BPR Pgm-Fi

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 ENGINE NUMBER

The frame serial number is stamped on the right side of the steering The engine serial number is stamped on the lower left side of the
head. crankcase.
THROTTLE BODY IDENTIFICATION NUMBER
THROTTLE BODY IDENTIFICATION NUMBER

The throttle body identification number is stamped on the front side
of the throttle body.
24-1
ANF125/M-5 ADDENDUM
SPECIFICATIONS
GENERAL
ITEM SPECIFICATIONS
Overall length 1,881 mm (74.1 in)
DIMENSIONS Overall width 706 mm (27.8 in)
Overall height 1,081.5 mm (42.58 in)
Wheelbase 1,239 mm (48.8 in)
Seat height 761 mm (30.0 in)
Footpeg height 266 mm (10.5 in)
Ground clearance 130 mm (5.1 in)
Curb weight ANF125 100.1 kg (220.7 lbs)
ANF125M 102.5 kg (226.0 lbs)
Frame type Back bone type
FRAME Front suspension Telescopic fork
Front axle travel 80.5 mm (3.17 in)
Rear suspension Swingarm
Rear axle travel 81.8 mm (3.22 in)
Rear damper Both side operation tube type
Front tire size 60/100–17M/C 33P
Rear tire size 70/90–17M/C 43P
Front brake Hydraulic disc brake
Rear brake Mechanical leading trailing
Caster angle 26° 30'
Trail length 68 mm (2.7 in)
Fuel tank capacity 3.7 liter (0.98 US gal 0.81 lmp gal)
Bore and stroke 52.4 x 57.9 mm (2.06 x 2.28 in)
ENGINE
Displacement 124.8 cm3 (7.61 cu-in)
Compression ratio 9.3 : 1
Valve train 2 valve, single chain driven SOHC
Intake valve opens at 1 mm 5° BTDC
closes (0.04 in) lift 22° ABDC
Exhaust valve opens 37° BBDC
closes –3° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Paper filter
Crankshaft type Assembled type
Cylinder arrangement Single cylinder inclined 80° from vertical
24-
ANF125/M-5 ADDENDUM
GENERAL (Cont'd)
ITEM
Type
CARBURATION PGM-FI (Programmed Fuel Injection)
Throttle bore
Multi-plate, wet
DRIVE TRAIN Clutch system Automatic centrifugal type
Clutch operation system Constant mesh, 4-speed
Transmission 3.350 (67/20)
Primary reduction 2.428 (34/14)
Final reduction 2.500 (35/14)
Gear ratio 1st 1.550 (31/20)
2nd 1.150 (23/20)
3rd 0.923 (24/26)
4th Left foot operated return system
Gearshift pattern (rotary system; only when the motorcycle is not
running)
N-1-2-3-4 (-N)
Ignition system Full transistor digital ignition
ELECTRICAL Starting system ANF125 Kickstarter
ANF125M Kickstarter and electric starter motor
Charging system Single phase output alternator
Regulator/rectifier SCR opened/single phase, half wave rectification
Alternator
Lighting system
24-3
ANF125/M-5 ADDENDUM
Unit: mm (in)
LUBRICATION SYSTEM
ITEM
STANDARD
At draining 0.7 liter (0.7 US qt, 0.6 lmp qt) —
At disassembly 0.9 liter (1.0 US qt, 0.8 lmp qt) —
Honda 4-stroke oil or equivalent motor oil
Recommended engine oil API service classification SE, SF or SG —
Viscosity: SAE 10W-30
—
Tip clearance 0.15 – 0.21 (0.006 – 0.008) 0.20 (0.008)
Oil pump rotor
Body clearance 0.03 – 0.09 (0.001 – 0.003) 0.26 (0.010)
Side clearance 0.15 (0.005)
FUEL SYSTEM (Programmed Fuel Injection)

ITEM SPECIFICATION
Throttle body identification number GQR0A
Idle speed 1,400 ± 100 min–1 (rpm)
Throttle grip free play 2 – 6 mm (0.1 – 0.2 in)
EOT (Engine Oil Temperature) sensor 20°C/68°F 2.5 – 2.8 kΩ
resistance 0.21 – 0.22 kΩ
100°C/212°F
Fuel injector resistance (at 20°C/68°F) 10.3 – 11.3 Ω
Fuel pressure 294 kPa (3.0 kgf/cm2, 43 psi)
Fuel pump flow (at 12V) 13.9 cm3 (0.47 US oz, 0.49 lmp oz) minimum/10 seconds
Unit: mm (in)
CYLINDER HEAD/VALVES
ITEM STANDARD SERVICE LIMIT
Cylinder compression 1,275 kPa (13.0 kgf/cm , 185 psi) at
2
—
600 min–1 (rpm)
Cylinder head warpage — 0.05 (0.002)
Valve, Valve clearance IN 0.05 ± 0.02 (0.002 ± 0.001) —
valve guide
EX 0.05 ± 0.02 (0.002 ± 0.001) —
Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.965 (0.195)
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.945 (0.195)
Valve guide I.D. IN 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.065 (0.0026)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.085 (0.0033)
Valve seat width IN/EX 1.0 (0.04) 1.6 (0.06)
Valve spring free length IN/EX 37.62 (1.481) 35.8 (1.41)
Rocker arm/shaft Rocker arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
Rocker arm shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.92 (0.391)
Camshaft Cam lobe height IN 32.278 – 32.518 (1.2708 – 1.2802) 31.94 (1.257)
EX 32.121 – 32.361 (1.2646 – 1.2741) 31.79 (1.252)
24-
ANF125/M-5 ADDENDUM
Unit: mm (in)
CYLINDER/PISTON
STANDARD SERVICE LIMIT
ITEM
I.D. 52.405 – 52.415 (2.0632 – 2.0636) 52.445 (2.0648)
Cylinder
Out of round — 0.10 (0.004)
Taper — 0.10 (0.004)
Warpage — 0.05 (0.002)
Piston mark direction “IN” mark facing toward the intake side —
Piston, piston
Piston O.D. 52.362 – 52.400 (2.0615 – 2.0630) 52.292 (2.0587)
Piston O.D. measurement point 10 mm (0.4 in) from bottom of skirt —
Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.03 (0.513)
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.98 (0.511)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.075 (0.0030)
Piston ring-to-ring Top 0.030 – 0.065 (0.0012 – 0.0026) 0.10 (0.004)
groove clearance Second 0.015 – 0.050 (0.0006 – 0.0020) 0.09 (0.004)
Piston ring end gap Top 0.10 – 0.30 (0.004 – 0.012) 0.5 (0.02)
Second 0.10 – 0.30 (0.004 – 0.012) 0.5 (0.02)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 1.1 (0.04)
Cylinder-to-piston clearance 0.005 – 0.053 (0.0002– 0.0021) 0.159 (0.0063)
Connecting rod small end I.D. 13.016 – 13.034 (0.5124 – 0.5131) 13.05 (0.514)
Connecting rod-to-piston pin clearance 0.016 – 0.040 (0.0006 – 0.0016) 0.07 (0.003)
Unit: mm (in)
CLUTCH/GEARSHIFT LINKAGE
ITEM
Disk thickness 2.5 – 2.7 (0.098 – 0.106) 2.2 (0.09)
Manual clutch
Plate warpage — 0.20 (0.008)
Clutch spring free length 27.4 (1.08) 26.8 (1.06)
Clutch outer guide O.D. 22.959 – 22.980 (0.9039 – 0.9047) 22.940 (0.9031)
Clutch outer I.D. 23.000 – 23.021 (0.9055 – 0.9063) 23.07 (0.908)
Clutch drum I.D. 104.0 – 104.2 (4.09 – 4.10) 104.3 (4.11)
Centrifugal clutch
Clutch weight lining thickness 1.5 (0.06) 1.0 (0.04)
One-way clutch drum I.D. 42.000 – 42.020 (1.6535 – 1.6543) 42.04 (1.655)
One-way clutch roller O.D. 4.990 – 5.000 (0.1965 – 0.1969) 4.97 (0.196)
Primary drive gear I.D. 21.030 – 21.058 (0.8280 – 0.8291) 21.11 (0.831)
Crankshaft O.D. at primary drive gear 20.967 – 20.980 (0.8255 – 0.8260) 20.92 (0.824)
Clutch brake lining thickness 3.35 (0.132) 2.5 (0.10)
24-5
ANF125/M-5 ADDENDUM
Unit: mm (in)
CRANKSHAFT/TRANSMISSION/KICKSTARTER
Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.60 (0.024)
Crankshaft
Connecting rod radial clearance 0.008 (0.0003) 0.05 (0.002)
Runout — 0.10 (0.004)
Gear I.D. M2,3 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
Transmission
C1 18.000 – 18.018 (0.7087 – 0.7094) 18.04 (0.710)
C4 20.000 – 20.021 (0.7874 – 0.7882) 20.040 (0.7890)
Bushing O.D. C1 17.966 – 17.984 (0.7073 – 0.7080) 17.94 (0.706)
Bushing I.D. C1 15.000 – 15.018 (0.5906 – 0.5913) 15.04 (0.592)
Gear-to-bushing clearance C1 0.016 – 0.052 (0.0006 – 0.0020) 0.1 (0.004)
Mainshaft O.D. M2,3 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667)
Countershaft O.D. C1 14.966 – 14.984 (0.5892 – 0.5899) 14.95 (0.589)
Gear-to-shaft clearance M2,3 0.016 – 0.052 (0.0006 – 0.0020) 0.09 (0.004)
Bushing-to-shaft clearance C1 0.016 – 0.052 (0.0006 – 0.0020) 0.09 (0.004)
Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.07 (0.396)
Shift fork/
Shift drum Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.90 (0.193)
Shift fork shaft O.D. 9.986 – 9.995 ( 0.3931– 0.3935) 9.93 (0.391)
Shift drum O.D. Left 23.959 – 23.980 (0.9433 – 0.9441) 24.07 (0.948)
Right 27.959 – 27.980 (1.1007 – 1.1016) 28.08 (1.106)
Shift drum journal I.D. Left 24.000 – 24.033 (0.9449 – 0.9462) 23.98 (0.944)
Right 28.000 – 28.021 (1.1024 – 1.1032) 27.98 (1.102)
Pinion I. D. 20.000 – 20.021 (0.7874 – 0.7882) 20.08 (0.791)
Kick starter
Shaft O.D. 19.959 – 19.980 (0.7858 – 0.7866) 19.94 (0.785)
24-
ANF125/M-5 ADDENDUM
Unit: mm (in)
FRONT WHEEL/SUSPENSION/STEERING
Minimum tire tread depth — To the indicator
Cold tire pressure Driver only 225 kPa (2.25 kgf/cm , 33 psi)
2 —
Driver and passenger 225 kPa (2.25 kgf/cm , 33 psi)
2 —
Axle runout — 0.20 (0.008)
Wheel rim runout Radial — 2.0 (0.08)
Axial — 2.0 (0.08)
Wheel hub-to-rim distance 19.5 ± 1 (0.77 ± 0.04) —
Fork Spring free length 316.3 (12.45) 310.0 (12.20)
Spring direction With the tapered end facing down —
Tube runout — 0.20 (0.008)
Recommended fork fluid Honda Ultra Cushion Oil No.10 —
Fluid level 68.5 (2.70) —
Fluid capacity 70.0 ± 1 cm3 (2.37 ± 0.03 US oz, —
2.46 ± 0.04 lmp oz)
Unit: mm (in)
REAR WHEEL/BRAKE/SUSPENSION
Minimum tire tread depth — To the indicator
Cold tire pressure Driver only 250 kPa (2.50 kgf/cm2, 36 psi) —
Driver and passenger 250 kPa (2.50 kgf/cm2, 36 psi) —
Axle runout — 0.20 (0.008)
Wheel rim runout Radial — 2.0 (0.08)
Axial — 2.0 (0.08)
Wheel hub-to-rim distance 10.0 ± 1 (0.39 ± 0.04) —
Drive chain Size/link 420 – 104 —
Slack 25 – 35 (1.0 – 1.4) —
Brake Brake drum I.D. 110.0 (4.33) 111.0 (4.37)
Brake pedal free play 20 – 30 (0.8 – 1.2) —
Unit: mm (in)
HYDRAULIC BRAKE
Specified brake fluid DOT 3 or 4 —
Brake pad wear indicator — To groove
Brake disc thickness 4.0 (0.157) 3.5 (0.138)
Brake disc runout — 0.30 (0.012)
Master cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022)
Master piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)
Caliper cylinder I.D. 25.400 – 25.450 (1.000 – 1.002) 25.460 (1.002)
Caliper piston O.D. 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)
24-7
ANF125/M-5 ADDENDUM
BATTERY/CHARGING SYSTEM
ITEM SPECIFICATIONS
Capacity ANF125 12 V – 2.5 Ah
Battery
ANF125M 12 V – 3.5 Ah
Current leakage 0.1 mA max.
Voltage Fully charged 13.0 – 13.2 V
Needs charging Below 12.3 V
Charging Normal 0.3 A/5 – 10 h
current ANF125
Quick 3.0 A/0.5 h
Normal 0.4 A/5 – 10 h
ANF125M
Quick 3.0 A/0.5 h
Capacity 0.150 kw/5,000 min–1 (rpm)
Alternator
Charging coil resistance (20°C/68°F) 0.2 – 1.0 Ω
Unit: mm (in)
IGNITION SYSTEM
ITEM SPECIFICATIONS
Spark plug NGK DENSO
Standard CPR6EA-9 U20EPR9
Optional CPR7EA-9 U22EPR9
Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in)
Ignition coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing 10° BTDC at idle
Unit: mm (in)
ELECTRIC STARTER
ITEM
Starter motor brush length 10.0 – 10.05 (0.39 – 0.40) 3.5 (0.14)
LIGHTS/METERS/SWITCHES
ITEM SPECIFICATIONS
Headlight (Hi/low beam) 12 V – 18/18W x 2

Bulbs
Brake/taillight 12 V – 18/5 W
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Meter light LED
Turn signal indicator LED x 2
High beam indicator LED
Gear position indicator LED x 4
Neutral indicator LED
PGM-FI malfunction indicator LED
Main 15 A
Fuse
Sub 10 A
24-
ANF125/M-5 ADDENDUM
TORQUE VALUES
TORQUE TORQUE
5 mm hex bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)

6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head) 9 (0.9, 6.5)
10 mm hex bolt and nut 34 (3.5 , 25) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9)
8 mm flange bolt and nut
10 mm flange bolt and nut 26 (2.7, 20)
• 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.
ENGINE
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
MAINTENANCE:
Oil drain bolt 1 12 24 (2.4, 17)
Crankshaft hole cap 1 30 8 (0.8, 5.8)
Timing hole cap 1 14 6 (0.6, 4.3)
Valve adjuster lock nut 2 5 9 (0.9, 6.5)
Oil centrifugal filter cover bolt 4 5 5 (0.5, 3.6) NOTE 1
Clutch adjuster lock nut 1 8 12 (1.2, 9)
Spark plug 1 10 16 (1.6, 12)
LUBRICATION SYSTEM:
Oil pump cover bolt 2 5 5 (0.5, 3.6)
FUEL SYSTEM (Programmed Fuel Injection):
EOT (Engine Oil Temperature) sensor 1 10 18 (1.8, 13)
Intake manifold mounting bolt 2 6 12 (1.2, 9)
ENGINE REMOVAL/INSTALLATION:
Drive sprocket fixing plate bolt 2 6 12 (1.2, 9)
CYLINDER HEAD/VALVES:
Cylinder head cap nut 4 8 24 (2.4, 17)
Cam sprocket cover bolt 1 6 10 (1.0, 7)
Cam sprocket bolt 2 5 9 (0.9, 6.5)
Cam chain tensioner lifter plug 1 6 4 (0.4, 2.9)
Plunger set bolt 1 6 10 (1.0, 7)
CLUTCH/GEARSHIFT LINKAGE:
Shift drum stopper arm bolt 1 6 12 (1.2, 9)
Shift return spring pin 1 8 30 (3.1, 22)
Gear shift cam plate socket bolt 1 6 10 (1.0, 7) NOTE 1
Centrifugal clutch lock nut 1 14 64 (6.5, 47) NOTE 2
Clutch lifter plate flange bolt 3 6 12 (1.2, 9)
Manual clutch center lock nut 1 14 64 (6.5, 47) NOTE 2
ALTERNATOR/STARTER CLUTCH:
Flywheel flange nut 1 12 64 (6.5, 47) NOTE 2
Starter clutch outer mounting socket bolt 6 6 16 (1.6, 12) NOTE 1
Stator mounting bolt 2 6 10 (1.0, 7)
Ignition pulse generator mounting bolt 2 6 10 (1.0, 7)
24-9
ANF125/M-5 ADDENDUM
Intake manifold band:

7 ± 1 mm
(0.3 ± 0.04 in)
INTAKE MANIFOLD
INTAKE MANIFOLD BAND 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)
24-
ANF125/M-5 ADDENDUM
FRAME THREAD TORQUE

ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
FRAME/BODY PANELS/EXHAUST SYSTEM:

Rear grip mounting socket bolt 4 8 27 (2.8, 20)
Exhaust pipe joint nut 2 8 27 (2.8, 20)
MAINTENANCE:
Drive chain case mounting bolt 4 6 6 (0.6, 4.4)
FUEL SYSTEM (Programmed Fuel Injection):
Fuel feed pipe mounting bolt 2 5 5.1 (0.5, 3.8)
Sensor unit torx screw 3 5 3.4 (0.3, 2.5)
Throttle cable bracket screw 1 5 3.4 (0.3, 2.5)
Bank angle sensor mounting screw 2 4 1.2 (0.1, 0.9)
Fuel pump mounting nut 5 6 12 (1.2, 9)
(see tightening sequence below)
ENGINE MOUNTING:
Engine hanger front bolt/nut 1 10 59 (6.0, 43)
Engine hanger rear upper bolt/nut 1 10 59 (6.0, 43)
Engine hanger rear lower bolt/nut 1 10 59 (6.0, 43)
FRONT WHEEL/BRAKE/SUSPENSION/STEERING:
Steering stem nut 1 26 See page 12-29
Steering stem top thread 1 26 See page 12-28
Bottom bridge pinch flange bolt 4 10 64 (6.5, 47)
Handlebar holder nut 1 10 59 (6.0, 43) NOTE 3
Handlebar mounting bolt 3 8 25 (2.5, 18)
Front axle nut 1 12 59 (6.0, 43) NOTE 3
Front brake disk bolt 4 8 42 (4.3, 31) NOTE 1
Front spoke 36 BC 3.2 3.2 (0.3, 2.3)
Handlebar weight screw 2 6 9 (0.9, 6.6)
Fork socket bolt 2 8 20 (2.0, 14) NOTE 1
Brake hose clamper bolt 1 6 12 (1.2, 9) NOTE 4
REAR WHEEL/BRAKE/SUSPENSION:
Rear axle nut 1 12 59 (6.0, 43) NOTE 3
Rear spoke 36 BC 3.2 3.2 (0.3, 2.3)
Driven sprocket UBS nut 4 8 32 (3.3, 24) NOTE 2
Driven sprocket stud bolt 4 8 20 (2.0, 14) NOTE 1
Rear brake arm nut 1 6 10 (1.0, 7) NOTE 3
Shock absorber upper mounting bolt 2 10 24 (2.4, 17)
Shock absorber lower mounting cap nut Swingarm pivot 2 10 24 (2.4, 17)
nut 1 10 39 (4.0, 29)
HYDRAULIC BRAKE:
Caliper bleed valve 1 8 5.4 (0.6, 4.0)
Caliper pad pin 1 10 17 (1.7, 12)
Caliper mounting bolt 2 8 30 (3.1, 22) NOTE 4
Brake hose oil bolt 2 10 34 (3.5, 25)
Master cylinder reservoir cover screw 2 4 1.5 (0.2, 1.1)
Front brake light switch screw 1 4 1.2 (0.1, 0.9)
Brake lever pivot bolt 1 6 1 (0.1, 0.7)
Brake lever pivot nut 1 6 5.9 (0.6, 4.4)
Caliper pin nut 1 8 22 (2.2, 16) NOTE 1
Pin bolt 1 8 17 (1.7, 12)
LIGHTS/METERS/SWITCHES
Key shutter socket bolt 1 6 10 (1.0, 7)
OTHERS:
Side stand pivot bolt 1 10 18 (1.8, 13)
Side stand pivot bolt/nut 1 10 44 (4.5, 33)
24-11
ANF125/M-5 ADDENDUM
TOOLS
NOTES: 1. Equivalent commercially available.
2. Alternative tool.
DESCRIPTION TOOL NUMBER REMARKS REF. SEC.

Fuel pressure gauge 07406 – 0040004 24
Fuel attachment joint 6-9 07ZAJ-S5A0150 24
Pressure gauge manifold 07ZAJ-S5A0111 24
Fuel attachment hose 6-9 07ZAJ-S5A0130 24
Fuel attachment hose 9-9 07ZAJ-S5A0120 24
DLC short connector 070PZ – ZY30100 22
Valve adjuster wrench 07708 – 0030400 3, 7
Wrench 8 x 9 mm 07708 – 0030100 3, 7
Spoke wrench, 4.5 x 5.1 mm 07701 – 0020200 3, 12, 13
Valve spring compressor 07757 – 0010000 7
Valve spring compressor attachment 07959 – KM30101 7
Valve guide driver 4.8 mm 07942 – MA60000 7
Valve guide reamer 5.0 mm 07984 – MA60001 7
Valve seat cutters
Seat cutter, 24 mm (45° IN) 07780 – 0010600 7
Seat cutter, 22 mm (45° EX) 07780 – 0010701 7
Flat cutter, 27 mm (32° IN) 07780 – 0013300 7
Flat cutter, 22 mm (32° EX) 07780 – 0012601 7
Interior cutter, 26 mm (60° IN) 07780 – 0014500 7
Interior cutter, 20.5 mm (60° EX) 07780 – 0014300 7
Cutter holder, 5.0 mm 07781 – 0010400 7
Lock nut wrench, 20 x 24 mm 07716 – 0020100 9
Extension bar 07716 – 0020500 9
Gear holder 07724 – 0010200 9
Universal holder 07725 – 0030000 9
Snap ring pliers 07914 – 3230001 9
Bearing remover set, 12 mm 07936 – 1660101 9, 11
— Bearing remover shaft, 12mm 07936 – 1660120 9, 11
— Bearing remover head, 12mm 07936 – 1660110 9, 11
Remover weight 07741 – 0010201 9, 11
Bearing remover shaft, 10 mm 07936 – GE00100 9
Bearing remover head, 10 mm 07936 – GE00200 9
Driver 07749 – 0010000 9, 11, 12, 13
Attachment, 28 x 30 mm 07946 – 1870100 9
Pilot, 10 mm 07746 – 0040100 9
Pilot, 12 mm 07746 – 0040200 9, 11, 12, 13
Flywheel holder 07725 – 0040000 9, 10
Flywheel puller, 28 mm 07933 – KG20000 10
Flywheel puller, 30 mm 07KMC – HE00100 10
Universal bearing puller 07631 – 0010000 11
Assembly set, 14 mm 07JMF – KW70100 11
Attachment, 22 x 24 mm 07746 – 0010800 11
Attachment, 32 x 35 mm 07746 – 0010100 11, 12, 13
Attachment, 37 x 40 mm 07746 – 0010200 11, 13
Attachment, 52 x 55 mm 07746 – 0010400 11, 12
Pilot, 17 mm 07746 – 0040400 11, 13
Pilot, 22 mm 07746 – 0041000 11
24-
ANF125/M-5 ADDENDUM
DESCRIPTION TOOL NUMBER REMARKS REF. SEC.
Inner driver, 35 mm 07746 – 0030400 12

Bearing remover shaft 07746 – 0050100 12
Bearing remover head, 12 mm 07746 – 0050300 12
Fork seal driver 07747 – 0010100 12
Fork seal driver attachment 07747 – 0010300 12
Steering stem socket 07916 – 3710101 12
Lock nut wrench 07916 – KM10000 12
Steering stem pin spanner 07702 – 0020001 12
Ball race remover, 40 mm 07953 – 4250002 12
Ball race remover, 34.5 mm 07948 – 4630100 12
Attachment, 45 x 50 mm 07946 – 6920100 12
Oil seal remover 07748 – 0010001 12
Snap ring pliers 07914 – SA50001 NOTE 2: 14
Peak voltage adaptor 07HGJ – 0020100 Imrie diagnostic 16
tester (model 625)
24-13
ANF125/M-5 ADDENDUM
LUBRICATION & SEAL POINTS

ENGINE
LOCATION MATERIAL REMARKS
Cylinder sleeve inner surface Honda 4-stroke oil or
Timing hole cap threads equivalent
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 Dripping (1.0-2.0 cm3)
IN/EX valve stem sliding surface
Camshaft cam surface
Cam chain surface
Cam set plunger whole surface
Cam decomp rotating surface Injecting (0.5-1.0 cm3)
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
Locking agent
4 mm (0.16 in)
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-
ANF125/M-5 ADDENDUM
ENGINE (Cont’d)
MATERIAL REMARKS
Left crankcase mating surface
Liquid sealant
Alternator grommet sealing surface

Alternator inner surface
Left crankcase shaft tapered area Degreasing
24-15
ANF125/M-5 ADDENDUM
FRAME LOCATION MATERIAL REMARKS

Steering head bearing sliding surface
Steering head dust seal lips Multi-purpose grease with
extreme pressure (example:
EXCELITE EP2 manufac-
tured by KYDO YUSHI,
Japan), Shell Alvania EP2
or equivalent
Front wheel dust seal lips Multi-purpose grease
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)
Throttle cable connecting area Silicone grease
Front disc brake lever pivot sliding surface About 0.1 cm3 (0.1 cc) Inject
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 fluid
Brake caliper piston sliding area DOT3 or DOT4
Brake caliper piston seal
Driven flange stud bolt threads Locking agent
Fork socket bolt threads
Brake caliper pin nut
Front brake disc bolt thread
Handle grip rubber inside Honda Bond A
Fork dust seal and oil seal lips Honda Ultra Cushion Oil
Fork bottom case inside No.10
Drive chain
Injector O-ring and seal ring SAE #80 or 90 gear oil
Drum brake cam dust seal Honda 4-stroke oil or
Drive sprocket nut equivalent
24-
ANF125/M-5 ADDENDUM
CABLE & HARNESS ROUTING
HEADLIGHT 3P CONNECTOR
TURN SIGNAL RELAY
LEFT HANDLEBAR
RIGHT HANDLEBAR
SWITCH WIRE
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
THROTTLE
CABLE
LEFT FRONT TURN
SIGNAL LIGHT (2P)
CONNECTOR
PULSE SECONDARY
AIR (PAIR) FILTER
FUEL FEED HOSE
AIR SUPPLY
HOSE
AIR INJECTION PIPE
EOT SENSOR WIRE
24-
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
PAIR CONTROL VALVE

REAR BRAKE LIGHT VACUUM TUBE
SWITCH WIRE
CRANKCASE
BREATHER TUBE
ANF125M :
STARTER MOTOR INJECTOR WIRE

CRANKCASE CABLE
BREATHER TUBE
SENSOR
UNIT WIRE
IGNITION COIL WIRE
SPARK PLUG
WIRE
REAR BRAKE LIGHT PAIR CONTROL VALVE

SWITCH WIRE VACUUM TUBE
GROUND CABLE
24-
ANF125/M-5 ADDENDUM
THROTTLE CABLE
EOT SENSOR WIRE
BANK ANGLE
SENSOR WIRE
FUEL FEED HOSE
ENGINE OIL TEMPERATURE SPEED SENSOR WIRE

AIR INJECTION PIPE (EOT) SENSOR
BATTERY POSITIVE CABLE

BATTERY NEGATIVE CABLE
MAIN FUSE
STARTER RELAY
SUB FUSE
(ANF125M only)
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-
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 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 **) may require more technical
information and tools. Consult your Honda dealer.
FREQUENCY ODOMETER READING (NOTE 1)

WHICHEVER REFER
COMES FIRST X1,000 mi 0.6 2.5 5 7.5
TO
X1,000 km 1 4 8 12 PAGE
ITEM MONTH 6 12 18
* FUEL LINE I I I 24-25
* THROTTLE OPERATION l l l 22-29
AIR CLEANER C C R 3-5
NOTE 2
CRANKCASE BREATHER C C C 3-5
NOTE 3
SPARK PLUG I R I 3-6
* VALVE CLEARANCE l I I I 3-7
ENGINE OIL R R R R 3-9
** ENGINE OIL STRAINER SCREEN C 3-10
** ENGINE OIL CENTRIFUGAL FILTER C 3-10
* ENGINE IDLE SPEED l I I I 24-25
* SECONDARY AIR SUPPLY SYSTEM l 3-12
NOTE 5
DRIVE CHAIN 3-13
BRAKE FLUID I I I 3-16
BRAKE SHOES/PADS WEAR I I I 3-17
BRAKE SYSTEM I I I I 3-17
* BRAKE LIGHT SWITCH I I I 3-18
* HEADLIGHT AIM I I I 3-19
SIDE STAND I I I 3-20
* SUSPENSION l I l 3-20
* NUTS, BOLTS, FASTENERS I I 3-21
** WHEELS/TIRES l I I I 3-21
** STEERING HEAD BEARINGS I I 3-22
* S h o u l d b e s e r v i c e d b y y o u r H o n d a d e a l e r, u n l e s s t h e o w n e r h a s p r o p e r t o o l s a n d s e r v i c e d a t a a n d i s
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-
ANF125/M-5 ADDENDUM
FUEL LINE FUEL FEED HOSE
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.
ENGINE IDLE SPEED IDLE ADJUSTING SCREW
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 min–1 (rpm)
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 sys-
tem.
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-
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)
24-27
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 opera-
tion.
• 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 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 reassem-
bly.
• Use a digital tester for PGM-FI system inspection.
• Refer to procedures for fuel level sensor inspection (page 24-77).
PGM-FI TROUBLESHOOTING
Engine won’t to start
• Intake air leak • Fuel supply too low
• Fuel contaminated/deteriorated – Faulty fuel supply system (page 24-54)
• Fuel supply too low – Clogged injector filter
– Faulty fuel pump operating system (page 24-58) • Ignition system malfunction (page 22-110, 24-74)
– Faulty fuel supply system (page 24-54)
– Clogged injector filter Poor performance (drive ability) and poor fuel economy
– Sticking injector needle • Air cleaner element contaminated
• Fuel supply too low
Engine stall, hard to start, rough idling – Faulty fuel supply system (page 24-54)
• Intake air leak – Clogged injector filter
• Fuel contaminated/deteriorated • Ignition system malfunction (page 22-110, 24-74)
• Fuel supply too high • Low cylinder compression
• Fuel supply too low
– Clogged injector filter
• Idle speed misadjusted
• Idle air passage clogged
• Low cylinder compression
Backfiring or misfiring during acceleration
24-28
ANF125/M-5 ADDENDUM
PGM-FI SYSTEM LOCATION
IGNITION SWITCH BANK ANGLE SENSOR
IGNITION SWITCH
INJECTOR FUEL PUMP
DATA LINK
CONNECTOR
SENSOR UNIT
(MAP, IAT, TP SENSORS)
IGNITION
PULSE GENERATOR REGULATOR/
ALTERNATOR RECTIFIER
EOT SENSOR ECM
GEAR POSITION
SWITCH
MAP SENSOR THROTTLE BODY
SENSOR
UNIT
IAT SENSOR
TP SENSOR
24-29
ANF125/M-5 ADDENDUM
PGM-FI SYSTEM DIAGRAM
(1) Ignition switch (12) Ignition coil

(2) Main fuse (15 A) (13) Intake air temperature sensor (IAT sensor)
(3) Sub fuse (10 A) (14) Throttle position sensor (TP sensor)
(4) Battery (15) Manifold absolute pressure sensor (MAP sensor)
(5) Regulator/rectifire (16) Injector
(6) Fuel meter (17) Spark plug
(7) Malfunction indicator lamp (MIL) (18) Gear (neutral) position switch
(8) Neutral position indicator (19) Ignition pulse generator
(9) Bank angle sensor (20) Engine oil temperature sensor (EOT sensor)
(10) Data Link Connector (DLC) (21) Alternator charging coil
(11) Fuel pump
24-30
ANF125/M-5 ADDENDUM
PGM-FI SELF-DIAGNOSIS INFOR- MALFUNCTION INDICATOR LAMP (MIL)

MATION
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 min–1 (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:
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 DATA LINK
(DLC). 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

If the ECM has no self diagnosis memory data, the MIL will illumi- MALFUNCTION INDICATOR LAMP (MIL)
nate, when you turn the ignition switch to “ON”.
Ignition switch to "ON"
MIL ON
OFF
If the ECM has self diagnosis memory data, the MIL will start blink-
ing 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. DATA LINK
CONNECTOR
1. Turn the ignition switch to “OFF”. (DLC)
2. Remove the front top cover (page 23-24).
Disconnect the connector cover from the data link connector

(DLC).
CONNECTOR COVER
3. Connect the special tool to the data link connector (DLC).
TOOL:
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 pat-
tern; see below).
DLC SHORT DLC SHORT

CONNECTOR 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. 2 – 3 sec.
MIL ON
OFF
FAILURE PATTERN RESET RECEIVING SUCCESSFUL PATTERN

PATTERN
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. 2 – 3 sec.
MIL ON
OFF
FAILURE PATTERN RESET RECEIVING UNSUCCESSFUL PATTERN

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).
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 Detection Item Causes Symptoms Refer to

No blinks Ignition pulse gen- • Faulty ignition pulse generator • Engine does not start 24-74
erator malfunction
Injector malfunction
No blinks • Clogged injector filter • Engine does not start —
ECM malfunction
• Sticking injector needle
ECM power/ground
No blinks • Faulty ECM • Engine does not start —
circuit malfunction
No blinks • Blown main-fuse (15 A) • Engine does not start 24-36
• Open circuit at the power input wire of
MIL circuit malfunc-
the ECM
tion
• Faulty ignition switch
Data link or MIL
No blinks • Faulty ECM • Engine operates normally —
circuit malfunction
• Open or short circuit in MIL wire
Stay lit • Short circuit in data link connector • Engine operates normally —
(DLC) wire
• Short circuit in Malfunction Indicator
Lamp (MIL) wire
Sensor unit power/
• Faulty ECM
ground circuit mal-
function
1, 8, 9 all • Loose or poor contact on sensor • Engine does not start 24-38
MAP sensor circuit
Blinks • Open or short circuit in sensor unit
malfunction
power/ground wire
• Faulty sensor unit
1 Blink • Loose or poor contact on sensor unit • Engine operates normally 24-40
EOT sensor circuit
• Open or short circuit in MAP sensor
malfunction
wire of the sensor unit
• Faulty MAP sensor
• Loose or poor contact on EOT sensor
TP sensor circuit
7 Blinks • Open or short circuit in EOT sensor wire • Hard start at a low temperature 24-42
malfunction
• Faulty EOT sensor
• Loose or poor contact on sensor unit
• Open or short circuit in TP sensor wire
of the sensor unit • Poor engine response and
IAT sensor circuit
8 Blinks • Faulty TP sensor performance when operating the 24-45
malfunction
• Loose or poor contact on sensor unit throttle quickly
• Open or short circuit in IAT sensor wire
of the sensor unit
• Faulty IAT sensor • Engine operates normally
Injector circuit mal-
9 Blinks • Loose or poor contact on injector con- 24-47
function
nector
• Open or short circuit in injector wire
• Faulty injector
• Engine does not start
12 Blinks 24-49
24-34
ANF125/M-5 ADDENDUM
MIL Detection Item Causes Symptoms Refer to

33 Blinks E -PROM in ECM
2 • Faulty ECM • Engine operates normally 24-51
malfunction • Does not hold the self-diagnosis
data
54 Blinks Bank angle sensor • Loose or poor contact on bank angle • Engine operates normally 24-52
malfunction sensor • Engine does not start
• Open or short circuit in bank angle sen-
sor wire
• Faulty bank angle sensor
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 sup-
ply.
• 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)
Disconnect the ECM 33P connector.

Check for loose or poor connect on the ECM 33P
connector.
ECM 33P CONNECTOR
Engine starts
Connect the ECM 33P connector. • Loose or poor contact on the ECM connector
Start the engine.
ECM 33P CONNECTOR
Engine dose not start
24-36
ANF125/M-5 ADDENDUM
Abnormal
Disconnect the ECM 33P connector. • Open circuit in Green wire
Check for continuity between the ECM connector of
ECM 33P CONNECTOR
CONNECTION: Green — Ground

Green/Black — Ground
STANDARD: Continuity
Normal
Out of range
Turn the ignition switch to “ON” and measure the bat- • Loose or poor connector contact
tery voltage between the ECM connector of the wire • Inspect the ignition switch (page 18-10)
• Blown main-fuse (15A)
• Open or short circuit in following wire harness:
ECM 33P CONNECTOR — 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.
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
No blink
Connect the sensor unit 5P connector and ECM 33P
connector. • Loose or poor contact on the sensor unit 5P connec-
Turn the ignition switch to “ON”. tor and/or ECM 33P connector
Check the MIL blinks.
SENSOR UNIT 5P
CONNECTOR
ECM 33P
CONNECTOR
1, 8, 9 blinks
24-38
ANF125/M-5 ADDENDUM
Disconnect the sensor unit 5P connector. Voltage exist

Turn the ignition switch to "ON". • Replace the sensor unit with a new one and inspect
Measure the voltage between the sensor unit 5P con-
nector terminals at the wire harness side.
SENSOR UNIT 5P CONNECTOR
CONNECTION:
Yellow/Red (+) – Green/Orange (–)
STANDARD: 4.75 – 5.25 V
Out of range
Abnormal
Check for continuity between the ECM 33P connector • Open circuit in Yellow/Red or Green/Orange wire
and sensor unit 5P connector at the wire harness side. • Short circuit in Yellow/Red wire
ECM 33P CONNECTOR
CONNECTION:
Yellow/Red – Yellow/Red
Green/Orange – Green/Orange
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)
1, 8, 9 all blinks
Reset the self diagnosis memory data (page 24-32). • Go to SENSOR UNIT POWER/GROUND CIR-
Turn the ignition switch to "ON". CUIT INSPECTION (page 24-38)
1 blink
Voltage exist
Disconnect the sensor unit 5P connector.
• Replace the sensor unit with a new one and inspect
Turn the ignition switch to "ON".
again (Faulty MAP sensor)
nector at the wire harness side and ground.
CONNECTION:
Light green/Yellow (+) – Ground (–)
STANDARD: 3.8 – 5.25 V
Out of range
(To page 24-41)
24-40
ANF125/M-5 ADDENDUM
Abnormal
• Open circuit in Light green/Yellow wire
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.
ECM 33P CONNECTOR
CONNECTION:
Light green/Yellow – Light green/Yellow
CONNECTION:
Light green/Yellow – Ground
Normal
24-41
ANF125/M-5 ADDENDUM
PGM-FI MIL 7 BLINKS (EOT SENSOR)

Disconnect the EOT 2P sensor connector.

Check for loose or poor contact on the EOT sensor
EOT SENSOR
2P CONNECTOR
Connect the EOT sensor 2P connector. No blink

Turn the ignition switch to “ON”. • Loose or poor contact on the EOT sensor connector
EOT SENSOR 2P CONNECTOR
44 blinks
Abnormal
Disconnect the EOT sensor 2P connector.
Measure the resistance at the EOT sensor terminals. • Inspect the EOT sensor (page 24-71)
EOT SENSOR
STANDARD: 2.5 – 2.8 kΩ (20°C/68°F)
Normal
24-42
ANF125/M-5 ADDENDUM
Check for continuity between the EOT sensor terminal Abnormal

and ground. • Faulty EOT sensor
EOT SENSOR
Normal
Measure the voltage between the EOT sensor connector Out of range
at the wire harness side. Normal • 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
(To page 24-44)
24-43
ANF125/M-5 ADDENDUM
(From page 24-43)
Abnormal
• Open or short circuit in Yellow/Blue wire
Check for continuity between the ECM 33P connec-
• Open or short circuit in Green/Orange wire
tor and EOT sensor 2P connector at the wire harness
side.
Check for no continuity between the EOT sensor 2P
ECM 33P CONNECTOR

CONNECTION:
Yellow/Blue – Yellow/Blue
CONNECTION:
Green/Orange – Ground
Yellow/Blue – Ground
Normal
24-44
ANF125/M-5 ADDENDUM
PGM-FI MIL 8 BLINKS (TP SENSOR)

1, 8, 9 all blinks
8 blinks
Voltage exist
CONNECTION: Yellow (+) – Ground (–)

STANDARD: 0 – 220 mV
Out of range
24-45
ANF125/M-5 ADDENDUM
Abnormal
• Open circuit in Yellow wire
ECM 33P CONNECTOR
CONNECTION:Yellow – Yellow
CONNECTION: Yellow – Ground
Normal
24-46
ANF125/M-5 ADDENDUM
PGM-FI MIL 9 BLINKS (IAT SENSOR)

1, 8, 9 all blinks
Turn the ignition switch to "ON". CUIT INSPECTION (page 24-38)
9 blinks
Voltage exist
again (Faulty IAT sensor)
CONNECTION:
Gray/Blue (+) – Ground (–)
STANDARD: 4.75 – 5.25 V
Out of range
(To page 24-48)
24-47
ANF125/M-5 ADDENDUM
(From page 24-47)
Abnormal
• Open circuit in Gray/Blue wire
• Short circuit in Gray/Blue wire
ECM 33P CONNECTOR
CONNECTION: Gray/Blue – Gray/Blue

CONNECTION:Gray/Blue – Ground
Normal
24-48
ANF125/M-5 ADDENDUM
PGM-FI MIL 12 BLINKS (INJECTOR)

Disconnect the injector 2P connector.

Check for loose or poor contact on the injector 2P
connector.
INJECTOR 2P CONNECTOR
No blink
Connect the injector 2P connector.
Turn the ignition switch to “ON”. • Loose or poor contact on the injector connector
12 blinks
(To page 24-50)
24-49
ANF125/M-5 ADDENDUM
(From page 24-49)
Out of range
Disconnect the injector 2P connector.
• Open or short circuit in Black/Blue wire
Turn the ignition switch to”ON”.
Measure the battery voltage between the injector con-
CONNECTION: Black/Blue (+) – Ground (–)

STANDARD: Battery voltage – 1.1 V minimum
Voltage exist
Abnormal
Check for continuity between the injector connector • Open or short circuit in Pink/Green wire
and ECM connector at the wire harness side.
Check for no continuity between the injector 2P con-
ECM 33P CONNECTOR
CONNECTION: Pink/Green – Pink/Green
CONNECTION: Pink/Green – Ground
Normal
24-50
ANF125/M-5 ADDENDUM
Abnormal
Measure the resistance at the injector terminals. • Faulty injector
INJECTOR
STANDARD: 10.2 – 11.4 Ω (20°C/68°F)
Normal
PGM-FI MIL 33 BLINKS (E2-PROM)
Reset the self-diagnosis memory No blink

data (page 24-32). • Intermittent failure
Check that the MIL blinks.
33 blinks
24-51
ANF125/M-5 ADDENDUM
PGM-FI MIL 54 BLINKS (BANK ANGLE SENSOR)

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. No blink

Turn the ignition switch to “ON”. • Loose or poor contact on the bank angle sensor 3P
Check the MIL blinks. connector
BANK ANGLE SENSOR

3P CONNECTOR
54 blinks
24-52
ANF125/M-5 ADDENDUM
Abnormal
• Open or short circuit in Green/Orange wire
Check for continuity between the bank angle sensor
• Open or short circuit in Yellow/Red wire
3P connector and ECM 33P connector at the wire
• Open or short circuit in Red/Blue wire
harness side.
Check for continuity between the bank angle sensor 3P
BANK ANGLE SENSOR

3P CONNECTOR
ECM 33P CONNECTOR
CONNECTION:
Yellow/Red – Yellow/Red
Red/Blue– Red/Blue
CONNECTION:
Yellow/Red – Ground
Red/Blue– Ground
Normal
Voltage exist
• Replace the bank angle sensor with a new one and
inspect again
Measure the voltage between the bank angle sensor 3P
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 TANK MOUNTING BOLT
FUEL PRESSURE RELIEVING/QUICK CON-

NECT 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 PUMP COVER SPECIAL SCREWS
— Fuel tank mounting bolt
— Fuel pump cover
Disconnect the fuel pump 5P (Black) connector.

FUEL PUMP 5P (BLACK) CONNECTOR
Start the engine, and let it idle until the engine stalls.
Disconnect the battery negative cable and then positive cable.
Check the fuel quick connect fitting for dirt, and clean if necessary.
SHOP TOWEL
Place a shop towel over the quick connect fitting.
FUEL CONNECT FITTING
Pull away the rubber.

RETAINER TABS
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. RUBBER
• 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 LOCKING PAWLS
down, and alternately pull and push the connector until it comes
CONNECTOR
of easily.
24-54
ANF125/M-5 ADDENDUM
To prevent damage and keep foreign matter out, cover the discon-
nected connector and pipe end with the plastic bags. PLASTIC BAGS PIPE
CONNECTOR
QUICK CONNECT FITTING INSTALLATION

CONNECTOR
NOTE:
• Always replace the retainer of the quick connect fitting when the
fuel feed hose is disconnected. HOOKS
• 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.

HOLES
Insert a new retainer into the connector joint with aligning the two
hooks of the retainer with the two holes on the connector joint. RETAINER
NOTE:
FUEL PUMP SIDE:
Do not bent or twist the fuel feed hose.
LOCKING PAWLS
Clean around the pipe.
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:
INJECTOR SIDE:
When connecting the quick connect fitting to the injector side
fuel feed pipe, align the tabs between the connector damper and
retainer. TABS
CONNECTOR RETAINER TABS

DAMPER
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.
Install the fuel pump cover.

Install and tighten the two special screws to the specified torque. FUEL TANK MOUNTING BOLT
TORQUE: 4.2 N•m (0.4 kgf•m, 3 lbf•ft)
Install and tighten the fuel tank mounting bolt securely.
Install the following:

FUEL PUMP COVER SPECIAL SCREWS
24-56
ANF125/M-5 ADDENDUM
FUEL PRESSURE TEST

PRESSURE
Relieve the fuel pressure and disconnect the quick connect fitting GAUGE
(page 24-54).
FUEL JOINT 6-9
Attach the fuel pressure gauge set and pressure gauge.
TOOLS: FUEL HOSE 9-9

Fuel pressure gauge 07406-0040004
Pressure gauge manifold 07ZAJ-S5A0111 FUEL
Fuel attachment hose 6-9 07ZAJ-S5A0130 HOSE
Fuel attachment hose 9-9 07ZAJ-S5A0120 6-9
Fuel attachment joint 6-9 07ZAJ-S5A0150
MANIFOLD
Temporally connect the positive cable and negative cable to the
battery.
Start the engine and let it idle.
Read the fuel pressure.

FUEL PRESSURE: 294 kPa (3.0 kgf/cm2, 43 psi)
If the fuel pressure is higher than specified, replace 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 07ZAL-S5A0130
NOTE:
Wipe off spilled out gasoline. FUEL ATTACHMENT
HOSE 6-9
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)
24-57
ANF125/M-5 ADDENDUM
FUEL PUMP FUEL PUMP 5P (BLACK) CONNECTOR
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:
Remove the body cover (page 23-27).

Remove the fuel pump cover (page 24-54).
Turn the ignition switch to “ON” and measure the voltage between
the terminals. FUEL PUMP 5P (BLACK) CONNECTOR
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)
REMOVAL
CLAMP FUEL PUMP WIRE
NOTE:
It is impossible to disassemble the fuel pump after removing it.
Clean around the fule pump.
(page 24-54).

Remove the fuel pump wire from the clamp.
Remove the fuel pump mounting nuts and clamp.

CLAMP
NUTS
24-58
ANF125/M-5 ADDENDUM
NOTE:
SET PLATE
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.
FUEL PUMP UNIT PACKING
INSPECTION
FUEL PUMP UNIT
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
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. SET PLATE
Install the set plate/fuel pump unit assembly to the fuel tank.
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 N•m (1.2 kgf•m, 9 lbf•ft) CLAMP
NUTS
Connect the fuel pump 5P (Black) connector.

Clamp the fuel pump wire. CLAMP FUEL PUMP WIRE
FUEL PUMPFUEL PUMP 5P (BLACK) CONNECTOR

4P CONNECTOR
FUEL TANK BOLTS
REMOVAL/INSTALLATION
(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). 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).

Relieve the fuel pressure (page 24-54).
Disconnect the following:

— Spark plug cap CRANKCASE BREATHER TUBE SCREW
— Crankcase breather tube
— Pair control valve vacuum tube
— Injector 2P connector
— Sensor unit 5P connector
Loosen the air cleaner connecting hose band 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. ADJUSTING NUT QUICK CONNECT FITTING
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: LOCK
Seal the cylinder head intake port with a shop towel or cover it with NUT
a piece of tape to prevent any foreign material from dropping into
the engine.
THROTTLE CABLE BOLTS
Remove the O-ring.

Loosen the band screw and remove the intake manifold from the SCREW
throttle body.
INTAKE MANIFOLD O-RING
24-61
ANF125/M-5 ADDENDUM
DISASSEMBLY
WHITE PAINTED
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.
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.
O-RING
— Idle adjusting screw
— O-ring
— Spring
SPRING
IDLE ADJUSTING SCREW
Remove the injector (page 24-69).

Remove the three torx screws and sensor unit from the throttle SENSOR UNIT
body.
O-RING
Remove the O-ring.
TORX SCREWS
Blow open each air passage in the throttle body with the compressed
air. T H R O T-
TLE
NOTE:
Do not use high pressure air or bring the nozzle too close to the
throttle body.
24-62
ANF125/M-5 ADDENDUM
ASSEMBLY
BOLT
IDLE ADJUSTING
5.1 N•m (0.5 kgf•m, 3.8 lbf•ft)
SCREW
O-RING
FUEL FEED PIPE
SPRING
O-RING
TORX SCREW INJECTOR

3.4 N•m (0.3 kgf•m,
2.5 lbf•ft)
SEAL RING
SENSOR UNIT
THROTTLE CABLE BRACKET
O-RING
T H R O T T L E SCREW
3.4 N•m (0.3 kgf•m, 2.5 lbf•ft)
NOTE:
THROTTLE BODY SENSOR UNIT
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.
NOTE: O-RING
The light pressure is sufficient to assemble the sensor unit and throttle CLIP OF THE
body in their correctly position. If you cannot set it easily, the clip BOSS OF THE THROTTLE VALVE TP SENSOR
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 N•m (0.3 kgf•m, 2.5 lbf•ft) SENSOR UNIT
Install the injector (page 24-69).
TORX SCREWS
24-63
ANF125/M-5 ADDENDUM

— 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 adjust-
ing screw is tightened against the seat.
Turn the idle adjusting screw out to its original position as noted SPRING
during removal. IDLE ADJUSTING SCREW
INSTALLATION
INTAKE MANIFOLD
NOTE: SCREW
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.
Align
O-RING
Tighten the intake manifold band screw so that the band ends clear-
ance 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 mani-
fold mounting bolts to the specified torque. ADJUSTING NUT QUICK CONNECT FITTING
TORQUE: 12 N•m (1.2 kgf•m, 9 lbf•ft)
Connect the throttle cable to the throttle drum and throttle cable
bracket, then adjust the throttle grip free play (page 22-29). LOCK
NUT
Tighten the air cleaner connecting hose band screw.
Connect the following:

— Sensor unit 5P connector THROTTLE CABLE BOLTS
— Injector 2P connector
— PAIR control valve vacuum tube
— Crankcase breather tube
— Spark plug cap
CRANKCASE BREATHER TUBE SCREW
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).

— Main pipe side cover (page 23-25)
PAIR CONTROL VALVE

VACUUM TUBE CONNECTORS
THROTTLE POSITION (TP) SENSOR RESET

PROCEDURE
1. Turn the ignition switch to “OFF”.
DATA LINK
CONNECTOR
2. Disconnect the connector cover from the data link connector
(DLC)
(DLC).
CONNECTOR COVER
3. Connect the special tool to the Data Link Connector (DLC).
TOOL:
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
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 24-67) for 10 seconds.
EOT SENSOR 2P
JUMPER WIRE 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. 0.3 sec.
0.1 sec. 0.3 sec.
MIL ON
1.2 sec.
OFF
RESET RECEIVING PATTERN SUCCESSFUL 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
1.2 sec.
OFF
RESET RECEIVING PATTERN UNSUCCESSFUL 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.
8. Disconnect the DLC short connector from the data link connector
(DLC).
TOOL:
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. IDLE ADJUSTING SCREW
Warm up the engine for about ten minutes.
Connect a tachometer.
Check the engine idle speed.
If the engine idle speed is out of specification, 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).
24-68
ANF125/M-5 ADDENDUM
ECM (ENGINE CONTROL MOD-

ULE)
RUBBER HOLDER
Remove the rubber holder and ECM.
Installation is in the reverse order of removal.
ECM 33P CONNECTOR ECM
INJECTOR BOLTS
REMOVAL
Remove the throttle body/sensor unit (page 24-61).
Remove the two bolts and injector assembly from the throttle
body.
INJECTOR ASSEMBLY
Remove the fuel feed pipe, O-ring and seal ring from the injector.
FUEL FEED PIPE
Check the removed parts for wear or damage and replace them 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. O-RING
• Be careful not to damage the O-ring and seal ring.
SEAL RING INJECTOR
Install a new O-ring and new seal ring to the injector.
Install the injector to the fuel feed pipe as shown.

INJECTOR
TAB
STOPPER
FUEL FEED PIPE
24-69
ANF125/M-5 ADDENDUM
NOTE:
Check that the location of the injector connector is between the stop- STOPPER INJECTOR
per of the fuel feed pipe and throttle body. CONNECTOR
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 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 3P CONNECTOR
— Utility box (page 22-25)

Remove the two mounting screws and bank angle sensor.
BANK ANGLE SENSOR SCREWS
Install the bank angle sensor with its “UP” mark facing up.
Install and tighten the mounting screws to the specified torque.

3P CONNECTOR
TORQUE: 1.2 N•m (0.1 kgf•m, 0.9 lbf•ft)
Connect the bank angle sensor 3P connector.

— Utility box (page 22-25)
BANK ANGLE SENSOR SCREWS
24-70
ANF125/M-5 ADDENDUM
EOT (ENGINE OIL TEMPERA- EOT SENSOR/SEALING WASHER

TURE) SENSOR
REMOVAL
Drain the engine oil (page 3-9).
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 heating ele-
ment.
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.
20°C (68°F) 100°C (212°F)

RESISTANCE 2.5 — 2.8 kΩ 0.16 — 0.27 kΩ
If the resistance is out of specification at any temperature listed, EOT SENSOR
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. SEALING WASHER
EOT SENSOR
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).
24-71
ANF125/M-5 ADDENDUM
24-72
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). Incorrect

• Faulty battery
Check the battery condition using the recom-mended
battery tester.
RECOMMENDED BATTERY TESTER:

BM–210 or BATTERY MATE or equivalent
Correct
Incorrect
Install the battery (page 15-4). Disconnect the regulator/rectifier 6P connector and
Check the battery current leakage (Leak test: page recheck the battery current leakage.
15-7).
SPECIFIED CURRENT LEAKAGE: 0.1 mA max

Incorrect Correct
Correct
Measure and record the battery voltage using a digital • Shorted wire harness • Faulty regulator/recti-
multimeter (page 15-4). • Faulty ignition switch fier
Start the engine.
Measure the charging voltage (page 16-6).
Compare the measurements to result of the following
calculation.
STANDARD: Correct
• Faulty battery
Measured BV < Measured CV < 15.5 V
• BV=Battery Voltage
• CV=Charging Voltage
Incorrect
Incorrect
Check the alternator charging coil (page 22-104). • Faulty charging coil
STANDARD: 0.2 – 1.0 Ω (20°C/68°F)
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 EOT SENSOR ALTERNATOR
GENERATOR
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
REGULATOR/RECTIFIER
STARTER
RELAY
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
FRONT BRAKE
TURN SIGNAL LIGHT SWITCH
SWITCH IGNITION
SWITCH
RIGHT REAR
TURN SIGNAL LIGHT
RIGHT FRONT BRAKE/TAIL
TURN SIGNAL LIGHT LIGHT
FUEL LEVEL
SENSOR
HORN SWITCH
LEFT FRONT
TURN SIGNAL
LIGHT
FUSES
HORN LEFT REAR
15A, 10A
BATTERY TURN SIGNAL
LIGHT
ECM
REAR BRAKE LIGHT
SWITCH
24-76
ANF125/M-5 ADDENDUM
FUEL METER/FUEL LEVEL SEN- FUEL PUMP 5P (BLACK)

SOR CONNECTOR
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 fuel pump cover (page 24-54). FUEL METER

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 Yel-
low/White wire. FUEL PUMP 5P (BLACK)
CONNECTOR
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.
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.
If the wires are normal, check the fuel level sensor (see below).
FUEL PUMP
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 EMPTY
If the fuel level sensor is normal, replace the meter panel with a new
one, and recheck.
24-77
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 Abnormal • Faulty the battery
system • Faulty the charging system
Normal
2. Check the PGM-FI Abnormal • Faulty ECM

system
Normal
3. Check for operating Sound not heard • Loose or disconnected fuel pump connector
sound of the fuel pump • Broken or shorted fuel pump wire
• Faulty fuel pump
Sound heard
4. Inspect the fuel pressure and Abnormal • Faulty fuel pump

fuel flow • Faulty ECM
Normal
5. Perform a spark test Weak or no spark • Faulty spark plug

• Fouled spark plug
• Broken or shorted spark plug wire
Good spark • Faulty ignition pulse generator
• Loose or disconnected ignition system wires
6. Test cylinder compression Low compression • Valve stuck open

• Worn cylinder and piston ring
• Damaged cylinder head gasket
Compression normal • Seized valve
• Improper valve timing
7. Starting following normal Engine starts but • Intake manifold leaking

procedure stops • Improper ignition timing (Faulty ignition pulse genera-
tor)
• Fuel contaminated
Engine does not start
24-81
ANF125/M-5 ADDENDUM
Wet plug • Clogged air cleaner

• Faulty ECM
Dry plug • Faulty injector
ENGINE LACKS POWER Possible cause
Wheels do not spin • Brake dragging

1. Raise wheel off the ground and
freely • Worn or damaged wheel bearing
Wheel spins freely
Pressure low • Faulty tire valve

• Punctured tire
Pressure normal
Engine speed doesn't • Clutch slipping

3. Accelerate rapidly from low to
change accordingly when • Worn clutch discs/plates
gear is changed • Warped clutch discs/plates
Engine speed reduced when • Weak clutch spring
gear is changed • Additive in engine oil
Engine speed does • Air cleaner dirty

not increase • Restricted fuel flow
Engine speed increase • Clogged muffler
• Pinched fuel tank breather
Incorrect • Faulty ECM

• Faulty ignition pulse generator
Correct
Incorrect • Valve stuck open

• Worn cylinder and piston rings
Normal • Leaking head gasket
• Improper valve timing
Abnormal • Faulty fuel pump

7. Inspect fuel pressure and fuel
• Faulty ECM
Normal
Fouled or discolored • Faulty spark plug
Not fouled or discolored
24-82
ANF125/M-5 ADDENDUM
Incorrect • Oil level too high

• Oil level too low
Correct • Contaminated oil
Valve train not lubricated • Clogged oil passage

10. Remove the valve adjuster hole cap
properly • Clogged oil control orifice
Valve train lubricated properly
Overheating • Excessive carbon build-up in combustion chamber

• Use of poor quality fuel
Not overheating • Wrong type of fuel
• Clutch slipping
Engine knocks • Worn piston and cylinder

• Wrong type of fuel
• Excessive carbon build-up in combustion chamber
• Ignition timing to advanced (faulty ECM)
Engine does not knock • Lean fuel mixture (faulty injector)
POOR PERFORMANCE AT LOW AND IDLE SPEED

Possible cause
Incorrect • Improper ignition timing

(Faulty ignition pulse generator)
Correct

2. Inspect the fuel pressure and fuel
• Faulty ECM
Normal
Leaking • Loose intake manifold band or mounting bolts

3. Check for leaks in the intake manifold
• Damaged intake manifold
Not leak
24-83
ANF125/M-5 ADDENDUM
Weak or intermittent spark • Faulty spark plug

• Faulty carbon or wet fouled spark plug
• Faulty ECM
• Faulty ignition coil
• Broken or shorted spark plug wire
Good spark • Faulty ignition pulse generator
• Faulty ignition switch
• Loose or disconnected ignition system wires
• Faulty injector
POOR PERFORMANCE AT HIGH SPEED

Possible cause
Incorrect • Faulty ECM
Correct

2. Inspect the fuel pressure and fuel
• Faulty ECM
Normal
Incorrect • Camshaft not installed properly
Correct
Weak • Faulty valve spring
Not weak
• Faulty injector
24-84

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ANF125/M-5 ADDENDUM

FRAME SERIAL NUMBER ENGINE SERIAL NUMBER

FRAME NUMBER ENGINE NUMBER

THROTTLE BODY IDENTIFICATION NUMBER

THROTTLE BODY IDENTIFICATION NUMBER

FUEL SYSTEM (Programmed Fuel Injection)

Clutch brake lining thickness 3.35 (0.132) 2.5 (0.10)

Headlight (Hi/low beam) 12 V – 18/18W x 2

5 mm hex bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)

• Torque speciﬁcations listed below are for important fasteners.

NOTES: 1. Apply a locking agent to the threads.

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)

FRAME THREAD TORQUE

FRAME/BODY PANELS/EXHAUST SYSTEM:

DESCRIPTION TOOL NUMBER REMARKS REF. SEC.

DESCRIPTION TOOL NUMBER REMARKS REF. SEC.

Inner driver, 35 mm 07746 – 0030400 12

LUBRICATION & SEAL POINTS

1.6 mm (0.06 in)

Alternator grommet sealing surface

FRAME LOCATION MATERIAL REMARKS

CABLE & HARNESS ROUTING

FRONT BRAKE LIGHT

FRONT BRAKE HOSE

IGNITION SWICH WIRE

FRONT BRAKE HOSE

FUEL FEED HOSE

AIR INJECTION PIPE

EOT SENSOR WIRE

MAIN WIRE HARNESS

RIGHT FRONT TURN SIGNAL

FRONT BRAKE HOSE

IGNITION COIL WIRE

PAIR CONTROL VALVE

STARTER MOTOR INJECTOR WIRE

REAR BRAKE LIGHT PAIR CONTROL VALVE

ENGINE OIL TEMPERATURE SPEED SENSOR WIRE

BATTERY POSITIVE CABLE

FUEL FEED HOSE

FUEL PUMP WIRE

ENGINE CONTROL MODULE

FREQUENCY ODOMETER READING (NOTE 1)

FUEL LINE FUEL FEED HOSE

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.

ENGINE IDLE SPEED IDLE ADJUSTING SCREW

Warm up the engine for about ten minutes.

IDLE SPEED: 1,400 ± 100 min–1 (rpm)

FUEL SUCTION FILTER

FUEL FEED HOSE

FUEL SYSTEM COMPONENT LOCATION