How to: Install 2nd Gen Gauge Cluster on 1st Gen - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 23 (permalink) Old 9-20-2009, 10:35 PM Thread Starter
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How to: Install 2nd Gen Gauge Cluster on 1st Gen

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
Soldering Iron
Solder
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!!

(Engine off)


Enjoy!

2000 R1 - Mig shorty, Barnett clutch, PZRacing Geartronic2, fleabay levers, Goodridge front lines, Galfer rear line.
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post #2 of 23 (permalink) Old 9-20-2009, 10:45 PM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

Awesome.
post #3 of 23 (permalink) Old 9-21-2009, 8:49 AM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

Very good - a great addition to the forum.

Recommend moving to the how-to section, and sticky-ing.
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post #4 of 23 (permalink) Old 9-21-2009, 3:03 PM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

Excellent write up!! I was thinking about how to do this the other day! I do have a few questions for you tho,

1. I can't tell from the photos, do the stock mounting holes line up?
2. How do the plastics line up? On the first gen you have those two huge pieces that do not look like they would fit on this one.
3. Do you have any pictures of this with the upper fairing on? I would love to see the final product!

Thanks!!!
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post #5 of 23 (permalink) Old 9-21-2009, 8:07 PM Thread Starter
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

I honestly haven't even started on actually mounting it yet. Once I do I can post some pictures. For mounting i'll probably use some sort of angle iron and just fab something up. As far as fitting into the fairing, i am sure it will work. For the trim pieces, not so sure. I might play around with it tonight or tomorrow and let you know how it goes.

First thing was first and that was to get it working on my bike!

2000 R1 - Mig shorty, Barnett clutch, PZRacing Geartronic2, fleabay levers, Goodridge front lines, Galfer rear line.
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post #6 of 23 (permalink) Old 9-23-2009, 1:57 AM Thread Starter
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

Alright I took some pics with the upper fairing on. I just set it in place and put two mirror screws to hold it.






I think it can work out alright after some trim work. Keep in mind it's still not mounted to the fairing stay yet.

2000 R1 - Mig shorty, Barnett clutch, PZRacing Geartronic2, fleabay levers, Goodridge front lines, Galfer rear line.
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post #7 of 23 (permalink) Old 6-15-2010, 12:14 AM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

any additional trim work yet?

90' ex500<br />US Marine<br />Firefighter
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post #8 of 23 (permalink) Old 6-22-2010, 2:46 PM Thread Starter
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

I've been playing around with the 1G trim work a little. I cut some up to fit in there but I want to get something that slips between the cluster and fork tubes to take up the gap, as the cluster doesn't come down as far as the stock one. (Probably the way I mounted it. Too close to the windscreen.)

I have also been thinking about the swap I did and i am still unsure if it is required to replace the tach board. I'm not sure if the one I had was functional or not. I bought from a guy and he said it was working the last time he used it. Who knows.

Overall i am pleased with the swap. It is still fully functional and working as it did the day I finished it up.

For a little clarification on how I actually mounted it.. I had some stainless steel sheet laying around that I cut a section out of to fit the fairing stay. I just measured, marked and cut along the way, marked and drilled holes and bought metric allen head bolts / washers / nuts from the hardware store to fit it on. The stainless sheet bolts to the fairing stay and then the cluster bolts onto the stainless sheet. I think I also used rubber grommets with the bolts just to keep it from making noise and kind of dampen any vibration.

Once I get the trim fitted I will post pictures.

2000 R1 - Mig shorty, Barnett clutch, PZRacing Geartronic2, fleabay levers, Goodridge front lines, Galfer rear line.
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post #9 of 23 (permalink) Old 1-6-2011, 8:40 PM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

i would like to know more about the tach mod . Wondering why the board had to be changed.
the tach should only need power ground and coil negative. very interesting read.
thanks for posting Brandon.
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post #10 of 23 (permalink) Old 2-21-2011, 5:02 PM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

Interested in an update. I might have to install a Gen 2 cluster on my Gen 1 as part of a swap.
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post #11 of 23 (permalink) Old 5-15-2011, 2:51 PM Thread Starter
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

Sorry for the late response. I don't visit the forum as often as I used to. I'm not sure exactly why the tach board had to be changed out. The one I received may have been a dud. I did get around to fitting the stock trim around it but I don't have pics of it and at the moment the front fairing is all busted up. All I did was just cut the trim pieces to fit around the new cluster though. The only bad side to this that I see is the speedometer is slightly off due to the wheels being 1 inch smaller than the 2G wheels. If you were to get a set of 2G wheels, it would be alright.

2000 R1 - Mig shorty, Barnett clutch, PZRacing Geartronic2, fleabay levers, Goodridge front lines, Galfer rear line.
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post #12 of 23 (permalink) Old 5-15-2011, 6:46 PM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

Quote:
Originally Posted by xfxBaker
Sorry for the late response. I don't visit the forum as often as I used to. I'm not sure exactly why the tach board had to be changed out. The one I received may have been a dud. I did get around to fitting the stock trim around it but I don't have pics of it and at the moment the front fairing is all busted up. All I did was just cut the trim pieces to fit around the new cluster though. The only bad side to this that I see is the speedometer is slightly off due to the wheels being 1 inch smaller than the 2G wheels. If you were to get a set of 2G wheels, it would be alright.
Thanks. Do you see any change in what the tack reads? I ended up doing the reverse of your install but your write-up was a huge help. When I swapped the Gen2 tack board into the gen1 it was reading very low and I had to adjust it. It's close now but now perfect (not sure if I can get it perfect anyway.

As for the speedo it shouldn't matter about the rim size and I believe the overall diameter of the wheel (rim + tire profile) should be almost equal between the Gen1 and Gen2 so the rotational speed will remain relative to each other.
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post #13 of 23 (permalink) Old 8-6-2012, 6:12 AM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

Has anyone done this that can put a picture of the completed install up? thinking of doing it myself.
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post #14 of 23 (permalink) Old 12-19-2012, 7:42 AM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

I might have to try this

[quote author=FOG link=topic=39738.msg584730#msg584730 date=1350218865]<br />The key to cornering and EX fast is to release your death grip on the bars, let them float ,get your ass off the seat ,load all you weight on the outside peg and drive your inside knee into the tank.[/quote]
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post #15 of 23 (permalink) Old 9-12-2015, 4:19 PM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

Just finished this mod the other day. Great instructions and pictures to go by!!

I did switch the tach board because I didnt want to skip a step. Plus my other tach was messing up.

Works great!! Now I have to figure out how to mount it.
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post #16 of 23 (permalink) Old 2-10-2016, 1:17 AM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

I just did this, but the opposite way. My 2nd gen didn't have a fairing or stock gauges, but i got my hands on a parts bike with a 1st gen fairing and gauges (thank you Urbane). The re-pin was easy with an awl. The only wire that doesn't have a connection is the wire for the headlamp warning light that would go to the reserve lighting module on a 1st gen.
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post #17 of 23 (permalink) Old 3-13-2016, 5:28 PM
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Re: How to: Install 2nd Gen Gauge Cluster on 1st Gen

Slowly working on my project. I heard my engine for first time yesterday. I received my compression gauge adapters, checked compression - 170# on 1 and 180# on 2-. Put the oil lines back in and poured gas down the hose into float bowls, jumped a car battey and I'm happy. My question-Will the Gen 2 headlight and bracket fit through the Gen 1 fairing? I'm using Gen 1 frame and front fairing, everything else I hope to be Gen 2.
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post #18 of 23 (permalink) Old 7-27-2016, 4:15 PM
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That is some good stuff. I was wondering if this could be done. I'm glad someone shared their hard work to make it easier for others.
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post #19 of 23 (permalink) Old 2-13-2017, 1:00 PM
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Tach board

Has anyone tried this without changing the tach board?

I have a Gen2 cluster lying on my desk ready to mod onto my Gen1.. And its not an insurmountable task if it is necessary, I'd just like to know if it definitely is.. necessary-

thanks
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post #20 of 23 (permalink) Old 2-14-2017, 12:01 AM
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It is definitely necessary.. They measure the speed of the engine using two different signals. I did a 2nd gen to 1st gen swap once, and it really was easy to get done.
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post #21 of 23 (permalink) Old 2-14-2017, 12:55 AM
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Quote:
Originally Posted by LokiCopenhagen View Post
Has anyone tried this without changing the tach board?

I have a Gen2 cluster lying on my desk ready to mod onto my Gen1.. And its not an insurmountable task if it is necessary, I'd just like to know if it definitely is.. necessary-

thanks
I've not done a swap like that as I have a Gen 2 already but I can tell you it's most likely gonna be neccesary to swap boards...
I'm guessing it has to do with the difference in the Gen 1 and Gen 2 pick up coil set up.
Gen 1 uses two pick ups and two triggers.
Gen 2 uses two pick ups and only one trigger.

Can't say that's 100% the reason though as I haven't read the write up on the swap.

O_E_M
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post #22 of 23 (permalink) Old 2-28-2017, 4:30 AM
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Quote:
Originally Posted by one_evil_monkey View Post
I've not done a swap like that as I have a Gen 2 already but I can tell you it's most likely gonna be neccesary to swap boards...
I'm guessing it has to do with the difference in the Gen 1 and Gen 2 pick up coil set up.
Gen 1 uses two pick ups and two triggers.
Gen 2 uses two pick ups and only one trigger.

Can't say that's 100% the reason though as I haven't read the write up on the swap.

O_E_M
Well I got the swap done, and it worked like a charm. Except for some reason my "black" connector plug is red, and some wires were different colors.

Picture related
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File Type: jpg 17036944_10212262878595596_53825098_o.jpg (145.6 KB, 17 views)
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post #23 of 23 (permalink) Old 3-1-2017, 2:13 PM
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Originally Posted by LokiCopenhagen View Post
Well I got the swap done, and it worked like a charm. Except for some reason my "black" connector plug is red, and some wires were different colors.

Picture related
The color differences may be due to being a European bike versus a North American one... possibly...

So did you wind up having to swap the boards?

O_E_M
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