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06/06 ZX636 ZX6R speedo upgrade and TRE

213K views 525 replies 183 participants last post by  Extr400 
#1 · (Edited)
05/06 ZX636 ZX6R speedo upgrade

Hello everyone.

A while ago there was a big discussion on how to fit a P7 style ZX6 speedo onto an older model bike (typically the 05/06 C1H model).

The main reason for doing this was to have the nice white dial easily readable clocks instead of the quite trick but less clear LCD type.

Well the long and short of it was that you could replace the speedo (indeed the mounting bolts are exactly the same for both models) so long as you made up an adapter (because the speedo used a different connector on the new model). However you had to put up with an annoying flashing warning light caused by no ECU communication to the clocks. The only solution at the time was to tape over the light, but then you wouldn't have the benefit of any real warnings.

At long last I've got around to reverse engineering the communication signal between a P7 ECU and a P7 speedo. The idea is we fit a little micro chip circuit to fool the new speedo and make it all work perfectly on an 05 ZX636. In fact, not only does the warning light behave, but we can also make the gear indicator work properly (ie make a TRE type gadget) too.

I don't expect this to be much use to most folks, but I wanted to put the info into the public domain as its apparently not known. You would need to be an electronics engineer to make use of this stuff.

OK, here we go with part1. The signals:

The speedo ECU comms line has a built in pull-up resistor to 10v so to inject a signal we need an open collector drive.
The comms line is normally HI (9.8v or so)
Data is sent in three packets at 10ms period between the start of each data byte.
The data signal is repeated at a period of 80ms (or roughly 60ms from the end of one packet to the start of the next).
If the data is interrupted, then after a few seconds the speedo will report a FI error and do the flashy red light (LED) thing, so we need to keep the data packets going continuously.
The data starts only when the ignition is turned on.
The three packets of data are all serial 8 bits plus one start bit (lo). The period of each bit is 64us.
(The following data is written as if it were a timing diagram)

1st gear ...10100000001..(10ms)..10000000001..(10ms)..10100000001..(60ms)..
2nd gear ...10010000001..(10ms)..10000000001..(10ms)..10010000001..(60ms)..
3rd gear ...10110000001..(10ms)..10000000001..(10ms)..10110000001..(60ms)..
4th gear ...10001000001..(10ms)..10000000001..(10ms)..10001000001..(60ms)..
5th gear ...10101000001..(10ms)..10000000001..(10ms)..10101000001..(60ms)..
6th gear ...10011000001..(10ms)..10000000001..(10ms)..10011000001..(60ms)..

So for 1st gear, if we monitor the speedo to ECU signal line (on a P7 speedo to P7 ECU of course) then we see the signal go to 0v for 64us then 9.8v for 64us then 0v for 448us then back to 9.8v
There is then a gap of 10ms (less 576us) to the middle packet which is a null frame: 0v for 576us
After another gap of 10ms (less 576us) the first data byte is repeated.
The data line is then inactive (still at 9.8v) for around 60ms until the whole thing is repeated.
(In the data sequence shown, dots represent where the data line is at a steady 9.8v level)

The speedo uses these data packets to continually verify the comms to the ECU, but of course these also represent what gear we are in.
So long as any of these 3 byte data packets are being sent then the FI/red LED will not be activated due to comms fail.
If the bike is in neutral then no gear is shown on the LCD part of the speedo.
If the bike is in gear then the LCD segment shows gear 1-6 depending on what data packets are being sent on the ECU comms line.

We are now in a position to make our own automatic gear indicator using engine RPM and wheel tacho signal. This is done by dividing the engine RPM count by the wheel tacho count. Both these signals already go to the speedo for displaying speed and revs.

OK, so I'll follow this up with a part2: cheap hardware to do all the signal controls.
Finally part3: this will be the software to program into a PIC micro.

Cheers

Extr400
 
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#464 ·
So here's the thing. A test victim in the USA was unable to get the adapter working despite months of effort which nearly drove me suicidal.
However we got it working with a second UK tester and ss far as i know he's still using it.
I'm kind of reluctant to persue it further unless its with another local member to the UK as its quite expensive sending things back and forth.
Also there is vertually no demand!
 
#470 ·
@snussnus: No, my adapter is only for using with 2007 to 2012 speedos. You will need to buy a speedohealer to fix it. @scavone128: Yes i have 05/06 adapters built up. I'll pm you back.

Update: i have a new batch of cable assemblys ready to fit on adapters for anyone with the 03/04 ZX6R or ZX636. Will pm those that were waiting for these to be ready.
 
#471 · (Edited)
Modern Gauges Finally!!

Extr400 Payment sent last night Bro! :cheers-004:

I have been waiting to pull the trigger for a while with this much needed upgrade. I wanted to see how well the adapters worked and Extr400 handles any service issues that might come up.. Well after watching Extr400 I am confident in his character and adapter design, I am looking forward to installing my modern mix rpm/mph gauge

if there is anyone considering buying one of these wonderful Adapters go for it the gear indicator alone is worth the price, I have to bump this thread and Extr400 he is always checking in on this thread and is still writing code support if it is needed and from what Ive seen over the years, Extr400 is always trying to improve upon his adapter. He could sell these adapters for more then what he is charging our members imo. much Respect to all Staff and Members!

I posted couple pics one of new projectors and mirrors, the other is showing how I soldered in modern bright Leds in old speedo and it did help a little in seeing speedo in the daytime and appearance was much improved, but overall, the speedo itself is worthless for a tool on street or track. This speedo upgrade is the only way to go..

Thanks JD
 

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#472 · (Edited)
The Adapter arrived last week in good shape, but I cannot install the adapter until a find a replacement 2009 gauge in good shape for fair price, The gauge I bought from Ebay last week was DOA and Ebay's only has a couple 09-11 gauges right now and they are over-priced or in bad shape.

Can you tell me the main differences between the 2007 gauges and 2009 gauges, I having trouble finding 2009-11 on Ebay right now but the 2007 are $50 to $75 cheaper and there are several. I already know the cosmetic differences but cannot find any info on the physical differences if there are any. :confused:

Extr400's Service and Communication has been 10 of 10, If your thinking about upgrading to this gauge, go ahead and buy one, Extr400 has made my buying experience smooth as hell and he deserves to make some R&D back with as much time and effort he has invested to make one SICK looking and Functioning Mod for our Bikes! :rock:
 
#475 ·
Just an update to say I have a new batch of adapters ready for the spring.
The ZX6 / ZX636 2005/6 type has the two connectors back to back (the type on the left, in the pic below). This is plug and play with no bike mods what so ever.

The 2003/4 type has the short harness to allow easier fitting on the clock brace. You still have to do a small amount of filing and use a couple of rubber washers to mount the new gauge. There is a very good 'how to' install guide for 03/04 model here:

http://www.kawiforums.com/2003-2004...r-speedo-cluster-fitment-extr400-adapter.html

Its also possible to use slight variation of the adapter on ZX6 models from 98-02. The more modern gauge is a bit more tricky to mount as the fixings don't line up. You have to make an adapter mounting plate. This also requires a special version adapter that re-scales the temperature sender signal and disables the fuel warning LED. This version also requires that the bike connector on the end of the loom has its pins re-arranged (called re-pinning). Its fairly easy to do. There is an instruction about it here:

http://www.kawiforums.com/how-tos-faqs/82684-how-03-06-636-gauges-g-j-model-600-a.html

Adapters are sent from the UK (Scotland) and cost £42 for the 03 to 06 type and £52 for the 98 to 02 type with additional temp rescale. Post by 1st class is £3
For USA, Europe and rest of world, cost is $70 for the 03 to 06 type plus $16.50 shipping by tracked airmail. Other countries at equivalent exchange rates.

If you want an adapter, I suggest you read over the thread on here as most questions have already been asked and answered.
Its a good idea to find a suitable new gauge first. Any ZX6 gauge from 2007 to 2012 will be OK. the 07/08 ones have smaller numbers, the 09/12 ones have larger numbers and look a bit more modern (garish?). ebay is the go for finding these. The adapter can be set to roll the ODO reading of the new gauge forward, you have to stop it when it matches the reading of the old gauge you are replacing. This allows you to keep the mileage history of your bike correct. You can NOT roll the ODO backwards!!!

The setup program will only run on a Windows PC (any version of Windows). It is not Mac or Linux compatible - so if you want you adapter set up all ready to go, please ask me to do this.

The adapters correct the engine speed signal of the bike to make it work with the new gauge. As part of this function it will correct gearing changes too. So for example if you have -1/+2 front/rear sprockets then you just select this option in the setup program and load it (via a supplied USB cable) into the adapter.

When enquiring, please send a PM and include your country and bike year and if you want me to setup your adapter with whatever gearing. Also supply me an email address if you want a paypal invoice to be sent (you don't have to have a paypal account to pay these if you don't have one already).

These adapters have been tested and developed with the help of forum members to which I'm most grateful. As a community project its small scale and non commercial, however they are designed to be as professional and reliable as possible.

Happy riding
Extr400
 

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