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27 May 2011

DIGITAL GEAR INDICATOR


 Introduction


This is a new design for a universal gear indicator that can be fitted to any motorcycle as an aftermarket accessory. Its main advantage is that its operation depends entirely on the gear shift lever movement, instead of connecting to speedometer and tachometer sensors (found in expensive commercial devices), which are rarely available in older motorcycles. It consists of a main circuit including a 7‑segment LED indicator, two Hall sensors that are attached to the motorcycle frame, and a small magnet placed on the gear shift lever.















Parts List



Part
Value
Comments (for suggested PCB)
R1
10 to 220 Ω ½W
Depending on preferred LED brightness
R2, R3
10 ΚΩ ¼W

C1
220 μF / 35V
Electrolytic capacitor
C2
100 nF
MKT/polyester capacitor
MCU
ATTINY25/45/85
Mouser Part 556-ATTINY25-20SU
COUNTER
4026
Mouser Part 595-CD4026BPWE4
IC1, IC2
Hall sensor
Melexis US5881LUA (available from adafruit)
IC3
7805
5V Regulator TO-220
BLUE
Kingbright 0.3"
Mouser part 604-SC03-11PBWA/A
RED
Kingbright 0.3"
Mouser part 604-SC03-12EWA
JPx
Pin connectors
As shown in silkscreen and pictures



Possible improvement 



In the current design, when the neutral switch is open (there is a gear on), 
there appears to be a very small current (< 0.5 mA) sinking through R3, due
 to the voltage difference between the neutral switch connection 
(TO_POWER-4) and the microcontroller. If the neutral indicator is of LED 
type (not a resistor bulb), there is a possibility that it stays dimmed, instead 
of being completely off. In that case, a small switching diode (1N4148) can 
nicely replace R3 (on the same PCB) in order to block this small incoming 
current when the neutral switch is open, as shown in the figure below : 








FINAL


Connections


























Installation Photos



Here are some photos and videos from the installation on my suzuki Intruder VS400 :







Custom Housing







Installation Videos



Gear shifting by hand
 Real gear shifting with engine on
Storing last gear in EEPROM

Action Video
Thanks for reading !
















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