter Ritual: The HS828 Survival Checklist
A disciplined pre-season inspection is the most effective way to prevent in-season failures. Before the first snowflake falls, dedicate an afternoon to a thorough check-up. This simple ritual can be the difference between a smoothly cleared driveway and a frustrating, cold breakdown.
Start by changing the engine oil with a high-quality 5W-30 synthetic oil, which provides better cold-start protection. Install a new spark plug and check the gap. Inspect the auger and drive belts for cracks or glazing and replace them if they show any signs of wear. Finally, check the condition of the scraper bar and the skid shoes, adjusting or replacing them to ensure the auger housing is protected. Properly preparing and storing this heavy unit can be a logistical challenge, much like figuring out how to get drywall into basement spaces, but the effort pays off in reliability.
Final Verdict: A Legend Worth Preserving
The Honda HS828 is not merely an old snow blower; it is a piece of legendary engineering that, with proper care, can continue to serve for another generation. Its common problems are not signs of poor design, but predictable consequences of age and neglect. The key to its longevity lies in the hands of a knowledgeable and proactive owner.
By understanding its specific vulnerabilities—particularly the carburetor’s sensitivity to modern fuel and the need for proactive gearbox lubrication—you can transform this potential liability into your most trusted winter tool. The satisfaction of maintaining this classic machine and the unmatched performance it delivers make the Honda HS828 a legend that is absolutely worth preserving.
