Motorcycle Universal Gear Indicator

A

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.

Image_1

The main circuit is based on an AVR ATTINY25/45/85 microcontroller, which reads the signals of the two Hall sensors and the neutral switch and outputs the current gear number to a 7‑segment LED indicator, through a 4026 counter/decoder.

At maximum output power there is significant heat produced by IC1 and for that reason we mounted it directly on the ground plane to achieve maximum heat radiation.

Schematic

Source Code

The source code is written in AVR-GCC (WinAVR) and can be programmed with the default fuses using an AVR programmer (default : ATTINY25 microcontroller and USBTiny programmer). Moreover, the constant TOP_GEAR 5 should be changed to 6 for six-gear motorbikes. Source code can be downloaded on the download section below.

PCB Design

The suggested implementation for the main circuit is a small size, double-sided PCB, with SMD packages for the microcontroller and the decoder ICs. The 7-segment LED is placed in a secondary PCB, connected vertically to the main one in a modular fashion (see pictures). Two PCBs for different Kingbright LED footprints (red and blue) are also provided.

Image_3

Parts List

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 :

Image_15

For a better insight in the above issue, the following script can be imported in Paul Falstad’s excellent circuit simulator:

http://www.falstad.com/circuit

$ 1 5.0E-6 10.20027730826997 62 5.0 50
R 192 96 192 48 0 0 40.0 5.0 0.0 0.0 0.5
R 512 96 512 48 0 0 40.0 12.0 0.0 0.0 0.5
r 192 96 192 176 0 10000.0
x 231 142 309 145 0 12 internal pullup
x 125 25 277 31 0 24 Gear Indicator
x 456 26 571 32 0 24 Motorcycle
M 192 176 96 176 0 2.0
x 65 157 118 160 0 12 AVR Input
w 192 176 192 256 0
162 512 96 512 160 1 2.1024259 1.0 0.0 0.0
r 512 160 512 256 0 470.0
d 512 320 512 400 1 0.805904783
x 413 388 499 391 0 12 protective diode
s 512 400 640 400 0 1 false
g 640 400 640 448 0
x 539 422 615 425 0 12 neutral switch
x 309 240 391 246 0 24 1N4148
x 132 377 269 380 0 12 in place of R3, and watch
d 304 256 400 256 1 0.805904783
r 304 336 400 336 0 10000.0
x 337 371 367 377 0 24 R3
S 192 320 272 320 0 1 false 0
w 192 256 192 320 0
w 304 256 272 256 0
w 272 256 272 304 0
w 304 336 272 336 0
w 400 256 400 304 0
w 400 304 448 304 0
w 400 336 400 304 0
w 448 304 512 304 0
w 512 304 512 320 0
w 512 304 512 256 0
x 131 359 276 362 0 12 flip switch to insert a diode
x 134 394 272 397 0 12 current drop to zero when
x 134 412 254 415 0 12 neutral switch is open

… or click here for direct Circuit Simulator Link
Contributed by Brett Walach

Photos

B

C

D

E

Connections

Image_8

Image_9

A successful circuit build will do a self-test when connected solely to 12V power (pins TO_POWER_1 and TO_POWER_2), by cycling through all digits on the 7-segment display (see video below). After the self-test, the current gear will be shown and can be changed by the shift lever movement. Note that a gear is changed when the magnet’s south pole is drawn away from the sensor (north pole will not work). Moreover, if a neutral gear is detected (from the neutral switch connected to TO_POWER_4), the display resets to zero (also acting as a self-calibrating feature if anything goes wrong). Finally, when the power is turned off, the last shown gear is stored in the MCU’s flash EEPROM and restored when the device is turned on again.

Image_10

The following video shows the initialization procedure of the gear indicator :

Self_Test

Sensor Cable

The following photos show the construction of the 4-wire sensors cable that is plugged to the TO_SENSORS connector. The visible sensor pin parts should be covered with plastic lacquer for protection as well.

Image_13

Image_14

 

After putting it all together the circuit is now operative and ready to be installed on the motorcycle. A video showing a simulation of gear shifting (by hand) is available below :

Circuit_Operation

Installation Photos

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

Image_16

Image_17

Image_18

Image_19

Image_20

 

Custom Housing

G

H

Image_5

 

Installation Videos

Installation1 – Gear shifting by hand

Installation2 Real gear shifting with engine on

Installation3 – Storing last gear in EEPROM

 

Thanks for reading !

Designed and built by Vassilis Papanikolaou © 2010

PCB

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slamet soegijono

tutorial burning script to mcu ATTINY25….what tools recomend….thanx…sory i’am indonesian

Mohsen

How much would this overall cost the circuit making and the actually product.?

Santosh

Nice Tutorial. Thank you.

John Allsop

Hello.
How much would the finished product cost if I ordered directly from you ?

Stuart Archer

Can’t you though? It would be nice.

Ben

Nice Project, But i would prefer N instead of the 0 for neutral, could this be written into the source code easily ?.

Thanks for sharing your project.

Onofrio

You can use “H” instead od “0” to indicate Neutral

Arnab Ghosh

There is also 17 segment alphanumeric display…

Ben

Sorry i meant the letter ‘n’ ie segments A,B,C,E,F ?.

ben

Yes thats exactly what i mean to replace the ‘0’ with the letter ‘n’ within the source code.

Manjit Hunjan

can this indicator be used for bicycle gear shifting ?

ben

Just a few ideas for your project.
You,ll need 2×7 digit displays 1 for the front cog selector ie 1>3 and one for your rear cogs ie 1>7 (presumed 21 speed).
I would utilize your gear change levers as they have pre-defined stops which makes your hardware a little simpler as each position could just be switch/wired to the pins of an mcu with at least 10 inputs and 7 outputs (mega16/328) thus you woud,nt need the counter ic or the hall effect sensors as all i/o would be handled by the mcu.

Hope this helps
ps the source code id use would be switch case and is not to difficult to write.

ben

Forgot to add the Outputs would look like this,
16 = 1st cog 6th gear
26 = 2nd cog 6th gear
36 = 3rd cog 6th gear Etc Etc

Mustafa

Can I use these codes with arduino?

Mustafa

Thank you.
This project I made before:

https://www.youtube.com/watch?v=3jV5GXFuvdM
https://www.youtube.com/watch?v=hOn4GFdmQQE

I’m going to try to do it with an Arduino.

Siddharth

I need universal gear indicator for my bike 200As pulsar. Plz send the were i get this product in mumbai.

Omkar Rahate

hey! thank you
it’s very usefull project!
will you please help me to change its program for 4 gears bike?
please help me about this

Phivas

Hello thank a lot to share this circuit, nice solution!
One question: I understand this circuit is made simple for universal use but is there a way to get an additionnal feedback of real engaged gear thus in case the shift lever is activated twice or gear doesen’t engage Indicator will show wrong number?

saurabh

Hi, can we use this method to hand gear shifting. if yes how it can be done.

Vladimir

Hi,
I need help for write source code.
My motocycle have 6 gear,and i have to change from 5 gear to 6 but i dont know how….
I opened the code from download section in WinAVR but but I do not know what I need to change.

can you help me,please!?

Stewart Graham

Is there a way to make this but instead of the output to an LED it have a 0-5 volt output? Reason I ask is I have an automated shifter on my race bike and can vary the shift time based on current gear… the box I use for shifting is looking for an input along these lines,
1st gear = 1.782v
2nd gear = 2.242v
3rd gear = 2.960v
4th gear = 3.630v
5th gear = 4.310v
6th gear = 4.660v
Neutral = 5.000v

Diptajit Dutta

Hello Sir,
I am from India and i am facing some problem with the components in India i couldn’t found the S.M.D I.C of M.C.U I.C and COUNTER I.C. I got the normal or big I.Cs. so please can u provide us as P.C.B sketch of both the side and a new eagle file using the normal or big I.Cs please.
Its my humble request to you Sir.

Diptajit Dutta

which kind of hall sensor are used for this project

Diptajit Dutta

thank you sir

tanmay

Pls guide me about source code…How can I program microcontroller …I don’t have any idea about programming but I want to do this project…

Manoj

Can we make it for those bike having all gear in forward side like N, 1, 2, 3, 4, 5. In my bike all gear front side. If yes please help me my email id is mk2.5280@gmail.com, I really need this for my bike.

Mikkel

Very nice project!
How does it distinguish from
– changing from 2nd to neutral with one push on the lever, from
– changing from 2nd to 1st also with one push?

Thanks a lot!
– Br Mikkel

Tanmay patil

Actually motorcycle had manual sequential transmission.so you can’t change gear from 2nd to neutral directly.you have to go through 1 St gear.

Ashish sonawane

in sports bike having gears 1 down 4 up we can go to neutral position from 2nd gear

Ashish sonawane

how could you detect the gear position at the time of starting of the vehicle?, if vehicle was stopped in 3rd gear will it show 3rd gear position at starting of vehicle or it shows 0 ?

BALAJI S

Hi I’m NT gtg ur code

Denis

Hello!
How I should change the code for 0(N)-1-2-3-4 gear? Anybody knows?

Sujit Mishra

Dear Sir, please clarify what do you mean by neutral switch ( To power 4 ).

Nilesh

How to place the magnet??
Can I get some installation videos

Elmer

Can i use attiny85 20PU?

ishita

I wanted to know if i could use arduino here..if yes can i get help with the code?

Elmer

how about for have a 5 gear losition?

Taijean .Moodie

Hi,

I got his tachometer here https://www.amazon.ca/Astra-Depot-Motorcycle-Speedometer-Tachometer/dp/B018APS3Y6/ref=sr_1_28?ie=UTF8&qid=1536337906&sr=8-28&keywords=universal+motorcycle+tachometer and it has 6 different wire for the gear indicator counting 1 gear for each wire. Is there a way I can use the wires going to the gear indicator led to connect to each wire? It just needs a low voltage signal to activate the gear indicator. also what is Vcc? is that the signal or voltage? where does it go? If the link does not work search up ss182 or koso rx2n tachometer replica.

Senthil Kumar

cd4026 ic counding up 1,2,3,4, 5 possible but down counding 5,4,3,2,1 ???

Prem Nath

Should we program the mcu????

Ibzan Jair Valenzuela Suarez

Hi, can you help me with the speedometer and tacometer reference? Its look amazing

sebastian

Hello Friend!
Which display was used?
Anode or cathode?

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