PGM Fi

Contents
Contents
PGM-FI System Introduction
ANF 125 FI PGM-FI System
• Outline
• Fuel Delivery System
• Electronic Control System
• Self-Diagnosis Function
• Service Tips & New Tools
Page 2
PGM-FI Introduction
PGM-FI System Introduction
• Basic understanding of the

PGM-FI system
Page 3
PGM-FI Introduction
Introduction
Overview
Improved:
-Exhaust gas emissions
-Fuel economy
Page 4
PGM-FI Introduction
Introduction
1982 CX500Turbo
Page 5
PGM-FI Introduction
Introduction
RC211V 2002 MotoGP World champion racer

Page 6
PGM-FI Introduction
Introduction
Honda’s Declaration of Environment Preservation
As a responsible member of a society that values the importance of the
earth’s environment, Honda, through all of its operations actively
contributes to the maintenance of people’s health and preservation of the
environment aiming for the advancement of these causes, we will continue
to strive for their achievement…
The following are the guidelines that we will follow in our daily operations:
1. In every process in the product’s life cycle, i.e. product research, development,
production, sales, servicing, and disposal; we strive to recycle material, and save
resources and energy.
2. In every waste generated in each step of the product’s life cycle, we strive for
the reduction of pollutants and proper waste disposal.
3. We, as an industry member, as well as a member of society, understands the

need for the maintenance of human health and environmental preservation, thus
we strive to actively to achieve these.
4. We, at the places of our operations, care for the effects to the people’s health
and environment, and we are striving to achieve a high-level of appraisal from the
society.
Page 7
PGM-FI Introduction
Introduction
82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03
GLX1800 01
VTX1800 01
Pan European 02
GL1200 86
X11 0099
CBR1100XX
CB900 Hornet 02
FireBrade 00
VFR800FI 98
NR750 92 RVF/RC45 94
CBR600F4i 01
SilverWing 01
CX500Turbo 82
Pantheon 03
History of Honda on-board FI for motorcycles Page 8

PGM-FI Introduction
Introduction
Emission Levels and Fuel Efficiency

FI 4-strokes
140
Improved fuel economy (%)
FI advantage
130
Carburated
4-strokes
120
4-stroke advantage
over 2-strokes
110
100 2-strokes
125/150cc Class
0 20 40 60 80
HC + NOx reduction (%) Page 9
PGM-FI Introduction
Introduction
ANF 125 FI Exhaust Emission Advantages
EURO2 Regulations (CO HC) ½ cleaner engine
(g/km)
CO HC NOx
*Internal Test Results
Page 10
PGM-FI Introduction
Introduction
ANF 125 FI Fuel Economy
+6%
*Internal Test Results

Page 11
Introduction
• Outline
• Fuel Delivery System
• Electronic Control System
• Self-Diagnosis Function
• Service Tips & New Tools
Page 12
Outline
Introduction
Outline
Outline
Introduction
ANF 125 FI PGM-FI System Outline
Page 13
Fuel Delivery System
Introduction

Introduction

System Flow:
• Fuel Pump Module
• Pressure Regulator
• Injector
• Throttle Body with Sensor Unit
• Engine Control Module
Fuel Pump
Throttle Body Pressure Regulator

ECM
Injector
Page 14
Introduction
Fuel Pump Module
Fuel Pressure Regulator
Fuel Pump
Fuel Suction Filter
Page 15
Introduction
Fuel Injector
Fuel Strainer Screen
Spring
Solenoid Coil
Fuel Passage Plunger
Nozzle Plate
Page 16
Introduction
Fuel Pump Module
Pressure Regulator
Throttle Body
Injector
Fuel Feed Hose Fuel Suction Filter
Page 17
Introduction

Pressure Regulator
Fuel Suction Filter
Page 18
Introduction
User Operations
• Ignition Switch ON
– MIL (Malfunction Indicator Lamp) illuminates
– Fuel Pump operation sound
– Speedometer Needle swings
Click for video
Page 19
Introduction
Throttle Body with Built-in Sensor Unit
Sensor Unit IAT (Intake Air

Temperature)
Sensor
TP (Throttle
MAP (Manifold Absolute
Position) sensor Throttle Body
Pressure) Sensor
Page 20
Introduction
Throttle Body with Built-in Sensor Unit

IAT Sensor
TP Sensor
MAP Sensor
Page 21
Introduction
-MAP Sensor -Intake Air Temp. (IAT) Sensor

-Air outlet Idle Adjusting Screw -Air inlet Idle Adjusting Screw
IAT Sensor port Air inlet Idle Adjusting Screw

MAP Sensor port
Air outlet Idle Adjusting Screw
Injection port
Intake Manifold side Air Cleaner side
Page 22
Introduction
Stop Screw
Throttle Body
Page 23
Electronic Control System
Introduction

Introduction
Electronic Controls
Page 24
Introduction
Electronic Controls
1. Engine Starting with good battery
Page 24
Introduction
Electronic Controls
2. While engine is running (with good battery)
Page 24
Introduction
Electronic Controls
3. Engine Starting with drained battery
Page 24
Introduction
Electronic Controls
4. While engine is running (with drained battery)
Page 24
Introduction
Engine Control Module (Inputs / outputs)
Page 25
Introduction
Injection Volume
• Basic injection volume determined by 2 maps
Fig. 1 Fig. 2
Low load High load
Page 26
Introduction
Injection Volume Compensations
Click for video

• Temperature
– Engine Oil Temperature
– Intake Air Temperature
• Acceleration
– Throttle Position
Page 27
Introduction
Injection and Ignition routine cycle
EXH. IN. COMP. POWER

STROKE
CRANK PULSE
MANIFOLD
PRESSURE
IGNITION
FUEL
INJECTION
Page 28
Introduction
Sensor Unit
TP Sensor MAP Sensor
IAT Sensor
Page 29
Introduction
Sensors
• Sensor types and electronic

behaviors
• Manifold Absolute Pressure (MAP)
Sensor
• Throttle Position (TP) Sensor
• Engine Oil Temperature (EOT)
Sensor
• Intake Air Temperature
(IAT) Sensor
Page 30
Introduction
Bank Angle Sensor
Page 31
Introduction
Bank Angle Sensor
55±5 55±5
° °
Range of angle detection Range of angle detection
Page 32
Introduction
Bank Angle Sensor
Page 33
Introduction
Bank Angle Sensor
While turning When tipped over
Centrifugal force
Weight
Weight
Page 34
Introduction
Let’s try it!
Click for video
Page 35
Self-Diagnosis Function
Introduction
Introduction
Self-Diagnosis
Page 36
Introduction
Self-Diagnostic Procedure
Ignition Switch to “ON”
MIL ON
OFF
DLC
Ignition Switch to “ON”
2.5 sec
MIL ON
OFF
Failure codes
DLC Short Connector

Page 37
Introduction
Self-Diagnosis
• System's Self-Diagnostic function - Engine Oil Temp. Sensor
Click for video
Page 38
Introduction
Self-Diagnosis
• System's Self-Diagnostic Function - Fuel Injector
Click for video
Page 39
Introduction
Self-diagnosis Reset Procedure

Click for video Successful pattern
Within 5sec. 2-3sec

MIL ON
OFF
Failure pattern Reset receiving Successful pattern

pattern
Click for video Unsuccessful pattern
Within 5sec. 2-3sec

MIL ON
OFF
Failure pattern Reset receiving Unsuccessful pattern

pattern
Page 40
Introduction
Demonstration
• Creating failure modes:

– Engine Oil Temperature Sensor
– Injector
• Erasing past memory
Page 41
Introduction
Measuring Fuel Pressure

Click for video
Page 42
Introduction
Demonstration
• Fuel pressure
Click for video
Page 43
Introduction
Throttle Body Calibration
DLC
Jumper Line
Page 44
Introduction
Throttle Body Calibration
Page 45
Service Tips & New Tools
Introduction

Introduction
Service Shop Tips

• Work precautions
– Checking spark at the Spark
Plug... Click for video
• Reg./rectifier
– Discharge capacitor for
storage/disposal
• Fuel Pump/ Fuel Feed Hose
– Disassembling Fuel Pump/Fuel
Feed Hose
Page 46
Introduction
Fuel Quick Connector
Page 47
Introduction
New Tools & Instruments

• Fuel Pressure Gauge, Attachment Hoses, Joint and Manifold
Page 48
Introduction
• DLC Short Connector
•PIN Probe-male
Page 49

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Contents

PGM-FI System Introduction

• Basic understanding of the

RC211V 2002 MotoGP World champion racer

3. We, as an industry member, as well as a member of society, understands the

History of Honda on-board FI for motorcycles Page 8

Emission Levels and Fuel Efficiency

ANF 125 FI Fuel Economy

*Internal Test Results

ANF 125 FI PGM-FI System

ANF 125 FI PGM-FI System Outline

Fuel Delivery System

Fuel Delivery System

Throttle Body Pressure Regulator

Fuel Pump Module

Fuel Pressure Regulator

Fuel Suction Filter

Fuel Passage Plunger

Fuel Delivery System

Fuel Pump Module

Fuel Feed Hose Fuel Suction Filter

Fuel Delivery System

Fuel Suction Filter

Throttle Body with Built-in Sensor Unit

Sensor Unit IAT (Intake Air

Throttle Body with Built-in Sensor Unit

-MAP Sensor -Intake Air Temp. (IAT) Sensor

IAT Sensor port Air inlet Idle Adjusting Screw

Intake Manifold side Air Cleaner side

Electronic Control System

Low load High load

Injection Volume Compensations

Click for video

Injection and Ignition routine cycle

EXH. IN. COMP. POWER

• Sensor types and electronic

Bank Angle Sensor

Bank Angle Sensor

Range of angle detection Range of angle detection

Bank Angle Sensor

Bank Angle Sensor

While turning When tipped over

Let’s try it!

Click for video

Ignition Switch to “ON”

DLC Short Connector

Self-diagnosis Reset Procedure

Within 5sec. 2-3sec

Failure pattern Reset receiving Successful pattern

Click for video Unsuccessful pattern

Within 5sec. 2-3sec

Failure pattern Reset receiving Unsuccessful pattern

• Creating failure modes:

Measuring Fuel Pressure

Click for video

Throttle Body Calibration

Throttle Body Calibration

Service Tips & New Tools