First up, Introductions.
Hi My name is Roy and I've been addicted to motorbikes for 21 years.
I'm new to the forum and have come in search of technical assistance.
I'm from Orange NSW and ride a 1982 Honda CB900F, which I have been improving on for the last 6 years.
I know its not a Kawasaki but bits of it now are.
I realize that some here will despise what i have done and i wont hold that against you, i just like building things.
There is a bit of reading ahead and any help you may offer would be greatly appreciated.
After having got all but the finer details sorted I thought I was happy with the bike, I was Wrong! (Or stupid)
All I needed for it was stiffer fork springs, rewiring, a few little cosmetic things and install the new exhaust.
I ended up buying some second hand wheels, forks, triples and controls.
So I set out with these goals in mind:
- Upgrade to wheels, forks, brakes, triple clamps and controls from a ZZR1200. [red]done[/red]
- Install CBR1100XX swing arm [red]done[/red]
- Make new headlight mounts [red]done[/red]
- Make new wire harness [red]delayed[/red]
- Install new exhaust [red]in progress[/red]
During the course of doing these things I also decided to:
- Custom taillights [red]next year[/red]
- Custom rear hugger guard [red]next year[/red]
- Coil on Plug setup [red]easy wiring mod[/red]
- Hydraulic over cable clutch system (no idea if it has any benefits) [red]later[/red]
- Braided Brake Lines [red]next year[/red]
- ZX10R instrument cluster [red]Current Issue[/red]
- fuel injection mod [red]next year[/red]
Back in march this year
Most Recent progress
So there's my introduction. Here is my Problem.
The Kawasaki ZX10R Instrument Cluster.
I am currently testing the cluster using the power supply from a pc.
Upon powering up it runs through the startup diags and everything is fine, as per the manual.
The blinkers, High beam, oil warning, neutral and shift lights all work as expected and the fuel warning light flashes.
First up, how to turn off the fuel warning light?
Second and most important how to wire up the speedo sensor?
Third, best way to input the Tach signal.
If you have got this far, thanks for sticking with me.
If you know what it is I need to do, please let me know.
I'll now run through what I have gathered from the manual.
Turning off the low fuel warning light: Replicating the Fuel Reserve Sensor
Basically a connection to ground and switches the warning "somewhere around" the 10 ohm resistance mark. (stated in the manual)
To test the function of the warning light the manual says to connect to negative with a rheostat set to roughly 10 ohms.
It doesn't tell you which side of the 10 ohms triggers the waring light.
I have both a 10 ohm resister and a 20k potentiometer. I tried both.
Directly earthing the contact to ground: no change
10 ohm resistor in line: no change
Potentiometer in line: turned off once, somehow. I have not been able to get it to work again.
The speed sensor.
The manual says put an oscilloscope in line and connect to negative. switching between 0v and 5v @ 575 Hz
Alternatively if you don't have access to an oscilloscope, raise the rear wheel and spin to see if there is a signal showing on the speedo.
2 problems here, no oscilloscope and no bike.
The sensor i have is from a 1998 ZX6 but is used on most the models zx6/9/10/12 through to the 2009 at least, except for the
06 07 model. Coincidently this is the model instrument cluster that I have. But it should still work.
The zx10r sensor has 3 contacts one to ground, another to ground throught the ECU and the other to the speedo.
Simple? perhaps.
The bit that gets me is that the wire to the speedo is also connected to the +5v from the ECU, not through the ecu to the speedo but also connected to the ecu. My guess is that the signal to the speedo is set at 5v and the sensor works to varying the signal + or - from that point to produce a frequency.
I haven't yet tried configuring the connections in this way. I will try tonight if I find the time.
Out of curiosity, I put the multimeter from ground to signal input on the cluster, strangely I get 12v. I just dont get it.
Tach Signal
The manual also states to test this with an oscilloscope, otherwise rapidly open and close a connection from negative to the input pin.
I think i have tested this but as i have been sick the last few days of testing i cant remember.
An easy test anyway.
But where to tie the input signal from? From my thinking, the pulse coils. They will give the correct frequency, but what about the voltage?
The manual says that when using the oscilloscope, to oscillate between 0v and 10v. Will it be safe to use the pulse coils?
Once again Thank you for your time.
, electrics are not my strong point so I wont try to answer your question but hopefully someone round here can 
