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GX25

SERIAL NUMBER ENGINE TYPE

OWNER’S MANUAL

1

Honda Motor Co., Ltd. 2002

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Thank you for purchasing a Honda engine.

This manual covers the operation and maintenance of your engine.

All information in this publication is based on the latest product information available at the time of printing.

Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.

No part of this publication may be reproduced without written permission.

This manual should be considered a permanent part of the engine and should remain with it if it is resold.

Pay special attention to statements preceded by the following words:

Indicates a strong possibility of severe personal injury or death if instructions are not followed.

Indicates a possibility of personal injury or equipment damage if instructions are not followed.

Indicates that equipment or property damage can result if instructions are not followed.

Gives helpful information.

If a problem should arise, or if you have any questions about your engine, consult an authorized Honda dealer.

The Honda engine is designed to give safe and dependable service if operated according to instructions. Read and understand the

Owner’s Manual before operating the engine. Failure to do so could result in personal injury or equipment damage.

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SAFETY INSTRUCTIONS

To ensure safe operation −

Honda engine is designed to give safe and dependable service if operated according to instructions. Read and understand the

Owner’s Manual before operating the engine. Failure to do so could result in personal injury or equipment damage.

Do not start the engine without mounting it on an equipment. It is designed to give safe and dependable service only when it is mounted on an equipment. Before operating the engine, read and understand the Owner’s Manual furnished with the equipment along with this Owner’s Manual.

Always make a pre-operation inspection (page 5 ) before you start the engine. You may prevent an accident or equipment damage.

To prevent fire hazards and to provide adequate ventilation, keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Do not place flammable objects close to the engine.

Children and pets must be kept away from the area of operation due to a possibility of burns from hot engine components or injury from any equipment the engine may be used to operate.

Know how to stop the engine quickly, and understand the operation of all controls. Never permit anyone to operate the engine without proper instructions.

Do not place flammable objects such as gasoline, matches, etc., close to the engine while it is running.

Refuel in a well-ventilated area with the engine stopped.

Gasoline is highly flammable and explosive under certain conditions.

Do not overfill the fuel tank. There should be no fuel in the filler neck.

Make sure that the filler cap is closed securely.

If any fuel is spilled, clean it up completely and allow petroleum vapours to dissipate before starting the engine.

Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stored.

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Safety Instruction

To ensure safe operation −

Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gases. Never run the engine in a closed garage or confined area.

Do not place anything on the engine, as it may create a fire hazard.

The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. To avoid severe burns or fire hazards, let the engine cool before transporting it or storing it indoors.

SAFETY INDICATION LOCATION

This indication warns you of potential hazards that can cause serious injury. Read it carefully.

READ OWNER’S MANUAL BEFORE OPERATION.

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PRE-OPERATION CHECK

1.

Engine oil level

Running the engine with insufficient oil can cause serious engine damage.

Be sure to check the engine on a level surface with the engine stopped.

1.

Remove the oil filler cap and check the oil level: it should reach

2.

the top of the oil filler neck.

If the level is low, fill to the top of the oil filler neck with the recommended oil.

Add the engine oil slowly to avoid overflowing, as the engine oil tank capacity is small.

Every 10 hours, check the engine oil level and replenish oil up to the top of the oil filler neck if the engine is operated for more than

10 hours continuously.

ENGINE OIL FILLER CAP

OIL FILLER NECK

UPPER OIL LEVEL

UPPER OIL LEVEL UPPER OIL LEVEL

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Use Honda 4-stroke, or an equivalent high detergent, premium quality motor oil certified to meet or exceed U.S. automobile manufacturer’s requirements for service classification SG, SF. Motor oils classified SG, SF will show this designation on the container.

SAE 10W-30 is recommended for general, all temperature use.

MULTI VISCOSITY

Ambient temperature

Using nondetergent oil or 2-stroke engine oil could shorten the engine’s service life.

Standard/Tiller type:

The recommended operating range of this engine is − 5 °C to

40 °C (23 °F to 104 °F).

Pump type:

The recommended operating range of this engine is 5 °C to 40 °C

(41 °F to 104 °F).

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2.

Air cleaner

Never run the engine without the air cleaner. Rapid engine wear will result.

Check cleaner for dirt or obstruction of element (page 19 ).

Standard/Pump type: Tiller type:

ELEMENT

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3.

Fuel

Use automotive unleaded gasoline with a Research Octane

Number of 91 or higher (a Pump Octane Number of 86 or higher).

Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.

Gasoline is extremely flammable and is explosive under certain conditions.

Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored.

Do not overfill the fuel tank (there should be no fuel in the filler neck). After refueling, make sure the tank cap is closed properly and securely.

Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

Avoid repeated or prolonged contact with skin or breathing of vapor.

KEEP OUT OF REACH OF CHILDREN.

Fuel tank capacity:

0.55

(0.145 US gal , 0.121 Imp gal)

Standard/Pump type:

FUEL TANK CAP

Tiller type:

MAXIMUM FUEL LEVEL

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Gasoline spoils very quickly depending on factors such as light exposure, temperature and time.

In worst cases, gasoline can be contaminated within 1 month.

Using contaminated gasoline can seriously damage the engine

(carburetor clogged, valve stuck).

Such damage due to spoiled fuel is disallowed from coverage by the warranty.

To avoid this please strictly follow these recommendations:

Only use specified gasoline (page 8 ).

To slow deterioration, keep gasoline in a certified fuel container.

If long storage (more than 1 month) is foreseen, drain fuel tank and carburetor.

GASOLINES CONTAINING ALCOHOL

If you decide to use a gasoline containing alcohol (gasohol), be sure it’s octane rating is at least as high as that recommended by

Honda. There are two types of ‘‘gasohol’’: one containing ethanol, and the other containing methanol. Do not use gasohol that contains more than 10% ethanol. Do not use gasoline containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. Never use gasoline containing more than 5% methanol, even if it has cosolvents and corrosion inhibitors.

Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty. Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete.

Before buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol, if it does, confirm the type and percentage of alcohol used. If you notice any undesirable operating symptoms while using a gasoline that contains alcohol, or one that you think contains alcohol, switch to a gasoline that you know does not contain alcohol.

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4.

Retightening bolts and nuts

Check for loose bolts and nuts. Tighten the bolts and nuts properly and securely, if necessary.

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STARTING THE ENGINE

1.

Standard/Tiller type: Turn the engine switch to the ON position

(on the equipment side).

Pump type: Turn the engine switch to the ON position.

ON

ENGINE SWITCH

[Pump type]

2.

Move the choke lever to the CLOSED position.

Do not use the choke if the engine is warm or the air temperature is high.

CHOKE LEVER

CLOSED

C L O S E D

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3.

Press the priming pump several times until a fuel flow in the fuel return tube is visually noticed.

FUEL RETURN TUBE

PRIMING PUMP

4.

Pull the starter grip lightly until resistance is felt, then pull briskly.

Do not allow the starter grip to snap back against the engine.

Return it gently to prevent damage to the starter.

Always pull the starter grip briskly. If not pulled briskly, sparks may fail to jump across the spark plug electrodes, resulting in failure to start the engine.

Standard/Pump type:

(EQUIPMENT SIDE)

Tiller [TE/TEZ] type:

STARTER GRIP

Tiller [TEZR] type:

STARTER GRIP

(EQUIPMENT SIDE)

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High altitude operation

At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase.

High altitude performance can be improved by specific modifications to the carburetor. If you always operate the engine at altitudes higher than 1,500 m (5,000 feet) above sea level, have your authorized Honda dealer perform these carburetor modifications.

Even with suitable carburetor jetting, engine horsepower will decrease approximately 3.5% for each 300 m (1,000 feet) increase in altitude. The effect of altitude on the horsepower will be greater than this if no carburetor modification is made.

Operation of the engine at an altitude lower than the carburetor is jetted for may result in reduced performance, overheating, and serious engine damage caused by an excessively lean air/fuel mixture.

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OPERATION

1.

Gradually move the choke lever to the OPEN position. Warm up the engine until it run smoothly.

CHOKE LEVER

O P E N

OPEN

2.

Standard/Tiller type: Position the throttle control lever for the desired engine speed (on the equipment side).

Pump type: Position the throttle control lever for the desired engine speed.

THROTTLE CONTROL LEVER

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STOPPING THE ENGINE

Standard/Tiller type:

To stop the engine in an emergency, turn the engine switch to the

OFF position (on the equipment side). Under normal conditions, use the following procedure:

1.

Position the throttle control lever fully to LOW (on the equipment side).

2.

Turn the engine switch to the OFF position (on the equipment side).

Pump type:

To stop the engine in an emergency, turn the engine switch to the

OFF position. Under normal conditions, use the following procedure:

1.

Position the throttle control lever fully to LOW.

THROTTLE CONTROL LEVER

2.

Turn the engine switch to the OFF position.

ENGINE SWITCH

OFF

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MAINTENANCE

Shut off the engine before performing any maintenance.

To prevent accidental start-up, turn OFF the engine switch.

The engine should be serviced by an authorized Honda dealer unless the owner has proper tools and service data and feels mechanically qualified.

Use only genuine Honda parts or their equivalent. The use of replacement parts which are not of equivalent quality may damage the engine.

Periodic inspection and adjustment of the Honda engine is essential if high level performance is to be maintained. Regular maintenance will also ensure a long service life. The required service intervals and the kind of maintenance to be performed are described on the table below.

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Maintenance Schedule

REGULAR SERVICE PERIOD (3)

ITEM

Performed at every indicated month or operating hour interval, whichever comes first.

Engine oil Check level

Change

Air cleaner

Spark plug

Check

Clean

Check-adjust

Replace

Clean Exhaust filter

(Tiller [TEZ/TEZR] types)

Spark arrester

(Optional parts

Clean except tiller [TE] type)

Engine cooling fins Check

Nuts, bolts, fasteners

Clutch Shoes

Idle speed

Valve Clearance

Combustion chamber

Check

(Retighten if necessary)

Check

Check-adjust

Check-adjust

Clean

Fuel filter

Fuel tank

Fuel tubes

Oil tube

Check

Clean

Check

Check

Each use

First month or

10 hrs.

Every

3 months or

25 hrs.

Every

6 months or

50 hrs.

Every year or

100 hrs.

Every

2 years or

300 hrs.

(4)

(1)(5)

(4)

(2)(4)

After every 300 hrs. (2)

(2)

(2)

Every 2 years (Replace if necessary) (2)

Every 2 years (Replace if necessary) (2)

(1) Service more frequently when used in dusty areas.

(2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to Honda Shop Manual for service procedures.

(3) For commercial use, log hours of operation to determine proper maintenance intervals.

(4) TEZ/TEZR should perform these items every year or 50 hours.

(5) TEZ/TEZR should perform every year or 25 hours.

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1.

Oil change

Drain the oil while the engine is still warm to assure rapid and complete draining.

1.

2.

Check the fuel filler cap is tightened.

Remove the oil filler cap and drain the oil into the oil container by inclining the engine toward the oil filler neck.

3.

Refill with the recommended oil (see page level (see page 5 ).

6 ) and check the oil

ENGINE OIL CAPACITY (Disassembly):

0.08

(0.08 US qt , 0.07 Imp qt)

The oil capacity with replaced is less than the oil capacity with disassembled.

FUEL FILLER CAP

UPPER OIL LEVEL

UPPER OIL LEVEL

OIL FILLER NECK

4.

Install the oil filler cap.

If any oil is spilled, make sure to wipe it.

Wash your hands with soap and water after handling used oil.

Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station for reclamation. Do not throw it in the trash, pour it on the ground, or down a drain.

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2.

Air cleaner service

A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the engine in extremely dusty areas.

Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result.

Never run the engine without the air cleaner. Rapid engine wear will result.

1.

Move the choke lever to the CLOSED (upwards) position.

2.

Remove the air cleaner cover by unhooking the upper tab on the top of the air cleaner cover and its two lower tabs.

3.

Wash the element in a nonflammable or high flash point solvent and dry it thoroughly.

4.

5.

6.

Soak the element in clean engine oil and squeeze out the excess oil.

Reinstall the air cleaner element.

Reinstall the air cleaner cover by inserting the lower tabs, then insert the upper tab.

CHOKE LEVER

UPPER TAB

AIR CLEANER

COVER

UPPER TAB LOWER TABS

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AIR CLEANER

ELEMENT

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3.

Spark plug service

Recommended spark plug:

CMR5H (NGK)

Never use a spark plug of incorrect heat range.

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

1.

Loosen the 5 mm hex bolt, then remove the top cover.

Do not pull the starter grip and start the engine without the top cover. There are rotating and hot parts under the cover.

TOP COVER

5 mm HEX BOLT

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2.

3.

Remove any dirt from around the spark plug area.

Remove the spark plug cap and use the proper size spark plug wrench to remove the spark plug.

If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.

SPARK PLUG

SPARK PLUG CAP

4.

Visually inspect the spark plug. Discard the spark plug if there is

5.

apparent wear, or if the insulator is cracked or chipped. Clean the spark plug with a wire brush if it is to be reused.

Measure the plug gap with a feeler gauge. Correct as necessary by bending the side electrode.

The gap should be:

0.60

− 0.70 mm (0.024

− 0.028 in)

0.60

−

(0.024

0.70 mm

− 0.028 in)

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6.

Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross-threading.

7.

After the spark plug is seated, tighten with a spark plug wrench to compress the washer.

When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. When reinstalling a used spark plug, tighten 1/8 − 1/4 turn after the spark plug seats to compress the washer.

8.

9.

Attach the spark plug cap.

Install the top cover, and tighten the 5 mm hex bolt securely.

The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and may damage the engine.

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4.

Spark arrester service

(Optional parts except tiller [TE] type)

If the engine has been running, the muffler will be very hot. Allow it to cool before proceeding.

The spark arrester must be serviced every 100 hours to keep it functioning as designed.

1.

Loosen the 5 mm hex bolt, then remove the top cover (see page

2.

20 ).

Remove the 3 × 6 mm tapping screw from the spark arrester, and remove the spark arrester from the muffler.

3 × 6 mm TAPPING SCREW

SPARK ARRESTER MUFFLER

3.

Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen.

The spark arrester must be free of breaks and holes. If it is damaged or fouled excessively, have it serviced by your Honda dealer.

SPARK ARRESTER SCREEN

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5.

Exhaust filter service (Tiller [TEZ/TEZR] types)

If the engine has been running, the muffler will be very hot. Allow it to cool before proceeding.

The exhaust filter must be serviced every 100 hours to keep it functioning as designed.

1.

Loosen the 5 mm hex bolt, then remove the top cover (see page

20 ).

2.

Remove the lock pin from the exhaust filter and remove the exhaust filter from the muffler.

LOCK PIN

EXHAUST FILTER

3.

Pinch the exhaust filter, strike lightly with a finger, and remove carbon deposits. Be careful not to strike strongly.

The exhaust filter must be free of breaks and holes. If it is damaged or fouled excessively, have it serviced by your Honda dealer.

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6.

Fuel filter service and Fuel tank cleaning

Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area.

1.

Check the engine oil filler cap is tightened securely.

2.

Remove the fuel filler cap and drain the fuel into the container by inclining the engine toward the fuel filler neck.

FUEL FILLER NECK

ENGINE OIL

FILLER CAP

3.

Pull out the fuel filter with the mechanic’s wire from the fuel

4.

filler neck gently.

For fuel filter service

− Check the fuel filter of its dirt. If the fuel filter is dirty, wash it gently with nonflammable or high flash point solvent. If the fuel filter is excessively dirty, replace it.

For fuel tank cleaning

− Remove water and dirt stood in the fuel tank by rinsing the inside of the fuel tank with nonflammable or high flash point solvent.

FUEL FILTER

5.

Return the fuel filter into the fuel tank and tighten the fuel filter cap securely.

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7.

Cooling fin service

1.

Loosen the 5 mm hex bolt, then remove the top cover (see page

20 ).

2.

Inspect the engine cooling fins, and clean out debris if they are clogged.

COOLING FIN

3.

Install the top cover, and tighten the 5 mm hex bolt securely.

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TRANSPORTING/STORAGE

When transporting the engine, tighten the fuel filler cap to prevent fuel spillage. Fuel vapor or spilled fuel may ignite.

Before storing the unit for an extended period;

1.

2.

Be sure the storage area is free of excessive humidity and dust.

Drain the fuel.

Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area.

a.

b.

Check the engine oil filler cap is tightened securely.

Remove the fuel filler cap and drain the fuel into the container by inclining the engine toward the fuel filler neck.

FUEL RETURN TUBE ENGINE OIL FILLER CAP

PRIMING PUMP

FUEL FILLER NECK c.

d.

Press the priming pump several times until all fuel left in the fuel return tube is returned into the fuel tank.

Tilt the engine toward the fuel filler neck again to drain the e.

fuel left in the fuel tank into the container.

Tighten the fuel filler cap securely after draining the fuel completely.

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3.

4.

5.

6.

Change the engine oil (page 18 ).

Clean the air cleaner (page 19 ).

Loosen the 5 mm hex bolt, then remove the top cover (page 20 ).

Remove the spark plug (page 21 ).

7.

8.

9.

Apply a couple of drops of clean engine oil into the cylinder.

Install the top cover temporarily.

Pull the starter grip several times to distribute the oil in the

10.

cylinder.

Remove the top cover, then reinstall the spark plug.

11.

12.

Install the top cover, and tighten the 5 mm hex bolt securely.

Pull the starter grip slowly until resistance is felt.

13.

Cover the engine to keep out dust.

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TROUBLESHOOTING

When it is hard to start the engine:

In some cases, restarting of the engine may become difficult sometime after stopping the engine because the mixture in the combustion chamber becomes excessively rich. In such a case, carry out the following procedures 1 − 4 to expel the rich mixture.

Standard/Tiller type:

1.

Turn the engine switch on the equipment side to the OFF position.

2.

3.

Move the choke lever to the OPEN position.

Keep the throttle control lever on the equipment side to the

4.

HIGH speed position.

Pull the starter grip 3 − 5 times.

Pump type:

1.

Turn the engine switch to the OFF position.

2.

3.

Move the choke lever to the OPEN position.

Keep the throttle control lever to the HIGH speed position.

4.

Pull the starter grip 3 − 5 times.

Be sure to turn the engine switch to the OFF position.

If this operation is executed with the engine switch at the ON position, the equipment may start to move when the engine starts, and a personal injury may result.

Start the engine referring to the procedures described in

STARTING THE ENGINE.

Start the engine with the choke lever in the OPEN position.

Tiller [TEZ/TEZR] type only:

If engine repeatedly stops during high rotation, take the engine to an authorized Honda dealer.

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When the engine will not start:

1.

Is the engine switch in the ON position (on the equipment side)?

2.

3.

Is there fuel in the fuel tank?

Is gasoline reaching the carburetor?

To check, press the priming pump several times.

4.

5.

Is the spark plug in good condition?(page 20)

If the engine still does not start, take the engine to an authorized

Honda dealer.

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SPECIFICATIONS

Dimensions

Model

Type SE

(Standard)

Power equipment description code

Length

Width

Height

Dry weight

(Without clutch)

GX25

TE

(Tiller)

GCAAM

WE

(Pump)

192 mm (7.6 in) 192 mm (7.6 in) 247 mm (9.7 in)

221 mm (8.7 in) 210 mm (8.3 in) 221 mm (8.7 in)

230 mm (9.1 in) 236 mm (9.3 in) 230 mm (9.1 in)

2.78 kg

(6.13 lbs)

2.96 kg

(6.53 lbs)

3.10 kg

(6.83 lbs)

Engine

Engine type

Displacement

Bore × Stroke

Max. output

Max. torque

Fuel consumption

Cooling system

Ignition system

PTO shaft rotation

4-stroke, overhead camshaft, 1 cylinder

25 cm (1.5 cu-in)

35 × 26 mm (1.4

× 1.0 in)

0.81 kW (1.1 PS)/7,000 rpm

1.25 N·m (0.13 kgf-m)/5,000 rpm

340 g/kWh (250 g/PSh)

Forced air

Transistor magneto

Counterclockwise

Specifications may vary according to the types, and are subject to change without notice.

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Dimensions

Model

Type

Power equipment description code

Length

Width

Height

Dry weight

(Without clutch)

Engine

Engine type

Displacement

Bore × Stroke

Max. output

Max. torque

Fuel consumption

Cooling system

Ignition system

PTO shaft rotation

GX25

TEZ

(Tiller)

TEZR

(Tiller)

GCABK

2.85 kg

(6.28 lbs)

236 mm (9.3 in)

210 mm (8.3 in)

192 mm (7.6 in)

2.88 kg

(6.35 lbs)

4-stroke, overhead camshaft, 1 cylinder

25 cm (1.5 cu-in)

35 × 26 mm (1.4

× 1.0 in)

0.64 kW (0.86 PS)/6,000 rpm

1.0 N·m (0.10 kgf-m)/5,000 rpm

385 g/kWh (283 g/PSh)

Forced air

C.D.I.

Counterclockwise

Specifications may vary according to the types, and are subject to change without notice.

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