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**Akkiben** · 11-10-2014, 10:13 AM

Re: Hero Honda Karizma ZMR

Hi everyone, I just finished doing a complete chain overhaul on my ZMR and it's now running butter smooth without any noise. Now when I turn on the ignition and start the bike there is a pgm fi light which just comes on and goes. I'm puzzled as to what could be the culprit here. :/ I did struggle to put the whole fairings on yesterday and may have disconnected something accidentally. I checked the pgm fi malfunction index and found the relevant one pointing to faulty ecu or disconnected pgm fi indicator. I'm feeling depressed as I did all the hard work yesterday and still have an issues, a new issue now. Experts, please help....

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**rreneav1987** · 11-10-2014, 11:17 AM

Re: Hero Honda Karizma ZMR

Originally posted by Akkiben View Post

Hi everyone, I just finished doing a complete chain overhaul on my ZMR and it's now running butter smooth without any noise. Now when I turn on the ignition and start the bike there is a pgm fi light which just comes on and goes. I'm puzzled as to what could be the culprit here. :/ I did struggle to put the whole fairings on yesterday and may have disconnected something accidentally. I checked the pgm fi malfunction index and found the relevant one pointing to faulty ecu or disconnected pgm fi indicator. I'm feeling depressed as I did all the hard work yesterday and still have an issues, a new issue now. Experts, please help....

Sent from my iPad using Tapatalk

Ok, you might have forgotten to connect the Bank Angle Sensor connection to the the headlight assembly..

it looks like the image below

Pic credit goes to [MENTION=53321]abhi7013[/MENTION]

just connect the wire to this sensor which is located behind the headlight assembly.

Pic credit goes to [MENTION=33160]Dan_GP[/MENTION]

Guess this should resolve the issue. Try to recollect if you connected this sensor wire or not??

**Balgi** · 11-10-2014, 11:34 AM

Re: Hero Honda Karizma ZMR

Originally posted by abhi7013 View Post

Well, in case of zmr, i feel they are easily serviceable. Twice I've had my fuel pump opened and cleaned. Injector and fuel filter are also accessible once the tank is removed and I've seen many zmrs being serviced that way, one of them being [MENTION=41586]Divya Sharan[/MENTION]. I guess that's a positive for us.
And nice to hear that you saved a lot by replacing under warranty! These svc idiots are adamant when it comes to warranty.

Sent from my C5502 using xBhp Connect mobile app

Maybe so bro. I for one wouldn't know as I sold my zmr after 3 months of purchase because of rattling noises and loose fairing issues (there's more but that is a story for another time). So I actually never got to the fuel pump on it. But you as a current owner would know better I guess. I spoke from my tryst with ktm fuel pumps only.

**Balgi** · 11-10-2014, 11:36 AM

Re: Hero Honda Karizma ZMR

Originally posted by rreneav1987 View Post

What is that small thing they are handling?? Is that a tank?? ZMRs fuel pump are not partially submerged under the tank. They are placed well outside the tank.

I have few pics of the ZMRs fuel injector being serviced.

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Check the duke threads and you'll see ktm pumps are bigger and more complex. There are picture in one of the duke threads.

**kmk0311** · 11-10-2014, 11:38 AM

Re: Hero Honda Karizma ZMR

Originally posted by Balgi View Post

No directly underneath it bolted to the base of the tank.

Our bikes have it below the fuel tank. Its easily accessible once you remove the tank

**rreneav1987** · 11-10-2014, 11:42 AM

Re: Hero Honda Karizma ZMR

Originally posted by Balgi View Post

Check the duke threads and you'll see ktm pumps are bigger and more complex. There are picture in one of the duke threads.

So you mean to say there are lots of Dukes with the Fuel Pump Issues??

besides, the Fuel Pump of ZMR are not submerged inside the fuel tank, they are situated outside the fuel tank.. infact below the fuel tank..

The Duke probably requires a powerful pump to pull out all that fuel in the tank to the Hungry engine

**kmk0311** · 11-10-2014, 11:45 AM

Re: Hero Honda Karizma ZMR

Originally posted by rreneav1987 View Post

So you mean to say there are lots of Dukes with the Fuel Pump Issues??

besides, the Fuel Pump of ZMR are not submerged inside the fuel tank, they are situated outside the fuel tank.. infact below the fuel tank..

The Duke probably requires a powerful pump to pull out all that fuel in the tank to the Hungry engine

He says most dukes have this problem as the guys in the petrol station insert the spout well inside the filler hole, so a lot of pressure is directly applied on the pump which apparently causes wear. And hence the lagging issues..

**rreneav1987** · 11-10-2014, 11:49 AM

Re: Hero Honda Karizma ZMR

Originally posted by kmk0311 View Post

He says most dukes has this problem as the guys in the petrol station insert the spout well inside the filler hole, so a lot of pressure is directly applied on the pump which apparently causes wear. And hence the lagging issues..

Yikes, that is a serious issue.. Thank God our bikes have it outside. Am not rich to spend 13000 every year

**kmk0311** · 11-10-2014, 11:52 AM

Re: Hero Honda Karizma ZMR

Originally posted by rreneav1987 View Post

Yikes, that is a serious issue.. Thank God our bikes have it outside. Am not rich to spend 13000 every year

Haha. But one advantage of fuel pumps submerged inside the tank is that they runs cooler than our pumps as they are directly cooled by petrol.

Btw.. What is that mesh like thing???

Attached Files

**rreneav1987** · 11-10-2014, 11:59 AM

Re: Hero Honda Karizma ZMR

Originally posted by kmk0311 View Post

Haha. But one advantage of fuel pumps submerged inside the tank is that they runs cooler than our pumps as they are directly cooled by petrol.

Btw.. What is that mesh like thing???

hope you do realize the disadvantages of the pumps submerged inside the tank.. Leave your tank empty and if you try to start the bike, EF'd up..

I don't know what the mesh like thing it.. looks like a small filter to me.. my friend sent it to me.. his Fuel Pump had issues and after changing his fuel pump, he got the old pump serviced...

**kmk0311** · 11-10-2014, 12:16 PM

Re: Hero Honda Karizma ZMR

Originally posted by rreneav1987 View Post

hope you do realize the disadvantages of the pumps submerged inside the tank.. Leave your tank empty and if you try to start the bike, EF'd up..

I don't know what the mesh like thing it.. looks like a small filter to me.. my friend sent it to me.. his Fuel Pump had issues and after changing his fuel pump, he got the old pump serviced...

The pump will go boom for sure xD

Btw few pics of the wash+wax I did on Saturday

**Akkiben** · 11-10-2014, 12:35 PM

Re: Hero Honda Karizma ZMR

Originally posted by rreneav1987 View Post

Ok, you might have forgotten to connect the Bank Angle Sensor connection to the the headlight assembly..

it looks like the image below

[ATTACH=CONFIG]163024[/ATTACH]

Pic credit goes to @abhi7013

just connect the wire to this sensor which is located behind the headlight assembly.

[ATTACH=CONFIG]163025[/ATTACH]

Pic credit goes to @Dan_GP

Guess this should resolve the issue. Try to recollect if you connected this sensor wire or not??

Can't thank you guys enough for this.

[MENTION=27501]rreneav1987[/MENTION] [MENTION=53321]abhi7013[/MENTION] and [MENTION=26389]Dan[/MENTION] GP

Though i have not checked to see this, im sure this is the culprit as i clearly remember removing even the stud bolts (as on pic) to disconnect the headlight assembly. I am not sure whether i have plugged in the switch correctly on to the socket when i refitted them. I will check for possible loose connectivity and may have to remove the plug and reconnect the switch, i will revert shortly.

Thanks again for the spontaneous response, i was so lost after seeing the light come on.

**Balgi** · 11-10-2014, 04:29 PM

Re: Hero Honda Karizma ZMR

Originally posted by rreneav1987 View Post

hope you do realize the disadvantages of the pumps submerged inside the tank.. Leave your tank empty and if you try to start the bike, EF'd up..

I don't know what the mesh like thing it.. looks like a small filter to me.. my friend sent it to me.. his Fuel Pump had issues and after changing his fuel pump, he got the old pump serviced...

No such disadvantage bro. The deal is that our pumps don't serve as reservoirs for small quantities of petrol, for that we have the fuel filter. The advantage however is having good fuel pressure and little to no quantity of unusable petrol.

**Akkiben** · 11-10-2014, 04:38 PM

Re: Hero Honda Karizma ZMR

@rreneav1987 : I checked the bank angle sensor plug, its sitting firm on the socket. I only removed the nuts from the studs so checked to see for any looseness. The malfunction lamp still comes up during self start so the problem is still at large. Did removing the stud nuts have caused this issue?? Im bewildered because the previous times when removing the fairing i just used to unplug the headlight and cluster manifold plug and re fit during fitting of fairings, this time i had chosen to remove the stud nuts. Iam again getting so lost here and my fingers are aching after each inspection.

P.S: How does one remove the plug of the bank angle sensor? I tried at my wits end to unplug it from the socket.

**rreneav1987** · 11-10-2014, 05:32 PM

Re: Hero Honda Karizma ZMR

Originally posted by Akkiben View Post

@rreneav1987 : I checked the bank angle sensor plug, its sitting firm on the socket. I only removed the nuts from the studs so checked to see for any looseness. The malfunction lamp still comes up during self start so the problem is still at large. Did removing the stud nuts have caused this issue?? Im bewildered because the previous times when removing the fairing i just used to unplug the headlight and cluster manifold plug and re fit during fitting of fairings, this time i had chosen to remove the stud nuts. Iam again getting so lost here and my fingers are aching after each inspection.

P.S: How does one remove the plug of the bank angle sensor? I tried at my wits end to unplug it from the socket.

Does your bike have any starting problems?? does the blinking light go off ever? or does it keep blinking. Are you sure you have connected the wire properly?? I never had such issues.

did it suddenly happen and prior to this you didn't have this issue, right? i mean before striping the fairing.. if this is the case, then the Bank Angle Sensor probably needs to be adjusted and the wire needs to be plugged in properly..

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