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Author Topic: Dead Fuel and Temp Gauge  (Read 4736 times)
jdj
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Evo 250 04


« on: April 24, 2012, 14:23:17 »

Hi there I have a dead fuel and Temp Gauge x9 250 evo all other instruments working apart from indicator switch which has just fallen apart. is there a common fuse for the gauges that I have missed or is it a (earth) fault with both gauges. Any pointers would be much appreciated.

Jeremy
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2004 X9 250 Evo finnaly running as it should a lovely ride
Dave Milnes
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« Reply #1 on: April 24, 2012, 19:20:14 »

The analogue gauges are stepper motor driven from a digital signal sent via the digital dash on the handlebars.
Do a reset procedure and see if they move then. Hold down the two RH buttons on the digidash and turn on the ignition. All 4 needles should do a full sweep and settle back to zero. If they still don't move then check the plugs on the back of the digidash and perhaps also the one where the loom connects to the analogue dash. The screen and instrument binnacle will have to be removed. There is a fuse for the digidash but if the speedo and rev counter are working it sounds like either a loom issue or the dash itself has developed a fault. There is a small PCB inside to split the signals to the 4 stepper motors.
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2004 X9 500 Evo in YELLOW - 2016 Maxsym 600i Sport
Anderton 2004, Pen-y-cae 2005, Matlock 2006, Hay on Wye 2007, Minehead 2008, St Florence 2010, Newent 2011, North Kyme 2012, Betsw-y-coed 2013, Hardraw 2014, Parkend 2015, Whitby 2016, Mundesley 2017, Derby 2018, Telford 2019.
jdj
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Evo 250 04


« Reply #2 on: April 24, 2012, 20:41:01 »

Thanks for that have just checked and holding the two buttons down gets all instruments doing full sweep, this tells me that I have power to all but not a signal from either Fuel or Temp Gauge is there a common earth for these?
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2004 X9 250 Evo finnaly running as it should a lovely ride
Dave Milnes
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« Reply #3 on: April 25, 2012, 20:49:02 »

Not sure. Somewheere there is a thread where I listed each pin out on the rear of the digidash plugs.
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2004 X9 500 Evo in YELLOW - 2016 Maxsym 600i Sport
Anderton 2004, Pen-y-cae 2005, Matlock 2006, Hay on Wye 2007, Minehead 2008, St Florence 2010, Newent 2011, North Kyme 2012, Betsw-y-coed 2013, Hardraw 2014, Parkend 2015, Whitby 2016, Mundesley 2017, Derby 2018, Telford 2019.
jdj
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Evo 250 04


« Reply #4 on: April 26, 2012, 19:22:08 »

Dave did the reset again and find that the fuel gauge only spins to three quarters of a tank then settles off the clock to the right temp gauge does full sweep, just wondering if there is any connection with indicators as I am waiting for a new indicator switch to arrive as springs or balls seem to have disapeared so no indicators or hazards. I there a common feed that I have missed on circuit diagram.
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2004 X9 250 Evo finnaly running as it should a lovely ride
Dave Milnes
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« Reply #5 on: April 26, 2012, 21:25:27 »

Both temp and fuel senders are variable resistance to ground with a 12V on the +ve.  Find the water temp sender on the engine and ground the wire, the gauge should rise to max. Could just be a dud sender unit, or a disconnected wire.
The fuel gauge sounds like the needle has moved on the spindle, or the stepper motor has thrown a wobbly and set it's resting point too far round. Does happen sometimes.
The fuel tank level sender connections are on the top of the tank under the tunnel top cover. If you can work out which wires are the coil and sweeper and bridge them, again the needle should rise to maximum.
The connections to the back of the digidash are

8 pin output to analogue dash
Pin 1 same on all models...GND
Pin 2 +ve battery on all but 500 EVO which is GND again?
Pin 3  Serial output on all but 500 EVO which is +ve battery
Pin 4  Immobiliser LED on all but 500 Evo which is Serial output
Pin 5 Serial Output on all but 500 Evo which is immobiliser LED
Pin 6 Panel illumination on all but 500 Evo which is Serial output
Pin 7 Not Used on all but 500 Evo which is panel lights
Pin 8 Not Used on all models
So a slight difference there only on the 500 EVO (if you believe the manuals!)

The 16 Pin middle plug is
Pin 9 is ECU warning light on both 500 models and 'general' warning light on others
Pin 10 is relay alarm (stand) on both 500 models and is ABS warning on others.
Pin 11 is ABS on 500 EVO, brake lamp failure on all others
Pin 12 is feed out to RH indicators all models
Pin 13 is RH button input all models
Pin 14 is LH button input all models
Pin 15 is high beam tell tale
Pin 16 is air temp sensor input on all models
Pin 17 is kill switch warning all models
Pin 18 is oil pressure warning on all models
Pin 19 is brake lamp failure all models except 500 Evo which is not used
Pin 20 is feed out to LH indicators all models
Pin 21 is indicator stop button all models
Pin 22 is service icon reset button all models
Pin 23 is coolant temp sensor input all models
Pin 24 is Fuel level sensor input all models

There is a bit of confusion on the 500 EVO diagram here as it is marked as having 4 pins used for the tacho and no speedo input so I am going to assume that three labelled as tachometer should say speedo, which effectively makes all pins the same on all models which would make sense
The right hand 12 pin socket is as follows:
Pin 25 is +ve battery all models
Pin 26 is Speedo sensor +ve all models (500 Evo which is listed as tachometer sensor I guess in error)
Pin 27 is Speedo sensor -ve  all models (500 Evo which is listed as tachometer gnd I guess in error)
Pin 28 is Tachometer input all models
Pin 29 is +ve on all models
Pin 30 is Anti-theft LED input all models
Pin 31 is Key positive terminal on all models (ignition on live?)
Pin 32 is speedo sensor input all models (500 Evo again listed as tachometer sensor input I guess in error)
Pin 33 is GND on all models except 500 Evo which is not used
Pin 34 is air temp sensor return on all models
Pin 35 is Hazard button on all models
Pin 36 is lights on input panel illumination and back light supply on all models

Pins 23 and 24 look like the ones to check along with Pin 25 and 29.
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2004 X9 500 Evo in YELLOW - 2016 Maxsym 600i Sport
Anderton 2004, Pen-y-cae 2005, Matlock 2006, Hay on Wye 2007, Minehead 2008, St Florence 2010, Newent 2011, North Kyme 2012, Betsw-y-coed 2013, Hardraw 2014, Parkend 2015, Whitby 2016, Mundesley 2017, Derby 2018, Telford 2019.
jdj
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Evo 250 04


« Reply #6 on: April 26, 2012, 21:46:37 »

Dave Thank you I now have a clear picture and hopefully I can get all registering correctly this weekend,as it looks as though the weather has definitely confined me to the garage.
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2004 X9 250 Evo finnaly running as it should a lovely ride
jdj
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Evo 250 04


« Reply #7 on: April 28, 2012, 15:14:08 »

Dave did a visual inspection lifted inspection cover under seat above cylinder head to check connection of sender wire. Sender unit is there but no wire and cannot see one hanging around with or without a spade connector. Have been looking for a wiring diagram, and should this be going to pin 23 on digi display as + Feed if so will look for the colour wire somewhere in the loom or where should I be able to pick it up from on the frame.
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2004 X9 250 Evo finnaly running as it should a lovely ride
Dave Milnes
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« Reply #8 on: April 28, 2012, 20:22:19 »

Manual with diagram should be inn the help section.
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2004 X9 500 Evo in YELLOW - 2016 Maxsym 600i Sport
Anderton 2004, Pen-y-cae 2005, Matlock 2006, Hay on Wye 2007, Minehead 2008, St Florence 2010, Newent 2011, North Kyme 2012, Betsw-y-coed 2013, Hardraw 2014, Parkend 2015, Whitby 2016, Mundesley 2017, Derby 2018, Telford 2019.
Lupingo
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« Reply #9 on: April 10, 2013, 17:03:26 »

I reset the digidash like you said Dave and i noticed: speed and rot/min did a full rotation. But temp. only 50% and fuel 75%. In off mode the temp. needle stays below "0" like in the picture what i posted a few days ago. Also the fuel needle, i think, it's working with some gap. Before this failure fuel capacity was 80%, after was full tank (indicated). You said i have to wait few days to automaticaly reset. I did already 500km and nothing. There is a way so i can fix this?
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Dave Milnes
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« Reply #10 on: April 10, 2013, 20:25:16 »

All the needles don't make it all the way round but as long as they all move and settle back, you know they are working.
The fix is to remove the screen, V-panel and dash pod and remove the dash. Take the unit apart and pull off the needles. Connect and do a couple of resets then replace the needles in the dead stop positions, switch on and off a few times to check the base settings, and when you are happy refit everything.
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2004 X9 500 Evo in YELLOW - 2016 Maxsym 600i Sport
Anderton 2004, Pen-y-cae 2005, Matlock 2006, Hay on Wye 2007, Minehead 2008, St Florence 2010, Newent 2011, North Kyme 2012, Betsw-y-coed 2013, Hardraw 2014, Parkend 2015, Whitby 2016, Mundesley 2017, Derby 2018, Telford 2019.
Lupingo
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« Reply #11 on: April 10, 2013, 20:44:08 »

and when you are happy refit everything.
Hahahahahaha !!!
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Geometrix
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« Reply #12 on: May 22, 2020, 02:55:10 »

Dear X9OwnersClub Forum,

I like Dave Milnes answer above.  He said that the stepper motor has "thrown a wobbly".

One day a couple of months ago, I started my 2005 X9 500 and drove off.  About 10 seconds after I drove off, I noticed that all of my gauges were showing opposite of what they should have been indicating.  I pulled over with engine ridling.  My gauges showed fuel empty (actually full), 180km/h (while stopped with engine idling), tach at 10,000 RPM (should have been at about 1200 RPM while idling), and temp gauge at H when the engine was still relatively cold.

I immediately turned off the engine, waited about 30 seconds, and then started it back up.

Now, my fuel gauge always shows about 1/4 tank less than actual (i.e. full tank shows 3/4).  Speedo is slightly affected as it shows a few MPH less than actual (I know this from some of the local speed indicators on the road that show you your speed).  Tachometer always shows about 900 RPM at idle when I know that it should be 1200 RPM.  And temp gauge needle used to be at 3 o'clock position when engine warmed up, but now always shows about 4 o'clock when warmed up.

When the engine off and key is in off position, the fuel gauge shows way below empty, speedo shows way below zero, tach shows way below 0, and temp gauge shows way below L.  Is this what it should look like?

I think that the needles must have gotten spun around on the gauge spindles because everything SEEMS to be functioning just fine.  I did the reset and this did not fix the problem.

So I think that I will take apart the gauges and fix the needles.

I do not know what could have caused the original episode with the needles going haywire.  Any suggestions?

TIA
--Neal
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Dave Milnes
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« Reply #13 on: May 22, 2020, 14:49:10 »

The needles are driven by digital stepper motors and when all is well they 'know' their zero point but if a spike in the power or a momentary loss of power to them causes them to reset in the position they were in or to at least 'forget' where they are. Removing the needles, doing a few resets then with the power off, then carefully replacing them at their zero position usually works. Do a few more resets or power on/off before refitting the dash and try not to bang it in the process.
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2004 X9 500 Evo in YELLOW - 2016 Maxsym 600i Sport
Anderton 2004, Pen-y-cae 2005, Matlock 2006, Hay on Wye 2007, Minehead 2008, St Florence 2010, Newent 2011, North Kyme 2012, Betsw-y-coed 2013, Hardraw 2014, Parkend 2015, Whitby 2016, Mundesley 2017, Derby 2018, Telford 2019.
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