125 E5

Diagnostic Tests
This guide is not designed to be a complete diagnostic manual and is produced only to
aid in the diagnostic process for your tech request. It is assumed that the technician per-
forming diagnostic routines is suitably trained and capable for these tasks.

Vehicle Reg; ________ Vehicle Mileage; ________

Last Service performed at; ________miles

Vehicle Tests
Please complete the following tests to aid the process of assisting your tech request. While
we aim to resolve each issue as swiftly as possible, we cannot offer assistance without
correct and complete information.
Please test the battery voltage and, if possible, the battery cranking voltage.
Battery
Battery Voltage; _____v
Cranking Voltage: _____v

Spark Plug Please check the spark plug condition and gap and, if possible, spark condition.
Spark Plug Gap: _____mm
Spark Plug Condition;
Normal ; _____ Oily;_____ Sooty;_____
White/Pitted;_____ Clean but Wet;_____

Please check the following conditions for the oil system.

Engine Oil
Oil Level; Oil Quality;
Correct; _____ Black/Thick; _____
Low; _____ Clean/New; _____
Overfilled; _____ Creamy; _____
Oil Filter/Screen (where possible)
Clean; _____
Engine Normal _____
Condition Blocked _____
Please check the following conditions for the general engine condition. If possible,
please perform a compression and leak down test.

Inlet Valve Gap; _______mm _______mm Cylinder Compression;

_________psi
Exhaust Valve Gap; _______mm _______mm Leakdown Test;
Leakage ________%
 Vehicle Tests
Please complete this leaflet and return along with your tech request
Please perform the following tests for the Stator output @ idle;
Charging charging system. Phase 1; _____v
Please note; These tests are
System necessary for running faults as well
Phase 2; _____v
as charging faults. Some running Phase 3; _____v
faults begin with a poor charging (Stator disconnected, engine
systems. running, AC voltage)

To perform this test correctly it is necessary to disconnect the Stator output @ 3000rpm;
Stator from the ECU but leave the crank position sensor Phase 1; _____v
connected to allow the engine to run. The machine will then run Phase 2; _____v
from battery power so it is important to have a fully charged
battery for this test.
Phase 3; _____v
(Stator disconnected, engine
running, AC voltage)

Battery Voltage;
(Stator connected)
At idle; _____v
At ≈4000rpm; _____v
EFI System
Please perform the pinout tests as shown overleaf. Please take note of the meter settings and bike and ECU
conditions for each test as differing test conditions can result in incorrect data.

For example, an Ohmmeter set to 200kΩ may give a different reading to the same Ohmmeter set to 20KΩ.

Carrying out ECU Pin Out Tests

ECU Pin out tests allow you to be able to confirm whether or not the ECU is receiving the expected
information from a specific component, allowing an effective diagnosis process to accurately narrow down
the root cause of a fault. If there is a suspected component issue you can use this test procedure to discount
wiring faults and narrow down your avenues for testing
 Pre-Checks
To carry out the Pin Out tests you will be probing the wiring on the loom side of the ECU connectors (NOT the ECU itself). Make sure the Engine and Ignition are switched off, and the ECU is disconnected from the wiring harness.
The engine should be cold and the battery should be in good, serviceable condition. Voltage tests should be done with the ECU connected and engine running where stated.
Testing using the supplied data
Identify the required component(s) for testing on the component ID column. Check and ensure any Test Conditions described have been followed. Set your Multimeter using the displayed Ohm or Volts range. Locate the required ECU
pins (ECU Pin location and Test to ECU Pin) and record the displayed reading. Compare this to the displayed value on the table. The values on the table are APPROXIMATE and so some variation can be expected.

ECU Plug ECU pin location wire colour Component ID Test to ECU Pin Meter Setting (ohms) Displayed Value Test Conditions
1 BLUE/RED IACV A Hi 11 200 52.7 Engine off, cold, ECU removed
2 BLACK/YELLOW Evap Solenoid 17 200 19.1 Engine off, cold, ECU removed
3 RED/ORANGE MIL
4
5
6 YELLOW/BLACK Tachometer
7 BROWN/PURPLE CANBUS
8 BROWN/RED CANBUS
9 GREEN Ground various
J1 (Grey)
10
11 BLUE/BLACK IACV A Lo 1 200 52.7 Engine off, cold, ECU removed
12 BLACK/RED IACV B Hi 13 200 51.5 Engine off, cold, ECU removed
13 GREEN/BROWN IACV B Lo 12 200 51.5 Engine off, cold, ECU removed
14
15 ORANGE/BLACK Vehicle Speed Sensor
16 GREY/WHITE Side Stand Switch
17 BLACK/ORANGE Fuel Pump ReCirc various
18 PINK Neutral Switch

1 GREEN/GREY Coil J1-17 200 0.9 Engine off, cold, ECU removed
2 GREEN Ground
3 YELLOW/WHITE OBD
4 BLUE/YELLOW Crank Pickup Hi 13 200 118.5 Engine off, cold, ECU removed
5 RED/BLUE Injector J1-17 200 11.9 Engine off, cold, ECU removed
6
7 BLUE/ORANGE Lambda Heater J1-17 200 17.9 Engine off, cold, ECU removed
8 ORANGE/GREY IAT (Inlet Temp) 10 20k 3.39 Engine off, cold, ECU removed
8 ORANGE/GREY IAT (Inlet Temp) 16 20k 4.82 Engine off, cold, ECU removed
9 BLACK/BLUE Fuel Pump Relay J1-17 200 1.7 Engine off, cold, ECU removed
J2 (Black) 10 GREEN/BLACK 5v RTN various
11 PURPLE/YELLOW MAP (Inlet Pressure) 10 20k 3.48 Engine off, cold, ECU removed
11 PURPLE/YELLOW MAP (Inlet Pressure) 16 20k 3.48 Engine off, cold, ECU removed
12 BROWN/BLACK TPS Reference 10 20k 2.05 Engine off, cold, ECU removed closed throttle - Wide Open Throttle
12 BROWN/BLACK TPS Reference 16 20k 3.13 Engine off, cold, ECU removed closed throttle - Wide Open Throttle
13 GREEN/WHITE Crank Pickup Lo 4 200 Engine off, cold, ECU removed
14 BROWN/GREEN ECT (engine Temp) 10 20K 3.22 Engine off, cold, ECU removed
15 BLACK/WHITE 12v IGN+
16 GREY/PURPLE 5v + various
17 WHITE/BLUE Lambda Signal
18 ORANGE/RED 12v Batt +
 m o t o r c yc l e s & s c o o t e r s

Llexeter Ltd is registered in England and Wales with company registration number 4940600
Address: Units 15-18, Greendale Business Park, Woodbury Salterton, Devon, EX5 1EW
TEL: 0844 567 8887 **1
FAX: 0844 567 0584
**1 Calls cost 7p per minute plus your phone company’s access charge.

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic or mechanical photocopy-
ing, recording or otherwise,without the prior written permission of LLexeter Ltd, UK
No liability can be accepted for any inaccuracies or omissions in this publication, al-
though every possible care has been taken to make it as complete and accurate as possi-
ble. This guide is NOT designed to be a complete diagnostic manual and is produced only
to aid in the diagnostic process for this model. It is assumed that the technician perform-
ing diagnostic routines is suitably trained and capable for these tasks.
We reserve the right to make changes at any time without prior notice and without incur-
ring an obligation to make such changes to products manufactured previously. See your
Motorcycle dealer for the latest information on product improvements or alterations incor-
porated after this publication.
All information contained in this publication is based on the latest product information
available at the time of publication. Illustrations and photographs in this publication are
intended for reference use only and may not depict actual model component parts.
All content compiled or created by Colin Price
1st edition December 2021