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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
N·m (kgf·m, lbf·ft)
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
N·m (kgf·m, lbf·ft)
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
N·m (kgf·m, lbf·ft)
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
CRANKCASEBREATHER TUBE
REAR BRAKE LIGHTSWITCH WIRE
STARTER MOTORCABLE
GROUND CABLE
REAR BRAKE LIGHTSWITCH WIRE
CRANKCASEBREATHER TUBE
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
24-24
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:
DLC short connector 070PZ-ZY30100
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).
MALFUNCTION INDICATOR LAMP (MIL)
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
MALFUNCTION INDICATOR LAMP (MIL)
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
• Loose or poor contact on sensorunit
• Open or short circuit in TP sensorwire of the sensor unit
• Faulty TP sensor
• Loose or poor contact on sensorunit
• 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 does not start
• Engine does not start
• Engine does not start
• Engine operates normally
• Engine operates normally
• Engine does not start
• Engine operates normally
• Hard start at a low tempera-ture
• Poor engine response andperformance when operat-ing the throttle quickly
• Engine operates normally
• Engine does not start
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
Turn the ignition switch to “OFF”.
Engine startsConnect the ECM 33P connector.Start the engine.
Turn the ignition switch to “OFF”.
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.
Turn the ignition switch to “OFF”.
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.
Turn the ignition switch to “OFF”.
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
SENSOR UNIT 5P CONNECTOR
ECM 33P CONNECTOR
• Replace the ECM with a new one and inspectagain
Normal
CONNECTION:
Yellow/Red – Yellow/Red
Green/Orange – Green/Orange
STANDARD: Continuity
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.
Turn the ignition switch to “OFF”.
• 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.
Turn the ignition switch to “OFF”.
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
SENSOR UNIT 5P CONNECTOR
CONNECTION:
Light green/Yellow (+) – Ground (–)
STANDARD: 3.8 – 5.25 V
Turn the ignition switch to “OFF”.
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
SENSOR UNIT 5P CONNECTOR
CONNECTION:
Light green/Yellow – Light green/Yellow
STANDARD: Continuity
CONNECTION:
Light green/Yellow – Ground
STANDARD: No continuity
• Replace the ECM with a new one and inspectagain
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.
Turn the ignition switch to “OFF”.
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.
Turn the ignition switch to “OFF”.
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.
STANDARD: No continuity
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
Turn the ignition switch to “OFF”.
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
• Replace the ECM with a new one and inspectagain
Normal
CONNECTION:
Green/Orange – Green/Orange
Yellow/Blue – Yellow/Blue
STANDARD: Continuity
CONNECTION:
Green/Orange – Ground
Yellow/Blue – Ground
STANDARD: No continuity
ECM 33P CONNECTOR
EOT SENSOR 2P 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.
Turn the ignition switch to “OFF”.
• 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.
Turn the ignition switch to “OFF”.
8 blinks
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: Yellow (+) – Ground (–)
STANDARD: 0 – 220 mV
Turn the ignition switch to “OFF”.
Out of range
SENSOR UNIT 5P CONNECTOR
• 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
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
CONNECTION:Yellow – Yellow
STANDARD: Continuity
CONNECTION: Yellow – Ground
STANDARD: No continuity
• Replace the ECM with a new one and inspectagain
Normal
ECM 33P CONNECTOR
SENSOR UNIT 5P 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.
Turn the ignition switch to “OFF”.
• 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.
Turn the ignition switch to “OFF”.
9 blinks
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:
Gray/Blue (+) – Ground (–)
STANDARD: 4.75 – 5.25 V
Turn the ignition switch to “OFF”.
Out of range
SENSOR UNIT 5P CONNECTOR
• 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
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
CONNECTION: Gray/Blue – Gray/Blue
STANDARD: Continuity
CONNECTION:Gray/Blue – Ground
STANDARD: No continuity
• Replace the ECM with a new one and inspectagain
Normal
ECM 33P CONNECTOR
SENSOR UNIT 5P 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.
Turn the ignition switch to “OFF”.
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.
Turn the ignition switch to “OFF”.
No blink
12 blinks
INJECTOR 2P CONNECTOR
INJECTOR 2P CONNECTOR
(To page 24-50)
24-50
ANF125/M-5 ADDENDUM
Abnormal
Normal
Turn the ignition switch to “OFF”.
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
STANDARD: Continuity
CONNECTION: Pink/Green – Ground
STANDARD: No continuity
• 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
INJECTOR 2P CONNECTOR
ECM 33P CONNECTOR
INJECTOR 2P CONNECTOR
(From page 24-49)
24-51
ANF125/M-5 ADDENDUM
• Replace the ECM with a new one and inspectagain
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)
Turn the ignition switch to “OFF”.
• 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.
Turn the ignition switch to “OFF”.
Disconnect the bank angle sensor 3P connec-tor.Check for loose or poor contact on the bankangle sensor 3P connector.
BANK ANGLE SENSOR3P CONNECTOR
BANK ANGLE SENSOR3P CONNECTOR
24-53
ANF125/M-5 ADDENDUM
Turn the ignition switch to “OFF”.
• 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:
Green/Orange – Green/Orange
Yellow/Red – Yellow/Red
Red/Blue– Red/Blue
STANDARD: Continuity
CONNECTION:
Yellow/Red – Ground
Red/Blue– Ground
STANDARD: No continuity
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
BANK ANGLE SENSOR3P CONNECTOR
CONNECTION: Yellow/Red (+) – Ground (–)
STANDARD: 4.75 – 5.25 V
BANK ANGLE SENSOR3P CONNECTOR
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.
Turn the ignition switch to “OFF”.
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
FUEL PUMP 5P (BLACK) CONNECTOR
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.
IDLE SPEED: 1,400 ± 100 min–1 (rpm)
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
Relieve the fuel pressure and disconnect the quick con-nect fitting (page 24-54).
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)
Connect the quick connect fitting (page 24-55).
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 5P (BLACK) CONNECTOR
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:
Turn the ignition switch to “OFF”.
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.
Relieve the fuel pressure and disconnect the quick con-nect fitting (page 24-54).
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
FUEL PUMP 5P (BLACK) CONNECTOR
CLAMP
NUTS
FUEL PUMP 5P (BLACK) CONNECTOR
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.
Connect the quick connect fitting (page 24-55).
CLAMP
NUTS
FUEL PUMP WIRECLAMP
FUEL PUMP 5P (BLACK) CONNECTOR
FUEL TANKREMOVAL/INSTALLATION
Relieve the fuel pressure and disconnect the quick con-nect fitting (page 24-54).
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.
Connect the quick connect fitting (page 24-55).
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.
TORQUE: 12 N•m (1.2 kgf•m, 9 lbf•ft)
Connect the quick connect fitting (page 24-55).
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
1. Turn the ignition switch to “OFF”.
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 070PZ-ZY30100
DLC SHORT CONNECTOR
DATA LINKCONNECTOR (DLC)
CONNECTOR COVER
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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
MALFUNCTION INDICATOR LAMP (MIL)
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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.
6. Turn the ignition switch to “OFF”.
7. Connect the EOT sensor 2P connector.
8. Disconnect the DLC short connector from the data linkconnector (DLC).
TOOL:
DLC short connector 070PZ-ZY30100
DLC SHORT CONNECTOR
EOT SENSOR 2P CONNECTOR
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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.
IDLE SPEED: 1,400 ± 100 min–1 (rpm)
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
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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
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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.
TORQUE: 5.1 N•m (0.5 kgf•m, 3.8 lbf•ft)
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.
TORQUE: 1.2 N•m (0.1 kgf•m, 0.9 lbf•ft)
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
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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.
TORQUE: 18 N•m (1.8 kgf•m, 13 lbf•ft)
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 2P CONNECTOR
EOT SENSOR/SEALING WASHER
EOT SENSOR 2P CONNECTOR
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
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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.
Turn the ignition switch to “OFF”.
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
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
• Faulty fuel pump• Faulty ECM
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
• Faulty fuel pump• Faulty ECM
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
• Faulty fuel pump• Faulty ECM
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