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ANF125/M-5 ADDENDUM

ANF125/M-5 ADDENDUM

IMPORTANT SAFETY NOTICE


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

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


Gives helpful information.

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render 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 each conceivable 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 nor vehicle safety will be jeopardized by the service methods or tools selected.

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

CODE ANF1255-III TH ANF125M5-III TH

AREA TYPE THAILAND (Kickstarter only type) THAILAND (Kickstarter and electric starter motor type)

24. ANF125/M-5 ADDENDUM


ANF125/M-5 ADDENDUM

HOW TO USE THIS MANUAL


This addendum contains information for the ANF125/ M-5. Refer to the ANF125 Shop Manual (62KPHAM2, 62KPHLM3, 62KTMFM5) for service procedures and data not included in this addendum. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING, Honda Motor Co., Ltd. RESERVES 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 MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE

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

ANF125/M-5 ADDENDUM

CONTENTS
MODEL IDENTIFICATION ............................................. 24-1 SPECIFICATIONS .......................................................... 24-2 TORQUE VALUES ......................................................... 24-9 TOOLS ......................................................................... 24-12 LUBRICATION & SEAL POINTS ................................. 24-14 CABLE & HARNESS ROUTING .................................. 24-17 MAINTENANCE SCHEDULE ...................................... 24-24 FUEL LINE ................................................................... 24-25 ENGINE IDLE SPEED .................................................. 24-25 TECHNICAL FEATURE ABSOLUTE PRESSURE FUEL SUPPLY SYSTEM ........... 24-26 FUEL SYSTEM COMPONENT LOCATION ................ 24-27 PGM-FI SERVICE INFORMATION .............................. 24-28 PGM-FI TROUBLESHOOTING ................................... 24-28 PGM-FI SYSTEM LOCATION ..................................... 24-29 PGM-FI SYSTEM DIAGRAM ...................................... 24-30 PGM-FI SELF-DIAGNOSIS INFORMATION ............... 24-31 MIL CODE INDEX ........................................................ 24-34 ECM POWER/GROUND INSPECTION ....................... 24-36 SENSOR UNIT POWER/ GROUND CIRCUIT INSPECTION ............................ 24-38 MIL TROUBLESHOOTING .......................................... 24-40 FUEL LINE INSPECTION ............................................ 24-54 FUEL PUMP ................................................................. 24-58 FUEL TANK ................................................................. 24-60 THROTTLE BODY/SENSOR UNIT .............................. 24-61 ECM (ENGINE CONTROL MODULE) ......................... 24-69 INJECTOR ................................................................... 24-69 BANK ANGLE SENSOR .............................................. 24-70 EOT (ENGINE OIL TEMPERATURE) SENSOR .......... 24-71 CHARGING SYSTEM DIAGRAM ............................... 24-72 CHARGING SYSTEM TROUBLESHOOTING ............. 24-73 IGNITION SYSTEM DIAGRAM .................................. 24-74 ELECTRIC STARTER SYSTEM DIAGRAM ................. 24-75 LIGHTS/METERS/ SWITCHES SYSTEM LOCATION .................... 24-76 FUEL METER/FUEL LEVEL SENSOR ......................... 24-77 WIRING DIAGRAMS ANF125 ............................................................ 24-79 ANF125M ......................................................... 24-80 TROUBLE SHOOTING ENGINE DOES NOT START OR IS HARD TO START ................................... 24-81 ENGINE LACKS POWER ................................. 24-82 POOR PERFORMANCE AT LOW AND IDLE SPEED ..................................................... 24-83 POOR PERFORMANCE AT HIGH SPEED ....... 24-84

ANF125/M-5 ADDENDUM

MODEL IDENTIFICATION
This 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 SERIAL NUMBER

ENGINE SERIAL NUMBER

FRAME NUMBER The frame serial number is stamped on the right side of the steering head. THROTTLE BODY IDENTIFICATION NUMBER

ENGINE NUMBER The engine serial number is stamped on the lower left side of the crankcase.

THROTTLE BODY IDENTIFICATION NUMBER The throttle body identification number is stamped on the front side of the throttle body.

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ANF125/M-5 ADDENDUM

SPECIFICATIONS
GENERAL
ITEM DIMENSIONS Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Curb weight Frame type Front suspension Front axle travel Rear suspension Rear axle travel Rear damper Front tire size Rear tire size Front brake Rear brake Caster angle Trail length Fuel tank capacity Bore and stroke Displacement Compression ratio Valve train Intake valve Exhaust valve SPECIFICATIONS 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) Back bone type Telescopic fork 80.5 mm (3.17 in) Swingarm 81.8 mm (3.22 in) Both side operation tube type 60/10017M/C 33P 70/9017M/C 43P Hydraulic disc brake Mechanical leading trailing 26 30' 68 mm (2.7 in) 3.7 liter (0.98 US gal 0.81 lmp gal) 52.4 x 57.9 mm (2.06 x 2.28 in) 124.8 cm3 (7.61 cu-in) 9.3 : 1 2 valve, single chain driven SOHC 5 BTDC 22 ABDC 37 BBDC 3 ATDC Forced pressure and wet sump Trochoid Air cooled Paper filter Assembled type Single cylinder inclined 80 from vertical

ANF125 ANF125M

FRAME

ENGINE

opens closes opens closes

at 1 mm (0.04 in) lift

Lubrication system Oil pump type Cooling system Air filtration Crankshaft type Cylinder arrangement

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ANF125/M-5 ADDENDUM

GENERAL (Cont'd)
CARBURATION DRIVE TRAIN

ITEM

SPECIFICATIONS PGM-FI (Programmed Fuel Injection) 22 mm (0.9 in) Multi-plate, wet Automatic centrifugal type Constant mesh, 4-speed 3.350 (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 is not running) N-1-2-3-4 (-N) Full transistor digital ignition Kickstarter Kickstarter and electric starter motor Single phase output alternator SCR opened/single phase, half wave rectification Alternator

Type Throttle bore Clutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio

1st 2nd 3rd 4th

Gearshift pattern

ELECTRICAL

Ignition system Starting system Charging system Regulator/rectifier Lighting system

ANF125 ANF125M

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ANF125/M-5 ADDENDUM

LUBRICATION SYSTEM
ITEM Engine oil capacity Recommended engine oil At draining At disassembly STANDARD 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 equivalent motor oil API service classification SE, SF or SG Viscosity: SAE 10W-30 Tip clearance Body clearance Side clearance 0.15 0.21 (0.006 0.008) 0.03 0.09 (0.001 0.003)

Unit: mm (in) SERVICE LIMIT

Oil pump rotor

0.20 (0.008) 0.26 (0.010) 0.15 (0.005)

FUEL SYSTEM (Programmed Fuel Injection)


ITEM Throttle body identification number Idle speed Throttle grip free play EOT (Engine Oil Temperature) sensor resistance Fuel injector resistance (at 20C/68F) Fuel pressure Fuel pump flow (at 12V) 20C/68F 100C/212F SPECIFICATION GQR0A 1,400 100 min1 (rpm) 2 6 mm (0.1 0.2 in) 2.5 2.8 k 0.21 0.22 k 10.3 11.3 294 kPa (3.0 kgf/cm2, 43 psi) 13.9 cm3 (0.47 US oz, 0.49 lmp oz) minimum/10 seconds

CYLINDER HEAD/VALVES
ITEM Cylinder compression Cylinder head warpage Valve, valve guide Valve clearance Valve stem O.D. Valve guide I.D. Stem-to-guide clearance Valve seat width Valve spring free length Rocker arm/shaft Camshaft Rocker arm I.D. Rocker arm shaft O.D. Cam lobe height IN EX IN EX IN EX IN EX IN/EX IN/EX IN/EX IN/EX IN EX STANDARD 1,275 kPa (13.0 kgf/cm , 185 psi) at 600 min1 (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)
2

Unit: mm (in) 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)

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CYLINDER/PISTON
ITEM Cylinder I.D. Out of round Taper Warpage Piston, piston rings 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 Piston ring-to-ring groove clearance Piston ring end gap Top Second Top Second Oil (side rail) Cylinder-to-piston clearance Connecting rod small end I.D. Connecting rod-to-piston pin clearance 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)

Unit: 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)

CLUTCH/GEARSHIFT LINKAGE
ITEM Manual clutch Disk thickness Plate warpage Clutch spring free length Clutch outer guide O.D. Clutch outer I.D. Centrifugal clutch 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 drive gear Clutch brake lining thickness 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) STANDARD 2.5 2.7 (0.098 0.106)

Unit: 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)

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CRANKSHAFT/TRANSMISSION/KICKSTARTER
ITEM Crankshaft Connecting rod side clearance Connecting rod radial clearance Runout Transmission Gear I.D. M2,3 C1 C4 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/ Shift drum Shift fork I.D. Shift fork claw thickness Shift fork shaft O.D. Shift drum O.D. Shift drum journal I.D. Kick starter Pinion I. D. Shaft O.D. Left Right Left Right C1 C1 C1 M2,3 C1 M2,3 C1 STANDARD 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)

Unit: mm (in) 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)

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FRONT WHEEL/SUSPENSION/STEERING
ITEM Minimum tire tread depth Cold tire pressure Axle runout Wheel rim runout Wheel hub-to-rim distance Fork Spring free length Spring direction Tube runout Recommended fork fluid Fluid level Fluid capacity 68.5 (2.70) 70.0 1 cm (2.37 0.03 US oz, 2.46 0.04 lmp oz)
3

Unit: mm (in) STANDARD 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) Honda Ultra Cushion Oil No.10

Driver only Driver and passenger Radial Axial

225 kPa (2.25 kgf/cm , 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

REAR WHEEL/BRAKE/SUSPENSION
ITEM Minimum tire tread depth Cold tire pressure Axle runout Wheel rim runout Wheel hub-to-rim distance Drive chain Brake Size/link Slack Brake drum I.D. Brake pedal free play Radial Axial 420 104 25 35 (1.0 1.4) 110.0 (4.33) 20 30 (0.8 1.2) Driver only Driver and passenger STANDARD 250 kPa (2.50 kgf/cm , 36 psi) 250 kPa (2.50 kgf/cm , 36 psi) 10.0 1 (0.39 0.04)
2 2

Unit: mm (in) SERVICE LIMIT To the indicator 0.20 (0.008) 2.0 (0.08) 2.0 (0.08) 111.0 (4.37) 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) 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)

HYDRAULIC BRAKE
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.

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BATTERY/CHARGING SYSTEM
ITEM Battery Capacity Current leakage Voltage Charging ANF125 current ANF125M Alternator Capacity Charging coil resistance (20C/68F) Fully charged Needs charging Normal Quick Normal Quick ANF125 ANF125M 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 min1 (rpm) 0.2 1.0

IGNITION SYSTEM
ITEM Spark plug Standard Optional Spark plug gap Ignition coil peak voltage Ignition pulse generator peak voltage Ignition timing NGK CPR6EA-9 CPR7EA-9 100 V minimum 0.7 V minimum 10 BTDC at idle SPECIFICATIONS

Unit: mm (in)

DENSO U20EPR9 U22EPR9

0.80 0.90 mm (0.031 0.035 in)

ELECTRIC STARTER
ITEM Starter motor brush length STANDARD 10.0 10.05 (0.39 0.40)

Unit: mm (in) SERVICE LIMIT 3.5 (0.14)

LIGHTS/METERS/SWITCHES
ITEM Bulbs 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 Fuse Main Sub SPECIFICATIONS 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

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TORQUE VALUES
FASTENER TYPE 5 mm hex bolt and nut 6 mm hex bolt and nut 8 mm hex bolt and nut 10 mm hex bolt and nut 12 mm hex bolt and nut TORQUE Nm (kgfm, lbfft) 5 (0.5, 3.6) 10 (1.0, 7) 22 (2.2, 16) 34 (3.5 , 25) 54 (5.5, 40) FASTENER TYPE 5 mm screw 6 mm screw 6 mm flange bolt (8 mm head) 6 mm flange bolt (10 mm head) and nut 8 mm flange bolt and nut 10 mm flange bolt and nut TORQUE Nm (kgfm, lbfft) 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. 2. 3. 4. Apply a locking agent to the threads. Apply engine oil to the threads and seating surfaces. U-nut. ALOCK bolt:replace with a new one.

ENGINE
ITEM MAINTENANCE: Oil drain bolt Crankshaft hole cap Timing hole cap Valve adjuster lock nut Oil centrifugal filter cover bolt Clutch adjuster lock nut Spark plug LUBRICATION SYSTEM: Oil pump cover bolt FUEL SYSTEM (Programmed Fuel Injection): EOT (Engine Oil Temperature) sensor Intake manifold mounting bolt ENGINE REMOVAL/INSTALLATION: Drive sprocket fixing plate bolt CYLINDER HEAD/VALVES: Cylinder head cap nut Cam sprocket cover bolt Cam sprocket bolt Cam chain tensioner lifter plug Plunger set bolt CLUTCH/GEARSHIFT LINKAGE: Shift drum stopper arm bolt Shift return spring pin Gear shift cam plate socket bolt Centrifugal clutch lock nut Clutch lifter plate flange bolt Manual clutch center lock nut ALTERNATOR/STARTER CLUTCH: Flywheel flange nut Starter clutch outer mounting socket bolt Stator mounting bolt Ignition pulse generator mounting bolt QTY

THREAD DIA. (mm) 12 30 14 5 5 8 10 5 10 6 6 8 6 5 6 6 6 8 6 14 6 14 12 6 6 6

TORQUE Nm (kgfm, lbfft) 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)

REMARKS

1 1 1 2 4 1 1 2 1 2 2 4 1 2 1 1 1 1 1 1 3 1 1 6 2 2

NOTE 1

NOTE 1 NOTE 2 NOTE 2 NOTE 2 NOTE 1

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ANF125/M-5 ADDENDUM
Intake manifold band: 7 1 mm (0.3 0.04 in)

INTAKE MANIFOLD BAND

INTAKE MANIFOLD BAND

Cylinder head stud bolt:

27.5 1 mm (1.08 0.04 in)

Cylinder stud bolt:

182 1 mm (7.2 0.04 in)

182 1 mm (7.2 0.04 in)

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ANF125/M-5 ADDENDUM

FRAME
ITEM FRAME/BODY PANELS/EXHAUST SYSTEM: Rear grip mounting socket bolt Exhaust pipe joint nut MAINTENANCE: Drive chain case mounting bolt FUEL SYSTEM (Programmed Fuel Injection): Fuel feed pipe mounting bolt Sensor unit torx screw Throttle cable bracket screw Bank angle sensor mounting screw Fuel pump mounting nut (see tightening sequence below) QTY

THREAD DIA. (mm) 8 8 6 5 5 5 4 6

TORQUE Nm (kgfm, lbfft) 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)

REMARKS

4 2 4 2 3 1 2 5

ENGINE MOUNTING: Engine hanger front bolt/nut Engine hanger rear upper bolt/nut Engine hanger rear lower bolt/nut FRONT WHEEL/BRAKE/SUSPENSION/STEERING: Steering stem nut Steering stem top thread Bottom bridge pinch flange bolt Handlebar holder nut Handlebar mounting bolt Front axle nut Front brake disk bolt Front spoke Handlebar weight screw Fork socket bolt Brake hose clamper bolt REAR WHEEL/BRAKE/SUSPENSION: Rear axle nut Rear spoke Driven sprocket UBS nut Driven sprocket stud bolt Rear brake arm nut Shock absorber upper mounting bolt Shock absorber lower mounting cap nut Swingarm pivot nut HYDRAULIC BRAKE: Caliper bleed valve Caliper pad pin Caliper mounting bolt Brake hose oil bolt Master cylinder reservoir cover screw Front brake light switch screw Brake lever pivot bolt Brake lever pivot nut Caliper pin nut Pin bolt LIGHTS/METERS/SWITCHES Key shutter socket bolt OTHERS: Side stand pivot bolt Side stand pivot bolt/nut

1 1 1 1 1 4 1 3 1 4 36 2 2 1 1 36 4 4 1 2 2 1 1 1 2 2 2 1 1 1 1 1 1 1 1

10 10 10 26 26 10 10 8 12 8 BC 3.2 6 8 6 12 BC 3.2 8 8 6 10 10 10 8 10 8 10 4 4 6 6 8 8 6 10 10

59 (6.0, 43) 59 (6.0, 43) 59 (6.0, 43) See page 12-29 See 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 3 NOTE 1

NOTE 1 NOTE 4 NOTE 3 NOTE 2 NOTE 1 NOTE 3

NOTE 4

NOTE 1

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ANF125/M-5 ADDENDUM

TOOLS
NOTES: 1. Equivalent commercially available. 2. Alternative tool. DESCRIPTION Fuel pressure gauge Fuel attachment joint 6-9 Pressure gauge manifold Fuel attachment hose 6-9 Fuel attachment hose 9-9 DLC short connector Valve adjuster wrench Wrench 8 x 9 mm Spoke wrench, 4.5 x 5.1 mm Valve spring compressor Valve spring compressor attachment Valve guide driver 4.8 mm Valve guide reamer 5.0 mm Valve 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 mm Extension bar Gear holder Universal holder Snap ring pliers Bearing remover set, 12 mm Bearing remover shaft, 12mm Bearing remover head, 12mm Remover weight Bearing remover shaft, 10 mm Bearing remover head, 10 mm Driver Attachment, 28 x 30 mm Pilot, 10 mm Pilot, 12 mm Flywheel holder Flywheel puller, 28 mm Flywheel puller, 30 mm Universal bearing puller Assembly set, 14 mm Attachment, 22 x 24 mm Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 52 x 55 mm Pilot, 17 mm Pilot, 22 mm TOOL NUMBER 07406 0040004 07ZAJ-S5A0150 07ZAJ-S5A0111 07ZAJ-S5A0130 07ZAJ-S5A0120 070PZ ZY30100 07708 0030400 07708 0030100 07701 0020200 07757 0010000 07959 KM30101 07942 MA60000 07984 MA60001 07780 0010600 07780 0010701 07780 0013300 07780 0012601 07780 0014500 07780 0014300 07781 0010400 07716 0020100 07716 0020500 07724 0010200 07725 0030000 07914 3230001 07936 1660101 07936 1660120 07936 1660110 07741 0010201 07936 GE00100 07936 GE00200 07749 0010000 07946 1870100 07746 0040100 07746 0040200 07725 0040000 07933 KG20000 07KMC HE00100 07631 0010000 07JMF KW70100 07746 0010800 07746 0010100 07746 0010200 07746 0010400 07746 0040400 07746 0041000 REMARKS REF. SEC. 24 24 24 24 24 22 3, 7 3, 7 3, 12, 13 7 7 7 7 7 7 7 7 7 7 7 9 9 9 9 9 9, 11 9, 11 9, 11 9, 11 9 9 9, 11, 12, 13 9 9 9, 11, 12, 13 9, 10 10 10 11 11 11 11, 12, 13 11, 13 11, 12 11, 13 11

24-12

ANF125/M-5 ADDENDUM
DESCRIPTION Inner driver, 35 mm Bearing remover shaft Bearing remover head, 12 mm Fork seal driver Fork seal driver attachment Steering stem socket Lock nut wrench Steering stem pin spanner Ball race remover, 40 mm Ball race remover, 34.5 mm Attachment, 45 x 50 mm Oil seal remover Snap ring pliers Peak voltage adaptor TOOL NUMBER 07746 0030400 07746 0050100 07746 0050300 07747 0010100 07747 0010300 07916 3710101 07916 KM10000 07702 0020001 07953 4250002 07948 4630100 07946 6920100 07748 0010001 07914 SA50001 07HGJ 0020100 REMARKS REF. SEC. 12 12 12 12 12 12 12 12 12 12 12 12 14 16

NOTE 2: Imrie diagnostic tester (model 625)

24-13

ANF125/M-5 ADDENDUM

LUBRICATION & SEAL POINTS


ENGINE
LOCATION MATERIAL Honda 4-stroke oil or equivalent REMARKS Cylinder sleeve inner surface Timing hole cap threads Crankshaft hole cap threads Valve adjuster hole cap threads Piston and cylinder sliding surface Piston pin and piston sliding surface Piston ring whole surface Connecting rod small end I.D. Connecting rod big end needle bearing IN/EX valve stem sliding surface Camshaft cam surface Cam chain surface Cam set plunger whole surface Cam decomp rotating surface Rocker arm roller surface and boss inner surface Rocker arm shaft whole surface Valve adjusting nut fastening surface Oil pump rotor sliding surface Clutch outer guide outer surface Manual clutch center lock nut fastening surface Clutch disc surface Centrifugal clutch lock nut fastening surface Oil pump drive gear inner surface M3, 4 gear inner surface M3 shift fork groove surface C1, 3, 4 gear inner surface C4 shift fork groove surface C1 bushing whole surface Shift fork shaft whole surface Starter driven gear I.D. and gear teeth (ANF125M only) Gearshift drum journal outer surface Kickstarter pinion gear inner surface Flywheel flange nut fastening surface Starter clutch rolling surface (ANF125M only) Starter reduction gear both journal (ANF125M only) Each gear sliding surface and gear teeth Each bearing rolling surface Each O-ring whole surface Each oil seal lip area Oil centrifugal filter cover bolt thread 4 mm (0.16 in)

Dripping (1.0-2.0 cm3)

Injecting (0.5-1.0 cm3)

Locking agent

1.6 mm (0.06 in) Main shaft bearing set plate bolt thread Gear shift cam plate socket bolt thread Starter clutch outer mounting socket bolt thread (ANF125M only) Primary drive gear Molybdenum oil (mixture of the engine oil and Molybdenum grease in a ratio 1 : 1)

24-14

ANF125/M-5 ADDENDUM

ENGINE (Contd)
LOCATION Left crankcase mating surface MATERIAL Liquid sealant REMARKS

Alternator grommet sealing surface Alternator inner surface Left crankcase shaft tapered area Degreasing

24-15

ANF125/M-5 ADDENDUM

FRAME

LOCATION

MATERIAL Multi-purpose grease with extreme pressure (example: EXCELITE EP2 manufactured by KYDO YUSHI, Japan), Shell Alvania EP2 or equivalent Multi-purpose grease

REMARKS

Steering head bearing sliding surface Steering head dust seal lips

Front wheel dust seal lips Rear wheel driven flange dust seal lip Rear wheel hub O-ring Brake panel anchor pin Brake cam and shaft Side stand pivot surface Kickstarter arm sliding surface Throttle housing and throttle pipe sliding surface Brake pedal pivot surface Steering handle lock sliding surface Seat lock sliding surface Throttle cable surface

Molybdenum oil (mixture of the engine oil and Molybdenum grease in a ratio 1 : 1) Silicone grease About 0.1 cm3 (0.1 cc) Inject

Throttle cable connecting area Front disc brake lever pivot sliding surface Front disc brake lever contacting area with piston Brake caliper bracket pin bolt and boot Brake master cylinder boot Brake caliper dust seal Brake master cylinder piston sliding area Brake caliper piston sliding area Brake caliper piston seal Driven flange stud bolt threads Fork socket bolt threads Brake caliper pin nut Front brake disc bolt thread Handle grip rubber inside Fork dust seal and oil seal lips Fork bottom case inside Drive chain Injector O-ring and seal ring Drum brake cam dust seal Drive sprocket nut

Brake fluid DOT3 or DOT4 Locking agent

Honda Bond A Honda Ultra Cushion Oil No.10 SAE #80 or 90 gear oil Honda 4-stroke oil or equivalent

24-16

ANF125/M-5 ADDENDUM

CABLE & HARNESS ROUTING

HEADLIGHT 3P CONNECTOR

TURN SIGNAL RELAY LEFT HANDLEBAR SWITCH WIRE

RIGHT HANDLEBAR SWITCH WIRE

FRONT BRAKE LIGHT SWITCH WIRE SPEEDOMETER WIRE THROTTLE CABLE

HORN WIRES

FRONT BRAKE HOSE

IGNITION SWICH WIRE

24-17

ANF125/M-5 ADDENDUM

FRONT BRAKE HOSE

LEFT FRONT TURN SIGNAL LIGHT (2P) CONNECTOR

THROTTLE CABLE

PULSE SECONDARY AIR (PAIR) FILTER

FUEL FEED HOSE

AIR SUPPLY HOSE

AIR INJECTION PIPE

EOT SENSOR WIRE

24-18

ANF125/M-5 ADDENDUM

HORN WIRES THROTTLE CABLE

MAIN WIRE HARNESS

SEAT LOCK CABLE

RIGHT FRONT TURN SIGNAL LIGHT (2P) CONNECTOR CRANKCASE BREATHER TUBE FRONT BRAKE HOSE

SPARK PLUG WIRE

24-19

ANF125/M-5 ADDENDUM
ANF125 : INJECTOR WIRE SENSOR UNIT WIRE

IGNITION COIL WIRE

SPARK PLUG WIRE

REAR BRAKE LIGHT SWITCH WIRE

PAIR CONTROL VALVE VACUUM TUBE

CRANKCASE BREATHER TUBE ANF125M : STARTER MOTOR CABLE INJECTOR WIRE

CRANKCASE BREATHER TUBE

SENSOR UNIT WIRE IGNITION COIL WIRE SPARK PLUG WIRE

REAR BRAKE LIGHT SWITCH WIRE

PAIR CONTROL VALVE VACUUM TUBE

GROUND CABLE

24-20

ANF125/M-5 ADDENDUM

THROTTLE CABLE

EOT SENSOR WIRE BANK ANGLE SENSOR WIRE

FUEL FEED HOSE

AIR INJECTION PIPE

ENGINE OIL TEMPERATURE (EOT) SENSOR

SPEED SENSOR WIRE

BATTERY POSITIVE CABLE BATTERY NEGATIVE CABLE MAIN FUSE

STARTER RELAY (ANF125M only)

SUB FUSE

24-21

ANF125/M-5 ADDENDUM

FUEL FEED HOSE REAR COMBINATION LIGHT WIRE

FUEL PUMP WIRE

SEAT LOCK CABLE

REGULATOR/ RECTIFIER WIRE

GROUND WIRE

REAR COMBINATION LIGHT WIRE

24-22

ANF125/M-5 ADDENDUM

ENGINE CONTROL MODULE (ECM) WIRE

FUEL FEED HOSE

24-23

ANF125/M-5 ADDENDUM

MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owners 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 **) may require more technical information and tools. Consult your Honda dealer. FREQUENCY WHICHEVER ODOMETER READING (NOTE 1) COMES X1,000 mi 2.5 5 0.6 FIRST X1,000 km 8 4 1 MONTH 6 I l NOTE 2 NOTE 3 l R C C I I R 12 I l C C R I R

7.5 12 18 I l R C I I R C C

REFER TO PAGE 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

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 NOTE 4 NOTE 5

I l

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

** WHEELS/TIRES ** STEERING HEAD BEARINGS

* Should be serviced by your Honda dealer, unless the owner has proper tools and service data and is mechanically 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 is carried 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.

24-24

ANF125/M-5 ADDENDUM

FUEL LINE
Remove the main pipe side cover (page 23-25). Check the fuel feed hose for deterioration, damage or leakage. 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.

FUEL FEED HOSE

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 carbon 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 engine maintenance items have been performed and are within specifications. The engine must be warm for accurate idle speed inspection and adjustment. Warm up the engine for about ten minutes. Connect a tachometer. Turn the idle adjusting screw as required to obtain the specified idle speed. IDLE SPEED: 1,400 100 min1 (rpm)

IDLE ADJUSTING SCREW

24-25

ANF125/M-5 ADDENDUM

TECHNICAL FEATURE
ABSOLUTE PRESSURE FUEL SUPPLY SYSTEM
The fuel delivery system consists of the following components: fuel tank, fuel suction filter, fuel pump, internal pressure regulator, fuel feed hose and injector. This system is eruipped with the absolute fuel pressure. There is no external fuel return hose or vacuum pressure regulator 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

PRESSURE REGULATOR

FUEL SUCTION FILTER

INJECTOR

FUEL FEED HOSE FUEL TANK

24-26

ANF125/M-5 ADDENDUM

FUEL SYSTEM COMPONENT LOCATION


4.2 Nm (0.4 kgfm, 3 lbfft)

12 Nm (1.2 kgfm, 9 lbfft)

24-27

ANF125/M-5 ADDENDUM

PGM-FI SERVICE INFORMATION


GENERAL
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 2431). 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 is secured 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 before 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 TROUBLESHOOTING
Engine wont 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

24-28

ANF125/M-5 ADDENDUM

PGM-FI SYSTEM LOCATION


IGNITION SWITCH IGNITION SWITCH BANK ANGLE SENSOR

INJECTOR

FUEL PUMP

DATA LINK CONNECTOR

SENSOR UNIT (MAP, IAT, TP SENSORS) IGNITION PULSE GENERATOR ALTERNATOR EOT SENSOR GEAR POSITION SWITCH ECM

REGULATOR/ RECTIFIER

MAP SENSOR

THROTTLE BODY

SENSOR UNIT

IAT SENSOR TP SENSOR

24-29

ANF125/M-5 ADDENDUM

PGM-FI SYSTEM DIAGRAM

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Ignition switch Main fuse (15 A) Sub fuse (10 A) Battery Regulator/rectifire Fuel meter Malfunction indicator lamp (MIL) Neutral position indicator Bank angle sensor Data Link Connector (DLC) Fuel pump

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21)

Ignition coil Intake air temperature sensor (IAT sensor) Throttle position sensor (TP sensor) Manifold absolute pressure sensor (MAP sensor) Injector Spark plug Gear (neutral) position switch Ignition pulse generator Engine oil temperature sensor (EOT sensor) Alternator charging coil

24-30

ANF125/M-5 ADDENDUM

PGM-FI SELF-DIAGNOSIS INFORMATION


SELF-DIAGNOSTIC PROCEDURE
Place the motorcycle on its centerstand. NOTE: The malfunction indicator lamp (MIL) will start blinking the ignition switch to ON or engine revs are below 2,000 min1 (rpm). In any other conditions, the MIL will illuminate and stay on. Turn the ignition switch to ON. The malfunction indicator blinks, note how many times the MIL blinks, and determine the cause of the problem (page 24-34). If the MIL does not light or blink, the system is normal. If you wish to read the PGM-FI memory for trouble data, perform the following:

MALFUNCTION INDICATOR LAMP (MIL)

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 connector (DLC). DATA LINK CONNECTOR (DLC)

CONNECTOR COVER

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

070PZ-ZY30100

DLC SHORT CONNECTOR

24-31

ANF125/M-5 ADDENDUM
Turn the ignition switch to ON. If the ECM has no self diagnosis memory data, the MIL will illuminate, when you turn the ignition switch to ON. Ignition switch to "ON" MALFUNCTION INDICATOR LAMP (MIL)

MIL ON OFF If the ECM has self diagnosis memory data, the MIL will start blinking when you turn the ignition switch to ON. Ignition switch to "ON"

2.5 sec MIL ON OFF FAILURE CODES Note how many times the MIL blinks, and determine the cause of the problem (page 24-34).

SELF-DIAGNOSIS RESET PROCEDURE


NOTE: The self-diagnosis memory data can not be erased only when 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 connector (DLC). DATA LINK CONNECTOR (DLC)

CONNECTOR COVER

3. 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
4. Turn the ignition switch to ON. 5. Disconnect the DLC short connector from the data link connector (DLC). 6. Connect the DLC short connector to the data link connector (DLC) again while the MIL lights about 5 seconds (reset receiving pattern; see below).

DLC SHORT CONNECTOR

DLC SHORT CONNECTOR

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

MALFUNCTION INDICATOR LAMP (MIL)

0.3 sec. 0.3 sec. within 5 sec. MIL ON OFF FAILURE PATTERN RESET RECEIVING PATTERN SUCCESSFUL PATTERN
2 3 sec.

The data link connector must be jumped while the indicator lights. If the DLC short connector are not connected with in about 5 seconds, the MIL turn off and it well illuminate (unsuccessful pattern; see below). Turn the ignition switch OFF and so try from step 3.

within 5 sec. MIL ON OFF FAILURE PATTERN NOTE: Note that the self diagnosis memory data cannot be erased if you turn off the ignition switch before the MIL starts blinking. If the MIL blinks 33 times, the data has not been erased, so try again. And yet if the MIL blinks 33 times, check the E2-PROM (page 24-51).

2 3 sec.

RESET RECEIVING UNSUCCESSFUL PATTERN PATTERN

24-33

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 0.3 seconds. When one long blink occur, and two short blink, that problem code is 12 (one long blink = 10 blinks, two short 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 order from the lowest number to highest number. For example, when the MIL blinks once, then blinks seven times, two failures have occurred. Follow the flow chart for failure codes 1 and 7.

MIL No blinks

Detection Item Ignition pulse generator malfunction Injector malfunction ECM malfunction ECM power/ ground circuit malfunction MIL circuit malfunction Data link or MIL circuit malfunction

Causes Faulty ignition pulse generator

Symptoms Engine does not start

Refer to 24-74

No blinks No blinks No blinks

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 Malfunction Indicator Lamp (MIL) wire Faulty ECM

Engine does not start Engine does not start Engine does not start

24-36

No blinks Stay lit

Engine operates normally Engine operates normally

1, 8, 9 all Blinks

Sensor unit power/ground circuit malfunction MAP sensor circuit malfunction

Loose or poor contact on sensor Open or short circuit in sensor unit power/ground wire Faulty sensor unit Loose or poor contact on sensor unit Open or short circuit in MAP sensor wire of the sensor unit Faulty MAP sensor Loose or poor contact on EOT sensor Open or short circuit in EOT sensor wire Faulty EOT sensor Loose or poor contact on sensor unit Open or short circuit in TP sensor wire of the sensor unit Faulty TP sensor Loose or poor contact on sensor unit Open or short circuit in IAT sensor wire of the sensor unit Faulty IAT sensor Loose or poor contact on injector connector Open or short circuit in injector wire Faulty injector

Engine does not start

24-38

1 Blink

Engine operates normally

24-40

7 Blinks

EOT sensor circuit malfunction

Hard start at a low temperature

24-42

8 Blinks

TP sensor circuit malfunction

Poor engine response and performance when operating the throttle quickly

24-45

9 Blinks

IAT sensor circuit malfunction

Engine operates normally

24-47

12 Blinks

Injector circuit malfunction

Engine does not start

24-49

24-34

ANF125/M-5 ADDENDUM
MIL 33 Blinks Detection Item E2-PROM in ECM malfunction Bank angle sensor malfunction Faulty ECM Causes Symptoms Engine operates normally Does not hold the selfdiagnosis data Engine operates normally Engine does not start Refer to 24-51

54 Blinks

Loose or poor contact on bank angle sensor Open or short circuit in bank angle sensor wire Faulty bank angle sensor

24-52

24-35

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 the second power supply. If the engine does not start with the kickstarter, inspect the ECM POWER/GROUND INSPECTION first, then inspect the 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)

Turn the ignition switch to OFF.

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

ECM 33P CONNECTOR

Connect the ECM 33P connector. Start the engine.

Engine starts

Loose or poor contact on the ECM connector

ECM 33P CONNECTOR

Engine dose not start Turn the ignition switch to OFF.

24-36

ANF125/M-5 ADDENDUM

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

Abnormal

Open circuit in Green wire

CONNECTION: Green Ground Green/Black Ground STANDARD: Continuity Normal Turn the ignition switch to ON and measure the battery voltage between the ECM connector of the wire harness side and ground. ECM 33P CONNECTOR Out of range 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 battery and ignition switch Black/Blue wire between the ignition switch and ECM

CONNECTION: Black/Blue (+) Ground () STANDARD: Battery voltage 1.1 V minimum

Voltage exist Replace the ECM with a new one, and inspect it again

24-37

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 and ECM 33P connector. Check for loose or poor contact on the sensor unit 5P connector and ECM 33P connector. SENSOR UNIT 5P CONNECTOR

ECM 33P CONNECTOR

Connect the sensor unit 5P connector and ECM 33P connector. Turn the ignition switch to ON. Check the MIL blinks. SENSOR UNIT 5P CONNECTOR

No blink

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

ECM 33P CONNECTOR

1, 8, 9 blinks Turn the ignition switch to OFF.

24-38

ANF125/M-5 ADDENDUM

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

Voltage exist

Replace the sensor unit with a new one and inspect again

CONNECTION: Yellow/Red (+) Green/Orange () STANDARD: 4.75 5.25 V Out of range Disconnect the ECM 33P connector. Check for continuity between the ECM 33P connector and sensor unit 5P connector at the wire harness side. Abnormal

Open circuit in Yellow/Red or Green/Orange wire Short circuit in Yellow/Red wire

SENSOR UNIT 5P CONNECTOR

ECM 33P CONNECTOR CONNECTION: Yellow/Red Yellow/Red Green/Orange Green/Orange STANDARD: Continuity CONNECTION: Yellow/Red Ground STANDARD: No continuity Normal

Replace the ECM with a new one and inspect again

24-39

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.

Reset the self diagnosis memory data (page 24-32). Turn the ignition switch to "ON". Check the MIL blinks. 1 blink Turn the ignition switch to OFF.

1, 8, 9 all blinks

Go to SENSOR UNIT POWER/GROUND CIRCUIT INSPECTION (page 24-38)

Disconnect the sensor unit 5P connector. Turn the ignition switch to "ON". Measure the voltage between the sensor unit 5P connector at the wire harness side and ground. SENSOR UNIT 5P CONNECTOR

Voltage exist

Replace the sensor unit with a new one and inspect again (Faulty MAP sensor)

CONNECTION: Light green/Yellow (+) Ground () STANDARD: 3.8 5.25 V Out of range Turn the ignition switch to OFF.

(To page 24-41)

24-40

ANF125/M-5 ADDENDUM
Disconnect the ECM 33P connector. Check for continuity between the ECM 33P connector and sensor unit 5P connector at the wire harness side. Check for no continuity between the sensor unit 5P connector at the wire harness side and ground. SENSOR UNIT 5P CONNECTOR Abnormal Open circuit in Light green/Yellow wire Short circuit in Light green/Yellow wire

ECM 33P CONNECTOR CONNECTION: Light green/Yellow Light green/Yellow STANDARD: Continuity CONNECTION: Light green/Yellow Ground STANDARD: No continuity

Normal

Replace the ECM with a new one and inspect again

24-41

ANF125/M-5 ADDENDUM

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 EOT sensor 2P connector.

EOT SENSOR 2P CONNECTOR

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

No blink

Loose or poor contact on the EOT sensor connector

EOT SENSOR 2P CONNECTOR 44 blinks Turn the ignition switch to OFF.

Disconnect the EOT sensor 2P connector. Measure the resistance at the EOT sensor terminals.

Abnormal

Inspect the EOT sensor (page 24-71)

EOT SENSOR STANDARD: 2.5 2.8 k (20C/68F) Normal

24-42

ANF125/M-5 ADDENDUM

Check for continuity between the EOT sensor terminal and ground. EOT SENSOR

Abnormal

Faulty EOT sensor

STANDARD: No continuity Normal Measure the voltage between the EOT sensor connector at the wire harness side. Normal Out of range

Open circuit in Green/Orange wire Loose or poor contact on the ECM connector

EOT SENSOR 2P CONNECTOR CONNECTION: Yellow/Blue Green/Orange STANDARD: 4.75 5.25 V Voltage exist Turn the ignition switch to OFF.

(To page 24-44)

24-43

ANF125/M-5 ADDENDUM

(From page 24-43)

Disconnect the ECM 33P connector. Check for continuity between the ECM 33P connector and EOT sensor 2P connector at the wire harness side. Check for no continuity between the EOT sensor 2P connector at the wire harness side and ground. ECM 33P CONNECTOR

Abnormal

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

EOT SENSOR 2P CONNECTOR CONNECTION: Green/Orange Green/Orange Yellow/Blue Yellow/Blue STANDARD: Continuity CONNECTION: Green/Orange Ground Yellow/Blue Ground STANDARD: No continuity Normal

Replace the ECM with a new one and inspect again

24-44

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.

Reset the self diagnosis memory data (page 24-32). Turn the ignition switch to "ON". Check the MIL blinks. 8 blinks Turn the ignition switch to OFF.

1, 8, 9 all blinks

Go to SENSOR UNIT POWER/GROUND CIRCUIT INSPECTION (page 24-38)

Disconnect the sensor unit 5P connector. Turn the ignition switch to "ON". Measure the voltage between the sensor unit 5P connector at the wire harness side and ground. SENSOR UNIT 5P CONNECTOR

Voltage exist

Replace the sensor unit with a new one and inspect again (Faulty TP sensor)

CONNECTION: Yellow (+) Ground () STANDARD: 0 220 mV Out of range Turn the ignition switch to OFF.

(To page 24-46)

24-45

ANF125/M-5 ADDENDUM
(From page 24-45)

Disconnect the ECM 33P connector. Check for continuity between the ECM 33P connector and sensor unit 5P connector at the wire harness side. Check for no continuity between the sensor unit 5P connector at the wire harness side and ground. SENSOR UNIT 5P CONNECTOR

Abnormal

Open circuit in Yellow wire Short circuit in Yellow wire

ECM 33P CONNECTOR CONNECTION:Yellow Yellow STANDARD: Continuity CONNECTION: Yellow Ground STANDARD: No continuity Normal

Replace the ECM with a new one and inspect again

24-46

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.

Reset the self diagnosis memory data (page 24-32). Turn the ignition switch to "ON". Check the MIL blinks. 9 blinks Turn the ignition switch to OFF.

1, 8, 9 all blinks

Go to SENSOR UNIT POWER/GROUND CIRCUIT INSPECTION (page 24-38)

Disconnect the sensor unit 5P connector. Turn the ignition switch to "ON". Measure the voltage between the sensor unit 5P connector at the wire harness side and ground. SENSOR UNIT 5P CONNECTOR

Voltage exist

Replace the sensor unit with a new one and inspect again (Faulty IAT sensor)

CONNECTION: Gray/Blue (+) Ground () STANDARD: 4.75 5.25 V Out of range Turn the ignition switch to OFF.

(To page 24-48)

24-47

ANF125/M-5 ADDENDUM

(From page 24-47)

Disconnect the ECM 33P connector. Check for continuity between the ECM 33P connector and sensor unit 5P connector at the wire harness side. Check for no continuity between the sensor unit 5P connector at the wire harness side and ground. SENSOR UNIT 5P CONNECTOR

Abnormal

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

ECM 33P CONNECTOR CONNECTION: Gray/Blue Gray/Blue STANDARD: Continuity CONNECTION:Gray/Blue Ground STANDARD: No continuity Normal

Replace the ECM with a new one and inspect again

24-48

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 injector 2P connector. INJECTOR 2P CONNECTOR

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

No blink

Loose or poor contact on the injector connector

INJECTOR 2P CONNECTOR 12 blinks Turn the ignition switch to OFF.

(To page 24-50)

24-49

ANF125/M-5 ADDENDUM
(From page 24-49)

Disconnect the injector 2P connector. Turn the ignition switch toON. Measure the battery voltage between the injector connector at the wire harness side and ground. INJECTOR 2P CONNECTOR

Out of range

Open or short circuit in Black/Blue wire

CONNECTION: Black/Blue (+) Ground () STANDARD: Battery voltage 1.1 V minimum Voltage exist Turn the ignition switch to OFF.

Disconnect the ECM 33P connector. Check for continuity between the injector connector and ECM connector at the wire harness side. Check for no continuity between the injector 2P connector at the wire harness side and ground. ECM 33P CONNECTOR

Abnormal

Open or short circuit in Pink/Green wire

INJECTOR 2P CONNECTOR CONNECTION: Pink/Green Pink/Green STANDARD: Continuity CONNECTION: Pink/Green Ground STANDARD: No continuity Normal

24-50

ANF125/M-5 ADDENDUM

Measure the resistance at the injector terminals. INJECTOR

Abnormal

Faulty injector

STANDARD: 10.2 11.4 (20C/68F)

Normal

Replace the ECM with a new one and inspect again

PGM-FI MIL 33 BLINKS (E2-PROM)


Turn the ignition switch to OFF.

Reset the self-diagnosis memory data (page 24-32). Turn the ignition switch to ON. Check that the MIL blinks.

No blink

Intermittent failure

33 blinks

Replace the ECM with a new one and inspect again

24-51

ANF125/M-5 ADDENDUM

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 connector. Check for loose or poor contact on the bank angle sensor 3P connector.

BANK ANGLE SENSOR 3P CONNECTOR

Connect the bank angle sensor 3P connector. Turn the ignition switch to ON. Check the MIL blinks. BANK ANGLE SENSOR 3P CONNECTOR

No blink

Loose or poor contact on the bank angle sensor 3P connector

54 blinks

24-52

ANF125/M-5 ADDENDUM

Turn the ignition switch to OFF.

Disconnect the ECM 33P connector. Check for continuity between the bank angle sensor 3P connector and ECM 33P connector at the wire harness side. Check for continuity between the bank angle sensor 3P connector at the wire harness side and ground. BANK ANGLE SENSOR 3P CONNECTOR ECM 33P CONNECTOR

Abnormal

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

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 connector. Turn the ignition switch to ON. Measure the voltage between the bank angle sensor 3P connector at the wire harness side and ground. Voltage exist

Replace the bank angle sensor with a new one and inspect again

BANK ANGLE SENSOR 3P CONNECTOR CONNECTION: Yellow/Red (+) Ground () STANDARD: 4.75 5.25 V Out of range Replace the ECM with a new one and inspet again

24-53

ANF125/M-5 ADDENDUM

FUEL LINE INSPECTION


FUEL PRESSURE RELIEVING/QUICK CONNECT FITTING REMOVAL
NOTE: Before disconnecting fuel feed hose, relieve pressure from the system by disconnecting the quick connect fitting in the 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 positive cable.

FUEL TANK MOUNTING BOLT

FUEL PUMP COVER

SPECIAL SCREWS

FUEL PUMP 5P (BLACK) CONNECTOR

Check the fuel quick connect fitting for dirt, and clean if necessary. Place a shop towel over the quick connect fitting.

SHOP TOWEL

FUEL CONNECT FITTING

Pull away the rubber. Hold the connector with one hand and squeeze the retainer tabs with the other hand release them from the locking pawls. Pull the connector off. NOTE: Prevent the remaining fuel in the fuel feed hose from following 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 connector until it comes of easily.

RETAINER TABS

RUBBER

LOCKING PAWLS CONNECTOR

24-54

ANF125/M-5 ADDENDUM
To prevent damage and keep foreign matter out, cover the disconnected connector and pipe end with the plastic bags. PLASTIC BAGS PIPE

CONNECTOR

QUICK CONNECT FITTING INSTALLATION


NOTE: Always replace the retainer of the quick connect fitting when the fuel feed hose is disconnected. If any retainer need replacing, use the same manufacture's retainer as the ones being removed (The several manufactures feature different retainer specifications). Clean around the fuel hose joint. Insert a new retainer into the connector joint with aligning the two hooks of the retainer with the two holes on the connector joint. NOTE: Do not bent or twist the fuel feed hose. Clean around the pipe. FUEL PUMP SIDE:

CONNECTOR

HOOKS

HOLES RETAINER

LOCKING PAWLS PIPE

Set the rubber correctly. RUBBER Align the quick connect fitting with the pipe and align the new retainer locking pawls with the connector grooves. Then press the quick connect fitting onto the pipe until both retainer pawls lock with a "CLICK". CONNECTOR If it is hard to connect, put a small amount of engine oil on the pipe end.

NOTE: When connecting the quick connect fitting to the injector side fuel feed pipe, align the tabs between the connector damper and retainer.

INJECTOR SIDE: TABS

CONNECTOR DAMPER

RETAINER TABS

24-55

ANF125/M-5 ADDENDUM
Make sure the connection is secure and that the pawls are firmly locked into place; check visually and by pulling the connector.

CONNECTOR

Connect the fuel pump 5P (Black) connector. Temporally connect the positive cable and negtive cable to the battery. NOTE: Do not start the engine. Turn the ignition switch "ON". The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat 2 or 3 times, and check that there is no leakage in the fuel supply system.

FUEL PUMP 5P (BLACK) CONNECTOR

Install the fuel pump cover. Install and tighten the two special screws to the specified torque. TORQUE: 4.2 Nm (0.4 kgfm, 3 lbfft) Install and tighten the fuel tank mounting bolt securely. Install the following: Body cover (page 23-27)

FUEL TANK MOUNTING BOLT

FUEL PUMP COVER

SPECIAL SCREWS

24-56

ANF125/M-5 ADDENDUM

FUEL PRESSURE TEST


Relieve the fuel pressure and disconnect the quick connect fitting (page 24-54). Attach the fuel pressure gauge set and pressure gauge. TOOLS: Fuel pressure gauge Pressure gauge manifold Fuel attachment hose 6-9 Fuel attachment hose 9-9 Fuel attachment joint 6-9 FUEL HOSE 9-9 07406-0040004 07ZAJ-S5A0111 07ZAJ-S5A0130 07ZAJ-S5A0120 07ZAJ-S5A0150

PRESSURE GAUGE FUEL JOINT 6-9

FUEL HOSE 6-9 MANIFOLD

Temporally connect the positive cable and negative cable to the battery. Start the engine and let it idle. Read the fuel pressure. IDLE SPEED: 1,400 100 min1 (rpm) FUEL PRESSURE: 294 kPa (3.0 kgf/cm2, 43 psi) If the fuel pressure is higher than specified, replace the fuel pump assembly. If the fuel pressure is lower than specified, inspect the following: 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 pressure 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 connect fitting (page 24-54). Connect the special tool to the fuel pump joint. TOOL: Fuel attachment hose 6-9 NOTE: Wipe off spilled out gasoline. Place the end of the hose into an approved gasoline container and measure the amount of fuel flow with the igniton switch turning "ON". NOTE: The fuel pump operates for two seconds. Repeat 5 times so 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).

07ZAL-S5A0130 FUEL ATTACHMENT HOSE 6-9

24-57

ANF125/M-5 ADDENDUM

FUEL PUMP
INSPECTION
Turn the ignition switch to ON and confirm that the fuel pump 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.

FUEL PUMP 5P (BLACK) CONNECTOR

Turn the ignition switch to ON and measure the voltage between 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)

FUEL PUMP 5P (BLACK) CONNECTOR

REMOVAL
NOTE: It is impossible to disassemble the fuel pump after removing it. Clean around the fule pump. Relieve the fuel pressure and disconnect the quick connect fitting (page 24-54). Disconnect the fuel pump 5P (Black) connector. Remove the fuel pump wire from the clamp.

CLAMP

FUEL PUMP WIRE

FUEL PUMP 5P (BLACK) CONNECTOR

Remove the fuel pump mounting nuts and clamp.

CLAMP

NUTS

24-58

ANF125/M-5 ADDENDUM
NOTE: Remove the fuel pump being careful not to damage the fuel level sensor float arm. Remove the set plate/fuel pump unit assembly and packing. SET PLATE

FUEL PUMP UNIT

PACKING

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 PUMP UNIT

FUEL SUCTION FILTER

INSTALLATION
FUEL PUMP UNIT 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.

PACKING

Install the set plate by aligning its holes with the tabs on the fuel pump unit. Install the set plate/fuel pump unit assembly to the fuel tank.

SET PLATE

FUEL PUMP UNIT

Align

24-59

ANF125/M-5 ADDENDUM
Install the clamp and tighten the fuel pump mounting nuts in the sequence shown. TORQUE: 12 Nm (1.2 kgfm, 9 lbfft) CLAMP

NUTS

Connect the fuel pump 5P (Black) connector. Clamp the fuel pump wire. Connect the quick connect fitting (page 24-55).

CLAMP

FUEL PUMP WIRE

FUEL PUMP 5P (BLACK) CONNECTOR FUEL PUMP 4P CONNECTOR

FUEL TANK
REMOVAL/INSTALLATION
Relieve the fuel pressure and disconnect the quick connect 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

24-60

ANF125/M-5 ADDENDUM

THROTTLE BODY/SENSOR UNIT


REMOVAL
NOTE: The sensor unit can be removed with the throttle body installed in the air cleaner and intake manifold. If you have removed sensor unit, reset the throttle position (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.

CRANKCASE BREATHER TUBE

SCREW

PAIR CONTROL VALVE VACUUM TUBE

CONNECTORS

Loosen the throttle cable lock nut and adjusting nut then disconnect the throttle cable from the throttle drum and cable bracket. Disconnect the quick connect fitting (page 24-54). Remove the two intake manifold mounting bolts and throttle body/sensor unit to the right side. NOTE: Seal the cylinder head intake port with a shop towel or cover it with a piece of tape to prevent any foreign material from dropping into the engine.

ADJUSTING NUT

QUICK CONNECT FITTING

LOCK NUT

THROTTLE CABLE

BOLTS

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

SCREW

INTAKE MANIFOLD

O-RING

24-61

ANF125/M-5 ADDENDUM

DISASSEMBLY
NOTE: The throttle body/sensor unit is factory pre-set. Do not disassemble in a way other than shown in this manual. 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. Do not damage the throttle body. It may cause incorrect throttle valve. Do not loosen or tighten the white painted nut of the throttle body. Loosening or tightening it can cause throttle body malfunction.

WHITE PAINTED

Turn the idle adjusting screw in and record the number of turns until it seats lightly. NOTE: Damage to the idle adjusting screw seat will occur if the idle adjusting screw is tighened against the seat. Remove the following: Idle adjusting screw O-ring Spring SPRING IDLE ADJUSTING SCREW

O-RING

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

SENSOR UNIT O-RING

TORX SCREWS

Blow open each air passage in the throttle body with the compressed air. NOTE: Do not use high pressure air or bring the nozzle too close to the throttle body.

THROTTLE BODY

24-62

ANF125/M-5 ADDENDUM

ASSEMBLY
IDLE ADJUSTING SCREW O-RING FUEL FEED PIPE BOLT 5.1 Nm (0.5 kgfm, 3.8 lbfft)

SPRING O-RING TORX SCREW 3.4 Nm (0.3 kgfm, 2.5 lbfft) INJECTOR SEAL RING

SENSOR UNIT O-RING

THROTTLE CABLE BRACKET

THROTTLE BODY

SCREW 3.4 Nm (0.3 kgfm, 2.5 lbfft)

NOTE: Install the O-ring to the throttle body properly. If the O-ring is not installed properly, the idle air will leaks and 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 the clip of the throttle position (TP) sensor and boss of the throttle valve.

THROTTLE BODY

SENSOR UNIT

O-RING NOTE: The light pressure is sufficient to assemble the sensor unit and throttle body in their correctly position. If you cannot set it easily, the clip may be misaligned, and do not force it but make sure that the clip is aligned at the right position. Install the three torx screws and tighten it to the specified torque. TORQUE: 3.4 Nm (0.3 kgfm, 2.5 lbfft) Install the injector (page 24-69). BOSS OF THE THROTTLE VALVE CLIP OF THE TP SENSOR

SENSOR UNIT

TORX SCREWS

24-63

ANF125/M-5 ADDENDUM
Install the following: Spring New O-ring Idle adjusting screw Turn the idle adjusting screw in until it seats lightly. O-RING NOTE: Damage to the idle adjusting screw seat will occur if the idle adjusting screw is tightened against the seat. Turn the idle adjusting screw out to its original position as noted during removal. SPRING IDLE ADJUSTING SCREW

INSTALLATION
NOTE: Be careful not to damage the intake manifold. Install the intake manifold by aligning its groove with the boss of the throttle body. Install a new O-ring to the intake manifold. SCREW

INTAKE MANIFOLD

Align O-RING

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

7 1 mm (0.3 0.04 in)

INTAKE MANIFOLD BAND

24-64

ANF125/M-5 ADDENDUM
Install the throttle body/sensor unit and tighten the two intake manifold mounting bolts to the specified torque. TORQUE: 12 Nm (1.2 kgfm, 9 lbfft) Connect the quick connect fitting (page 24-55). Connect the throttle cable to the throttle drum and throttle cable bracket, then adjust the throttle grip free play (page 22-29). 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 the engine idle speed (page 24-25). If you have removed sensor unit, reset the throttle position (TP) sensor (page 24-65). Install the following: Main pipe side cover (page 23-25) PAIR CONTROL VALVE VACUUM TUBE CONNECTORS THROTTLE CABLE BOLTS ADJUSTING NUT QUICK CONNECT FITTING

LOCK NUT

CRANKCASE BREATHER TUBE

SCREW

THROTTLE POSITION (TP) SENSOR RESET PROCEDURE


1. Turn the ignition switch to OFF. 2. Disconnect the connector cover from the data link connector (DLC). DATA LINK CONNECTOR (DLC)

CONNECTOR COVER

3. Connect the special tool to the Data Link Connector (DLC). TOOL: DLC short connector

070PZ-ZY30100

DLC SHORT CONNECTOR

24-65

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

JUMPER WIRE EOT SENSOR 2P CONNECTOR

5. Turn the ignition switch to ON then disconnect the jumper wire from the EOT sensor 2P connector while the MIL blinking (reset receiving pattern; see page 2467) for 10 seconds.

JUMPER WIRE

EOT SENSOR 2P CONNECTOR

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

MALFUNCTION INDICATOR LAMP (MIL)

24-66

ANF125/M-5 ADDENDUM
within 10 sec. 0.1 sec. MIL ON OFF RESET RECEIVING PATTERN If the jumper wire is not disconnected within 10 seconds, the MIL will illuminate (unsuccessful pattern; see below) and try again from the step 4. within 10 sec. 0.1 sec. MIL ON OFF RESET RECEIVING PATTERN 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 (page 24-32), so try from step 4. 6. Turn the ignition switch to OFF. 7. Connect the EOT sensor 2P connector. UNSUCCESSFUL PATTERN SUCCESSFUL PATTERN 0.3 sec. 0.3 sec.

1.2 sec.

1.2 sec.

EOT SENSOR 2P CONNECTOR

8. Disconnect the DLC short connector from the data link connector (DLC). TOOL: DLC short connector

070PZ-ZY30100

DLC SHORT CONNECTOR

24-67

ANF125/M-5 ADDENDUM
9. Connect the connector cover to the data link connector (DLC).

DATA LINK CONNECTOR (DLC)

CONNECTOR COVER

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 min1 (rpm) If the engine idle speed is out of specification, turn the idle adjusting screw as required to obtain the specified idle speed. If the idle speed does not fall within the specification, check the POOR PERFORMANCE AT LOW AND IDLE SPEED (page 24-83).

IDLE ADJUSTING SCREW

24-68

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

INJECTOR
REMOVAL
Remove the throttle body/sensor unit (page 24-61). Remove the two bolts and injector assembly from the throttle body.

BOLTS

INJECTOR ASSEMBLY

Remove the fuel feed pipe, O-ring and seal ring from the injector. Check the removed parts for wear or damage and replace them if necessary.

FUEL FEED PIPE

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. Install the injector to the fuel feed pipe as shown. TAB INJECTOR SEAL RING O-RING INJECTOR

STOPPER FUEL FEED PIPE

24-69

ANF125/M-5 ADDENDUM
NOTE: Check that the location of the injector connector is between the 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 bolts to the specified torque. TORQUE: 5.1 Nm (0.5 kgfm, 3.8 lbfft) Install the throttle body/sensor unit (page 24-64) INJECTOR ASSEMBLY THROTTLE BODY STOPPER INJECTOR CONNECTOR

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. BANK ANGLE SENSOR

3P CONNECTOR

SCREWS

Install the bank angle sensor with its UP mark facing up.

Install and tighten the mounting screws to the specified torque. TORQUE: 1.2 Nm (0.1 kgfm, 0.9 lbfft) 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) BANK ANGLE SENSOR

3P CONNECTOR

SCREWS

24-70

ANF125/M-5 ADDENDUM

EOT (ENGINE OIL TEMPERATURE) SENSOR


REMOVAL
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.

EOT SENSOR/SEALING WASHER

EOT SENSOR 2P CONNECTOR 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 heating element. Suspend the EOT sensor in a pan of coolant (50-50 mixture) on an electric heating element and measure the resistance at the EOT sensor terminals as the coolant heats up. NOTE: Soak the EOT sensor in coolant up to its threads with at least 40 mm (1.57 in) from the bottom of the pan to the bottom of the sensor. Keep the temperature constant for 3 minutes before testing. A sudden change of temperature will result in incorrect reading. Do not let the thermometer or EOT sensor touch the pan. Measure the resistance at the EOT sensor terminals as shown. 100C (212F) 20C (68F) RESISTANCE 2.5 2.8 k 0.16 0.27 k EOT SENSOR

If the resistance is out of specification at any temperature listed, 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 Nm (1.8 kgfm, 13 lbfft) Connect the EOT sensor 2P connector. Install the main pipe side cover (page 23-25). Fill the recommended engine oil (page 3-9). EOT SENSOR 2P CONNECTOR EOT SENSOR SEALING WASHER

24-71

ANF125/M-5 ADDENDUM

CHARGING SYSTEM DIAGRAM


IGNITION SWITCH REGULATOR/ RECTIFIER MAIN FUSE 15A

ALTERNATOR BATTERY

R: Red Y: Yellow G: Green W: White

ANF125/ 12V 2.5AH ANF125M/ 12V 3.5AH

24-72

ANF125/M-5 ADDENDUM

CHARGING SYSTEM TROUBLESHOOTING


Battery is damaged or weak Remove the battery (page 15-4). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM210 or BATTERY MATE or equivalent Correct Install the battery (page 15-4). Check the battery current leakage (Leak test: page 15-7). SPECIFIED CURRENT LEAKAGE: 0.1 mA max Correct Measure and record the battery voltage using a digital multimeter (page 15-4). Start the engine. Measure the charging voltage (page 16-6). Compare the measurements to result of the following calculation. STANDARD: Measured BV < Measured CV < 15.5 V BV=Battery Voltage CV=Charging Voltage Incorrect Check the alternator charging coil (page 22104). STANDARD: 0.2 1.0 (20C/68F) Incorrect Faulty charging coil Correct Shorted wire harness Faulty regulator/rectifier Faulty ignition switch Incorrect Disconnect the regulator/rectifier 6P connector and recheck the battery current leakage. Incorrect Faulty battery

Incorrect

Correct

Faulty battery

Correct

Perform the regulator/rectifier wire harness inspection (page 22-104)

24-73

ANF125/M-5 ADDENDUM

IGNITION SYSTEM DIAGRAM


Refer to ANF125 Shop Manual (62KPHLM3) for troubleshooting in this section. IGNITION IGNITION SWITCH COIL MAIN FUSE 15A

ECM

REGULATOR/RECTIFIER

SENSOR UNIT

SPARK PLUG

IGNITION PULSE GENERATOR

EOT SENSOR

ALTERNATOR BANK ANGLE SENSOR BATTERY ANF125/12V 2.5AH ANF125M/12V 3.5AH

R: Red Bl: Black Bu: Blue P: Pink G: Green Y: Yellow W: White

24-74

ANF125/M-5 ADDENDUM

ELECTRIC STARTER SYSTEM DIAGRAM


Refer to ANF125 Shop Manual (62KPHAM2) for troubleshooting in this section. STARTER SWITCH

STARTER RELAY

REGULATOR/RECTIFIER

IGNITION SWITCH

STARTER MOTOR

MAIN FUSE 15A BATTERY

R: Red Y: Yellow Bl: Black Bu: Blue W: White G: Green

24-75

ANF125/M-5 ADDENDUM

LIGHTS/METERS/SWITCHES SYSTEM LOCATION


Refer to ANF125 Shop Manual (62KPHAM2) for troubleshooting in this section.

TURN SIGNAL RELAY TURN SIGNAL SWITCH FRONT BRAKE LIGHT SWITCH IGNITION SWITCH

RIGHT REAR TURN SIGNAL LIGHT BRAKE/TAIL LIGHT

RIGHT FRONT TURN SIGNAL LIGHT FUEL LEVEL SENSOR HORN SWITCH

LEFT FRONT TURN SIGNAL LIGHT

HORN

FUSES 15A, 10A BATTERY ECM REAR BRAKE LIGHT SWITCH

LEFT REAR TURN SIGNAL LIGHT

24-76

ANF125/M-5 ADDENDUM

FUEL METER/FUEL LEVEL SENSOR


FUEL METER INSPECTION
Turn the ignition switch to ON and make sure the fuel meter comes ON. If the fuel meter does not indicate properly, preform the following: 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 is normal. If the fuel meter indication is Full, check for short circuit in Yellow/White wire. Turn the ignition switch to OFF. Ground the fuel pump 5P (Black) connector terminals with a 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 normal. If the fuel meter indication is Empty, check for open circuit in Yellow/White wire and green wire.

FUEL PUMP 5P (BLACK) CONNECTOR

FUEL METER

FUEL PUMP 5P (BLACK) CONNECTOR

FUEL METER

FUEL PUMP If the wires are normal, check the fuel level sensor (see below).

FUEL LEVEL SENSOR INSPECTION


Remove the fuel pump (page 24-58). Connect the ohmmeter to the fuel level sensor terminals of the fuel pump 5P (Black) connector. CONNECTION: Yellow/White Green Inspect the resistance of the float at the top and bottom positions. FULL Resistance (20C/68F) 57 EMPTY 204 210

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

24-77

ANF125/M-5 ADDENDUM

MEMO

24-78

ANF125/M-5 ADDENDUM

WIRING DIAGRAMS

ANF125:

24-79

ANF125/M-5 ADDENDUM

ANF125M:

24-80

ANF125/M-5 ADDENDUM

TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START


Possible cause 1. Check the charging system Normal Abnormal Faulty the battery Faulty the charging system

2. Check the PGM-FI system

Abnormal

Faulty ECM

Normal

3. Check for operating sound of the fuel pump Sound heard

Sound not heard

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

4. Inspect the fuel pressure and fuel flow

Abnormal

Faulty fuel pump Faulty ECM

Normal

5. Perform a spark test

Weak or no spark

Good spark

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

Low compression

Compression normal

Valve stuck open Worn cylinder and piston ring Damaged cylinder head gasket Seized valve Improper valve timing

7. Starting following normal procedure Engine does not start

Engine starts but stops

Intake manifold leaking Improper ignition timing (Faulty ignition pulse generator) Fuel contaminated

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ANF125/M-5 ADDENDUM

8. Remove and inspect spark plug

Wet plug

Clogged air cleaner Faulty ECM

Dry plug

Faulty injector

ENGINE LACKS POWER


1. Raise wheel off the ground and spin by hand Wheel spins freely Wheels do not spin freely

Possible cause Brake dragging Worn or damaged wheel bearing

2. Check tire pressure Pressure normal

Pressure low

Faulty tire valve Punctured tire

3. Accelerate rapidly from low to second Engine speed reduced when gear is changed 4. Accelerate lightly Engine speed increase

Engine speed doesn't change accordingly when gear is changed

Clutch slipping Worn clutch discs/plates Warped clutch discs/plates Weak clutch spring Additive in engine oil Air cleaner dirty Restricted fuel flow Clogged muffler Pinched fuel tank breather

Engine speed does not increase

5. Check ignition timing Correct

Incorrect

Faulty ECM Faulty ignition pulse generator

6. Test cylinder compression Normal

Incorrect

Valve stuck open Worn cylinder and piston rings Leaking head gasket Improper valve timing

7. Inspect fuel pressure and fuel flow Normal

Abnormal

Faulty fuel pump Faulty ECM

8. Remove spark plug Not fouled or discolored

Fouled or discolored

Faulty spark plug

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ANF125/M-5 ADDENDUM

9. Check oil level and condition Correct

Incorrect

Oil level too high Oil level too low Contaminated oil

10. Remove the valve adjuster hole cap and inspect lubrication Valve train lubricated properly

Valve train not lubricated properly

Clogged oil passage Clogged oil control orifice

11.Check for engine overheating Not overheating

Overheating

Excessive carbon build-up in combustion chamber Use of poor quality fuel Wrong type of fuel Clutch slipping 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)

12.Accelerate or run at high speed

Engine knocks

Engine does not knock

POOR PERFORMANCE AT LOW AND IDLE SPEED


Possible cause 1. Check ignition timing Correct Incorrect Improper ignition timing (Faulty ignition pulse generator)

2. Inspect the fuel pressure and fuel flow Normal

Abnormal

Faulty fuel pump Faulty ECM

3. Check for leaks in the intake manifold Not leak

Leaking

Loose intake manifold band or mounting bolts Damaged intake manifold

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ANF125/M-5 ADDENDUM

4. Perform spark test

Weak or intermittent spark

Good spark

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

Faulty injector

POOR PERFORMANCE AT HIGH SPEED


Possible cause 1. Check ignition timing Correct Incorrect Faulty ECM

2. Inspect the fuel pressure and fuel flow Normal

Abnormal

Faulty fuel pump Faulty ECM

3. Check valve timing Correct

Incorrect

Camshaft not installed properly

4. Check valve spring

Weak

Faulty valve spring

Not weak

Faulty injector

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