FLASH INFORMATION

SALES DIVISION
NETWORK TECHNICAL INFORMATION

ELYSTAR 125cc-150cc CONFIDENTIAL

Subject: DIAGNOSTIC AID

Please find enclosed a document setting out some general information on troubleshooting Elystar
125cc -150 cc machines.

This document does not claim to cover all known or possible problems you may encounter on these
machines. On the other hand, we have covered the most frequently occurring faults and how to remedy
them.

For the proper comprehension of this document, we must emphasise the absolute need to be fully
familiar with the functioning principles of the EFI 125cc-150cc system, which you will find in the
workshop manuals you received in 2002.

This confidential document is strictly for use by the Peugeot Motocycles network and must under no
circumstances be duplicated or divulged under whatever form.

This document pertaining to the Elystar 125cc - 150 cc completes the Elystar 50 cc document supplied
in the Information Flash N°23.

We hope that this information will enable you to work more quickly and efficiently on your customers'
machines.

Dealership Spare parts Mechanic 1 Mechanic 2 Mechanic 3

Signa-
ture

DC 503 rev 1 dated 04/98 – QK 0001 01/2003 N° 23

Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
ELYSTAR 125cc-150cc Electronic injection system diagnostic Main problems encountered

12 JN Ignition coil control 1 VE ECU earth

13 RS Idle valve 2 Not connected
14 JN-VE Fuel pump relay power 3 OR Fuel injector control
15 RG Battery positive power F25A 4 BE Injection diagnostic light
16 JN-NR -5V power to sensors 5 RG-BA Temperature gauge
17 RG-NR Ignition on power F15A 6 Not connected
18 BC +5V power to sensors 7 VI Throttle potentiometer
19 JN-BE Engine speed sensor. 8 BA Air pressure sensor
20 VE-NR Engine speed sensor. 9 BA-BE Engine temperature sensor
21 BA-NR Diagnostic plug 10 Not connected
22 GR Air temperature sensor rear view of 11 Not connected
ECU connector

Reminder:
• all of the components receive their positive power supply through the 25A fuse and are operated through earthing in the ECU
• the sensors powered by the ECU with 5V are the throttle potentiometer and the altimetric sensor.
Problem Checks Operation
After driving in heavy rain: Read the fault codes with the diagnostic tool. Unplug the ECU connector.
• Various machine Various fault codes shown. If there is water in it, remove the injection ECU and dry it.
running faults. Dry the injection ECU connector and grease with special
• Injection diagnostic light electrical terminal grease (non-conductive Esso 3106
on available from Automobiles Peugeot part number: 973568).
Refit the cover (1) correctly.
Fit an ECU protective flap (2) see XAL-XAM campaign.
Cause: water ingress into If after drying the faults cannot be cleared, change the
ECU connector ECU.

Production change:
Injection ECU connector fitted with grease as from:
18/11/2002 VIN N° VGAH2AB0030100255 for
125cc
VIN N° VGAH2AC0030100592 for 150cc
Fitting of protective flap to injection ECU bracket as from:
(1) connector cover (2) Flap part number 761640 13/12/2002 VIN N° VGAH2AB0030100257 for 125cc
: 13/12/2002 VIN N° VGAH2AC0030100593 for 150cc

Diagnostic procedures Page 1

ELYSTAR 125cc-150cc Electronic injection system diagnostic
Problem
Machine lacks power
Cause: injector incorrectly
positioned
• Engine stalls under hard
deceleration
• Engine stops after filling
the fuel tank
Spark plug very black.
Cause: non-conformity of the
pump system, fuel entering the
regulator vacuum circuit.
Diagnostic procedures
Main problems encountered
Checks Operation
Check that the XAI recall campaign modification has Fit injector positioning lug part number 705008.
been made. Load the new calibration ref EL 1202-3-1 min. into the
ECU.
Production change:
Injector position warranty since: 26/09/2002 VIN N°
VGAH2AB0030100247 for 125cc
VGAH2AB0030100340 for 150cc
Check that the XAG recall campaign modification has Check mark on gauge 113.2
been made. Change the pump assembly if the mark is incorrect.
The pump assemblies conform if the mark on the gauge
is above: 113.2.
Production change:
New pump assembly fitted since: 05/06/2002
VIN N° VGAH2AB0030000708 for 125cc
Start of production for 150 cc
Page 2
ELYSTAR 125cc-150cc Electronic injection system diagnostic Main problems encountered

Problem Checks Operation

Engine does not start. On turning on the ignition, If the pump is running and there is no pressure, invert
Check the pump is running. the two pump (1) power supply wires (2) on the pump
Cause: fuel pump running Check there is pressure in the fuel hose on the pump output (hose assembly.
backwards. should be hard).

Production change:
Connection guaranteed since: 25/07/2002
VIN N° VGAH2AB0030001870 for 125cc
VIN N° VGAH2AC0030000882 for 150cc

Diagnostic procedures Page 3

ELYSTAR 125cc-150cc Electronic injection system diagnostic
Problem
Diagnostic light on.
Cause: ECU fault
Diagnostic procedures
Main problems encountered
Checks Operation
Read the fault codes with the diagnostic tool:
battery voltage fault
With the diagnostic tool, check the voltage detected by
the ECU (Ucalculation)
Using a multimeter, check the actual battery
voltage (Ubatt) (battery connected)
If Ubatt shows >12.5V and Ucalculation incorrect, then:
Check the injection ECU power supply voltage. With the
connector connected and ignition on, Uconnect, is
measured on the ECU connector between terminals 1 and
15.
Injection ECU identification
if Uconnect is incorrect < Ubatt, test the wiring harness
if Uconnect is good = Ubatt, change the ECU
Production change:
ECUs affected: manufactured by Philips
ECUs under warranty:
As from manufacturing order n° 325-026-0C the letter must
be later than C
Page 4
ELYSTAR 125cc-150cc Electronic injection system diagnostic
Problem
Cold starting difficult, the
engine will not rev.
Instrument cluster
reading error.
Diagnostic light flashes.
Cause: Inversion of
engine temperature
sensor (white) and idle
valve (blue) connectors
Cold starting difficult, the
engine will not rev.
Cause: throttle housing
problem, potentiometer
cursor skip
Machine does not work
Diagnostic light on
Cause: short circuit on
light blue wire (sensors
power supply)
Diagnostic procedures
Checks
Read the fault codes with the diagnostic tool:
Engine temperature sensor fault
Read the fault codes with the diagnostic tool:
potentiometer speed fault
Read the fault codes with the diagnostic tool:
throttle potentiometer, sensors power supply air pressure and air
temperature sensor fault.
Main problems encountered
Operation
Check correct fitting of the connectors:
White connector on engine temperature sensor.
Blue connector on idle valve.
Production change:
Fitting guaranteed since: 22/10/02
VIN N° VGAH2AB0030100593 for 125cc
VIN N° VGAH2AC0030100257 for 150cc
Change the throttle unit and initialise it with the
diagnostic tool.
Use the diagnostic tool to check the power supply
voltage to the “read parameters” sensors
If the value is incorrect, disconnect the sensors
involved one by one: throttle potentiometer, and air
pressure sensor and check the power supply voltage
with the diagnostic tool.
If the voltage is 5 volts, one of the sensors is short-
circuiting, test the sensor and change it if necessary.
If the voltage is under 5 volts, test the isolation from
the earth of the light blue wire on terminal 18.
If the isolation is correct change the ECU.
Page 5
ELYSTAR 125cc-150cc Electronic injection system diagnostic Main problems encountered

Problem Checks Operation

• Engine does not start. Read the fault codes with the diagnostic tool: Use the diagnostic tool to read the parameters.
no fault When the starter motor is cranked the engine speed should
• Engine starts but will change. If it stays at zero, test the engine speed sensor
not rev.
Read the parameters with the diagnostic tool:
engine speed
Cause: engine speed
sensor faulty

With the ECU disconnected, use an ohmmeter on the ECU

connector
between terminals 19 and 20 to measure the sensor resistance
which should be R=110Ω ±2%

Between terminal 19 and earth, the wire isolation should be R=8

Between terminal 20 and earth, the wire isolation should be R=8

Diagnostic procedures Page 6

ELYSTAR 125cc 150cc Electronic injection instrument cluster diagnostic Main problems encountered

1 VC Hazard warning lights 20 VI Direction indicator unit

2 JN-BE Headlight warning light 19 JN-VE Fuel gauge
3 BA-NR or BE Oil pressure sensor 18 Not connected
4 NR Ignition on power F15A 17 VE Instrument cluster earth
5 BC ABS/PBS diagnostic light
6 MR or MC Sidelights power supply
7 BA Coded immobiliser warning
light
8 BE Injection diagnostic light 16 Not connected
9 JN-BA Fuel gauge 15 Not connected
10 Not connected 14 MC Machine speed signal
11 RG-BA Temperature gauge rear view of 13 RG Battery positive power
12 instrument cluster connector F15A

Problem Checks Operation

The coded immobiliser Carry out the “ECU immobiliser function test” (see page 3 of
LED stays on and the the Information Flash N° 23 Elystar 50cc Diagnostic Aid) to
machine starts confirm it is no longer active.
In case of confirmation, change the injection ECU and turn on
the ignition with the red key to program in the key codes then
Cause: Coded set the throttle flap with the diagnostic tool ("service
immobiliser function functions" - "initial potentiometer").
neutralised in the Start the machine, the coded immobiliser light (1) should go
injection ECU. off.
Production change:
This function is necessary for machines without a coded
immobiliser, no production change necessary.
Instrument cluster warning Check that the green wire, terminal 17 on the
lights stay slightly on instrument cluster, is properly earthed and not cut.
Cause: instrument cluster
bad earth

Diagnostic procedures Page 7

ELYSTAR 125cc 150cc Electronic injection instrument cluster diagnostic Main problems encountered

Problem Checks Operation

Malfunction in instrument Check the instrument cluster connector is properly clipped on.
cluster, no speed reading, Check correct positioning of wires (the right colour to the right
or no display at all. terminal) and each wire is properly clipped into the connector.
If all is correct, change the instrument cluster.
(ABS warning light does
not come on) Production change:
Instrument cluster modified as from 15/07/02
Cause: bad contacts or VIN N° VGAH2AB0030001664 for 125cc
cluster connector badly VIN N° VGAH2AC0030100740 for 150cc
fitted or cluster quality
Fuel level reading fault Check that the speedo is functioning correctly Check the correct position of the wires in the instrument
Reminder: cluster connector (see diagram page 7).
Cause: inversion of wires The fuel level is only updated when the machine is Check the correct position of the wires in the fuel gauge
connector, 3-pin connector, yellow-green wire in middle
or cluster quality. driving (speed signal) or when the ignition is turned off terminal 2, yellow-white wire in terminal 1, and terminal 3
and on again unused.
(See manual and method N° 14)

full 2/3 1/3

Using an ohmmeter, check that the gauge resistance varies

with the position of the float. (full 10 Ω empty 90 Ω approx)
Test the continuity of the two wires between the gauge and
the instrument cluster
If all is correct, change the instrument cluster.
reserve 1 reserve 2 empty
Production change:
Harness manufacture warranty since 25/07/02
Cluster changed since 15/07/02
VIN N° VGAH2AB0030001870 for 125cc
VIN N° VGAH2AC0030100882 for 150cc

Diagnostic procedures Page 8

ELYSTAR 125cc 150cc Electronic injection instrument cluster diagnostic
Problem
Speedo needle does not
return to zero
Cause: cluster quality
ABS/PBS warning light
permanently on and
system operates
normally.
Cause: wire between
warning light and ECU is
cut
Diagnostic procedures
Checks
The light blue wire should be earthed to turn off the light.
Important: the warning light only goes off when the machine
exceeds 5 km/h
Use a voltmeter to test that terminal 18 of the modulator goes
to earth when the front wheel speed exceeds 5 km/h.
Terminal 18 is earthed: check the harness and the instrument
cluster.
Terminal 18 is not earthed: change the ABS/PBS modulator.
Main problems encountered
Operation
Change instrument cluster
Production change:
Instrument cluster modified as from 15/07/02
VIN N° VGAH2AB0030001664 for 125cc
VIN N° VGAH2AC0030100740 for 150cc
If the light does not go off when the machine exceeds
5 km/h
Use a piece of wire on the instrument cluster
connector to connect terminal 5 (light blue wire) to
earth
If the light stays on, change the instrument cluster
If the light goes off, check the continuity of the light
blue wire between the instrument cluster terminal 5
and the ABS/PBS module terminal 18 R<1Ω.
instrument cluster connector
Page 9
ELYSTAR 125cc 150cc Electronic injection miscellaneous diagnostic
Problem
Hazard warning lights do
not work on one side but
the direction indicators
work.
Hazard warning lights do
not work with ignition off
Cause: hazard warning
lights relay fault
Battery charge light on
Cause: battery is flat
Diagnostic procedures
Main problems encountered
Checks Operation
Reminder: the hazard warning lights can only operate with the Check the relays are properly clipped into the
ignition off if they were turned on before turning off the ignition connectors and the terminals in the connectors.
Check the wires are properly clipped into the
The hazard warning lights are controlled by a set of 3 relays connectors.
located in the bottom right of the lower panel
Clean the relay contacts and grease them.
(Esso 3106 non-conductive grease available from
Automobiles Peugeot part number: 973568).
Production change:
Relay connectors greased since: 14/06/2002
VIN N° VGAH2AB0030000768 for 125cc
1 - hazard warning lights relay LH side VIN N° VGAH2AC0030100127 for 150cc
2 - hazard warning lights relay RH side
3 - hazard warning lights re-supply relay
The battery charge warning light comes on if the battery Check the battery voltage, which should be over 12.5
voltage drops below 11.7 volts. volts.
The ABS/PBS diagnostic light comes on, and a battery
voltage fault is recorded if the battery voltage drops
under 9.5 volts
The injection diagnostic warning light comes on, and a
battery voltage fault is memorised if the battery voltage
drops to under 8.5 volts.
Recharge the battery.
Test the charging circuit. The charge voltage must be
between 14 and 15 volts.
Reminder: when preparing a new machine, the battery
must be on charge for at least 2 hours before handing
1 coded immobiliser warning light 3 injection system warning light over the machine to the customer.
2 charging circuit warning light. ABS/PBS system warning light
Page 10
ELYSTAR 125cc 150cc Electronic injection miscellaneous diagnostic
Problem
15A or 25A fuse blown
Causes: short-circuit on a
component or on the
harness
15A fuse incorrect or
inverted with 25A fuse
Diagnostic procedures
Checks
Change the blown fuse using the tool below (made
locally)
Make the above tool by using a blown fuse and solder on
two wires supplying a 12 V 10 W bulb.
If the bulb does not light, there is no short-circuit and the
fuse should not blow.
If the bulb lights, there is a short-circuit on the harness.
Main problems encountered
Operation
Check the fuses are correct, main fuse 25A, ignition
on fuse 15A
Connect the tool opposite in place of the blown fuse.
Disconnect the circuit components one by one until
the bulb goes off. When the bulb goes off, it means it
is the disconnected component or its wiring which is
faulty.
Test the component and the relevant harness
insulation.
If all the components are disconnected and the bulb
stays lit, then it is the harness itself which is short-
circuiting.
Check fitting of the harness (wear against the frame or
securing lug, etc.)
Production change:
Fitting of an after ignition on fuse of 15A since:
30/02/2002
VIN N° VGAH2AB0030000498 for 125cc
Start of production for 150 cc
Page 11
ELYSTAR 125cc 150cc Electronic injection miscellaneous diagnostic Main problems encountered

Problem Checks Operation

Battery discharged after 1 Use a blown fuse, and solder on test wires enabling Check the battery voltage, which should be over 12.5
or 2 days. connection of a multimeter volts.
The multimeter should be set to the ammeter position
Causes: enabling measurement of a 10A current.
• Permanent current
drain on a component
• Charging circuit faulty

Recharge the battery.

Test the charging circuit. The charge voltage must be
between 14 and 15 volts.

Reminder: when preparing a new machine, the battery

must be on charge for at least 2 hours before handing
over the machine to the customer.

Connect the tool opposite in place of the 25A fuse.

Take care when measuring that the current is not greater
With the ignition off:
than the multimeter capacity.
The power consumption must not exceed 20mA

If the power consumption is over 20 mA disconnect

the components permanently powered from the
battery positive until the one drawing the current is
found.
Test the component and its electrical circuit, repair it
or change it if necessary.
Test the component and its electrical circuit. Repair or
change as necessary.

Diagnostic procedures Page 12