Greetings all. I have just finished converting my 1999 gauge cluster to work with my 1992 EX-500. I made a write-up on how to do it for those interested. I know there have been a few people who have asked but nobody really knew the answer. I don't think anybody else has done this yet, but I am uncertain.
Just a few notes first before we get started.
First off I must apologize for picture quality. I hate this camera and I need a new one. It never focuses right. Also, I have not compared the tachometer to another to make sure it is 100% true. It seems to work perfect, but you never know. Another last thing I would like to add is that I take no responsibility if something happens because of this modification. Theoretically it should work 100% like the original cluster.
Alright, so you're tired of the old school clusters used on the 1st gen bikes and want to upgrade to a 2nd gen cluster. Here's how.
First you need to remove your old cluster from the bike.
Obtain a 2nd gen cluster.
Now go find some tools. Here is what you will need.
1 set of precision screwdrivers
1 good sized phillips head screwdriver
Desolder braid (if you have it [I didn't have any on hand])
Alright, so far so good. Just remember NOT to throw your old cluster away. It is very important in this project! You will have to re-use two parts from it in order for everything to work properly.
Now, in order to use the new cluster you will have to re-pin the connectors and also use a connector from your 1st gen cluster. (The black one) The new cluster has a 6 pin connector that will fit your harness, but the other connector is only 4-pin and needs to have 6.
What I did was push the smallest precision flat blade screwdriver down into the connector to push the spade tab towards the spade. This would allow you to use the other flat blade to push the spade out of the connector. If you're good enough, you can re-pin the connectors in half an hour or less.
(You can also use a paperclip to push/move the tab)
In this picture I am removing the top left wire.
Using this method, take the black connector from the old cluster and put it in place of the 4-pin connector on the new cluster.
The following diagram shows how to re-pin the connectors.
Here are some added pics for reference.
Now that you've successfully set up the new cluster to work with your bike's harness, there is one more thing you have to do in order for the tachometer to work.
You will have to open both gauge clusters to gain access to the tachometers. Since the circuitry (I assume since mine didn't work before this 2nd mod) is different between the two generations, the tachometer will not work unless you re-use your old cluster's circuit board from the tach. Don't worry, you DO NOT have to remove the needles.
Go ahead and heat up your soldering iron.
In the following picture there are 4 screws you have to remove on your old cluster. (Labeled as "Housing")
Now remove these two screws.
Unscrew the temp gauge, speedometer and tachometer screws.
Pull back on this tab with one hand and with the other hand, pull the cover away from the housing.
There is another surrounding piece that just comes right off.
The gauges should be free to come out so place your hand in front of the face, turn the unit upside down and pull the housing away.
On the back of the tachometer you will see a hunk of plastic surrounding a circuit board. (I had already removed it in the pic-sorry)
This is the circuit board AND housing you want to put into your 2nd gen cluster.
To remove this housing you must take a small flat blade precision screw driver and carefully pry where the housing meets the dial housing. Pry a little on each side to work it up. It is only held on there by two tabs
Once that is off of the dial housing, lay it over and prepare to remove the two wires from the circuit board.
Take note of the orientation. The positive wire hooks up in front of the diode, the negative is on the other side.
To remove these wires from the board you want to use your desolder braid to soak up the old solder so you can remove the wires. If you don't have braid you can slightly pull on the wire, away from the board and heat up the solder joint. When the solder melts, the wire should pull out.
Once you have removed the circuit board and housing, you can do whatever you want with the old cluster. It is history!
Now you must take apart the new cluster to swap out the circuit boards.
The tripometer reset knob must be unscrewed. Turn it to the left to unscrew.
Remove the 5 housing screws.
Remove the tachometer wires from the back of the tachometer.
Remove the two tachometer housing screws.
The cluster cover should now be free to remove. Be careful since the tachometer is loose in there from removing the screws.
Carefully pull out the tachometer.
Gently pry on both sides of the circuit board housing just like you did on the old cluster and remove it.
Flip it over and desolder the wires. Note that the wires are in the same position as the old cluster. The old and new circuit board housings are the same size.
Do whatever you want with the circuit board you just removed.
Now it's time to solder up the old cluster tach board to the new cluster tach.
If you were lucky when you pulled out the wires on the old cluster circuit board, it left holes to slip the wires right in. (If you didn't have desolder braid) If you weren't lucky then place the right wire in the right place on the bottom and heat up the solder to slide the wire through the hole. Do this to both wires and make sure you have the wires in the right spot! The red wire goes to the diode side!
Now that you have at least 1 wire in place, solder it in. Once you have both done, installation is reverse of removal and you are ready to rock and roll !!
You should now have a fully functional 2nd gen gauge cluster on your 1st gen!!