Sport Classic Instrument Cluster Problems - Solution
I just purchased a 2006 Sport Classic. I had an intermittent tach needle that would fluctuate upon power up, and during riding. It was not a wiring issue, and the bike would run fine. I did a little research on here, but did not really find a solution – so I came up with one.
In my case, the stepper motors were at fault. This seems to be the common problem with these bikes. Some of the members have sent in the instrument clusters to Mr. Whizard. This seems to be a great option, if you are not able to do a little soldering. Average repair price is around $260.
My option – replace the motors myself. The motors are manufactured by Switech / Juken. The model number you will see on the back of the motors is X15-689. There are also some other numbers, but these are just tracking numbers. X15 symbolizes the size and style (front mount). The 689 symbolizes the type and electronic portion. Switech doesn't make the X15 anymore, but have no fear, the X25 and X27 are fully compatible. So order the X27-689. The motors are $12 each. I recommend replacing both the speedometer and tachometer motors at the same time.
How to do this (if you can’t do any of these steps without pictures, send the cluster in):
- Pull your instrument cluster off the bike.
- Disassemble the outer housing.
- Carefully pry the needles off the motor stems.
- Pull off the white front gauge face.
- Remove the circuit board from the outer housing.
- You will see two white stepper motors on the back of the board (pictured).
- Un-solder the 4 connections for each motor.
- Drop in the two new motors, and solder them in place.
- Re-assemble the unit, except the front glass bezel. The white face should be on. Loosely put on the two needles.
- Connect the cluster to the bike.
- Turn the bike on (don’t start) – the needles should do a sweep.
- Rotate the needles counter-clockwise until they both line up with zero.
- Repeat turning the bike on and aligning the needles until proper.
- Firmly push the needles in place (but not too deep so they don’t turn).
- Finish assembling the gauge cluster.
- Install cluster.
- Done, cost = $24.