Repairing Gen 1 Hayabusa Instrument Cluster

[@TheElectronicDilettante]

I’ve been watching your videos for years now, and realized you’re a Suzuki guy. Nice!! The Hayabusa is a BMF!!! I’m starting a modernization project on my 1989 GSX/R 1100. With all your experience with Suzuki electronics, would you mind if I asked you some questions regarding my little experiment?? I didn’t want to just lay it all out here and have the world comment on it. Thanks for all your great videos and software. They’re an invaluable resource to anyone trying to learn Radio, ECE. Just an FYI, I use your vna software and read the documentation regularly. Thanks for taking the time to write it all. Side note, you should make a paid video series on how to make a program like Solver64. I’d pay for that in a heart beat. Anyway, let me know if I can pick your brain about my GSX/R experiment. Thanks again

[@joesmith-je3tq]

KZbin comments is a poor platform to start such a conversation. If you want the world to comment, consider creating an account on EEVBLOG or other forum. Start a new topic and provide me with a link and we can get started.

[@ligius3]

I always wanted to know about those boxes in the background, now I do. Great work, must have been a lot of hours.

[@joesmith-je3tq]

That was a labor of love for sure. It's been a nice tool to have around for troubleshooting and changing the factory firmware. The logger software runs on a tablet computer that mounts to the bike. It can record basically forever and collects the data at the same rate the ECM sends it to the cluster.

[@dominikbratko7646]

Could You change a scale of rpm's (up to 15k rpm) and at the odometer (scale from 0 to 420 kph (261mph))? So that they are at least as accurate as in the original scale.

[@joesmith-je3tq]

Sounds like you are asking about making new scales for the two gauges. That is certainly possible.

[@dominikbratko7646]

@@joesmith-je3tq scale will be ready by then added to the cluster. So at Yours ground will be only to program.

[@joesmith-je3tq]

@@dominikbratko7646 It wouldn't help you with the tach but there was a company who sold a small box that sat between the pickup and head to allow you to use different sprockets. I wonder if they allowed for that high of MPH. It may be easier to get an aftermarket cluster.

[@wktodd]

Sorry, I fell about laughing when at the sound of the motor . I just wasn't expecting that level of simulation 😁

[@johnboyd1167]

As the new proud owner of a Brymen 869S, and idea where i can find Amp Jack Plug, For Digital Multimeter.. the Fluke version is purchased fall out. Video was great as usual, thanks for sharing your work.

[@joesmith-je3tq]

mine came from one of the CEM meters that was damaged. cap plugs makes some that may fit.

[@johnboyd1167]

@@joesmith-je3tq Thanks👍

[@tonyfremont]

Why do you have a custom adapter card in the PC? I assume communications is part of it, but what else does it do?

[@joesmith-je3tq]

The card in the PC is what is used to create all of the signals for the ECM as well as read the signals from it. Nothing to do with the serial communications used to talk with the cluster. That other program I show is separate and used to sniff that serial bus. I used it to review a couple of automotive meters a while ago. Have a look: kzbin.info/www/bejne/p5CbaqSle7KcrMk

[@bloviatingbeluga8553]

Do the stepper comtrollers have an ROM in them that has the step gradient? Or are they not so sophisticated

[@joesmith-je3tq]

I was never able to find a datasheet for the part.

[@reedreamer9518]

I think there's little or no waterproofing to protect that cluster. Mine still works, but it's got a massive mineral stain on the inside of the tachometer lenses from washing the bike, which is annoying.

[@joesmith-je3tq]

There is a gasket that fits between the two case halves. On the bottom, there is the rubber boot that fits over the connector. That's really about it. Odd that the stain is on the inside of your lens. I wonder if it is getting in through the rubber push buttons. Maybe they are starting to deteriorate over the years.

[@Compaan79]

Hi Joe,i have x2 99 Hayabusa"s but on one the speedometer does not register while bike in motion but when I switch bike on the stepper motor does the self test and pass ,when i swap the clocks the other clock work just fine meaning it is not the sensor,I have opened the instrument and could not see any damage ,I assume it is the speed controller chip,,, any advice

[@joesmith-je3tq]

If it runs through the self test, then it's not the stepper motor or controller IC. This is good as these parts are hard to come by. So something else. Problem is this is really a job for a electronics wiz. So unless that is your background, I wouldn't suggest you do anything with it as you may do a lot more harm than good. Opening the unit up without proper ESD protection could easily damage the sensitive parts. Soldering surface mount parts without the proper skills could not only damage components but the main circuit board. Being yours are a 99, I suspect your clusters don't have conformal coating. If the problem does happen to be one of the unobtainable ICs, then you would need to rob the parts from another cluster (like I did for this video). Is it worth having repaired? The labor alone may far exceed the costs of a used one. You may be better off selling the dead one for parts.

[@Compaan79]

Thanks Joe ,will make use of a Gps speedometer for the time being untill I can find replacement clocks

[@joesmith-je3tq]

I just want to be clear that what you refer to as a "clock" is indeed the instrument cluster. To me, a clock would be something that measures time or in the case of the instrument cluster, it has internal clocks that drive the logic. I thing you mean cluster. If that is the case, one thing you may want to do is just have a look at the speed sensor. Make sure that the gap is still correct, the part that mounts to the sprocket is tight. Nothing funny going it. I suspect you swapped the entire cluster but one may be less sensitive than the other to problems with the actual sensor. Easy to check. Good luck.

[@akbikeriders93]

Brother, this is the costume that you are showing off.

[@patrikisaksson3869]

I have a 2000 gen 1 with broken led displays (only shows partcial numbers). Do you think that would be possible to repare and get back correct mileage? Everything else works Great, just thoose 2 led displays that are wonky. And if you think it would be possible to repair, would you take on such a job if I sent it to you? (From sweden, so km/h gauges)

[@patrikisaksson3869]

Hayabusa that us 😅

[@joesmith-je3tq]

@@patrikisaksson3869 I am guessing you mean the LCD displays are not working as I have never seen one with LEDs. If that is the case, you may be able to just bend the tabs that hold them to the PCB and remove them. Clean all the contacts. Then reinstall them. I've seen LCDs fail in this manner. If you decide to try it, first, make sure you are grounded. Wear a wrist strap or something. Use IPA as a cleaner on a swab. Millage isn't stored in the LCD so you should be fine.

[@patrikisaksson3869]

@@joesmith-je3tq Yepp, LCD is correct :) Thanks, I will try that this winter

[@shazam6274]

I'm Stunned! Can't believe you made a specific diagnostic computer program and an emulator for a motorcycle and its instrument cluster. Hardware, firmware, software and FPGA! Watched in awe, mesmerized by it all...until 5:02 when I almost fell out of my chair! Synthesized matching engine sound! Many many questions, but the only one I'll ask here: Is Kawasaki aware of any of this and have they said anything to you? Amazing work and highest respect from a retired OFAE (Old Fart Analog Engineer) !

[@joesmith-je3tq]

If Kawasaki is aware, they have not contacted me. I made this simulator several years ago and posted about it on one of the large forums. May have been dragbike.com. There are also some early videos showing more detail on how it works. I created a playlist for motorcycles where you can easily find them.

[@shazam6274]

@@joesmith-je3tq I looked at your previous videos and was also amazed. I would guess that Kawasaki themselves do not have such a flexible and sophisticated tool. Again, Congratulations on the stunning work.

[@joesmith-je3tq]

@@shazam6274 Thanks. Let me know if you have any specific questions about the simulator.

[@shazam6274]

@@joesmith-je3tq Looks like it's Labview. What now since you have dropped NI (as did I years ago)?

[@joesmith-je3tq]

@@shazam6274 Yes, it was all written in LabView. The original simulator used both C and LabView. The low level synchronous model was all in C. LabView was just the user interface to the model. I wanted to try and use SciLab at one time. Similar to MatLab's Simulink and the real time workshop. I had upgraded LabView at some point and then bought a new PC. The PC was so fast, I ditched C and did all the software in LabView. I think if I were going to design an HIL simulator today, I would ditch the interface card and use a standard high speed serial bus to control the hardware from the PC. After Emerson bought NI, I was contacted by NI to renew my license. They called several time and wrote me emails. They even threatened to lock out my software. They must have inflated the numbers before the company was sold as my account should have been closed. They had refunded my payment and I had removed all of their software. This does not prevent me from using my perpetual license. I can still develop LabView but am locked into 2011. At some point, that software will no longer run on the new computers and that will be the end of it.

[@hussainbinkaram9129]

Hi bro, how are you? I want to find used speedometer from where i buy it My busa is 2006 in need in kilometres

[@joesmith-je3tq]

Outside of ebay, not sure.

[@akbikeriders93]

BRO this miter coupler wire has come out how to fix it please tell us please make a video and post it on youtube channel we will see

[@joesmith-je3tq]

Depending on how much damage was done, you may be able to salvage the pin. I suggest you take it somewhere to have it done rather than risk further damage.

[@khalifaalzaabi8230]

Hello my friend, if you can review the scale UNI-T UT117C

[@joesmith-je3tq]

At a glance, at least they don't claim 200MHz on this one. They show a name brand fuse. Who knows, they may be trying to improve their product line. Personally, I would rather see an improved version of the UT181A. Posted the UNI-T's video review of it on EEVBLOG. Let's see if there is any interest.

[@akbikeriders93]

Please send pics of this meter's wiring please please please

[@joesmith-je3tq]

Easiest thing would be to purchase a manual: haynes.com/en-us/suzuki/gsxr1300r-hayabusa/1999-2007 There are also some free scans on-line.

[@akbikeriders93]

hi bro how are you

[@akbikeriders93]

Bro help me

[@tonyfremont]

Gotta say that's incredibly lame with the gauges being wrong. Doing 27, but it says 20 is a real problem for attracting unwanted attention from a LEO. From an embedded coding standpoint, it looks to me like the ECM code for the stepper motors is treating the scale like it's closer to 360°, instead of the 320ish degrees it actually occupies. This was completely avoidable, just poor coding, leaving it pretty much unfixable. Makes me wonder about the rest of the firmware inside the ECM.

[@joesmith-je3tq]

ECM has never given me any problems, firmware or hardware. The firmware in the early cluster though indeed could use some help but there's not much you can do about it. If that main controller IC hadn't been damaged, I would have swapped it out to upgrade that cluster.

[@saadelectricalandelectroni1832]

After greeting I tried to call you I want to help me send a program (VI) to the card ADS1262