ATTENTION: HARDWARE TEST FOR 6-PIN BIKE-SIDE HARNESS THAT WILL OFTEN SOLVE YOUR ISSUES
NOTE: THIS TEST IS FOR THE 6-PIN BIKE-SIDE HARNESS. IF YOU HAVE A 4-PIN BIKE-SIDE HARNESS (THE PART NUMBER ON THE LABEL BEGINS WITH THE PREFIX "4P"), PLEASE USE THIS TEST.
The bike-side harness requires careful installation to insure a complete and error-free flash process. About 90% of the issues that cause error codes we see can be traced to a hardware connection problem. This test is more definitive than the software test interface that a lot of users have suddenly started trying to use after seeing it in a couple of posts; without the proper steps and looking at the correct data, all it does is confuse the issue.
This test is easy to do, and requires just a small jumper wire or paper clip, and a multi-tester.
Take the bike-side harness connector, and remove the weather-seal cap (or disconnect it from your USB Data Link cable). Looking at the face of the connector (opposite the side where the wires are inserted), determine where each color wire (there are four: Red, Orange, Yellow, and Black) pin is located. With your bike's ignition key turned off, use the small jumper wire or bent paper clip to jump the Red and Orange wire pins by inserting it into the respective pin locations on the face of the connector. Turn the ignition key on; if you hear your bike's fuel pump priming, that means you have a connection issue with either the Red or Orange wires (or both). Check them carefully to ensure that the pins are seated correctly (all the way into the connector, and that the crimped portions are facing up towards the connector's locking latch).
If you don't hear the fuel pump, then turn the ignition key off, then jumper the Red and Yellow wires. Turn the ignition key on; if you hear the fuel pump priming, then you have an issue with your Yellow wire. Check its connections carefully.
If you don't hear the fuel pump at that stage, take a multimeter and connect the Black and Orange pins. You should see a consistent 5V. Then connect the Black and Yellow pins. Again, you should see a consistent 5V. Anything less, or inconsistent readings, means that you have a problem with your black (ground) wire. Ensure that the eyelet is solidly connected to a metal surface on the frame; it must be metal to metal contact, no paint or clear-coated surfaces will allow a solid ground connection.