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MPG mod
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Discussion Starter · #1 ·
Ok kiddies, todays lesson, fun with LED's. After a lot of hemming and hawing. I decided to tackle this project myself and not send it out for someone else to do. My bike looked weird being blue/black with 6500k HID's and a blue Acumen gear indicator but the amber gauge backlighting.

This is a very straightforward project but...thats a big BUT is not for the squeamish or impatient. It is a very delicate process that requires a very good knowledge of soldering and basic knowledge of electronics. I recommend that you don nit do this if you have nay misgivings cause you do run the risk of ruining your cluster.

Now, here are some tools that I used to get this done.



The soldering station is pretty essential as you can burn the LED's up or damage other components on the board with too much heat. Obviously a desoldering station is preferred but they are expensive if you aren't using them on a regular basis.

I have two solder suckers but prefer the blue one as it seems to do a better job an the first attempt. I also got the desoldering braid cause with the tight multiple joints on the LCD display it helps to make short work as it wicks the solder from the pins.

Solder is a must...duh. A good quality solder that is as thin as you can get helps to make the resolder process much neater. A rosin core solder isn't essential since you can get the rosin separately but it eliminates an entire step.

I also have a small pick and screwdriver for helping to make sure the pins on the LCD are loose. A standard no.1 and 2 phillips head are also needed.

I used tweezers to help install and remove the LEDs. You can use any similar type tool.

This was performed on my 05 750. So this will apply to a 04/05 600/750. Other applications may be similar but double check your LED requirements with your bike as they may be different.

Now lets get started.

First remove the cluster from the bike...this may seem obvious to most but I like to be thorough.

Place it face down on a soft rag and remove all the black screws.



Now lift the back off and remove the single silver screw near the black connector block. There are three others that mount the LCD but you can leave them for now.



Now a lot of people like to take spoons and pull the needle off in order to get the tach off. I am not a fan of that method for a lot of reasons.



Instead, keeping the cluster face down. You will see four solder joints and for metal tabs that mount the motor to the board. Straighten these tabs, I used a flat blade screwdriver. Be careful not to stab yourself or scratch the board and damage the tracers (this will lead to more work if you do). after you straighten the tabs, desolder the four motor pins. You will see a clear plastic tab near the bottom of the board. Press that towards the opening and remove the entire tach. WARNING: Do NOT force the tach off the board. If it feels resistant, make sure your tabs are straightened enough and that you have properly removed all the solder. It may be necessary to heat the pins as you pull on the gauge. Be patient it will come loose.

 

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MPG mod
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Discussion Starter · #2 ·
Now this is where your patience and skills will be tested.

Removing the LCD.

Start by going across each pin with the solder sucker and getting the bulk of the solder off. Then, lay your braid across the top or bottom of the pins and remove what you can of the excess. This should clear a very good portion of the solder. Remove the three black screws and then take a break and give your eyes a rest. You will thank me later.



After you have had your Dr. Pepper start by grasping the LCD and giving it a light wiggle. See what, if any, pins are loose. This will become the idea through it's removal. I like to start at an end and work my way down. I will do two to five pins at one end and the move to the far end to allow the other to cool before going back to work on it. Once you get the idea you will know what to do. Keep wiggling and desolder with he braid or whatever method you prefer. With a lot of patience and practice you will eventually start to to get some space between the LCD and the board. I put a LITTLE pressure on the LCD in order to make sure the pins don reseat themselves. Be careful not to apply too much heat in any one spot you could do a lot of damage that may not be repairable.

Assuming that you haven't trashed you board or given up you should have this.



It is important to identify what LEDs need to be replaced. In this particular example it is LEDs 200, 201, 202, and 203. They are in a circular pattern around the motor's position.



In order to identify what you will need. Use a dial caliper and measure the case. Mine are surface mount PLCC-2 LEDs. There are several sites that have the specs in PDF format to help you determine your application.

Also, note the polarity mark on the lower right hand corner of each LED this is critical considering that they are diodes.

Here are the LEDs for the LCD.



These are the four in a line LED 204, 205, 206 and 207. There are only 6 other LEDs on the board. Two are through holes and the other four are different types in a crescent moon shape that are for your idiot lights.
 

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MPG mod
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Discussion Starter · #3 ·
Using your tweezers or similar type tool start removing the old LEDs. I grasp the case and move back and forth side to side until the LED comes off the board. DO NOT forcibly remove the LED. You will tear the pad off the board and then you are screwed. Just move back and forth and will lift. After you have removed the LED reflow the solder on the pad to get you set up for the install process.

I did two different colors on mine. So I did the tach first then the LCD. Remove all the LEDs then replace them one by one. I wouldn't recommend removing one them replacing it right away it can get confusing as to the last one you did. When installing the new LEDs, flow the solder on one pad and place the LED in place. Although there is some room for movement on the board try to get them oriented as straight and as low as possible.

Once you have on side soldered down, take your tweezers and put a LITTLe pressure on the unsoldered side then flow the solder there. You may have to go back and reheat the other side real quick. Just repeat the steps for all the remaining LEDs.

Here are my new ones.



I went with the blue for the tach and white for the LCD. I purchased six of each from www.oznium.com I didn't want to get stuck with a dead LED or if I messed one up. For as cheap as they are it's worth it.

Once you have all your new bling on. Before you mount the displays back on, plug it back into your bike and check to see that they all work. If so, remount the LCD lining up the pins if it doesn't sit flush against the board heat the pins until it does. Once the LCD is in place insert the three black screws BEFORE you solder them back in.
 

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MPG mod
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Discussion Starter · #4 ·
If you solder the pins first, you risk damaging the LCD. SO screw then solder. Very important.

After that is done, line up the mounting tabs for the motor and line the gauge face up to the board. This is a little trick but far from difficult. There is one tab smaller than the others it has a dedicated hole on the board to maintain proper orientation. Install the silver screw into the gauge face and I put a little pressure against the tach needle while I soldered the motor back to the board. I didn't bend the tabs down as they are quite stiff and didn't want to risk damaging the board. After that reinstall the casing in the order you took it apart.

Heres mine before:



and after:



TA-DA!




Good luck and have fun. Remember patience is key.
 

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Wow, :impressed:. Nice job man!
 

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Very nice looking! Awesome write-up as well!
 

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gixxerfool That looks sweet as hell! Very nice write up!!:thumbup:

:shiftyOOO And since you all ready have the tools, experience annnd :shifty:shifty the patience needed for the job I'll be sending you mine to do:D
 

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I want to do it so bad but electronics is not my strong suit so I will have to find somebody to either do it for me or hold my hand while doing it:lol:
 

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Discussion Starter · #9 ·
Thanks guys. I am really glad I went through with it. I am more a function than form kind of person. It looked ridiculous though with the amber lighting.
 

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I tried this and all I can say is unless uve done leds or electronics have somebody else do it. I ordered a set of LED's off of ebay and they werent marked at all so half of them got put in backwards. Once this happens the LEDs can't be reused because most of the time LEDs will burn up. After I got this far I took them to a local computer shop thinking they would be able to fix it with new LED's and have all the RIGHT tools. Well they got the LEDs replaced but this time the entire LCD display was burnt up. My only option from there was to buy a whole new cluster and I sent both gauges to bluegauges.com for the mileage upgrade and I had them go ahead and put in blue LEDs. So I spent money on 2 sets of LEDs and eventually had to get a new cluster and have them sent off anyways. Was this worth the effort of tryin to do it cheaply for myself in the first place?...NO
 

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LED's are a diode and should only pass power one way. Use a multimeter on ohms to find out which leads are which or look close on the bulb since there is either a flat spot or other manufacturers marking to keep it straight on which lead is which. Or just buy more than enough and spot the mark or difference and hook power up till you know for a fact which is which lead.
 

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dude can we work something out like i send mine in and you do it for me? i would like that better then me tring all this. you already did it once and looks like you know how to do it. let me know send me a pm.:thumbup:
 

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Discussion Starter · #14 ·
gixxerfool That looks sweet as hell! Very nice write up!!:thumbup:

:shiftyOOO And since you all ready have the tools, experience annnd :shifty:shifty the patience needed for the job I'll be sending you mine to do:D

PM sent

dude can we work something out like i send mine in and you do it for me? i would like that better then me tring all this. you already did it once and looks like you know how to do it. let me know send me a pm.:thumbup:
You have to clear out your PM box I cant send you one.

Good writeup. Your thread has been promoted to the Tech FAQ section.
Thanks Tee.
 

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I was so impressed with the writeup until i got to your signature then i lost it!

HAHAH.. very nice indeed!
 

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