Honda Crf250l Service Manual

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PGM-FI SYSTEM
2. Bank Angle Sensor Signal Line Short CircuitInspection
Turn the ignition switch OFF.
Disconnect the ECM 33P (Black) connector (page
4-50).
Check for continuity between the bank angle sensor
2P connector [1] of the wire side and ground.
Is there continuity?
YES – Short circuit in Red/blue wire
NO – GO TO STEP 3.
3. Bank Angle Sensor Signal Line Open Circuit Inspection
Turn the ignition switch OFF.
Check for continuity between the bank angle sensor
2P connector [1] and ECM 33P (Black) connector
[2] of the wire side.
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in Red/blue wire
4. Bank Angle Sensor Inspection Replace the bank angle sensor with a known good
one (page 4-48).
Connect the bank angle sensor 2P connector and
ECM 33P (Black) connector.
Erase the DTC’s (page 4-5).
Turn the ignition switch ON and engine stop switch
.
Check if the MIL blinks.
Does the MIL blink 54 times?
YES – Replace the ECM with a known good one,
and recheck.
NO – Faulty original the bank angle sensor.
Connection: Red/blue – Ground
R/Bu
[1]
Connection: Red/blue – Red/blue
TOOL:
Test probe 07ZAJ-RDJA110
R/Bu
[2]
R/Bu[1] 
						

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PGM-FI SYSTEM
MIL CIRCUIT TROUBLESHOOTING
Before starting the inspection, check the speedometer
power input line (page 20-6).
With The Ignition Switch ON, The MIL 
Does Not Come On
If the engine can be started but the MIL does not come
on when the ignition switch is turned ON and engine
stop switch  , check as follows:
Turn the ignition switch OFF.
Disconnect the ECM 33P (Black) connector (page 4-
50).
Ground the following terminal of the wire harness side
ECM 33P (Black) connector [1] with a jumper wire [2].
Turn the ignition switch ON and engine stop switch  
the MIL should come on.
– If the MIL comes on, repl ace the ECM with a known
good one and recheck the MIL indication.
– If the MIL does not come on, check for open circuit in the White/blue wire between the speedometer
and ECM 33P (Black) connector.
If the wire is OK, replace the speedometer.
With The Ignition Switch ON, The MIL 
Does Not Go Off Within A Few 
Seconds (Engine starts)
Turn the ignition switch OFF.
Disconnect the ECM 33P (Black) connector (page 4-
50).
Turn the ignition switch ON and engine stop switch  .
– If the MIL comes on, check for short circuit in theWhite/blue wire between  the speedometer and
ECM.
If the White/blue wire is  OK, replace the ECM with a
known good one and recheck.
– If the MIL turns off, check the following.
Check the continuity between the ECM 33P (Black)
connector [1] of the wire side and ground.
If there is continuity, check for short circuit in the Blue
wire between the DLC and ECM.
If there is no continuity, replace the ECM with a known
good one and recheck. CONNECTION: White/ blue – Ground
TOOL:
Test probe 07ZAJ-RDJA110
W/Bu
[1]
[2]
CONNECTION: Blue – Ground
STANDARD: No continuity
TOOL:
Test probe 07ZAJ-RDJA110
Bu
[1] 
						

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PGM-FI SYSTEM
SENSOR UNIT
REMOVAL/INSTALLATION
Remove the left fuel tank shroud (page 2-4).
Disconnect the sensor unit 5P connector [1].
Remove the torx screws [2] and sensor unit [3] from the
throttle body.
Remove the O-ring [1].
Install a new O-ring to the throttle body properly.
If the O-ring is not installed properly, the idle air will leak
and engine idle speed will be unstable.
Install the sensor unit [2] to the throttle body by aligning
the following:
– Clip of the TP sensor with the boss of the throttle
valve
– IAT sensor of the sensor unit with the hole of the throttle body
Install and tighten the sensor unit torx screws [1] to the
specified torque.
Connect the sensor unit 5P connector [2].
Install the left fuel tank shroud (page 2-4).
Perform the TP sensor reset procedure (page 4-45).
[2]
[1]
[3]
[2]
[1]Align
Align
TORQUE: 3.4 N·m (0.3  kgf·m, 2.5 lbf·ft)
[1]
[2] 
						

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PGM-FI SYSTEM
TP SENSOR RE SET PROCEDURE
If the sensor unit is removed, reset the throttle valve
fully closed position as following.
1. Erase the DTC (page 4-5).
2. Turn the ignition switch OFF.
3. Remove the dummy connector.
4. Short the DLC [1] using the special tool.
5. Disconnect the ECT sensor 3P connector [1].
Short the ECT sensor 3P connector terminals of the
wire harness side with a jumper wire [2].
6. Turn the ignition switch ON and engine stop switch  , then MIL will start blinking.
Disconnect the jumper wir e while the MIL blinking
(within 10 seconds).
7. After disconnection of the jumper wire, the MIL will start short blinking.
Check if the MIL blinks.
8. Turn the ignition switch OFF.
9. Connect the ECT sensor 3P connector.
10.Install the dummy connector to the DLC. TOOL:
[2] SCS connecto
r 070PZ-ZY30100
[1]
[2]
Connection: Yellow/blue – Green/white
[1]
[2]
If the MIL begins short blink (0.3 seconds), the TP sensor is reset successfully.
If the MIL remains ON, the TP sensor is not reset, repeat the reset procedure from step 1.
MIL ON
MIL OFF
0.1 sec.
1.2 sec.
within 10 sec.0.3 sec.
0.3 sec.
RESET RECEIVING PATTERNSUCCESSFUL PATTERN 
						

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PGM-FI SYSTEM
ECT SENSOR
REMOVAL/INSTALLATION
Drain the coolant (page 9-5).
Disconnect the ECT sensor 3P connector [1].
Remove the ECT sensor [2] and sealing washer [3].
Installation is in the reverse order of removal.
 • Replace the sealing washer with a new one.
Fill the cooling system with recommended coolant
(page 9-5).
INSPECTION
Remove the ECT sensor [1] (page 4-46).
Heat the coolant with an electric heating element.
Suspend the ECT sensor in heated coolant and check
the continuity through the sensor as the coolant heats
up.
 • Soak the ECT sensor in coolant up to its threads
with at least 40 mm (1.6 in) from the bottom of the
pan to the bottom of the sensor.
 • Keep temperature const ant for 3 minutes before
testing. A sudden change  of temperature will result
in incorrect readings. Do not let the thermometer [2]
or ECT sensor touch the pan.
Replace the ECT sensor if it  is out of specifications by
more than 10%.
Install the ECT sensor (page 4-46).
Remove the ECT
sensor while the engine is cold.
TORQUE: ECT sensor: 25 N·m (2.5 kgf·m, 18 lbf·ft)
[1]
[2][3]
Wear insulated
gloves and
adequate eye
protection.
Keep flammable
materials away from
the burner.
CONNECTION: A – B
Temperature 20 °C /68°F 80 °C/176°F
Resistance 2.3 – 2.6 k Ω0.31 – 0.33 k Ω
[1]
[2]
AB 
						

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PGM-FI SYSTEM
O2 SENSOR
 • Do not get grease, oil or other materials in the O2
sensor air hole.
 •The O2 sensor may be damaged if dropped.
Replace it with a new one, if dropped.
REMOVAL/INSTALLATION
 • Handle the O2 sensor with care.
 • Do not service the O
2 sensor while it is hot.
 • Do not use an impact wrench while removing or
installing the O
2 sensor, or it may be damaged.
Remove the left fuel tank shroud (page 2-4).
Disconnect the O
2 sensor 1P (Black) connector [1].
Remove the wire band [2] from the frame.
Disconnect the O
2 sensor cap [1].
Remove the O
2 sensor [2].
Installation is in the reverse order of removal.
 • Take care not to tilt the O
2 sensor cap when
connecting the cap to the O2 sensor.
 • Do not turn the O
2 sensor cap after connecting it.
[1][2]
TORQUE:
O
2 sensor: 25 N·m (2.5  kgf·m, 18 lbf·ft)
[1]
[2] 
						

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PGM-FI SYSTEM
BANK ANGLE SENSOR
REMOVAL/INSTALLATION
Remove the reserve tank cover (page 2-4).
Disconnect the bank angle sensor 2P connector [1].
Remove the bank angle sensor mounting nuts [2], bolts
[3], bank angle sensor [4] and plate [5].
Remove the collars [6] and mounting rubbers [7] from
the bracket.
Installation is in the reverse order of removal.
 • Install the bank angle sensor with its UP mark [8]facing up.
SYSTEM INSPECTION
Remove the bank angle sensor (page 4-48).
Connect the bank angle sensor 2P connector.
Place the bank angle sensor horizontal as shown.
Start the engine.
Incline the bank angle sensor 70  ± 5° to the left or
right.
The bank angle sensor is normal if the engine stops. TORQUE:
Bank angle sensor mounting nut
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
[2]
[3]
[1]
[5][4]
[6][7]
[8]
70° BANK ANGLE POSITION
HORIZONTAL 70 ± 5°
70 ± 5° 
						

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PGM-FI SYSTEM
ECM
ECM POWER/GROUND LINE 
INSPECTION
Before starting the inspection, check for loose or poor
contact on the ECM 33P (Black) connector and recheck
the MIL blinking.
ENGINE DOES NOT START (MIL does not blink)
1. ECM Power Input Voltage InspectionDisconnect the ECM 33P (Black) connector [1]
(page 4-50).
Turn the ignition switch ON and engine stop switch
.
Measure the voltage at the ECM 33P (Black)
connector of the wire side and ground.
Does the standard voltage exist?
YES – GO TO STEP 2.
NO –  • Open circuit in Black/blue wire
 • Faulty ignition switch
 • Blown main fuse (30 A)
 • Blown FI, IGN fuse (10 A)
 • Faulty engine stop switch
2. Sensor Unit Power Line Inspection Turn the ignition switch OFF.
Check for continuity between the ECM 33P (Black)
connector [1] of the wire side and ground.
Is there continuity?
YES – Short circuit in Yellow/red wire
NO – GO TO STEP 3.
3. ECM Ground Line Inspection Turn the ignition switch OFF.
Check for continuity between the ECM 33P (Black)
connector [1] of the wire side and ground.
Is there continuity?
YES – Replace the ECM with a known good one,
and recheck.
NO –  • Open circuit in Green/black wire
 • Open circuit in Green wires
Connection: Black/blue (+) – Ground (–)
Standard: Battery voltage
TOOL:
Test probe
07ZAJ-RDJA110
Bl/Bu
[1]
Connection: Yellow/red – Ground
TOOL:
Test probe 07ZAJ-RDJA110
Y/R
[1]
Connection: Green/black – Ground
Green – Ground
Green – Ground
TOOL:
Test probe 07ZAJ-RDJA110
G
G/BlG
[1] 
						

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PGM-FI SYSTEMREMOVAL/ INSTALLATION
Remove the reserve tank cover (page 2-4).
Turn the ignition switch OFF.
Disconnect the ECM 33P (Black) connector [1].
Remove the rubber holder [2] and ECM [3].
Remove the ECM from the rubber holder.
Installation is in the reverse order of removal.[1]
[2][3] 
						

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5
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5. IGNITION SYSTEM
SERVICE INFORMATION ·····························5-2
TROUBLESHOOTING···································5-2
SYSTEM LOCATION·····································5-3
SYSTEM DIAGRAM ······································5-3IGNITION SYSTEM INSPECTION ················ 5-4
IGNITION TIMING ········································· 5-6
IGNITION COIL ············································· 5-6