I just picked up an 04 919 and have a little wiring issue to chase down. None of the dummy lights work (Neutral, Low Fuel, High Beam, etc). Also the Coolant Temp gauge isn't working. All of the other lights seem to be working, the speedometer and tach work, the clock/odometer work. The bike has some damage to the gauge cluster:
Is it possible that a single ground could be the problem? I checked all of the fuses, and they were all good. I looked through the wiring schematic, and it is hard to tell if they all run off the same ground or not. It seems to me that if the whole dash ran off of one ground, the whole thing would be dead, and not just the dummy lights. I suppose I should just take the gauges off and give the whole thing a look over.
I checked the fuses under the seat, and they were all good. The Service Manual references a 10A sub-fuse, several times, but doesn't specify where it is located. Are there other fuses besides the ones under the seat?
Most of the warning lights are activated by signals through the 6 pin Dsub connector on the far left side of the instrument circuit board (viewed from the back of the board). Since that is where the damage to the housing is it is likely that either the connector is partially disconnected from the board or there is damage to the board itself. If the former just seat the connector and that should do the trick. If the latter it may be possible to repair the board if you have a fine tip soldering iron and the knowledge of how to work on fine circuit traces. If not any television repair business may be able to do it for you depending on the extent of the damage. If it is too badly damaged it will probably be necessary to replace it. Unfortunately Honda only offers the board as a complete assembly including the gauges, which are easily swapped out. Darn it. I guess it makes it less attractive to someone who wants to roll back the mileage when selling their bike.
Oh, all the warning lights are LED's soldered to the board, not incandescent bulbs, so it is unlikely they are "blown" or disconnected by whatever caused the damage to the housing.
If it has already been done, it is safe to assume it is possible to do it.
On the other hand, if it has not been done never assume it is impossible to do it.
------- Rob --------
AHA! That's is a perfect pic. Do you have any other pics of that corner of the board? I am REALLY hoping it is just that connector is loose. If not, I have soldering tools and pros at work. Is it difficult to take the gauges apart far enough to get to that connector?