bpr supra x 125 pgm-fi

ANF125/M-5 ADDENDUM

ANF125/M-5 ADDENDUM

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

CAUTION: Indicates a possibility of equipment damage if instructions are not followed.

NOTE: Gives helpful information.

Detailed descriptions of standard workshop procedures, safety principles and service operations are notincluded. It is important to note that this manual contains some warnings and cautions against some specificservice methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle orrender it unsafe. Please understand that those warnings could not cover all conceivable ways in which service,whether or not recommended by Honda, might be done or of the possibly hazardous consequences of eachconceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools,whether or not recommended by Honda, must satisfy himself thoroughly that neither personal safety norvehicle safety will be jeopardized by the service methods or tools selected.

IMPORTANT SAFETY NOTICE

TYPE CODE

• Throughout this manual, the following abbreviations are used to identify individual model.

AREA TYPE

THAILAND (Kickstarter only type)

THAILAND (Kickstarter and electric starter motor type)

CODE

ANF1255-III TH

ANF125M5-III TH

ANF125/M-5 ADDENDUM

HOW TO USE THIS MANUALThis addendum contains information for the ANF125/M-5.

Refer to the ANF125 Shop Manual (62KPHAM2,62KPHLM3, 62KTMFM5) for service procedures anddata not included in this addendum.

Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS

AND SPECIFICATIONS INCLUDED IN THIS PUBLICA-

TION ARE BASED ON THE LATEST PRODUCT IN-

FORMATION AVAILABLE AT THE TIME OF AP-

PROVAL FOR PRINTING, Honda Motor Co., Ltd. RE-

SERVES THE RIGHT TO MAKE CHANGES AT ANY

TIME WITHOUT NOTICE AND WITHOUT INCURRING

ANY OBLIGATION WHATEVER. NO PART OF THIS

PUBLICATION MAY BE REPRODUCED WITHOUT

WRITTEN PERMISSION. THIS MANUAL IS WRITTEN

FOR PERSONS WHO HAVE ACQUIRED BASIC

KNOWLEDGE OF MAINTENANCE ON Honda MO-

TORCYCLES, MOTOR SCOOTERS OR ATVS.

24. ANF125/M-5 ADDENDUM

Date of Issue: March, 2005© Honda Motor Co., Ltd.

ANF125/M-5 ADDENDUM

CONTENTSMODEL IDENTIFICATION ............................................. 24-1SPECIFICATIONS .......................................................... 24-2TORQUE VALUES ......................................................... 24-9TOOLS ......................................................................... 24-12LUBRICATION & SEAL POINTS................................. 24-14CABLE & HARNESS ROUTING.................................. 24-17MAINTENANCE SCHEDULE ...................................... 24-24FUEL LINE ................................................................... 24-25ENGINE IDLE SPEED .................................................. 24-25TECHNICAL FEATURE

ABSOLUTE PRESSURE FUEL SUPPLY SYSTEM ........... 24-26FUEL SYSTEM COMPONENT LOCATION ................ 24-27PGM-FI SERVICE INFORMATION .............................. 24-28PGM-FI TROUBLESHOOTING ................................... 24-28PGM-FI SYSTEM LOCATION ..................................... 24-29PGM-FI SYSTEM DIAGRAM ...................................... 24-30PGM-FI SELF-DIAGNOSIS INFORMATION ............... 24-31MIL CODE INDEX........................................................ 24-34ECM POWER/GROUND INSPECTION ....................... 24-36SENSOR UNIT POWER/

GROUND CIRCUIT INSPECTION............................ 24-38MIL TROUBLESHOOTING.......................................... 24-40FUEL LINE INSPECTION ............................................ 24-54FUEL PUMP................................................................. 24-58FUEL TANK ................................................................. 24-60THROTTLE BODY/SENSOR UNIT.............................. 24-61ECM (ENGINE CONTROL MODULE) ......................... 24-69INJECTOR ................................................................... 24-69BANK ANGLE SENSOR.............................................. 24-70

EOT (ENGINE OIL TEMPERATURE) SENSOR .......... 24-71CHARGING SYSTEM DIAGRAM ............................... 24-72CHARGING SYSTEM TROUBLESHOOTING............. 24-73IGNITION SYSTEM DIAGRAM .................................. 24-74ELECTRIC STARTER SYSTEM DIAGRAM ................. 24-75LIGHTS/METERS/

SWITCHES SYSTEM LOCATION .................... 24-76FUEL METER/FUEL LEVEL SENSOR ......................... 24-77WIRING DIAGRAMS

ANF125 ............................................................ 24-79ANF125M ......................................................... 24-80

TROUBLE SHOOTINGENGINE DOES NOT STARTOR IS HARD TO START................................... 24-81ENGINE LACKS POWER ................................. 24-82POOR PERFORMANCE AT LOW ANDIDLE SPEED ..................................................... 24-83POOR PERFORMANCE AT HIGH SPEED ....... 24-84

24-1

ANF125/M-5 ADDENDUM

MODEL IDENTIFICATIONThis manual covers 2 types of ANF125 models:• ANF125: kick starter and Programmed Fuel Injection (PGM-FI)• ANF125M: kick starter, electric starter motor and Programmed Fuel Injection (PGM-FI)

FRAME NUMBERThe frame serial number is stamped on the right side ofthe steering head.

ENGINE NUMBERThe engine serial number is stamped on the lower left sideof the crankcase.

THROTTLE BODY IDENTIFICATION NUMBERThe throttle body identification number is stamped on thefront side of the throttle body.

FRAME SERIAL NUMBER

THROTTLE BODY IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

24-2

ANF125/M-5 ADDENDUM

SPECIFICATIONS

Overall lengthOverall widthOverall heightWheelbaseSeat heightFootpeg heightGround clearanceCurb weight ANF125

ANF125M

DIMENSIONS 1,881 mm (74.1 in)706 mm (27.8 in)1,081.5 mm (42.58 in)1,239 mm (48.8 in)761 mm (30.0 in)266 mm (10.5 in)130 mm (5.1 in)100.1 kg (220.7 lbs)102.5 kg (226.0 lbs)

GENERAL

52.4 x 57.9 mm (2.06 x 2.28 in)124.8 cm3 (7.61 cu-in)9.3 : 12 valve, single chain driven SOHC5° BTDC22° ABDC37° BBDC–3° ATDCForced pressure and wet sumpTrochoidAir cooledPaper filterAssembled typeSingle cylinder inclined 80° from vertical

ENGINE Bore and strokeDisplacementCompression ratioValve trainIntake valve opens at 1 mm

closes (0.04 in) liftExhaust valve opens

closesLubrication systemOil pump typeCooling systemAir filtrationCrankshaft typeCylinder arrangement

Back bone typeTelescopic fork80.5 mm (3.17 in)Swingarm81.8 mm (3.22 in)Both side operation tube type60/100–17M/C 33P70/90–17M/C 43PHydraulic disc brakeMechanical leading trailing26° 30'68 mm (2.7 in)3.7 liter (0.98 US gal 0.81 lmp gal)

Frame typeFront suspensionFront axle travelRear suspensionRear axle travelRear damperFront tire sizeRear tire sizeFront brakeRear brakeCaster angleTrail lengthFuel tank capacity

FRAME

ITEM SPECIFICATIONS

24-3

ANF125/M-5 ADDENDUM

ITEM SPECIFICATIONS

TypeThrottle bore

CARBURATION

Multi-plate, wetAutomatic centrifugal typeConstant mesh, 4-speed3.350 (67/20)2.428 (34/14)2.500 (35/14)1.550 (31/20)1.150 (23/20)0.923 (24/26)Left foot operated return system(rotary system; only when the motorcycle isnot running)N-1-2-3-4 (-N)

Clutch systemClutch operation systemTransmissionPrimary reductionFinal reductionGear ratio 1st

2nd3rd4th

Gearshift pattern

DRIVE TRAIN

Full transistor digital ignitionKickstarterKickstarter and electric starter motorSingle phase output alternatorSCR opened/single phase, half wave rectifi-cationAlternator

ELECTRICAL Ignition systemStarting system ANF125

ANF125MCharging systemRegulator/rectifier

Lighting system

PGM-FI (Programmed Fuel Injection)22 mm (0.9 in)

GENERAL (Cont'd)

24-4

ANF125/M-5 ADDENDUM

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Engine oil capacity At draining

At disassembly

0.7 liter (0.7 US qt, 0.6 lmp qt)

0.9 liter (1.0 US qt, 0.8 lmp qt)

Honda 4-stroke oil or equivalentmotor oilAPI service classification SE, SF or SGViscosity: SAE 10W-30

—

0.15 – 0.21 (0.006 – 0.008)

0.03 – 0.09 (0.001 – 0.003)

Recommended engine oil

Tip clearance

Body clearance

Side clearance

Oil pump rotor

—

—

—

0.20 (0.008)

0.26 (0.010)

0.15 (0.005)

LUBRICATION SYSTEM

ITEM SPECIFICATION

Throttle body identification number

Idle speed

Throttle grip free play

EOT (Engine Oil Temperature) sensorresistance

Fuel injector resistance (at 20°C/68°F)

Fuel pressure

Fuel pump flow (at 12V)

GQR0A

1,400 ± 100 min–1 (rpm)

2 – 6 mm (0.1 – 0.2 in)

2.5 – 2.8 kΩ

0.21 – 0.22 kΩ

10.3 – 11.3 Ω

294 kPa (3.0 kgf/cm2, 43 psi)

13.9 cm3 (0.47 US oz, 0.49 lmp oz) minimum/10 seconds

FUEL SYSTEM (Programmed Fuel Injection)

Unit: mm (in)

ITEM

Cylinder compression

Cylinder head warpage

Valve,valve guide

Valve spring free length

Rocker arm/shaft

Camshaft

STANDARD

1,275 kPa (13.0 kgf/cm2, 185 psi) at600 min–1 (rpm)

—

0.05 ± 0.02 (0.002 ± 0.001)

0.05 ± 0.02 (0.002 ± 0.001)

4.975 – 4.990 (0.1959 – 0.1965)

4.955 – 4.970 (0.1951 – 0.1957)

5.000 – 5.012 (0.1969 – 0.1973)

5.000 – 5.012 (0.1969 – 0.1973)

0.010 – 0.037 (0.0004 – 0.0015)

0.030 – 0.057 (0.0012 – 0.0022)

1.0 (0.04)

37.62 (1.481)

10.000 – 10.015 (0.3937 – 0.3943)

9.972 – 9.987 (0.3926 – 0.3932)

32.278 – 32.518 (1.2708 – 1.2802)

32.121 – 32.361 (1.2646 – 1.2741)

SERVICE LIMIT

—

0.05 (0.002)

—

—

4.965 (0.195)

4.945 (0.195)

5.03 (0.198)

5.03 (0.198)

0.065 (0.0026)

0.085 (0.0033)

1.6 (0.06)

35.8 (1.41)

10.10 (0.398)

9.92 (0.391)

31.94 (1.257)

31.79 (1.252)

Valve clearance

Valve stem O.D.

Valve guide I.D.

Stem-to-guide clearance

Valve seat width

Rocker arm I.D.

Rocker arm shaft O.D.

Cam lobe height

CYLINDER HEAD/VALVES

20°C/68°F

100°C/212°F

IN

EX

IN

EX

IN

EX

IN

EX

IN/EX

IN/EX

IN/EX

IN/EX

IN

EX

24-5

ANF125/M-5 ADDENDUM

ITEM STANDARD

52.405 – 52.415 (2.0632 – 2.0636)

—

—

—

“IN” mark facing toward the intake side

52.362 – 52.400 (2.0615 – 2.0630)

10 mm (0.4 in) from bottom of skirt

13.002 – 13.008 (0.5119 – 0.5121)

12.994 – 13.000 (0.5116 – 0.5118)

0.002 – 0.014 (0.0001 – 0.0006)

0.030 – 0.065 (0.0012 – 0.0026)

0.015 – 0.050 (0.0006 – 0.0020)

0.10 – 0.30 (0.004 – 0.012)

0.10 – 0.30 (0.004 – 0.012)

0.20 – 0.70 (0.008 – 0.028)

0.005 – 0.053 (0.0002– 0.0021)

13.016 – 13.034 (0.5124 – 0.5131)

0.016 – 0.040 (0.0006 – 0.0016)

I.D.

Out of round

Taper

Warpage

Piston mark direction

Piston O.D.

Piston O.D. measurement point

Piston pin bore I.D.

Piston pin O.D.

Piston-to-piston pin clearance

Cylinder

Piston, pistonrings

Piston ring-to-ringgroove clearance

Piston ring endgap

Top

Second

Top

Second

Oil (side rail)

Cylinder-to-piston clearance

Connecting rod small end I.D.

Connecting rod-to-piston pin clearance

CYLINDER/PISTONUnit: mm (in)

SERVICE LIMIT

52.445 (2.0648)

0.10 (0.004)

0.10 (0.004)

0.05 (0.002)

—

52.292 (2.0587)

—

13.03 (0.513)

12.98 (0.511)

0.075 (0.0030)

0.10 (0.004)

0.09 (0.004)

0.5 (0.02)

0.5 (0.02)

1.1 (0.04)

0.159 (0.0063)

13.05 (0.514)

0.07 (0.003)

ITEM STANDARD

2.5 – 2.7 (0.098 – 0.106)

—

27.4 (1.08)

22.959 – 22.980 (0.9039 – 0.9047)

23.000 – 23.021 (0.9055 – 0.9063)

104.0 – 104.2 (4.09 – 4.10)

1.5 (0.06)

42.000 – 42.020 (1.6535 – 1.6543)

4.990 – 5.000 (0.1965 – 0.1969)

21.030 – 21.058 (0.8280 – 0.8291)

20.967 – 20.980 (0.8255 – 0.8260)

3.35 (0.132)

Disk thickness

Plate warpage

Clutch spring free length

Clutch outer guide O.D.

Clutch outer I.D.

Clutch drum I.D.

Clutch weight lining thickness

One-way clutch drum I.D.

One-way clutch roller O.D.

Primary drive gear I.D.

Crankshaft O.D. at primary drivegear

Manual clutch

Centrifugalclutch

Clutch brake lining thickness

CLUTCH/GEARSHIFT LINKAGEUnit: mm (in)

SERVICE LIMIT

2.2 (0.09)

0.20 (0.008)

26.8 (1.06)

22.940 (0.9031)

23.07 (0.908)

104.3 (4.11)

1.0 (0.04)

42.04 (1.655)

4.97 (0.196)

21.11 (0.831)

20.92 (0.824)

2.5 (0.10)

24-6

ANF125/M-5 ADDENDUM

Connecting rod side clearance

Connecting rod radial clearance

Runout

Gear I.D.

Bushing O.D.

Bushing I.D.

Gear-to-bushing clearance

Mainshaft O.D.

Countershaft O.D.

Gear-to-shaft clearance

Bushing-to-shaft clearance

Shift fork I.D.

Shift fork claw thickness

Shift fork shaft O.D.

Shift drum O.D.

Shift drum journal I.D.

Pinion I. D.

Shaft O.D.

ITEM

Unit: mm (in)

STANDARD SERVICE LIMIT

0.60 (0.024)

0.05 (0.002)

0.10 (0.004)

17.04 (0.671)

18.04 (0.710)

20.040 (0.7890)

17.94 (0.706)

15.04 (0.592)

0.1 (0.004)

16.95 (0.667)

14.95 (0.589)

0.09 (0.004)

0.09 (0.004)

10.07 (0.396)

4.90 (0.193)

9.93 (0.391)

24.07 (0.948)

28.08 (1.106)

23.98 (0.944)

27.98 (1.102)

20.08 (0.791)

19.94 (0.785)

Crankshaft

Transmission

0.10 – 0.35 (0.004 – 0.014)

0.008 (0.0003)

—

17.000 – 17.018 (0.6693 – 0.6700)

18.000 – 18.018 (0.7087 – 0.7094)

20.000 – 20.021 (0.7874 – 0.7882)

17.966 – 17.984 (0.7073 – 0.7080)

15.000 – 15.018 (0.5906 – 0.5913)

0.016 – 0.052 (0.0006 – 0.0020)

16.966 – 16.984 (0.6680 – 0.6687)

14.966 – 14.984 (0.5892 – 0.5899)

0.016 – 0.052 (0.0006 – 0.0020)

0.016 – 0.052 (0.0006 – 0.0020)

10.000 – 10.018 (0.3937 – 0.3944)

4.93 – 5.00 (0.194 – 0.197)

9.986 – 9.995 ( 0.3931– 0.3935)

23.959 – 23.980 (0.9433 – 0.9441)

27.959 – 27.980 (1.1007 – 1.1016)

24.000 – 24.033 (0.9449 – 0.9462)

28.000 – 28.021 (1.1024 – 1.1032)

20.000 – 20.021 (0.7874 – 0.7882)

19.959 – 19.980 (0.7858 – 0.7866)

Shift fork/Shift drum

Kick starter

M2,3

C1

C4

C1

C1

C1

M2,3

C1

M2,3

C1

Left

Right

Left

Right

CRANKSHAFT/TRANSMISSION/KICKSTARTER

24-7

ANF125/M-5 ADDENDUM

Unit: mm (in)

ITEM STANDARD

Minimum tire tread depth

Cold tire pressure

Axle runout

Wheel rim runout

Wheel hub-to-rim distance

Fork

Driver only

Driver and passenger

Radial

Axial

Spring free length

Spring direction

Tube runout

Recommended fork fluid

Fluid level

Fluid capacity

—

225 kPa (2.25 kgf/cm2, 33 psi)

225 kPa (2.25 kgf/cm2, 33 psi)

—

—

—

19.5 ± 1 (0.77 ± 0.04)

316.3 (12.45)

With the tapered end facing down

—

Honda Ultra Cushion Oil No.10

68.5 (2.70)

70.0 ± 1 cm3 (2.37 ± 0.03 US oz,2.46 ± 0.04 lmp oz)

FRONT WHEEL/SUSPENSION/STEERING

Unit: mm (in)

Unit: mm (in)

STANDARD

DOT 3 or 4

—

4.0 (0.157)

—

12.700 – 12.743 (0.5000 – 0.5017)

12.657 – 12.684 (0.4983 – 0.4994)

25.400 – 25.450 (1.000 – 1.002)

25.318 – 25.368 (0.9968 – 0.9987)

ITEM

Specified brake fluid

Brake pad wear indicator

Brake disc thickness

Brake disc runout

Master cylinder I.D.

Master piston O.D.

Caliper cylinder I.D.

Caliper piston O.D.

HYDRAULIC BRAKE

ITEM

Minimum tire tread depth

Cold tire pressure

Axle runout

Wheel rim runout

Wheel hub-to-rim distance

Drive chain

Brake

STANDARD

—

250 kPa (2.50 kgf/cm2, 36 psi)

250 kPa (2.50 kgf/cm2, 36 psi)

—

—

—

10.0 ± 1 (0.39 ± 0.04)

420 – 104

25 – 35 (1.0 – 1.4)

110.0 (4.33)

20 – 30 (0.8 – 1.2)

Driver only

Driver and passenger

Radial

Axial

Size/link

Slack

Brake drum I.D.

Brake pedal free play

REAR WHEEL/BRAKE/SUSPENSION

SERVICE LIMIT

To the indicator

—

—

0.20 (0.008)

2.0 (0.08)

2.0 (0.08)

—

310.0 (12.20)

—

0.20 (0.008)

—

—

—

SERVICE LIMIT

To the indicator

—

—

0.20 (0.008)

2.0 (0.08)

2.0 (0.08)

—

—

—

111.0 (4.37)

—

SERVICE LIMIT

—

To groove

3.5 (0.138)

0.30 (0.012)

12.755 (0.5022)

12.645 (0.4978)

25.460 (1.002)

25.31 (0.996)

24-8

ANF125/M-5 ADDENDUM

ITEM SPECIFICATIONS

12 V – 2.5 Ah

12 V – 3.5 Ah

0.1 mA max.

13.0 – 13.2 V

Below 12.3 V

0.3 A/5 – 10 h

3.0 A/0.5 h

0.4 A/5 – 10 h

3.0 A/0.5 h

0.150 kw/5,000 min–1 (rpm)

0.2 – 1.0 Ω

Battery

Alternator

Capacity

Current leakage

Voltage

Chargingcurrent

Capacity

Charging coil resistance (20°C/68°F)

BATTERY/CHARGING SYSTEM

ITEM SPECIFICATIONS

Spark plug

Spark plug gap

Ignition coil peak voltage

Ignition pulse generator peak voltage

Ignition timing

Standard

Optional

NGK DENSO

CPR6EA-9 U20EPR9

CPR7EA-9 U22EPR9

0.80 – 0.90 mm (0.031 – 0.035 in)

100 V minimum

0.7 V minimum

10° BTDC at idle

Unit: mm (in)IGNITION SYSTEM

Unit: mm (in)

ITEM STANDARD

Starter motor brush length 10.0 – 10.05 (0.39 – 0.40)

SERVICE LIMIT

3.5 (0.14)

ELECTRIC STARTER

ANF125

ANF125M

ITEM

Bulbs

Fuse

SPECIFICATIONS

Headlight (Hi/low beam)

Brake/taillight

Front turn signal light

Rear turn signal light

Meter light

Turn signal indicator

High beam indicator

Gear position indicator

Neutral indicator

PGM-FI malfunction indicator

Main

Sub

LIGHTS/METERS/SWITCHES

12 V – 18/18W x 2

12 V – 18/5 W

12 V – 10 W x 2

12 V – 10 W x 2

LED

LED x 2

LED

LED x 4

LED

LED

15 A

10 A

ANF125

ANF125M

Fully charged

Needs charging

Normal

Quick

Normal

Quick

24-9

ANF125/M-5 ADDENDUM

TORQUE VALUES

FASTENER TYPE

5 mm hex bolt and nut6 mm hex bolt and nut8 mm hex bolt and nut10 mm hex bolt and nut12 mm hex bolt and nut

TORQUE

N·m (kgf·m, lbf·ft)

TORQUE


5 mm screw6 mm screw6 mm flange bolt (8 mm head)6 mm flange bolt (10 mm head) andnut8 mm flange bolt and nut10 mm flange bolt and nut

FASTENER TYPE

4 (0.4, 2.9)9 (0.9, 6.5)9 (0.9, 6.5)

12 (1.2, 9)

26 (2.7, 20)39 (4.0, 29)

• Torque specifications listed below are for important fasteners.• Others should be tightened to standard torque values listed above.

NOTES: 1. Apply a locking agent to the threads.2. Apply engine oil to the threads and seating surfaces.3. U-nut.4. ALOCK bolt:replace with a new one.

5 (0.5, 3.6)10 (1.0, 7)22 (2.2, 16)34 (3.5 , 25)54 (5.5, 40)

ITEM REMARKSTORQUE


THREAD

DIA. (mm)Q’TY

MAINTENANCE:

Oil drain boltCrankshaft hole capTiming hole capValve adjuster lock nutOil centrifugal filter cover boltClutch adjuster lock nutSpark plug

LUBRICATION SYSTEM:

Oil pump cover boltFUEL SYSTEM (Programmed Fuel Injection):

EOT (Engine Oil Temperature) sensorIntake manifold mounting bolt

ENGINE REMOVAL/INSTALLATION:

Drive sprocket fixing plate boltCYLINDER HEAD/VALVES:

Cylinder head cap nutCam sprocket cover boltCam sprocket boltCam chain tensioner lifter plugPlunger set bolt

CLUTCH/GEARSHIFT LINKAGE:

Shift drum stopper arm boltShift return spring pinGear shift cam plate socket boltCentrifugal clutch lock nutClutch lifter plate flange boltManual clutch center lock nut

ALTERNATOR/STARTER CLUTCH:

Flywheel flange nutStarter clutch outer mounting socket boltStator mounting boltIgnition pulse generator mounting bolt

1112411

2

12

2

41211

111131

1622

NOTE 1

NOTE 1NOTE 2

NOTE 2

NOTE 2NOTE 1

24 (2.4, 17)8 (0.8, 5.8)6 (0.6, 4.3)9 (0.9, 6.5)5 (0.5, 3.6)12 (1.2, 9)

16 (1.6, 12)

5 (0.5, 3.6)

18 (1.8, 13)12 (1.2, 9)

12 (1.2, 9)

24 (2.4, 17)10 (1.0, 7)9 (0.9, 6.5)4 (0.4, 2.9)10 (1.0, 7)

12 (1.2, 9)30 (3.1, 22)10 (1.0, 7)

64 (6.5, 47)12 (1.2, 9)

64 (6.5, 47)

64 (6.5, 47)16 (1.6, 12)10 (1.0, 7)10 (1.0, 7)

123014558

10

5

106

6

86566

686

146

14

12666

ENGINE

24-10

ANF125/M-5 ADDENDUM

7 ± 1 mm(0.3 ± 0.04 in)

INTAKE MANIFOLD BANDINTAKE MANIFOLDBAND

Intake manifold band:

Cylinder head stud bolt:

Cylinder stud bolt:

27.5 ± 1 mm (1.08 ± 0.04 in)

182 ±

1 m

m (

7.2

± 0

.04

in) 182 ± 1 m

m (7.2 ± 0.04 in

)

24-11

ANF125/M-5 ADDENDUM

ITEM REMARKSTORQUE


THREAD

DIA. (mm)Q’TY

FRAME/BODY PANELS/EXHAUST SYSTEM:

Rear grip mounting socket boltExhaust pipe joint nut

MAINTENANCE:

Drive chain case mounting boltFUEL SYSTEM (Programmed Fuel Injection):

Fuel feed pipe mounting boltSensor unit torx screwThrottle cable bracket screwBank angle sensor mounting screwFuel pump mounting nut(see tightening sequence below)

42

4

23125

27 (2.8, 20)27 (2.8, 20)

6 (0.6, 4.4)

5.1 (0.5, 3.8)3.4 (0.3, 2.5)3.4 (0.3, 2.5)1.2 (0.1, 0.9)

12 (1.2, 9)

88

6

55546

FRAME

ENGINE MOUNTING:

Engine hanger front bolt/nutEngine hanger rear upper bolt/nutEngine hanger rear lower bolt/nut

FRONT WHEEL/BRAKE/SUSPENSION/STEERING:

Steering stem nutSteering stem top threadBottom bridge pinch flange boltHandlebar holder nutHandlebar mounting boltFront axle nutFront brake disk boltFront spokeHandlebar weight screwFork socket boltBrake hose clamper bolt

REAR WHEEL/BRAKE/SUSPENSION:

Rear axle nutRear spokeDriven sprocket UBS nutDriven sprocket stud boltRear brake arm nutShock absorber upper mounting boltShock absorber lower mounting cap nutSwingarm pivot nut

HYDRAULIC BRAKE:

Caliper bleed valveCaliper pad pinCaliper mounting boltBrake hose oil boltMaster cylinder reservoir cover screwFront brake light switch screwBrake lever pivot boltBrake lever pivot nutCaliper pin nutPin bolt

LIGHTS/METERS/SWITCHES

Key shutter socket boltOTHERS:

Side stand pivot boltSide stand pivot bolt/nut

111

114131436221

136441221

1122211111

1

11

101010

262610108

128

BC 3.2686

12BC 3.2

886

101010

8108

10446688

6

1010

59 (6.0, 43)59 (6.0, 43)59 (6.0, 43)

See page 12-29See page 12-28

64 (6.5, 47)59 (6.0, 43)25 (2.5, 18)59 (6.0, 43)42 (4.3, 31)

3.2 (0.3, 2.3)9 (0.9, 6.6)20 (2.0, 14)12 (1.2, 9)

59 (6.0, 43)3.2 (0.3, 2.3)32 (3.3, 24)20 (2.0, 14)10 (1.0, 7)24 (2.4, 17)24 (2.4, 17)39 (4.0, 29)

5.4 (0.6, 4.0)17 (1.7, 12)30 (3.1, 22)34 (3.5, 25)

1.5 (0.2, 1.1)1.2 (0.1, 0.9)1 (0.1, 0.7)

5.9 (0.6, 4.4)22 (2.2, 16)17 (1.7, 12)

10 (1.0, 7)

18 (1.8, 13)44 (4.5, 33)

NOTE 3

NOTE 3NOTE 1

NOTE 1NOTE 4

NOTE 3

NOTE 2NOTE 1NOTE 3

NOTE 4

NOTE 1

24-12

ANF125/M-5 ADDENDUM

TOOLSNOTES: 1. Equivalent commercially available.

2. Alternative tool.

DESCRIPTION

Fuel pressure gaugeFuel attachment joint 6-9Pressure gauge manifoldFuel attachment hose 6-9Fuel attachment hose 9-9DLC short connectorValve adjuster wrenchWrench 8 x 9 mmSpoke wrench, 4.5 x 5.1 mmValve spring compressorValve spring compressor attachmentValve guide driver 4.8 mmValve guide reamer 5.0 mmValve seat cutters

Seat cutter, 24 mm (45° IN)Seat cutter, 22 mm (45° EX)Flat cutter, 27 mm (32° IN)Flat cutter, 22 mm (32° EX)Interior cutter, 26 mm (60° IN)Interior cutter, 20.5 mm (60° EX)Cutter holder, 5.0 mm

Lock nut wrench, 20 x 24 mmExtension barGear holderUniversal holderSnap ring pliersBearing remover set, 12 mm— Bearing remover shaft, 12mm— Bearing remover head, 12mmRemover weightBearing remover shaft, 10 mmBearing remover head, 10 mmDriverAttachment, 28 x 30 mmPilot, 10 mmPilot, 12 mmFlywheel holderFlywheel puller, 28 mmFlywheel puller, 30 mmUniversal bearing pullerAssembly set, 14 mmAttachment, 22 x 24 mmAttachment, 32 x 35 mmAttachment, 37 x 40 mmAttachment, 52 x 55 mmPilot, 17 mmPilot, 22 mm

REF. SEC.TOOL NUMBER

07406 – 004000407ZAJ-S5A015007ZAJ-S5A011107ZAJ-S5A013007ZAJ-S5A0120070PZ – ZY3010007708 – 003040007708 – 003010007701 – 002020007757 – 001000007959 – KM3010107942 – MA6000007984 – MA60001

07780 – 001060007780 – 001070107780 – 001330007780 – 001260107780 – 001450007780 – 001430007781 – 001040007716 – 002010007716 – 002050007724 – 001020007725 – 003000007914 – 323000107936 – 166010107936 – 166012007936 – 166011007741 – 001020107936 – GE0010007936 – GE0020007749 – 001000007946 – 187010007746 – 004010007746 – 004020007725 – 004000007933 – KG2000007KMC – HE0010007631 – 0010000

07JMF – KW7010007746 – 001080007746 – 001010007746 – 001020007746 – 001040007746 – 004040007746 – 0041000

REMARKS

2424242424223, 73, 73, 12, 137777

7777777999999, 119, 119, 119, 11999, 11, 12, 13999, 11, 12, 139, 10101011111111, 12, 1311, 1311, 1211, 1311

24-13

ANF125/M-5 ADDENDUM

DESCRIPTION

Inner driver, 35 mmBearing remover shaftBearing remover head, 12 mmFork seal driverFork seal driver attachmentSteering stem socketLock nut wrenchSteering stem pin spannerBall race remover, 40 mmBall race remover, 34.5 mmAttachment, 45 x 50 mmOil seal removerSnap ring pliersPeak voltage adaptor

REF. SEC.TOOL NUMBER

07746 – 003040007746 – 005010007746 – 005030007747 – 001010007747 – 001030007916 – 371010107916 – KM1000007702 – 002000107953 – 425000207948 – 463010007946 – 692010007748 – 001000107914 – SA5000107HGJ – 0020100 NOTE 2:

Imrie diagnostictester (model 625)

REMARKS

1212121212121212121212121416

24-14

ANF125/M-5 ADDENDUM

LUBRICATION & SEAL POINTS

LOCATION

Cylinder sleeve inner surfaceTiming hole cap threadsCrankshaft hole cap threadsValve adjuster hole cap threadsPiston and cylinder sliding surfacePiston pin and piston sliding surfacePiston ring whole surfaceConnecting rod small end I.D.Connecting rod big end needle bearingIN/EX valve stem sliding surfaceCamshaft cam surfaceCam chain surfaceCam set plunger whole surfaceCam decomp rotating surfaceRocker arm roller surface and boss inner surfaceRocker arm shaft whole surfaceValve adjusting nut fastening surfaceOil pump rotor sliding surfaceClutch outer guide outer surfaceManual clutch center lock nut fastening surfaceClutch disc surfaceCentrifugal clutch lock nut fastening surfaceOil pump drive gear inner surfaceM3, 4 gear inner surfaceM3 shift fork groove surfaceC1, 3, 4 gear inner surfaceC4 shift fork groove surfaceC1 bushing whole surfaceShift fork shaft whole surfaceStarter driven gear I.D. and gear teeth (ANF125M only)Gearshift drum journal outer surfaceKickstarter pinion gear inner surfaceFlywheel flange nut fastening surfaceStarter clutch rolling surface (ANF125M only)Starter reduction gear both journal (ANF125M only)Each gear sliding surface and gear teethEach bearing rolling surfaceEach O-ring whole surfaceEach oil seal lip area

Oil centrifugal filter cover bolt thread

Main shaft bearing set plate bolt threadGear shift cam plate socket bolt threadStarter clutch outer mounting socket bolt thread(ANF125M only)

Primary drive gear

REMARKS

Dripping (1.0-2.0 cm3)

Injecting (0.5-1.0 cm3)

MATERIAL

Honda 4-stroke oil orequivalent

ENGINE

Locking agent

Molybdenum oil(mixture of the engineoil and Molybdenumgrease in a ratio 1 : 1)

4 mm (0.16 in)

1.6 mm (0.06 in)

24-15

ANF125/M-5 ADDENDUM

REMARKSMATERIALENGINE (Cont’d)

Left crankcase mating surface

Alternator grommet sealing surface

Alternator inner surfaceLeft crankcase shaft tapered area

Liquid sealant

Degreasing

LOCATION

24-16

ANF125/M-5 ADDENDUM

LOCATION REMARKSMATERIAL

Steering head bearing sliding surfaceSteering head dust seal lips

Front wheel dust seal lipsRear wheel driven flange dust seal lipRear wheel hub O-ringBrake panel anchor pinBrake cam and shaftSide stand pivot surfaceKickstarter arm sliding surfaceThrottle housing and throttle pipe sliding surfaceBrake pedal pivot surfaceSteering handle lock sliding surfaceSeat lock sliding surface

Throttle cable surface

Throttle cable connecting areaFront disc brake lever pivot sliding surfaceFront disc brake lever contacting area with pistonBrake caliper bracket pin bolt and bootBrake master cylinder bootBrake caliper dust seal

Brake master cylinder piston sliding areaBrake caliper piston sliding areaBrake caliper piston seal

Driven flange stud bolt threadsFork socket bolt threadsBrake caliper pin nutFront brake disc bolt thread

Handle grip rubber inside

Fork dust seal and oil seal lipsFork bottom case inside

Drive chain

Injector O-ring and seal ringDrum brake cam dust sealDrive sprocket nut

Multi-purpose greasewith extreme pressure(example: EXCELITEEP2 manufactured byKYDO YUSHI, Japan),Shell Alvania EP2 orequivalent

Multi-purpose grease

Molybdenum oil(mixture of the engineoil and Molybdenumgrease in a ratio 1 : 1)

Silicone grease

Brake fluidDOT3 or DOT4

Locking agent

Honda Bond A

Honda Ultra CushionOil No.10

SAE #80 or 90 gear oil

Honda 4-stroke oil orequivalent

FRAME

About 0.1 cm3 (0.1 cc) Inject

24-17

ANF125/M-5 ADDENDUM

CABLE & HARNESS ROUTING

RIGHT HANDLEBARSWITCH WIRE

HORN WIRES

LEFT HANDLEBARSWITCH WIRE

HEADLIGHT 3P CONNECTORTURN SIGNAL RELAY

FRONT BRAKE HOSE

SPEEDOMETER WIRE

IGNITION SWICH WIRE

THROTTLE CABLE

FRONT BRAKE LIGHTSWITCH WIRE

24-18

ANF125/M-5 ADDENDUM

THROTTLECABLE

FRONT BRAKE HOSE

LEFT FRONT TURNSIGNAL LIGHT (2P)CONNECTOR

PULSE SECONDARYAIR (PAIR) FILTER

FUEL FEED HOSE

AIR INJECTION PIPE

AIR SUPPLYHOSE

EOT SENSOR WIRE

24-19

ANF125/M-5 ADDENDUM

RIGHT FRONT TURN SIGNALLIGHT (2P) CONNECTOR

HORN WIRES

SEAT LOCKCABLE

FRONT BRAKE HOSESPARK PLUG WIRE

CRANKCASEBREATHER TUBE

THROTTLE CABLE

MAIN WIRE HARNESS

24-20

ANF125/M-5 ADDENDUM

ANF125 :

ANF125M :

IGNITION COIL WIRE

INJECTOR WIRE

PAIR CONTROL VALVEVACUUM TUBE

SPARK PLUGWIRE

IGNITION COIL WIRE

INJECTOR WIRE

SENSORUNIT WIRE

PAIR CONTROL VALVEVACUUM TUBE

SPARKPLUG WIRE


REAR BRAKE LIGHTSWITCH WIRE

STARTER MOTORCABLE

GROUND CABLE

REAR BRAKE LIGHTSWITCH WIRE


SENSOR UNIT WIRE

24-21

ANF125/M-5 ADDENDUM

FUEL FEED HOSE

EOT SENSOR WIRE

SPEED SENSOR WIREENGINE OIL TEMPERATURE(EOT) SENSORAIR INJECTION PIPE

BANK ANGLESENSOR WIRE

BATTERY NEGATIVE CABLE

BATTERY POSITIVE CABLE

MAIN FUSE

SUB FUSESTARTER RELAY(ANF125M only)

THROTTLE CABLE

24-22

ANF125/M-5 ADDENDUM

REAR COMBINATION LIGHT WIREFUEL FEED HOSE

REGULATOR/RECTIFIER WIRE

FUEL PUMP WIRE

GROUND WIRE

REAR COMBINATIONLIGHT WIRE

SEAT LOCKCABLE

24-23

ANF125/M-5 ADDENDUM

FUEL FEED HOSEENGINE CONTROL MODULE(ECM) WIRE

24-24

ANF125/M-5 ADDENDUM

MAINTENANCE SCHEDULEPerform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.The following items require some mechanical knowledge. Certain items (particularly those marked * and **) mayrequire more technical information and tools. Consult your Honda dealer.

*

*

*

**

**

*

*

*

*

*

*

**

**

FREQUENCY

ITEM

FUEL LINE

THROTTLE OPERATION

AIR CLEANER

CRANKCASE BREATHER

SPARK PLUG

VALVE CLEARANCE

ENGINE OIL

ENGINE OIL STRAINER SCREEN

ENGINE OIL CENTRIFUGAL FILTER

ENGINE IDLE SPEED

SECONDARY AIR SUPPLY SYSTEM

DRIVE CHAIN

BRAKE FLUID

BRAKE SHOES/PADS WEAR

BRAKE SYSTEM

BRAKE LIGHT SWITCH

HEADLIGHT AIM

SIDE STAND

SUSPENSION

NUTS, BOLTS, FASTENERS

WHEELS/TIRES

STEERING HEAD BEARINGS

WHICHEVERCOMESFIRST

NOTE 2

NOTE 3

NOTE 5

NOTE 4

ODOMETER READING (NOTE 1)X1,000 mi

X1,000 km

MONTH

0.6

1

l

R

l

I

I

l

I

2.5

4

6

I

l

C

C

I

I

R

I

I

I

I

I

I

I

l

I

5

8

12

I

l

C

C

R

I

R

I

I

I

I

I

I

I

I

I

I

24-25

22-29

3-5

3-5

3-6

3-7

3-9

3-10

3-10

24-25

3-12

3-13

3-16

3-17

3-17

3-18

3-19

3-20

3-20

3-21

3-21

3-22

REFERTOPAGE

* Should be serviced by your Honda dealer, unless the owner has proper tools and service data and ismechanically qualified.

** In the interest of safety, we recommend these items be serviced only by your Honda dealer.Honda recommends that your Honda dealer should road test your motorcycle after each periodic maintenance iscarried out.

NOTES: 1. At higher odometer reading, repeat at the frequency interval established here.2. Service more frequently when riding in unusually wet or dusty areas.3. Service more frequently when riding in rain or at full throttle.4. Replace every 2 years. Replacement requires mechanical skill.5. Replace every 3 years or 24,000 km (15,000 mi). Replacement requires mechanical skill.

7.5

12

18

I

l

R

C

I

I

R

C

C

I

l

I

I

I

I

I

I

l

I

I

EVERY 1,000 km (600 mi): I, L

24-25

ANF125/M-5 ADDENDUM

FUEL LINERemove the main pipe side cover (page 23-25).

Check the fuel feed hose for deterioration, damage or leak-age.

Replace the fuel feed hose if necessary (page 24-54).

Also, check the fuel feed hose fittings for leakage.

Install the removed parts in the reverse order of removal.

ENGINE IDLE SPEED

If the engine must be running to do some work, make

sure the area is well ventilated. Never run the engine in

an enclosed area. The exhaust contains poisonous car-

bon monoxide gas that may cause loss of consciousness

and may lead to death. Run the engine in an open area or

with an exhaust evacuation system in enclosed area.

NOTE:

• Inspect and adjust the idle speed after all other enginemaintenance items have been performed and are withinspecifications.

• The engine must be warm for accurate idle speed in-spection and adjustment.

Warm up the engine for about ten minutes.Connect a tachometer.Turn the idle adjusting screw as required to obtain thespecified idle speed.

IDLE SPEED: 1,400 ± 100 min–1 (rpm)

IDLE ADJUSTING SCREW

FUEL FEED HOSE

24-26

ANF125/M-5 ADDENDUM

TECHNICAL FEATUREABSOLUTE PRESSURE FUEL SUPPLY SYSTEM

The fuel delivery system consists of the following components: fuel tank, fuel suction filter, fuel pump, internal pres-sure regulator, fuel feed hose and injector.This system is eruipped with the absolute fuel pressure. There is no external fuel return hose or vacuum pressureregulator with this system.The fuel pressure in the fuel delivery system is regulated by the internal pressure regulator and always kept absolute;294 kPa (3.0 kgf/cm2, 43 psi).The internal pressure regurator returns the fuel by opening a valve when the fuel pressure increases more than 294 kPa(3.0 kgf/cm2, 43 psi).This system optimizes injection volume by the ECM control.

FUEL PUMP

PRESSUREREGULATOR

FUEL SUCTION FILTER

INJECTOR

FUEL FEED HOSEFUEL TANK

24-27

ANF125/M-5 ADDENDUM

FUEL SYSTEM COMPONENT LOCATION

4.2 N•m (0.4 kgf•m, 3 lbf•ft)

12 N•m (1.2 kgf•m, 9 lbf•ft)

24-28

ANF125/M-5 ADDENDUM

PGM-FI SERVICE INFORMATIONGENERAL

• Be sure to relieve the fuel pressure while the engine is “OFF”.• Before disconnecting fuel feed hose, relieve pressure from the system by disconnecting the quick connect fitting in

the fuel pump (page 24-54).• Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bend,

resulting in loss of vehicle control.• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored

can cause a fire or explosion.• Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause

incorrect idle operation.• Seal the cylinder head intake port with tape or a clean cloth to keep dirt and debris from entering the intake port after

the throttle body has been removed.• Do not damage the throttle body. It may cause incorrect throttle valve.• Prevent dirt and debris from entering the throttle bore and fuel feed hose, clean them using compressed air.• Always reset the TP sensor when you remove the sensor unit from the throttle body.• The throttle body/sensor unit is factory pre-set. Do not disassemble in a way other than shown in this manual.• Do not loosen or tighten the white painted nut of the throttle body. Loosening or tightening them can cause throttle

body malfunction.• Always replace the packing when the fuel pump is removed.• The programmed fuel injection (PGM-FI) system is equipped with the Self-Diagnostic System described (page 24-

31). If the malfunction indicator lamp (MIL) blinks, follow the Self-Diagnostic Procedures to remedy the problem.• When checking the PGM-FI, always follow the steps in the troubleshooting flow chart (page 24-36).• The PGM-FI system is provided with fail-safe function to secure a minimum running capability even when there is

any trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability issecured by making use of the numerical values of a situation preset in advance in the simulated program map.The engine does not start, if the injector or ignition pulse generator has a problem.

• Refer to PGM-FI system location (page 24-29).• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections be-

fore proceeding.• When disassembling the programmed fuel injection parts, note the location of the O-rings. Replace them with new

ones upon reassembly.• Use a digital tester for PGM-FI system inspection.• Refer to procedures for fuel level sensor inspection (page 24-77).

PGM-FI TROUBLESHOOTINGEngine won’t to start

• Intake air leak• Fuel contaminated/deteriorated• Fuel supply too low

– Faulty fuel pump operating system (page 24-58)– Faulty fuel supply system (page 24-54)– Clogged injector filter– Sticking injector needle

Engine stall, hard to start, rough idling

• Intake air leak• Fuel contaminated/deteriorated• Fuel supply too high

– Faulty fuel supply system (page 24-54)• Fuel supply too low

– Faulty fuel supply system (page 24-54)– Clogged injector filter

• Idle speed misadjusted• Idle air passage clogged• Low cylinder compression

Backfiring or misfiring during acceleration

• Fuel supply too low– Faulty fuel supply system (page 24-54)– Clogged injector filter

• Ignition system malfunction (page 22-110, 24-74)

Poor performance (drive ability) and poor fuel economy

• Air cleaner element contaminated• Fuel supply too low

– Faulty fuel supply system (page 24-54)– Clogged injector filter

• Ignition system malfunction (page 22-110, 24-74)• Low cylinder compression

24-29

ANF125/M-5 ADDENDUM

PGM-FI SYSTEM LOCATION

IGNITION SWITCH

IGNITION SWITCH

INJECTOR

BANK ANGLE SENSOR

FUEL PUMP

ECMGEAR POSITIONSWITCH

ALTERNATOREOT SENSOR

IGNITIONPULSE GENERATOR

DATA LINKCONNECTOR

SENSOR UNIT(MAP, IAT, TP SENSORS)

MAP SENSOR THROTTLE BODY

IAT SENSOR

TP SENSOR

SENSORUNIT

REGULATOR/RECTIFIER

24-30

ANF125/M-5 ADDENDUM

PGM-FI SYSTEM DIAGRAM

(1) Ignition switch(2) Main fuse (15 A)(3) Sub fuse (10 A)(4) Battery(5) Regulator/rectifire(6) Fuel meter(7) Malfunction indicator lamp (MIL)(8) Neutral position indicator(9) Bank angle sensor(10) Data Link Connector (DLC)(11) Fuel pump

(12) Ignition coil(13) Intake air temperature sensor (IAT sensor)(14) Throttle position sensor (TP sensor)(15) Manifold absolute pressure sensor (MAP sensor)(16) Injector(17) Spark plug(18) Gear (neutral) position switch(19) Ignition pulse generator(20) Engine oil temperature sensor (EOT sensor)(21) Alternator charging coil

24-31

ANF125/M-5 ADDENDUM

PGM-FI SELF-DIAGNOSIS INFORMA-TIONSELF-DIAGNOSTIC PROCEDURE

Place the motorcycle on its centerstand.

NOTE:

The malfunction indicator lamp (MIL) will start blinkingthe ignition switch to “ON” or engine revs are below2,000 min–1 (rpm). In any other conditions, the MIL will il-luminate and stay on.

Turn the ignition switch to “ON”.

The malfunction indicator blinks, note how many timesthe MIL blinks, and determine the cause of the problem(page 24-34).

If the MIL does not light or blink, the system is normal. Ifyou wish to read the PGM-FI memory for trouble data,perform the following:

MALFUNCTION INDICATOR LAMP (MIL)

DATA LINKCONNECTOR(DLC)

CONNECTOR COVER

To read the stored problem data

Turn the ignition switch to “OFF”.

Remove the front top cover (page 23-24).

Disconnect the connector cover from the data link con-nector (DLC).

Connect the special tool to the data link connector (DLC).

TOOL:

DLC short connector 070PZ-ZY30100

DLC SHORT CONNECTOR

24-32

ANF125/M-5 ADDENDUM

SELF-DIAGNOSIS RESET PROCEDURE

NOTE:

The self-diagnosis memory data can not be erased onlywhen you disconnect the battery negative cable.

1. Turn the ignition switch to “OFF”.

2. Remove the front top cover (page 23-24).

Disconnect the connector cover from the data link con-nector (DLC).

3. Connect the special tool to the data link connector (DLC).

TOOL:


Turn the ignition switch to “ON”.If the ECM has no self diagnosis memory data, the MILwill illuminate, when you turn the ignition switch to “ON”.

If the ECM has self diagnosis memory data, the MIL willstart blinking when you turn the ignition switch to “ON”.

Note how many times the MIL blinks, and determine thecause of the problem (page 24-34).


DATA LINKCONNECTOR(DLC)

CONNECTOR COVER

DLC SHORT CONNECTOR

Ignition switch to "ON"

MIL ON

OFF

MIL ON

OFF

Ignition switch to "ON"

FAILURE CODES

2.5 sec

24-33

ANF125/M-5 ADDENDUM

4. Turn the ignition switch to “ON”.

5. Disconnect the DLC short connector from the data linkconnector (DLC).

6. Connect the DLC short connector to the data link con-nector (DLC) again while the MIL lights about 5 sec-onds (reset receiving pattern; see below).

Self-diagnosis memory data is erased, if the MIL turnoff and start blinking (successful pattern; see below).

The data link connector must be jumped while theindicator lights. If the DLC short connector are notconnected with in about 5 seconds, the MIL turn offand it well illuminate (unsuccessful pattern; see below).Turn the ignition switch “OFF” and so try from step 3.

NOTE:

Note that the self diagnosis memory data cannot beerased if you turn off the ignition switch before the MILstarts blinking.

If the MIL blinks 33 times, the data has not been erased,so try again. And yet if the MIL blinks 33 times, checkthe E2-PROM (page 24-51).

DLC SHORTCONNECTOR

DLC SHORTCONNECTOR

within 5 sec.

SUCCESSFUL PATTERN

MIL ON

OFF

FAILURE PATTERN RESET RECEIVINGPATTERN

2 – 3 sec.

0.3 sec.

0.3 sec.

within 5 sec. 2 – 3 sec.

MIL ON

OFF

FAILURE PATTERN RESET RECEIVINGPATTERN

UNSUCCESSFUL PATTERN


24-34

ANF125/M-5 ADDENDUM

MIL CODE INDEX• The PGM-FI malfunction indicator lamp (MIL) denotes the failure codes (the number of blinks from 0 to 54). The MIL

has two types of blinks, a long blinks and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for 0.3seconds. When one long blink occur, and two short blink, that problem code is 12 (one long blink = 10 blinks, twoshort blink = 2 blink). Then, go to the flow chart and see problem code 12.

• When the Engine Control Module (ECM) stores some failure codes, the MIL shows the failure codes in the orderfrom the lowest number to highest number. For example, when the MIL blinks once, then blinks seven times, twofailures have occurred. Follow the flow chart for failure codes 1 and 7.

Causes

• Faulty ignition pulse generator

• Clogged injector filter• Sticking injector needle

• Faulty ECM

• Blown main-fuse (15 A)• Open circuit at the power input

wire of the ECM• Faulty ignition switch

• Faulty ECM• Open or short circuit in MIL wire

• Short circuit in data link connector(DLC) wire

• Short circuit in MalfunctionIndicator Lamp (MIL) wire

• Faulty ECM

• Loose or poor contact on sensor• Open or short circuit in sensor

unit power/ground wire• Faulty sensor unit

• Loose or poor contact on sensorunit

• Open or short circuit in MAPsensor wire of the sensor unit

• Faulty MAP sensor

• Loose or poor contact on EOTsensor

• Open or short circuit in EOTsensor wire

• Faulty EOT sensor


• Open or short circuit in TP sensorwire of the sensor unit

• Faulty TP sensor


• Open or short circuit in IAT sensorwire of the sensor unit

• Faulty IAT sensor

• Loose or poor contact on injectorconnector

• Open or short circuit in injector wire• Faulty injector

Symptoms

• Engine does not start




• Engine operates normally




• Hard start at a low tempera-ture

• Poor engine response andperformance when operat-ing the throttle quickly



Refer to

24-74

—

—

24-36

—

—

24-38

24-40

24-42

24-45

24-47

24-49

Detection Item

Ignition pulsegeneratormalfunction

Injector malfunc-tion

ECM malfunction

ECM power/ground circuitmalfunction

MIL circuitmalfunction

Data link or MILcircuit malfunc-tion

Sensor unitpower/groundcircuit malfunc-tion

MAP sensorcircuit malfunction

EOT sensorcircuit malfunc-tion

TP sensor circuitmalfunction

IAT sensor circuitmalfunction

Injector circuitmalfunction

MIL

No blinks

No blinks

No blinks

No blinks

No blinks

Stay lit

1, 8, 9 allBlinks

1 Blink

7 Blinks

8 Blinks

9 Blinks

12 Blinks

24-35

ANF125/M-5 ADDENDUM

Causes

• Faulty ECM

• Loose or poor contact on bankangle sensor

• Open or short circuit in bank anglesensor wire

• Faulty bank angle sensor

MIL

33 Blinks

54 Blinks

Symptoms

• Engine operates normally• Does not hold the self-

diagnosis data

• Engine operates normally• Engine does not start

Refer to

24-51

24-52

Detection Item

E2-PROM in ECMmalfunction

Bank anglesensor malfunc-tion

24-36

ANF125/M-5 ADDENDUM

ECM POWER/GROUND INSPECTION• This vehicle has two types of power supply to operate the ECM.

If the battery is in proper-working condition, it is used as the first power supply.If the battery is not in proper-working condition, the alternator voltage generated by the kickstarter is used as thesecond power supply.

• If the engine does not start with the kickstarter, inspect the ECM POWER/GROUND INSPECTION first, then inspectthe alternator (page 22-104) and regulator/rectifier (page 22-104) as the secondary power supply.

• Before inspecting the ECM POWER/GROUND INSPECTION, be sure to charge or replace the battery with a new one.

Engine does not start (MIL does not blink)

• Loose or poor contact on the ECM connector

Engine dose not start


Engine startsConnect the ECM 33P connector.Start the engine.


Disconnect the ECM 33P connector.Check for loose or poor connect on the ECM33P connector.

ECM 33P CONNECTOR

ECM 33P CONNECTOR

24-37

ANF125/M-5 ADDENDUM

Disconnect the ECM 33P connector.Check for continuity between the ECM connec-tor of the wire harness side and ground.

CONNECTION: Green — Ground

Green/Black — Ground

STANDARD: Continuity

Normal

• Open circuit in Green wireAbnormal

Out of rangeTurn the ignition switch to “ON” and measurethe battery voltage between the ECM connec-tor of the wire harness side and ground.

CONNECTION: Black/Blue (+) — Ground (–)

STANDARD: Battery voltage — 1.1 V minimum

• Replace the ECM with a new one, and inspectit again

• Loose or poor connector contact• Inspect the ignition switch (page 18-10)• Blown main-fuse (15A)• Open or short circuit in following wire harness:

— Red wire or Red/Yellow wire between the bat-tery and ignition switch

— Black/Blue wire between the ignition switchand ECM

ECM 33P CONNECTOR

ECM 33P CONNECTOR

Voltage exist

24-38

ANF125/M-5 ADDENDUM

SENSOR UNIT POWER/GROUND CIRCUIT INSPECTION

PGM-FI MIL 1, 8, 9 ALL BLINKS (MAP, TP, IAT SENSOR)• Before starting the inspection, recheck the MIL blinking. If the MIL does not light or blink, the system is normal.


Disconnect the sensor unit 5P connector andECM 33P connector.Check for loose or poor contact on the sensorunit 5P connector and ECM 33P connector.

• Loose or poor contact on the sensor unit 5Pconnector and/or ECM 33P connector

Connect the sensor unit 5P connector and ECM33P connector.Turn the ignition switch to “ON”.Check the MIL blinks.


No blink

1, 8, 9 blinks

SENSOR UNIT 5PCONNECTOR

ECM 33PCONNECTOR

ECM 33PCONNECTOR

SENSOR UNIT 5PCONNECTOR

24-39

ANF125/M-5 ADDENDUM

Disconnect the sensor unit 5P connector.Turn the ignition switch to "ON".Measure the voltage between the sensor unit5P connector terminals at the wire harness side.

Voltage exist

Out of range

• Replace the sensor unit with a new one andinspect again

CONNECTION:

Yellow/Red (+) – Green/Orange (–)

STANDARD: 4.75 – 5.25 V

SENSOR UNIT 5P CONNECTOR

AbnormalDisconnect the ECM 33P connector.Check for continuity between the ECM 33P con-nector and sensor unit 5P connector at the wireharness side.

• Open circuit in Yellow/Red or Green/Orangewire

• Short circuit in Yellow/Red wire


ECM 33P CONNECTOR

• Replace the ECM with a new one and inspectagain

Normal

CONNECTION:

Yellow/Red – Yellow/Red

Green/Orange – Green/Orange


CONNECTION:

Yellow/Red – Ground

STANDARD: No continuity

24-40

ANF125/M-5 ADDENDUM

MIL TROUBLESHOOTING

PGM-FI MIL 1 BLINK (MAP SENSOR)• Before starting the inspection, recheck the MIL blinking. If the MIL does not light or blink, the system is normal.


• Go to SENSOR UNIT POWER/GROUNDCIRCUIT INSPECTION (page 24-38)

1, 8, 9 all blinksReset the self diagnosis memory data (page24-32).Turn the ignition switch to "ON".Check the MIL blinks.


1 blink

• Replace the sensor unit with a new one andinspect again (Faulty MAP sensor)

Disconnect the sensor unit 5P connector.Turn the ignition switch to "ON".Measure the voltage between the sensor unit5P connector at the wire harness side andground.

Voltage exist


CONNECTION:

Light green/Yellow (+) – Ground (–)

STANDARD: 3.8 – 5.25 V


Out of range

(To page 24-41)

24-41

ANF125/M-5 ADDENDUM

• Open circuit in Light green/Yellow wire• Short circuit in Light green/Yellow wire

Disconnect the ECM 33P connector.Check for continuity between the ECM 33Pconnector and sensor unit 5P connector at thewire harness side.Check for no continuity between the sensorunit 5P connector at the wire harness side andground.

Abnormal

ECM 33P CONNECTOR


CONNECTION:

Light green/Yellow – Light green/Yellow


CONNECTION:

Light green/Yellow – Ground



Normal

24-42

ANF125/M-5 ADDENDUM

• Loose or poor contact on the EOT sensorconnector

Connect the EOT sensor 2P connector.Turn the ignition switch to “ON”.Check the MIL blinks.


No blink

44 blinks

Disconnect the EOT sensor 2P connector.Measure the resistance at the EOT sensor ter-minals.

STANDARD: 2.5 – 2.8 kΩ (20°C/68°F)

Abnormal

Normal

• Inspect the EOT sensor (page 24-71)

PGM-FI MIL 7 BLINKS (EOT SENSOR)• Before starting the inspection, recheck the MIL blinking. If the MIL does not light or blink, the system is normal.


Disconnect the EOT 2P sensor connector.Check for loose or poor contact on the EOTsensor 2P connector.

EOT SENSOR2P CONNECTOR

EOT SENSOR 2P CONNECTOR

EOT SENSOR

24-43

ANF125/M-5 ADDENDUM

Check for continuity between the EOT sensorterminal and ground.


Abnormal

Normal

• Faulty EOT sensor

EOT SENSOR

Normal

CONNECTION: Yellow/Blue – Green/Orange

STANDARD: 4.75 – 5.25 V

Out of range• Open circuit in Green/Orange wire• Loose or poor contact on the ECM connector

Measure the voltage between the EOT sensorconnector at the wire harness side.

EOT SENSOR2P CONNECTOR


Voltage exist

(To page 24-44)

24-44

ANF125/M-5 ADDENDUM

• Open or short circuit in Yellow/Blue wire• Open or short circuit in Green/Orange wire

Disconnect the ECM 33P connector.Check for continuity between the ECM 33Pconnector and EOT sensor 2P connector at thewire harness side.Check for no continuity between the EOT sen-sor 2P connector at the wire harness side andground.

Abnormal


Normal

CONNECTION:


Yellow/Blue – Yellow/Blue


CONNECTION:

Green/Orange – Ground

Yellow/Blue – Ground


ECM 33P CONNECTOR


(From page 24-43)

24-45

ANF125/M-5 ADDENDUM

PGM-FI MIL 8 BLINKS (TP SENSOR)• Before starting the inspection, recheck the MIL blinking. If the MIL does not light or blink, the system is normal.





8 blinks


Voltage exist

CONNECTION: Yellow (+) – Ground (–)

STANDARD: 0 – 220 mV


Out of range


• Replace the sensor unit with a new one andinspect again (Faulty TP sensor)

(To page 24-46)

24-46

ANF125/M-5 ADDENDUM

(From page 24-45)

• Open circuit in Yellow wire• Short circuit in Yellow wire


Abnormal

CONNECTION:Yellow – Yellow


CONNECTION: Yellow – Ground



Normal

ECM 33P CONNECTOR


24-47

ANF125/M-5 ADDENDUM

PGM-FI MIL 9 BLINKS (IAT SENSOR)• Before starting the inspection, recheck the MIL blinking. If the MIL does not light or blink, the system is normal.





9 blinks


Voltage exist

CONNECTION:

Gray/Blue (+) – Ground (–)

STANDARD: 4.75 – 5.25 V


Out of range


• Replace the sensor unit with a new one andinspect again (Faulty IAT sensor)

(To page 24-48)

24-48

ANF125/M-5 ADDENDUM

• Open circuit in Gray/Blue wire• Short circuit in Gray/Blue wire


Abnormal

CONNECTION: Gray/Blue – Gray/Blue


CONNECTION:Gray/Blue – Ground



Normal

ECM 33P CONNECTOR


(From page 24-47)

24-49

ANF125/M-5 ADDENDUM

PGM-FI MIL 12 BLINKS (INJECTOR)• Before starting the inspection, recheck the MIL blinking. If the MIL does not light or blink, the system is normal.


Disconnect the injector 2P connector.Check for loose or poor contact on the injector2P connector.

• Loose or poor contact on the injectorconnector

Connect the injector 2P connector.Turn the ignition switch to “ON”.Check the MIL blinks.


No blink

12 blinks

INJECTOR 2P CONNECTOR


(To page 24-50)

24-50

ANF125/M-5 ADDENDUM

Abnormal

Normal


Disconnect the ECM 33P connector.Check for continuity between the injector con-nector and ECM connector at the wire harnessside.Check for no continuity between the injector2P connector at the wire harness side andground.

CONNECTION: Pink/Green – Pink/Green


CONNECTION: Pink/Green – Ground


• Open or short circuit in Pink/Green wire

Disconnect the injector 2P connector.Turn the ignition switch to”ON”.Measure the battery voltage between the in-jector connector at the wire harness side andground.

CONNECTION: Black/Blue (+) – Ground (–)

STANDARD: Battery voltage – 1.1 V minimum

Out of range

Voltage exist

• Open or short circuit in Black/Blue wire


ECM 33P CONNECTOR


(From page 24-49)

24-51

ANF125/M-5 ADDENDUM


Measure the resistance at the injector termi-nals.

STANDARD: 10.2 – 11.4 Ω (20°C/68°F)

Abnormal • Faulty injector

Normal

INJECTOR

PGM-FI MIL 33 BLINKS (E2-PROM)


• Intermittent failureReset the self-diagnosis memorydata (page 24-32).Turn the ignition switch to “ON”.Check that the MIL blinks.

No blink

33 blinks• Replace the ECM with a new one and inspect

again

24-52

ANF125/M-5 ADDENDUM

• Loose or poor contact on the bank anglesensor 3P connector

Connect the bank angle sensor 3P connector.Turn the ignition switch to “ON”.Check the MIL blinks.

No blink

54 blinks

PGM-FI MIL 54 BLINKS (BANK ANGLE SENSOR)• Before starting the inspection, recheck the MIL blinking. If the MIL does not light or blink, the system is normal.


Disconnect the bank angle sensor 3P connec-tor.Check for loose or poor contact on the bankangle sensor 3P connector.

BANK ANGLE SENSOR3P CONNECTOR


24-53

ANF125/M-5 ADDENDUM


• Open or short circuit in Green/Orange wire• Open or short circuit in Yellow/Red wire• Open or short circuit in Red/Blue wire

Disconnect the ECM 33P connector.Check for continuity between the bank anglesensor 3P connector and ECM 33P connectorat the wire harness side.Check for continuity between the bank anglesensor 3P connector at the wire harness sideand ground.

Abnormal

CONNECTION:


Yellow/Red – Yellow/Red

Red/Blue– Red/Blue


CONNECTION:

Yellow/Red – Ground

Red/Blue– Ground


Normal

Disconnect the bank angle sensor 3P connec-tor.Turn the ignition switch to “ON”.Measure the voltage between the bank anglesensor 3P connector at the wire harness sideand ground.

Out of range

Voltage exist


CONNECTION: Yellow/Red (+) – Ground (–)

STANDARD: 4.75 – 5.25 V


ECM 33P CONNECTOR

• Replace the ECM with a new one and inspetagain

• Replace the bank angle sensor with a newone and inspect again

24-54

ANF125/M-5 ADDENDUM

FUEL PUMP 5P (BLACK) CONNECTOR

SHOP TOWEL

FUEL CONNECT FITTING

FUEL LINE INSPECTIONFUEL PRESSURE RELIEVING/QUICKCONNECT FITTING REMOVAL

NOTE:

Before disconnecting fuel feed hose, relieve pressure fromthe system by disconnecting the quick connect fitting inthe fuel pump.

Remove the following:— Body cover (page 23-27)— Two special screws— Fuel tank mounting bolt— Fuel pump cover

Disconnect the fuel pump 5P (Black) connector.

Start the engine, and let it idle until the engine stalls.


Disconnect the battery negative cable and then positivecable.

Check the fuel quick connect fitting for dirt, and clean ifnecessary.

Place a shop towel over the quick connect fitting.

Pull away the rubber.

Hold the connector with one hand and squeeze the retainertabs with the other hand release them from the lockingpawls.Pull the connector off.

NOTE:

• Prevent the remaining fuel in the fuel feed hose fromfollowing out with a shop towel.

• Be careful not to damage the hose or other parts.• Do not use tools.• If the connector does not move, keep the retainer tabs

pressed down, and alternately pull and push the con-nector until it comes of easily.

RETAINER TABS

SPECIAL SCREWS

FUEL TANK MOUNTING BOLT

FUEL PUMP COVER

LOCKING PAWLSCONNECTOR

RUBBER

24-55

ANF125/M-5 ADDENDUM

To prevent damage and keep foreign matter out, coverthe disconnected connector and pipe end with the plasticbags.

QUICK CONNECT FITTING INSTALLATION

NOTE:

• Always replace the retainer of the quick connect fittingwhen the fuel feed hose is disconnected.

• If any retainer need replacing, use the samemanufacture's retainer as the ones being removed (Theseveral manufactures feature different retainer specifi-cations).

Clean around the fuel hose joint.

Insert a new retainer into the connector joint with aligningthe two hooks of the retainer with the two holes on theconnector joint.

NOTE:

Do not bent or twist the fuel feed hose.

Clean around the pipe.

Set the rubber correctly.

Align the quick connect fitting with the pipe and align thenew retainer locking pawls with the connector grooves.Then press the quick connect fitting onto the pipe untilboth retainer pawls lock with a "CLICK".

If it is hard to connect, put a small amount of engine oil onthe pipe end.

PIPEPLASTIC BAGS

CONNECTOR

HOOKS

CONNECTOR

RETAINER

HOLES

PIPE

LOCKING PAWLS

CONNECTOR

FUEL PUMP SIDE:

RUBBER

NOTE:

When connecting the quick connect fitting to the injectorside fuel feed pipe, align the tabs between the connectordamper and retainer.

INJECTOR SIDE:

CONNECTORDAMPER

TABS

RETAINER TABS

24-56

ANF125/M-5 ADDENDUM

Connect the fuel pump 5P (Black) connector.

Temporally connect the positive cable and negtive cableto the battery.

NOTE:

Do not start the engine.

Turn the ignition switch "ON".

The fuel pump will run for about 2 seconds, and fuel pres-sure will rise.Repeat 2 or 3 times, and check that there is no leakage inthe fuel supply system.

Install the fuel pump cover.Install and tighten the two special screws to the specifiedtorque.

TORQUE: 4.2 N•m (0.4 kgf•m, 3 lbf•ft)

Install and tighten the fuel tank mounting bolt securely.

Install the following:— Body cover (page 23-27)

SPECIAL SCREWS

FUEL TANK MOUNTING BOLT

FUEL PUMP COVER


Make sure the connection is secure and that the pawls arefirmly locked into place; check visually and by pulling theconnector.

CONNECTOR

24-57

ANF125/M-5 ADDENDUM

FUEL ATTACHMENTHOSE 6-9

FUEL PRESSURE TEST

Relieve the fuel pressure and disconnect the quick con-nect fitting (page 24-54).

Attach the fuel pressure gauge set and pressure gauge.

TOOLS:

Fuel pressure gauge 07406-0040004

Pressure gauge manifold 07ZAJ-S5A0111

Fuel attachment hose 6-9 07ZAJ-S5A0130

Fuel attachment hose 9-9 07ZAJ-S5A0120

Fuel attachment joint 6-9 07ZAJ-S5A0150

Temporally connect the positive cable and negative cableto the battery.Start the engine and let it idle.Read the fuel pressure.


FUEL PRESSURE: 294 kPa (3.0 kgf/cm2, 43 psi)

If the fuel pressure is higher than specified, replace thefuel pump assembly.If the fuel pressure is lower than specified, inspect the fol-lowing:— Fuel line leaking— Fuel pump (page 24-58)— Clogged fuel suction filter (Assembly of the fuel pump)

After inspection, remove the fuel pressure gauge and pres-sure gauge set from the fuel pump.

Connect the quick connect fitting (page 24-55).

FUEL FLOW INSPECTION


Connect the special tool to the fuel pump joint.

TOOL:

Fuel attachment hose 6-9 07ZAL-S5A0130

NOTE:

Wipe off spilled out gasoline.

Place the end of the hose into an approved gasoline con-tainer and measure the amount of fuel flow with the ignitonswitch turning "ON".

NOTE:

The fuel pump operates for two seconds. Repeat 5 timesso that the total measuring time.

Amount of fuel flow:

13.9 cm3 (0.47 US oz, 0.49 Imp oz) minimum/

10 seconds at 12 V

If the fuel flow is less than specified, inspect the following:— Fuel pump (page 24-58)— Clogged fuel suction filter (Assembly of the fuel pump)


P R E S S U R EGAUGE

FUELHOSE6-9

MANIFOLD

FUEL JOINT 6-9

FUEL HOSE 9-9

24-58

ANF125/M-5 ADDENDUM


FUEL PUMP WIRE

FUEL PUMPINSPECTION

Turn the ignition switch to “ON” and confirm that the fuelpump operates for a few seconds.If the fuel pump does not operate, inspect as follows:


Remove the body cover (page 23-27).Remove the fuel pump cover (page 24-54).

Disconnect the fuel pump 5P (Black) connector.

REMOVAL

NOTE:

It is impossible to disassemble the fuel pump after remov-ing it.

Clean around the fule pump.


Disconnect the fuel pump 5P (Black) connector.Remove the fuel pump wire from the clamp.

Turn the ignition switch to “ON” and measure the voltagebetween the terminals.

CONNECTION: Black/Blue (+) — Brown (–)

STANDARD: Battery voltage — 1.1 V minimum

If there is specified value, replace the fuel pump.

If there is out of specified value, inspect the following:— Main fuse 15 A— Open circuit in Black/Blue or Brown wire— ECM (page 24-36)

Remove the fuel pump mounting nuts and clamp.

CLAMP


CLAMP

NUTS


24-59

ANF125/M-5 ADDENDUM

SET PLATE

PACKING

NOTE:

Remove the fuel pump being careful not to damage thefuel level sensor float arm.

Remove the set plate/fuel pump unit assembly and pack-ing.

FUEL PUMP UNIT

INSPECTION

Check the fuel pump unit for wear or damage.Check the fuel suction filter for wear or damage.

Replace the fuel pump unit if necessary

FUEL SUCTION FILTER

INSTALLATION

NOTE:

• Always replace the packing with a new one.• Install the fuel pump being careful not to damage the

fuel level sensor float arm.• Be careful not to pinch the dirt and bedris between the

fuel pump and packing.

Place a new packing onto the fuel pump unit.

FUEL PUMP UNIT

FUEL PUMP UNIT

PACKING

Install the set plate by aligning its holes with the tabs onthe fuel pump unit.

Install the set plate/fuel pump unit assembly to the fueltank.

SET PLATE

AlignFUEL PUMP UNIT

24-60

ANF125/M-5 ADDENDUM

FUEL PUMP 4P CONNECTOR

Install the clamp and tighten the fuel pump mounting nutsin the sequence shown.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf•ft)

Connect the fuel pump 5P (Black) connector.Clamp the fuel pump wire.


CLAMP

NUTS

FUEL PUMP WIRECLAMP


FUEL TANKREMOVAL/INSTALLATION


Remove the fuel pump wire from the clamp.Remove the three mounting bolts and the fuel tank.

Installation is in the reverse order of removal.


BOLTS

FUEL TANK

24-61

ANF125/M-5 ADDENDUM

Loosen the throttle cable lock nut and adjusting nut thendisconnect the throttle cable from the throttle drum andcable bracket.

Disconnect the quick connect fitting (page 24-54).

Remove the two intake manifold mounting bolts andthrottle body/sensor unit to the right side.

NOTE:

Seal the cylinder head intake port with a shop towel orcover it with a piece of tape to prevent any foreign mate-rial from dropping into the engine.

THROTTLE BODY/SENSOR UNITREMOVAL

NOTE:

• The sensor unit can be removed with the throttle bodyinstalled in the air cleaner and intake manifold.

• If you have removed sensor unit, reset the throttle po-sition (TP) sensor (page 24-65).

Remove the main pipe side cover (page 23-25).Relieve the fuel pressure (page 24-54).

Disconnect the following:— Spark plug cap— Crankcase breather tube— Pair control valve vacuum tube— Injector 2P connector— Sensor unit 5P connector

Loosen the air cleaner connecting hose band screw.

SCREW

CONNECTORSPAIR CONTROL VALVEVACUUM TUBE

CRANKCASE BREATHER TUBE

BOLTS

ADJUSTING NUT

LOCKNUT

THROTTLE CABLE

QUICK CONNECT FITTING

Remove the O-ring.Loosen the band screw and remove the intake manifoldfrom the throttle body.

SCREW

INTAKE MANIFOLD O-RING

24-62

ANF125/M-5 ADDENDUM

Turn the idle adjusting screw in and record the number ofturns until it seats lightly.

NOTE:

Damage to the idle adjusting screw seat will occur if theidle adjusting screw is tighened against the seat.

Remove the following:— Idle adjusting screw— O-ring— Spring

DISASSEMBLY

NOTE:

• The throttle body/sensor unit is factory pre-set. Do notdisassemble in a way other than shown in this manual.

• Do not snap the throttle valve from full open to full closeafter the throttle cable has been removed. It may causeincorrect idle operation.

• Do not damage the throttle body. It may cause incor-rect throttle valve.

• Do not loosen or tighten the white painted nut of thethrottle body. Loosening or tightening it can causethrottle body malfunction.

WHITE PAINTED

O-RING

SPRINGIDLE ADJUSTING SCREW

Remove the injector (page 24-69).Remove the three torx screws and sensor unit from thethrottle body.

Remove the O-ring.

SENSOR UNIT

TORX SCREWS

O-RING

Blow open each air passage in the throttle body with thecompressed air.

NOTE:

Do not use high pressure air or bring the nozzle too closeto the throttle body.

THROTTLEBODY

24-63

ANF125/M-5 ADDENDUM

NOTE:

Install the O-ring to the throttle body properly.If the O-ring is not installed properly, the idle air will leaksand engine idle speed will be unstable.

Install a new O-ring to the throttle body.

Install the sensor unit to the throttle body by aligning theclip of the throttle position (TP) sensor and boss of thethrottle valve.

NOTE:

The light pressure is sufficient to assemble the sensor unitand throttle body in their correctly position. If you cannotset it easily, the clip may be misaligned, and do not forceit but make sure that the clip is aligned at the right posi-tion.

Install the three torx screws and tighten it to the specifiedtorque.

TORQUE: 3.4 N•m (0.3 kgf•m, 2.5 lbf•ft)

Install the injector (page 24-69).

THROTTLE BODY SENSOR UNIT

O-RING

BOSS OF THE THROTTLE VALVECLIP OF THETP SENSOR

ASSEMBLY

TORX SCREW3.4 N•m (0.3 kgf•m,2.5 lbf•ft)

SENSOR UNIT

THROTTLE BODY

SPRING

IDLE ADJUSTINGSCREW

SCREW3.4 N•m (0.3 kgf•m, 2.5 lbf•ft)

THROTTLE CABLE BRACKET

O-RING

BOLT5.1 N•m (0.5 kgf•m, 3.8 lbf•ft)

O-RINGFUEL FEED PIPE

O-RING

INJECTOR

SENSOR UNIT

TORX SCREWS

SEAL RING

24-64

ANF125/M-5 ADDENDUM

INSTALLATION

NOTE:

Be careful not to damage the intake manifold.

Install the intake manifold by aligning its groove with theboss of the throttle body.Install a new O-ring to the intake manifold.

Install the following:— Spring— New O-ring— Idle adjusting screw

Turn the idle adjusting screw in until it seats lightly.

NOTE:

Damage to the idle adjusting screw seat will occur if theidle adjusting screw is tightened against the seat.

Turn the idle adjusting screw out to its original position asnoted during removal.

O-RING

SPRINGIDLE ADJUSTING SCREW

SCREWINTAKE MANIFOLD

O-RINGAlign

INTAKE MANIFOLD BAND

7 ± 1 mm(0.3 ± 0.04 in)

Tighten the intake manifold band screw so that the bandends clearance is 7 ± 1 mm (0.3 ± 0.04 in).

24-65

ANF125/M-5 ADDENDUM

Install the throttle body/sensor unit and tighten the twointake manifold mounting bolts to the specified torque.



Connect the throttle cable to the throttle drum and throttlecable bracket, then adjust the throttle grip free play (page22-29).

Tighten the air cleaner connecting hose band screw.

Connect the following:— Sensor unit 5P connector— Injector 2P connector— PAIR control valve vacuum tube— Crankcase breather tube— Spark plug cap

NOTE:

• If you have removed idle adjusting screw, adjust theengine idle speed (page 24-25).

• If you have removed sensor unit, reset the throttle po-sition (TP) sensor (page 24-65).

Install the following:— Main pipe side cover (page 23-25)

BOLTS

ADJUSTING NUT

LOCKNUT

THROTTLE CABLE

QUICK CONNECT FITTING

SCREW

CONNECTORSPAIR CONTROL VALVEVACUUM TUBE

CRANKCASE BREATHER TUBE

THROTTLE POSITION (TP) SENSOR RE-SET PROCEDURE


2. Disconnect the connector cover from the data link con-nector (DLC).

3. Connect the special tool to the Data Link Connector(DLC).

TOOL:


DLC SHORT CONNECTOR

DATA LINKCONNECTOR (DLC)

CONNECTOR COVER

24-66

ANF125/M-5 ADDENDUM

4. Disconnect the EOT sensor 2P connector.

Connect the EOT sensor terminals with a jumper wire.

CONNECTION: Yellow/Blue – Green/Orange

EOT SENSOR 2P CONNECTORJUMPER WIRE

5. Turn the ignition switch to “ON” then disconnect thejumper wire from the EOT sensor 2P connector whilethe MIL blinking (reset receiving pattern; see page 24-67) for 10 seconds.

After disconnection of the jumper wire, the MIL start toblinking (successful pattern; see page 24-67).

EOT SENSOR 2PCONNECTORJUMPER WIRE


24-67

ANF125/M-5 ADDENDUM

If the jumper wire is not disconnected within 10 sec-onds, the MIL will illuminate (unsuccessful pattern; seebelow) and try again from the step 4.

MIL ON

OFF

RESET RECEIVING PATTERN

within 10 sec.

0.1 sec.

UNSUCCESSFUL PATTERN

1.2 sec.

0.1 sec.

MIL ON

OFF

RESET RECEIVING PATTERN

within 10 sec. 0.3 sec.

SUCCESSFUL PATTERN

1.2 sec.

0.3 sec.

NOTE:

When the self-diagnosis memory data is stored for ECM,the MIL start to blinking of the problem code.Be sure to reset the self-diagnosis memory data (page24-32), so try from step 4.


7. Connect the EOT sensor 2P connector.

8. Disconnect the DLC short connector from the data linkconnector (DLC).

TOOL:


DLC SHORT CONNECTOR


24-68

ANF125/M-5 ADDENDUM

9. Connect the connector cover to the data link connector(DLC).

10. Place the motorcycle with its center stand.Shift the transmission into neutral.Warm up the engine for about ten minutes.Connect a tachometer.Check the engine idle speed.


If the engine idle speed is out of specification, turnthe idle adjusting screw as required to obtain the speci-fied idle speed.If the idle speed does not fall within the specification,check the “POOR PERFORMANCE AT LOW AND IDLESPEED” (page 24-83).

DATA LINKCONNECTOR (DLC) CONNECTOR COVER

IDLE ADJUSTING SCREW

24-69

ANF125/M-5 ADDENDUM

ECM (ENGINE CONTROL MODULE)REMOVAL/INSTALLATION

Remove the body cover (page 23-27).Remove the rubber holder and ECM.Disconnect the ECM 33P connector.

Installation is in the reverse order of removal.

RUBBER HOLDER

ECM 33P CONNECTOR ECM

INJECTORREMOVAL

Remove the throttle body/sensor unit (page 24-61).

Remove the two bolts and injector assembly from thethrottle body.

INJECTOR ASSEMBLY

BOLTS

FUEL FEED PIPE

O-RING

Remove the fuel feed pipe, O-ring and seal ring from theinjector.

Check the removed parts for wear or damage and replacethem if necessary.

INSTALLATION

Coat a new O-ring and seal ring with engine oil.

NOTE:

• Replace the O-ring and seal ring with new ones.• Be careful not to damage the O-ring and seal ring.

Install a new O-ring and new seal ring to the injector.

INJECTORSEAL RING

INJECTOR

FUEL FEED PIPE

Install the injector to the fuel feed pipe as shown.

TAB

STOPPER

24-70

ANF125/M-5 ADDENDUM

STOPPER INJECTORCONNECTOR

NOTE:

Check that the location of the injector connector is betweenthe stopper of the fuel feed pipe and throttle body.

Install the injector assembly to the throttle body.

Install and tighten the two fuel feed pipe mounting boltsto the specified torque.


Install the throttle body/sensor unit (page 24-64)INJECTOR ASSEMBLY THROTTLE BODY

BANK ANGLE SENSOR

REMOVAL/INSTALLATION

Remove the following:— Main pipe side cover (page 23-25)— Body cover (page 23-27)— Utility box (page 22-25)

Disconnect the bank angle sensor 3P connector.Remove the two mounting screws and bank angle sensor.

Install the bank angle sensor with its “UP” mark facingup.

Install and tighten the mounting screws to the specifiedtorque.


Connect the bank angle sensor 3P connector.

Install the following:— Utility box (page 22-25)— Body cover (page 23-27)— Main pipe side cover (page 23-25)

3P CONNECTOR

BANK ANGLE SENSOR SCREWS

3P CONNECTOR

BANK ANGLE SENSOR SCREWS

24-71

ANF125/M-5 ADDENDUM

EOT (ENGINE OIL TEMPERATURE)SENSORREMOVAL

Drain the engine oil (page 3-9).

Remove the main pipe side cover (page 23-25).

NOTE:

Replace the EOT sensor while the engine is cold.

Disconnect the EOT sensor 2P connector from the sensor.Remove the EOT sensor and sealing washer.

INSPECTION

NOTE:

Keep all flammable materials away from the electric heat-ing element.

Suspend the EOT sensor in a pan of coolant (50-50 mix-ture) on an electric heating element and measure the re-sistance at the EOT sensor terminals as the coolant heatsup.

NOTE:

• Soak the EOT sensor in coolant up to its threads with atleast 40 mm (1.57 in) from the bottom of the pan to thebottom of the sensor.

• Keep the temperature constant for 3 minutes beforetesting. A sudden change of temperature will result inincorrect reading. Do not let the thermometer or EOTsensor touch the pan.

Measure the resistance at the EOT sensor terminals asshown.

If the resistance is out of specification at any temperaturelisted, replace the EOT sensor.

INSTALLATION

NOTE:

Always replace a sealing washer with a new one.

Install the new sealing washer and EOT sensor.Tighten the EOT sensor to the specified torque.


Connect the EOT sensor 2P connector.

Install the main pipe side cover (page 23-25).

Fill the recommended engine oil (page 3-9).

RESISTANCE

20°C (68°F)

2.5 — 2.8 kΩ

100°C (212°F)

0.16 — 0.27 kΩEOT SENSOR


EOT SENSOR/SEALING WASHER


SEALING WASHEREOT SENSOR

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ANF125/M-5 ADDENDUM

CHARGING SYSTEM DIAGRAM

R: RedY: YellowG: GreenW: White

IGNITIONSWITCH

REGULATOR/RECTIFIER

ALTERNATORBATTERY

∗ ANF125/12V 2.5AHANF125M/12V 3.5AH

MAIN FUSE 15A

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ANF125/M-5 ADDENDUM

• Shorted wire harness• Faulty ignition switch

Incorrect Correct

CHARGING SYSTEM TROUBLESHOOTINGBattery is damaged or weak

• Faulty battery

• Faulty battery

• Perform the regulator/rectifier wire harness in-spection (page 22-104)

• Faulty charging coil

Measure and record the battery voltageusing a digital multimeter (page 15-4).Start the engine.Measure the charging voltage (page 16-6).Compare the measurements to result of thefollowing calculation.

Remove the battery (page 15-4).Check the battery condition using the recom-mended battery tester.

Install the battery (page 15-4).Check the battery current leakage (Leak test:page 15-7).

Check the alternator charging coil (page 22-104).

RECOMMENDED BATTERY TESTER:

BM–210 or BATTERY MATE or equivalent

Correct

SPECIFIED CURRENT LEAKAGE: 0.1 mA max

STANDARD:

Measured BV < Measured CV < 15.5 V

• BV=Battery Voltage• CV=Charging Voltage

Incorrect

Correct

STANDARD: 0.2 – 1.0 Ω (20°C/68°F)

Incorrect

Incorrect

Correct

Incorrect

Correct

Disconnect the regulator/rectifier 6P connectorand recheck the battery current leakage.

• Faulty regulator/rec-tifier

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ANF125/M-5 ADDENDUM

IGNITION SYSTEM DIAGRAMRefer to ANF125 Shop Manual (62KPHLM3) for troubleshooting in this section.

R: RedBl: BlackBu: BlueP: PinkG: GreenY: YellowW: White

∗ ANF125/12V 2.5AHANF125M/12V 3.5AH

IGNITION SWITCH

ECM

IGNITIONCOIL

REGULATOR/RECTIFIER

SPARK PLUG

ALTERNATORIGNITIONPULSEGENERATOR

BATTERYBANK ANGLE SENSOR

EOT SENSOR

SENSOR UNIT

MAIN FUSE 15A

24-75

ANF125/M-5 ADDENDUM

ELECTRIC STARTER SYSTEM DIAGRAMRefer to ANF125 Shop Manual (62KPHAM2) for troubleshooting in this section.

R: RedY: YellowBl: BlackBu: BlueW: WhiteG: Green

STARTERSWITCH

STARTERRELAY

REGULATOR/RECTIFIER

BATTERY

STARTERMOTOR

IGNITIONSWITCH

MAINFUSE 15A

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ANF125/M-5 ADDENDUM

LIGHTS/METERS/SWITCHES SYSTEM LOCATIONRefer to ANF125 Shop Manual (62KPHAM2) for troubleshooting in this section.

TURN SIGNALRELAY

RIGHT FRONTTURN SIGNAL LIGHT

FRONT BRAKELIGHT SWITCH

IGNITIONSWITCH

FUEL LEVELSENSOR

RIGHT REARTURN SIGNAL LIGHT

BRAKE/TAILLIGHT

LEFT REARTURN SIGNALLIGHT

ECM

REAR BRAKE LIGHTSWITCH

BATTERYHORN

HORN SWITCH

TURN SIGNALSWITCH

LEFT FRONTTURN SIGNALLIGHT

FUSES15A, 10A

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ANF125/M-5 ADDENDUM

FUEL METER

FUEL METER/FUEL LEVEL SENSORFUEL METER INSPECTION

Turn the ignition switch to “ON” and make sure the fuelmeter comes “ON”.If the fuel meter does not indicate properly, preform thefollowing:

Remove the body cover (page 23-27).Remove the fuel pump cover (page 24-54).

Disconnect the fuel pump 5P (Black) connector.Turn the ignition switch “ON” and check the fuel meter.

If the fuel meter indication is “Empty”, wire harness isnormal.If the fuel meter indication is “Full”, check for short circuitin Yellow/White wire.


Ground the fuel pump 5P (Black) connector terminals witha jumper wire.

CONNECTION: Yellow/White – Green

Turn the ignition switch “ON” and check the fuel meter.

If the fuel meter indication is “Full”, wire harness is nor-mal.

If the fuel meter indication is “Empty”, check for open cir-cuit in Yellow/White wire and green wire.

If the wires are normal, check the fuel level sensor (seebelow).

FUEL LEVEL SENSOR INSPECTION

Remove the fuel pump (page 24-58).

Connect the ohmmeter to the fuel level sensor terminalsof the fuel pump 5P (Black) connector.

CONNECTION: Yellow/White – Green

Inspect the resistance of the float at the top and bottompositions.

FUEL METER

FUEL PUMP

Resistance (20˚C/68˚F)

FULL

5 – 7 Ω

EMPTY

204 – 210 Ω

If the fuel level sensor is normal, replace the meter panelwith a new one, and recheck.

FUEL PUMP 5P (BLACK)CONNECTOR

FUEL PUMP 5P (BLACK)CONNECTOR

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ANF125/M-5 ADDENDUM

MEMO

24-79

ANF125/M-5 ADDENDUM

WIRING DIAGRAMSAN

F125

:

24-80

ANF125/M-5 ADDENDUMAN

F125

M:

24-81

ANF125/M-5 ADDENDUM

TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO START

2. Check the PGM-FIsystem

• Faulty ECM

3. Check for operatingsound of the fuelpump

• Loose or disconnected fuel pump connector• Broken or shorted fuel pump wire• Faulty fuel pump

4. Inspect the fuel pres-sure and fuel flow

• Faulty fuel pump• Faulty ECM

5. Perform a spark test • Faulty spark plug• Fouled spark plug• Broken or shorted spark plug wire• Faulty ignition pulse generator• Loose or disconnected ignition system wires

6. Test cylinder compression • Valve stuck open• Worn cylinder and piston ring• Damaged cylinder head gasket• Seized valve• Improper valve timing

Abnormal

Sound not heard

Abnormal

Weak or no spark

Low compression

Sound heard

Normal

Good spark

Compression normal

Possible cause

7. Starting following normalprocedure

Engine starts butstops

• Intake manifold leaking• Improper ignition timing (Faulty ignition pulse

generator)• Fuel contaminated

Engine does not start

1. Check the chargingsystem

• Faulty the battery• Faulty the charging system

Abnormal

Normal

Normal

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ANF125/M-5 ADDENDUM

Possible cause

8. Remove and inspect spark plug • Clogged air cleaner• Faulty ECM

1. Raise wheel off the groundand spin by hand

• Brake dragging• Worn or damaged wheel bearing

Wet plug

ENGINE LACKS POWER

Wheel spins freely

2. Check tire pressure • Faulty tire valve• Punctured tire

Pressure normal

3. Accelerate rapidly fromlow to second

• Clutch slipping• Worn clutch discs/plates• Warped clutch discs/plates• Weak clutch spring• Additive in engine oil

Engine speed reducedwhen gear is changed

4. Accelerate lightly • Air cleaner dirty• Restricted fuel flow• Clogged muffler• Pinched fuel tank breather

Engine speed increase

5. Check ignition timing • Faulty ECM• Faulty ignition pulse generator

Correct

6. Test cylinder compression • Valve stuck open• Worn cylinder and piston rings• Leaking head gasket• Improper valve timing

Normal

7. Inspect fuel pressure andfuel flow


Normal

8. Remove spark plug • Faulty spark plug

Not fouled or discolored

Wheels do not spinfreely

Pressure low

Engine speed doesn'tchange accordinglywhen gear is changed

Engine speed doesnot increase

Incorrect

Incorrect

Abnormal

Fouled or discolored

• Faulty injectorDry plug

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ANF125/M-5 ADDENDUM

POOR PERFORMANCE AT LOW AND IDLE SPEEDPossible cause

2. Inspect the fuel pressureand fuel flow


1. Check ignition timing • Improper ignition timing(Faulty ignition pulse generator)

Correct

Incorrect

Normal

Abnormal

10. Remove the valve adjuster holecap and inspect lubrication

• Clogged oil passage• Clogged oil control orifice

9. Check oil level and condition • Oil level too high• Oil level too low• Contaminated oilCorrect

11.Check for engine overheating • Excessive carbon build-up in combustionchamber

• Use of poor quality fuel• Wrong type of fuel• Clutch slipping

Valve train lubricated properly

12.Accelerate or run at high speed • Worn piston and cylinder• Wrong type of fuel• Excessive carbon build-up in combustion

chamber• Ignition timing to advanced (faulty ECM)• Lean fuel mixture (faulty injector)

Not overheating

Incorrect

Valve train not lubri-cated properly

Overheating

Engine knocks

Engine does not knock

3. Check for leaks in the intakemanifold

• Loose intake manifold band or mounting bolts• Damaged intake manifold

Not leak

Leaking

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ANF125/M-5 ADDENDUM

4. Perform spark test • Faulty spark plug• Faulty carbon or wet fouled spark plug• Faulty ECM• Faulty ignition coil• Broken or shorted spark plug wire• Faulty ignition pulse generator• Faulty ignition switch• Loose or disconnected ignition system wires

Good spark

Weak or intermittentspark

POOR PERFORMANCE AT HIGH SPEEDPossible cause

2. Inspect the fuel pressureand fuel flow


1. Check ignition timing • Faulty ECM

Correct

Incorrect

Abnormal

Normal

3. Check valve timing • Camshaft not installed properlyIncorrect

4. Check valve spring • Faulty valve spring

Correct

Weak

Not weak

• Faulty injector

• Faulty injector

bpr supra x 125 pgm-fi

Documents

electric heating

programmed

malfunction

diagnosis

front brake

crankcase

bank angle

fuel feed