Project: Chinese gauge set on GSX1100G

[GS1000G Shopper]

Both of the needles have broken off the gauges on my GSX1100G. I had added some dual-purpose gauges for oil pressure & temperature as well as volts and fuel level. My other gauges are air temperature and gear position.

After looking over the "Ali Express" site (cheap stuff made in China), I found a gauge set I liked:
motorcycle tachometer speedometer fuel meter universal aguge

You have to get past the really bad English. This set has:
Speed,
RPM,
Fuel level,
Volts,
Clock, and
Gear position (GP)

It also has the normal indicator lights, and apparently a "check engine" light.

My GSX-G has been modified with a GP switch from a GS1150. It is full-size, about the same size as the stock gauges. Acewell makes great gauges, but they are tiny. The site offers buyer protection in the event the gauges are not as described. There are only limited ways to pay, such as Visa/Mastercard.

I communicated with the vendor and decided for $63 shipped it was worth a try. An identical gauge on eBay was over $100 + shipping. While it shipped within a couple of days, It will probably take a few weeks to get here.

The main drawback is the speedometer is KMH only. Putting my thinking cap on, I looked at the input parameters (number of magnets and tire circumference) and designed a spreadsheet to allow a calibration for MPH that will allow the gauge to indicate MPH. If this works as theorized, I'll post it here since it can be used for any similar gauge.

Here are some pics from the vendor's page:


I'll update as I make progress.

UPDATE
I just realized I can't attach version 2 of the spreadsheet (Open Office format) since only PDF and graphic files can be attached. I found another way to do so via the below link, it is a zip file with the spreadsheet and instructions. Please give it a try, any constructive criticism is welcome as I tend to miss stuff I've read a few dozen times or after doing so presume someone knows something I know. The goal is to make it user-friendly for someone else that wants to do this.

EDIT
V2 of the spreadsheet has more data fields, and it has been protected so all you have to enter are the tire specs.

Tiny Upload Link

 

[mikerophone]

Tagging along. I've often considered ordering from alibaba or ali express but never have. Cheap prices and an interesting model that connects buyers directly with the manufacturer that could change the future of the way we do business, cutting out middle men and distributor mark ups. I just can't quite yet get over the risk factor and the site and English/grammar are pretty bad in sone cases.

That is a nice looking gauge pod and I like that it's not too modern, nor too retro. Interested in how you proceed with the kph to mph conversion as well, thanks for taking the plunge!

 

[posplayr]

Is the spreadsheet anything more than this? miles/Km=1/.621371

Based on this: 1 km = 0.621371 miles

 

[JEEPRUSTY]

get over the risk facto I have used aliexpress dipping my toe with small purchases. It works and no billionaire guy wha towns it is going to readily let members screw it up for him.

 

[stain]

It looks to have a volt meter, fuel gauge and gear display also. I wonder how those are hooked up? Stock wiring?

 

[GS1000G Shopper]

Is the spreadsheet anything more than this? miles/Km=1/.621371

Based on this: 1 km = 0.621371 miles

Yes and more. I tend to over-think things, so I went the roundabout way of calculating tire sizes based upon the width & aspect ratio part (e.g. 100/90) and then adding in the rim diameter. I then used the circumference data in inches and mm and the number of pulses to determine what the gauge would expect using various numbers of magnets and the circumference, versus what the sensor would actually generate with fewer magnets. While I don't have the manual yet, if it works like the Acewell I had set up on my former Sabre, you are allowed input of the number of pulses per revolution (this is the number of magnets) and the tire circumference. From what I can tell of my new gauges, the limits are 1-12 pulses and 1,000-2,999 mm.

I found that the closest ratio when using two sets (actual vs virtual) of 1-12 magnets to the 1 mile=1.61 KM was 5 and 8 (8/5=1.6). For my GSX-G with a 110/80-18 front tire, this returned an error of -.58% at 60 MPH, or a reading of (edit, corrected the math) 59.6 MPH when you were doing 60. This is better than what most of my Suzukis read anyway (5 MPH error). I read someplace that was a result of the KPH to MPH math used in the 80's, so it makes sense.

Using a formula to calculate the ideal circumference, I was able to reduce the error to 0. I added a field so the correction circumference would be automatically generated based upon the stock tire circumference.

I just realized I can't attach version 1 of the spreadsheet (Open Office format) since only PDF and graphic files can be attached. I found another way to do so via the below link, it is a zip file with the spreadsheet and instructions. Please give it a try, any constructive criticism is welcome as I tend to miss stuff I've read a few dozen times or after doing so presume someone knows something I know. The goal is to make it user-friendly for someone else that wants to do this.

Tiny Upload Link
Version 2 with more data fields and protected data entry.

 

[GS1000G Shopper]

It looks to have a volt meter, fuel gauge and gear display also. I wonder how those are hooked up? Stock wiring?

The aftermarket gauges I've used in the past have allowed you to set the fuel level resistance for full and empty, most Japanese bikes are fairly similar. I expect this one will be the same.

I'm hoping it will allow direct wiring for gear position. My GSX-G has the GP switch from a GS1150 added in (easy conversion), so I have wires for 1-5. Looking at the connectors and the Chinese writing on the unit's page, that is my best guess at this point.

 

[jbird7262]

Hope all works well for you, I've had nothing but BAD experiances from Ali Express, mostly with returns and the way they handle comunication and correcting incorrect orders.:sour:

 

[mikerophone]

get over the risk facto I have used aliexpress dipping my toe with small purchases. It works and no billionaire guy wha towns it is going to readily let members screw it up for him.

Hope all works well for you, I've had nothing but BAD experiances from Ali Express, mostly with returns and the way they handle comunication and correcting incorrect orders.:sour:

It's nice to have actual good and bad user reviews on this, I don't know anyone else that's tried it so I'm still holding out, even though there are items in my cart and I get emails to come back and complete the purchase. For now I'm good on eBay or mostly Amazon due to the user reviews. My brother works at eBay and I talked to a couple of employees that work there recently about the PayPal split and reviews. They said eBay is planning to include reviews (of products, not just feedback) soon.

Curious how this gauge works out for you GS1000G Shopper, and do appreciate your work on this for posterity and the community here, keep us posted when you finally get it and how the install/conversion goes.

 

[GS1000G Shopper]

Curious how this gauge works out for you GS1000G Shopper, and do appreciate your work on this for posterity and the community here, keep us posted when you finally get it and how the install/conversion goes.

Glad to do so. I had found another one that would be a good fit on an older GS. There was conflicting info on what all it did and due to the language barrier I never got a good answer, and I see now it is no longer available. I think the one I ordered will look better on the more modern GSX.



Link

 

[eil]

I'll be watching with interest, those gauges sure look pretty nice in the photos.

There was a thread some time back about people buying used gauges from GSX-Rs on eBay and fitting them to their GSes. Worked well and looked good, from what I remember.

 

[GS1000G Shopper]

Spreadsheet has been updated. I found that the -.58% error using magnets alone is apparently a constant. I tried several sizes of tires and it remained the same, the only thing that changed was the circumference correction figure. I have also protected the sheet so that tire data is all that can be entered. There is no password for the protection.

 

[GS1000G Shopper]

I'll be watching with interest, those gauges sure look pretty nice in the photos.

There was a thread some time back about people buying used gauges from GSX-Rs on eBay and fitting them to their GSes. Worked well and looked good, from what I remember.

I have downloaded shop manuals for a bunch of bikes so I could see how they were wired. The 80's GS750ES and 1100ES were nice if dated panels that had cable-drive speedometers, oil temp gauges, and gear position indicators.

The problem with the more modern bikes for the most part is getting the speedometer sorted, most used sensors that were in the transmission and would require an expensive calibrator if you could generate a signal from the front wheel. Other functions were not as bad, nearly all of the fuel level gauges were the same or very close. As I recall, one issue with GSXR type of panels was that they had no fuel level gauge, just a warning light. I'm not going to add a panel and have less features than I had.

One of the best panels I have looked at for functions is from a Yamaha FJR1300, but it uses a proprietary speedometer drive that would require using the bike's computer.

The ZX14 has a nice panel with a lot of features as well. I can't remember why I did not look into it further, it may have been the cost or the speedometer calibration.

 

[GS1000G Shopper]

The gauge set arrived today. Overall it's not too bad. The main issue at this point is that the speedometer is reading 10 KMH. I guess it realizes it's going on a really fast bike! I have emailed the seller since it carries buyer protection. It may need to power cycle to reset to 0.

It is slightly different than depicted, the neutral indicator is on the tach dial. The drawback for GS use is that there is no oil pressure lamp, but seeing as how I don't need a coolant lamp I can use that instead. I will add an oil pressure/temp gauge.

It appears my math was possibly for nothing. The instructions show it does both KM and Miles.

I was able to fabricate an aluminum bracket to mount the sensor using existing threaded holes on the left front caliper bracket. The sensor only has 4 magnets, and they are too large to fit into the allen openings of the six rotor bolts. The instructions say either 2 or 4 magnets are optimum. I can use my spreadsheet to calculate my settings.

The supplied gauge mount is only 1/4" short of bolting on to the GSX-G bracket openings- the on-center part is spot on. I'll see if I can make one out of two. Worst case I can weld on a couple of short legs o I may just make my own bracket.

There are three connectors, 2x 9 pin and 1x 3 pin.

The 3 pin is the speedometer sensor:
Red: Speed signal
Yellow: +5V
Green: Sensor ground

The 9 pins are not broken down or depicted in the instructions, there is just a list of 18 wires broken down by color:
Black: Ignition +12V
Purple: Battery +12V
Green: Ground
Green/Blue: Water temp sensor (idiot light?)
Light Blue: Right turn +
Orange: Left turn +
Blue: High beam +
Brown/Red: Best guess: Check engine icon- instructions say "Electronic injection indicator"
Green/Red: Neutral
Pink: 1st gear (Yeah! I was hoping it was hardwired)
Blue/Red: 2nd gear
Green/Black: 3rd gear
Yellow/Red: 4th gear
Brown/White: 5th gear
Red/White: 6th gear
Yellow/White: Fuel gauge
Black/Yellow: RPM

I will post some pictures as I make progress, and I'll also try to scan the manual into a PDF (edit: it's almost 3MB and won't upload to attach).

UPDATE
Here are the first batch of pics, thumbnails should be clickable:
Gauges front


Gauges rear:


Rear cover removed:


Wiring connectors:


Speedometer sensor bracket:






Sensor bracket installed:

 

[mikerophone]

The gauge arrived today. Overall it's not too bad. The main issue at this point is that the speedometer is reading 10 KMH.

It is slightly different than depicted, the neutral indicator is on the tach dial. The drawback for GS use is that there is no oil pressure lamp.

I will post some pictures as I make progress, and I'll also try to scan the manual into a PDF.

I suppose neither of those issues are deal breakers but that's common with similar concerns I've heard of people having had on the "Ali" sites - items not as pictured or described, and sometimes defective or with slight issues. Granted I haven't heard much actual feedback from people and some has been neutral and even positive, so I'll take the plunge eventually I'm sure.

Appreciate your work on this, can't wait to see how it turns out and what other issues or observations you have. I've got a 750 and an 850 I'd love to mount up some aftermarket gauges too someday as well. Post those pictures when you can!

 

[GS1000G Shopper]

Using the KISS method, I flattened the mounting bracket and gained enough room to where the ignition switch housing interfered. I ground the inside leg of the bracket and then enlarged the holes. It fits well, but of course there is a gap between the lower part and the ignition switch. Not bad for $63.

Next comes wiring.

Function: China color vs Suzuki color
Ignition +12V: Black vs Orange/Green
Battery: +12V: Purple vs Red (ignition switch harness)
Ground: Green vs Black/White
Water temp sensor (oil pressure lamp): Green/Blue vs Green/Yellow; need to check polarity
Right turn (+): Light blue vs Light green
Left turn (+): Orange vs Black
High beam (+): Blue vs Yellow
Check engine icon: Brown/Red vs Not used
Neutral: Green/Red vs Blue/Black (-); need to check polarity
RPM: Black/Yellow vs Black/Red
Fuel gauge: Yellow/White vs Yellow/Black; need to check polarity;
Note: China gauge is full @ 10 ohms vs Suzuki sender's 3 ohms, China empty @ 95 ohms vs Suzuki's 110 ohms

GS1150 gear position add-on wiring:
1st gear: Pink vs White/Yellow
2nd gear: Blue/Red vs Red/Blue
3rd gear: Green/Black vs Same
4th gear: Yellow/Red vs Yellow/Black
5th gear: Brown/White vs Brown/Orange
6th gear: Red/White vs Green/Orange (not used GSX-G)

Note: Suzuki GPI research
1984 GS1150ES
Gear switch 37720-49211 $62.00 Shows as superceded by 37720-24A01 , same price
O-ring ID: 36.2mm 2.4mm thick part# 09280-36001 $2.00 (same as GSX1100G)
Switch part #37720-49211 shows as unique to the 84-86 1150ES
Switch part #37720-24A01 shows no model usage

Suzuki made at least two sizes of gear position switches. If the same o-ring is used then the switch can be used.

Upon inspection of the connectors, the following discrepancies were found:
Red/White (6th gear) and Black/Yellow (RPM) not present; 2x Brown and a Blue/White mystery wires are on the black connector.

I suspect the Red/White is missing since the gauge is only set up for gears 1-5. I'll check the wires and see what I can determine. Hopefully one of the brown wires is 6th gear and the other is RPM. No idea what Blue/White does.

If it was easy, anyone could do it.

UPDATE
Brown wire #1 is illumination (undocumented feature)! Good to know since I have a photocell to dim my LED oil pressure/temperature gauge.
Brown wire #2 is the 6th gear wire.
Blue & White must be RPM.

The better news is once the gauge was powered on the needles did a sweep and reset to 0.

 

[GS1000G Shopper]

I decided to re-pin the connectors. I made one 6-way for the GPI and neutral wire, another 6-way for power, ground, and fuel level, then I used the remaining 9-pin connector for high beam, turn signals, oil pressure lamp, and check engine lamp. I used to have an air temperature LED, combo oil pressure/volts and oil temperature/fuel level gauges on top of the stock cluster. I'm relocating the air temp thermometer to the left side of the fairing (along with the photocell for gauge dimming) and will relocate new single oil pressure/temp gauges to the top of the fairing by the windshield. In the process of doing this, I saw one of the horn wires was cut, so I'm going to layout a plan for dual horns.

I have now wired the panel and almost everything works- the fuel gauge seems to be fluctuating and I cannot get into the setup screen. Following the instructions, a "long press" of the left & right buttons makes an icon named "USB" flash, but nothing can be changed. EDIT: There is a USB port on one end of the gauge visible when the back cover is off. I'll try & connect it to a PC and see what happens.

The good news is the tach setting seems to be right even though I can't adjust anything. I did start the bike and the needle looked to be accurate.
Here's a list of proper functions:

• RPM
• Gear position 1-5
• Neutral lamp
• Left turn
• Right turn (also hazard flashers)
• High beam
• Oil pressure lamp (wired to the coolant icon)
• Fuel (using Suzuki yellow/black wire, the OEM gauge also used a blue/black wire that was a ground, I may ground this and see if it helps)
• Gauge illumination- tested with my photocell & it cycled as it should
• Clock- was able to set the time
• LCD color change
• Miles to KM and vice-versa. No idea if this affects the speedometer, but if it works like other English/Metric gauges it should.

I have not tested the speedometer yet.

I have emailed the seller, probably won't hear anything until Monday.

I'll take some more pics after it cools down.

 

[GS1000G Shopper]

I heard from the seller & he says the USB port is for charging a phone. I verified this by plugging mine in and going to "USB" mode on the panel. It uses an "A male" to "A male" cable, so I can't plug it into my PC. I was able to plug it into a Windows tablet and nothing happened.

He is on vacation so it will be a few days until he can access his computer to resolve the problem. I'm hoping at this point it is something as simple as a button press sequence.

 

[GS1000G Shopper]

Success! I played around with several options, and got to the setup menu by holding down the L&R buttons and then powering the dash. While I tried this initially with just the power & ground wires, it also works with the dash installed.

That was the good news, the bad news is pressing the KM/MPH button while riding did not change the speedometer needle. Since there are only 4 magnets and I need 5 to be accurate, I can't complete the setup per my spreadsheet. I did use 2 actual magnets and 5 virtual and this seemed fairly close (seat of the pants) for the driveway runs I was making at about 15 MPH max even though the ratio was 2.5 where the desired ratio is 1.61. The higher the virtual magnets the lower the speed.

One other oddity was that the cylinder setting options are 1,2,4 and 8. I tried 4 and it read way too low, so I put it back to the default 1 and it seemed accurate. The instructions mention a "P" or "N" visible on the dash to determine the type of ignition (positive or negative) while programming, I did not see either.

The dash press sequence in setup is as follows:
Tire circumference (4 digits, 1,000-2,999 mm): Left button raises the number flashing, right button changes to the next number and after the 4th digit advances to the next setting. I began with my OEM size of 1,989 mm. For an exact reading with 5:8 magnets, my spreadsheet says to use 2,001 mm.

Number of cylinders (1,2,4,8): Again, left raises it, and right advances to the next setting.

Pulses (1-12): I need to set this up per my spreadsheet, for 5 actual pulses I'll set it to 8 virtual pulses.

I plugged in 4:4 magnets into the spreadsheet and this required a corrected tire circumference of 3,201 which is beyond the maximum 2,999. According to my calculations, using 4 or less actual magnets, the optimum is 3:5, which returns a raw error of 3.44% (5:8 was -.58%). Reducing the front tire to 1,921 is within range, so I will give that a try.

 

[SVSooke]

The lost spark ignition might make the 2 setting better for the tach.