Maestro Edge 125 BSVI - Programmed FI TESTING

Multimeter Multimeter Multimeter

SENSOR TYPE Test Type Test Result Action to be taken
Knob Setting ( RED Probe) ( Black Probe)
DLC DLC
VOLTAGE TEST 20 V DC BATTERY VOLTAGE
BLACK RED GREEN
DLC
VOLTAGE TEST 20 V DC GROUND BATTERY VOLTAGE
BLACK RED
If Voltage is NOT OK - check fuse, Ignition swicth and power wires
DLC DLC
VOLTAGE TEST 20 V DC 2.0 V TO 3.3 V
ORANGE WHITE GREEN
DLC DLC
VOLTAGE TEST 20 V DC 2.0 V TO 3.3 V
BLUE WHITE GREEN
VCI NOT RESPONDING
DLC
CONTINUITY TEST CONTINUITY GROUND CONTINUITY
GREEN
DLC
CONTINUITY TEST CONTINUITY ECU - PIN 1 CONTINUITY
BLACK RED If all are OK - check with a known Hero VCI tool. If any one reading is NOT OK - Repair or Replace
DLC Wiring Harness
CONTINUITY TEST CONTINUITY ECU - PIN 4 CONTINUITY
ORANGE WHITE
DLC
CONTINUITY TEST CONTINUITY ECU - PIN 5 CONTINUITY
BLUE WHITE

VOLTAGE TEST 20 V DC ECU- PIN 1 GROUND BATTERY VOLTAGE

IF Voltage is OK - Replace ECU. If Voltage is NOT OK - check fuse, Ignition swicth and power wires
VOLTAGE TEST 20 V DC ECU- PIN 33 GROUND BATTERY VOLTAGE

ECU
CONTINUITY TEST CONTINUITY ECU - PIN 2 GROUND CONTINUITY
POWER/GROUND
CONTINUITY TEST CONTINUITY ECU - PIN 15 GROUND CONTINUITY If all are OK - Replace ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness

CONTINUITY TEST CONTINUITY ECU - PIN 31 GROUND CONTINUITY

SENSOR UNIT 5P
VOLTAGE TEST 20 V DC GROUND 3.8 - 5.25 V IF Voltage is OK - Replace Sensor
LIGHT GREEN/YELLOW

If Voltage is NOT OK, Then test the following

MAP SENSOR
(DTC P0107, P0108) SENSOR UNIT 5P
CONTINUITY TEST CONTINUITY ECU - PIN 43 CONTINUITY
LIGHT GREEN/YELLOW
If all are OK - Replace ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness
SENSOR UNIT 5P
CONTINUITY TEST CONTINUITY Ground NO CONTINUITY
LIGHT GREEN/YELLOW
SENSOR UNIT 5P
VOLTAGE TEST 20 V DC Ground 4.75 - 5.25 V IF Voltage is OK - check sensor resistance
GREY BLUE

RESISTANCE TEST 20k Ω ECU - PIN 35 ECU - PIN 18 1.136 KOhm ± 8.4% If Resistance is NOT OK - Replace sensor Unit

INTAKE AIR TEMP. SENSOR If Voltage is NOT OK, Then test the following
IAT
SENSOR UNIT 5P
(DTC P0112, P0113) CONTINUITY TEST CONTINUITY ECU - PIN 35
GREY BLUE
CONTINUITY

SENSOR UNIT 5P
CONTINUITY TEST CONTINUITY ECU - PIN 18 CONTINUITY If Both are OK - Replace ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness
GREEN ORANGE
SENSOR UNIT 5P
CONTINUITY TEST CONTINUITY GROUND NO CONTINUITY
GREEN ORANGE
SENSOR UNIT 5P
VOLTAGE TEST 20 V DC Ground 5 ± 0.1 V IF Voltage is OK - Check sensor
LIGHT GREEN/BLACK
Full close throttle
RESISTANCE TEST 20k Ω
0.82 KOhm (0.80 - 0.83 KOhm)
ECU - PIN 21 ECU - PIN 18 If Resistance is NOT OK - Replace sensor unit
Fully open Throttle
THROTTLE POSITION SENSOR RESISTANCE TEST 20k Ω
3.14 KOhm (3.00 - 3.20 KOhm)
TPS
(DTC: P0122, P0123) If Resistance is NOT OK, Then test the following

SENSOR UNIT 5P
CONTINUITY TEST CONTINUITY ECU - PIN 21 CONTINUITY
LIGHT GREEN/BLACK
If Both are OK - Replace ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness
SENSOR UNIT 5P
CONTINUITY TEST CONTINUITY Ground NO CONTINUITY
LIGHT GREEN/BLACK

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 Maestro Edge 125 BSVI - Programmed FI TESTING
Multimeter Multimeter Multimeter
SENSOR TYPE Test Type Test Result Action to be taken
Knob Setting ( RED Probe) ( Black Probe)
VOLTAGE TEST - - - 0 to 1.0 V Check the voltage in Hero VCI Live data by warming up the engine to 90°C

CONTINUITY TEST CONTINUITY ECU - PIN 18 GREEN/ ORANGE CONTINUITY

O2 SENSOR
If NOT OK - Repair or replace Wire Harness
(DTC P0131, P0132)
CONTINUITY TEST CONTINUITY ECU - PIN 38 BLACK/ ORANGE CONTINUITY

IF ABOVE POINTS ARE OK - Replace the O2 sensor with new one and check for DTC P0131, P0132. If still appears then replace the ECU.

RESISTANCE TEST 20 KΩ ECU - PIN 18 ECU - PIN 36 2.645 K OHMS ± 5% If Resistance is NOT OK - Replace Sensor

EOT 2P EOT 2P
VOLTAGE TEST 20 V DC 5 ± 0.1 V IF Voltage is OK - Replace Sensor
YELLOW/BLUE GREEN/ORANGE
ENGINE OIL TEMPARATURE
EOT SENSOR If Voltage is NOT OK, Then test the following
(DTC P0197, P0198, P0217)
EOT 2P
CONTINUITY TEST CONTINUITY ECU - PIN 18 CONTINUITY
GREEN/ORANGE
If Both are OK - Replace ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness
EOT 2P
CONTINUITY TEST CONTINUITY ECU - PIN 36 CONTINUITY
YELLOW/BLUE

Run the Actuator Test of Injector in Hero VCI. If successful, then ECU is OK. If not OK, then test the following

INJECTOR 2P
VOLTAGE TEST 20 V DC GROUND BATTERY VOLTAGE IF Voltage is OK - Check Injector Resistance
BLACK / RED

RESISTANCE TEST 200 Ω IINJECTOR PIN 1 INJECTOR PIN 2 12.0 ± 0.6 Ohm If Resistance is NOT OK - Replace Injector
FUEL INJECTOR
(DTC: P0201) If Voltage is NOT OK, Then test the following

INJECTOR 2P
CONTINUITY TEST CONTINUITY ECU - PIN 13 CONTINUITY
PINK/ GREEN
If Both are OK - Replace ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness
INJECTOR 2P
CONTINUITY TEST CONTINUITY GROUND NO CONTINUITY
PINK / GREEN
ENGINE OVERSPEED Disconnect CKP sensor 2P connector, check for loose or poor contact. If NOT OK check CKP sensor trobleshooting for diagnosis
(DTC: P0219)
Run the Actuator Test of Fuel Pump in Hero VCI. If successful, then ECU is OK. If not OK, then test the following

FUEL PUMP 3P
VOLTAGE TEST 20 V DC GROUND 2.7 to 3.0 V
BROWN BLUE
FUEL PUMP 3P
VOLTAGE TEST 20 V DC GROUND 2.7 to 3.0 V If Voltage is NOT OK - check the wire harness
BROWN YELLOW
FUEL PUMP 3P
VOLTAGE TEST 20 V DC GROUND 2.7 to 3.0 V
BROWN WHITE

If Voltage is NOT OK, Then test the following

FUEL PUMP FUEL PUMP 3P

CONTINUITY TEST CONTINUITY ECU - PIN 16 CONTINUITY
(DTC: P0230) BROWN WHITE
FUEL PUMP 3P
CONTINUITY TEST CONTINUITY ECU - PIN 10 CONTINUITY
BROWN YELLOW
FUEL PUMP 3P
CONTINUITY TEST CONTINUITY ECU - PIN 11 CONTINUITY
BROWN BLUE
If OK - Replace FUEL PUMP/ ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness
FUEL PUMP 3P
CONTINUITY TEST CONTINUITY GROUND NO CONTINUITY
BROWN WHITE
FUEL PUMP 3P
CONTINUITY TEST CONTINUITY GROUND NO CONTINUITY
BROWN YELLOW
FUEL PUMP 3P
CONTINUITY TEST CONTINUITY GROUND NO CONTINUITY
BROWN BLUE

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 Maestro Edge 125 BSVI - Programmed FI TESTING
Multimeter Multimeter Multimeter
SENSOR TYPE Test Type Test Result Action to be taken
Knob Setting ( RED Probe) ( Black Probe)
PEAK VOLTAGE TEST
20 V DC ECU - PIN 7 ECU - PIN 25 1.3 v minimum If OK replace ECU. If NOT OK, check at CKP sensor 2P connector
(Use peak volt adaptor)
PEAK VOLTAGE TEST CKP SENSOR 2P CKP SENSOR 2P
20 V DC 1.3 v minimum If OK - Check for an open or loose connection from CKP sensor 2P connector to ECU 48P connector.
(Use peak volt adaptor) BLUE YELLOW WHITE YELLOW
Crank Position Sensor
If both are NOT OK, then check the following
(DTC: P0335)
CKP SENSOR 2P CKP SENSOR 2P If NOT OK - Replace the CKP sensor and check again
RESISTANCE TEST 2000 Ω 109-280 Ω
BLUE YELLOW WHITE YELLOW If resistance is normal and peak voltage is abnormal replace the ACG and check again.

If peak voltage and resistance both are normal replace the ECU and check again.

Run the Actuator Test of Ignition Coil in Hero VCI. If successful, then ECU is OK. If not OK, the test the following

IGNITION COIL 1P
VOLTAGE TEST 20 V DC GROUND BATTERY VOLTAGE If Voltage is NOT OK - check fuse and for open or short circuit in Red/Black wire.
BLACK RED
IGNITION COIL 1P
VOLTAGE TEST 20 V DC GROUND NO BATTERY VOLTAGE If NOT OK - check for short circuit in Pink/blue wire.
PINK BLUE
IGNITION COIL
If Voltage is OK, Then Do the following
(DTC P0351)
IGNITION COIL 1P
CONTINUITY TEST CONTINUITY ECU PIN 1 CONTINUITY If NOT OK - check for short circuit in Red/Black wire.
BLACK RED
IGNITION COIL 1P
CONTINUITY TEST CONTINUITY ECU PIN 32 CONTINUITY If NOT OK - check for open circuit in Pink/blue wire.
PINK BLUE
RESISTANCE TEST
200 Ω ECU PIN 7 ECU PIN25 2.3 Ω ± 10% If NOT OK - Replace the ignition coil; If OK - replace the ECU and inspect again.
(Connect Ignition Coil wires)

Run the Actuator Test of Purge Valve in Hero VCI. If successful, then ECU is OK. If not OK, the test the following

IGNITION COIL 1P PURGE VALVE 2P

VOLTAGE TEST 20 V DC BATTERY VOLTAGE
BLACK RED LIGHT GREEN RED
If OK - Check PURGE VALVE
IGNITION COIL 1P
VOLTAGE TEST 20 V DC GROUND BATTERY VOLTAGE
BLACK RED
Purge Valve
RESISTANCE TEST 200 Ω PURGE VALVE PIN 1 PURGE VALVE PIN 2 32 ± 3 Ohm If Resistance is NOT OK - Replace PURGE VALVE
(DTC: P0458, P0459)
If Voltage is NOT OK, then check the following

IGNITION COIL 1P
CONTINUITY TEST CONTINUITY ECU - PIN 1 CONTINUITY
BLACK RED
If Both are OK - Replace ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness
PURGE VALVE 2P
CONTINUITY TEST CONTINUITY ECU - PIN 47 CONTINUITY
LIGHT GREEN RED

If DTC appear then check for blown fuse 15A or 10A x 2 in the fuse box

Starter Relay 4P Starter Relay 4P

VOLTAGE TEST 20 V DC BATTERY VOLTAGE
BLACK WHITE GREEN
Starter Relay 4P Starter Relay 4P
VOLTAGE TEST 20 V DC BATTERY VOLTAGE
RED WHITE GREEN
Starter Relay 4P
VOLTAGE TEST 20 V DC GROUND BATTERY VOLTAGE
BLACK
STARTER RELAY CIRCUIT Starter Relay 4P
VOLTAGE TEST 20 V DC GROUND BATTERY VOLTAGE
(DTC: P0616, P0617) RED

If Voltage is NOT OK, then check the following

Starter Relay 4P
CONTINUITY TEST CONTINUITY ECU - PIN 46 CONTINUITY
WHITE GREEN
Starter Relay 4P Fuse
CONTINUITY TEST CONTINUITY CONTINUITY If OK - Replace Starter Relay/ ECU. If reading is NOT OK - Repair or Replace Wiring Harness
BLACK BLACK
Starter Relay 4P Battery
CONTINUITY TEST CONTINUITY CONTINUITY
RED Red

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 Maestro Edge 125 BSVI - Programmed FI TESTING
Multimeter Multimeter Multimeter
SENSOR TYPE Test Type Test Result Action to be taken
Knob Setting ( RED Probe) ( Black Probe)
SENSOR UNIT 5P
VOLTAGE TEST 20 V DC GROUND 4.75 TO 5.25 V IF Voltage is OK - Replace Sensor
GREY/BLUE

SENSOR SUPPLY VOLTAGE If Voltage is NOT OK, then check the following
(VCC)
SENSOR UNIT 5P
(DTC: P0642, P0643, P06A6) CONTINUITY TEST CONTINUITY ECU - PIN 17
GREY/BLUE
CONTINUITY
If all are OK - Replace ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness
SENSOR UNIT 5P
CONTINUITY TEST CONTINUITY GROUND NO CONTINUITY
GREY/BLUE

Run the Supplementary Idle Air Control Valve Test of Idle Air Control Solenoid in Hero VCI. If not OK, then replace ECU. If successful, ECU is OK, then check the following.

STARTER SOLENOID 2P STARTER SOLENOID 2P

VOLTAGE TEST 20V BATTERY VOLTAGE
BLACK RED BROWN ORANGE
If OK - Check Starter Solenoid
STARTER SOLENOID 2P
VOLTAGE TEST 20V GROUND BATTERY VOLTAGE
BLACK RED
STARTER SOLENOID
RESISTANCE TEST 200 Ω Starter Solenoid Pin 1 Starter Solenoid Pin 2 130 ± 13 Ohm If Resistance is NOT OK - Replace starter solenoid
(DTC: P15A1, P15A2)
If Voltage is NOT OK, then check the following

STARTER SOLENOID 2P
CONTINUITY TEST CONTINUITY ECU - PIN 1 CONTINUITY
BLACK RED
If all are OK - Replace ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness
STARTER SOLENOID 2P
CONTINUITY TEST CONTINUITY ECU - PIN 14 CONTINUITY
BROWN ORANGE
BAS 4P BAS 4P
VOLTAGE TEST 20V 4 ± 0.4 V
GREEN ORANGE GREY BLUE
BAS 4P BAS 4P
VOLTAGE TEST 20V 4 ± 0.4 V
GREEN ORANGE RED BLUE
If OK - Replace BAS
BAS 4P
VOLTAGE TEST 20V GROUND 4 ± 0.4 V
GREY BLUE
BAS 4P
ROLL OVER SENSOR / BANK VOLTAGE TEST 20V GROUND 4 ± 0.4 V
RED BLUE
ANGLE SENSOR
(DTC: P1531, P1532) If Voltage is NOT OK, Then test the following

BAS 4P
CONTINUITY TEST CONTINUITY ECU - PIN 20 CONTINUITY
RED BLUE
BAS 4P
CONTINUITY TEST CONTINUITY ECU - PIN 17 CONTINUITY IF OK Replace BAS/ECU. If NOT OK - Repair or Replace Wiring Harness
GREY BLUE
BAS 4P
CONTINUITY TEST CONTINUITY ECU - PIN 20 CONTINUITY
RED BLUE

If DTC appear then check for blown fuse 10A in the fuse box

VOLTAGE TEST 20 V DC ECU- PIN 1 ECU- PIN 15 BATTERY VOLTAGE

IF Voltage is OK - Replace ECU. If Voltage is NOT OK - check fuse, Ignition swicth and power wires
IGNITION SWITCH 4P
VOLTAGE TEST 20 V DC GROUND BATTERY VOLTAGE
BLACK RED
IGP VOLTAGE
If Voltage is NOT OK, Then test the following
(DTC: P1559)
IGNITION SWITCH 4P
CONTINUITY TEST CONTINUITY ECU - PIN 1 CONTINUITY
BLACK RED
IGNITION SWITCH 4P IGNITION SWITCH 4P
CONTINUITY TEST CONTINUITY CONTINUITY If all are OK - Replace ECU. If any one reading is NOT OK - Repair or Replace Wiring Harness
BLACK RED RED
IGNITION SWITCH 4P FUSE
CONTINUITY TEST CONTINUITY CONTINUITY
RED GREY RED GREY

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