Kawasaki ER5 rev counter

[lotuscorty]

Hi, can anyone help?

The rev counter on my 2002 ER5 is not working, does anyone know where the feed for this comes from so that I can check that it is getting power?

It only has 3 wires on it, does anyone know where they come from?

Thanks for any help.

[iCraig]

The rev counter goes to the CDI as far as I know on the ER-5.

[sickpup]

This is gonna sound stupid but please check the output of your reg/rec immediattely.

[lotuscorty]

How do I do this?

Thanks for the help.

[sickpup]

Multimeter across the battery while the engines running.

Now the explanation.

For some reason Kawasaki decided that the er5 would run a 9 volt (or so) ignition system.

When the reg/rec goes it burns out the resistor in the ignition switch, the tacho and then the CDI so whenever I see a tacho not working on one of these I always check the reg/rec output.

[lotuscorty]

Hi, so if it`s not 9v then I need a new reg/rec?

Are they all the same through the years? and would a GPZ 500 one be the same?

Thanks again for the info!

[Smooth]

[Stelmer]

Also take a look at the ER5 owners club forum here:

https://www.bikersoracle.com/er5/forum/

There's an ongoing thread regarding the Reg/Rec and associated components it takes out.

Check the charging voltage isn't higher than 15v.

Mine is:
14.2 at idle with no load, 14.8v at 4k
13v with everything on at idle, 14.5v at 4k.

Usually the charging system gets over 16v when the reg has gone.

If the reg/rec has gone then it takes out the CDI and Battery as well as the Rev counter.

Another symptom is blowing or blown bulbs preceded by abnormally bright bulbs...

[Smooth]

cheers for that. I sense a trip to Maplin and some soldering
____________________
TDM850

[IamMurdock]

sorry to open an old thread, but its taken me hours to fix mine so might aswell save some others some agro...

when you open the cluster and take out the tacho, you will see a fried resistor at the top, you need to replace this with a 30 ohm 0.5W resistor (orange, black, black, gold).

This is the one i got from maplin :
https://www.maplin.co.uk/p/metal-film-06w-30-ohm-resistor-m30r

also the diode wedged next to the two capacitors blew on mine too. not replacing this will just blow the new resistor (found out the hard way), so you will probs have to change this too (a bit more fiddly). its a 1n4004 standard diode.

the one i used from maplin is:
https://www.maplin.co.uk/p/1n4004s-1a-silicon-rectifier-ql76h

hope this saves someone some hassle, i was trawling through hundreds of obscure polish webpages for hours!

[Trooper125]

[Sheshka]

Just to add to it, I recently managed to get a tach off ebay for a fairly reasonable price.
Whilst this thread has been by far the most useful bit to the fix, I did at one point find a picture of pre-firey-death tach. I promptly forgot where it was, and never managed to find it again.

For those that would appreciate the reassurance of a picture of the original:
https://i.imgur.com/0sXSUAe.jpg
https://i.imgur.com/StQ8ZAP.jpg

Good luck to any of the rest of you that have the same problem, I had to buy another as I'd soldered the replacement resistor too close to the board, and when the resistor went (yes, should've just done both the resistor and the diode), it irreparably burned the board. Being kinda useless at electronics anyway, I didn't fancy trying to bridge the now-knackered connection on the board.

Hopefully I won't have to deal with this one again...hopefully

[john24ssj]

The only issue I have is my rev counter light going off and on whenever it chooses. Hopefully my rev counter will keep working.

And for for the pictures they should be helpful to people
____________________
Bikes: Honda CBR600Fi, Kawasaki ER5