Installing Powerlet Sockets on the ‘Wing

I recently bought myself a heated vest from Aerostich. I chose the BMW-style connector because I had a bunch of Powerlet sockets that I had installed on my previous bike and they seemed to offer better weather protection than the Aerostich Quickconnect plugs. So my project last weekend was to install sockets on the ‘Wing to power the vest as well as my GoPro. I wanted the sockets to be in a location that was very easy to reach, where the plug would not hit my leg and where I would be unlikely to snag the plug or kick it inadvertently when mounting or dismounting the bike.

Right
Right side
Powerlet socket
Powerlet socket

After removing the center top shelter, there appeared to be enough space in front of the gas tank to install the plugs in the sides of the left top shelter and the right top shelter.

Top shelter removed
Top shelter removed

After removing the left front shelter, I was able to verify that the plug would fit.

This is where the sockets will go - in front of the gas tank
This is where the sockets will go – in front of the gas tank

Determining exactly where to drill the holes was pretty straightforward. Using a square, I lined up the top edge of the square with the front edge of the mounting bracket for the left front shelter.

Line up the square with the front edge of the mounting tab
Line up the square with the front edge of the mounting tab

I used a marker to make a dot 1 7/8″ from the top. I did the same thing with the right front shelter.

1 7/8" from the top edge
1 7/8″ from the top edge

I used a center punch to ensure that the drill wouldn’t wander across the paint and leave a scratch.

Center punch
Center punch

I used a step bit and drilled a 13/16″ hole.

Drilling the holes with a step bit
Drilling the holes with a step bit

Now I needed to install connecters that would allow me to disconnect the outlets to allow removal of the left and right front shelters in the future. I had some 2-pin nylon connectors leftover from another project.

2-Pin nylon latching connector and spade terminals
2-Pin nylon latching connector and spade terminals

And I had previously purchased a crimping tool after becoming utterly frustrated with cheap crimping tools. I got the crimper and the connectors from Vintage Connections. This crimper is AWESOME. Perfect crimps every time. I also bought the assortment of supplemental die-sets so that I could use the tool for nylon-sheathed connectors as well.

Crimping spade terminal
Crimping spade terminal
Perfecto!
Perfecto!
Voila!
Voila!
Verifying clearance
Verifying clearance
Foam cut away
Foam cut away
Install with the rubber boot
Installed with the rubber boot

I had previously installed a length of corrugated loom to protect the wires for the Clearwater lights as well as the power leads for my Zumo 660 cradle. I cut open the cable ties so that I could add the power leads for the Powerlet sockets.

Clearwater lights wires and Zumo 660 cradle wires
Clearwater lights wires and Zumo 660 cradle wires
Corrugated loom cable protection
Corrugated loom cable protection
Corrugated loom cable protection
Feeding the power leads into the loom

Once I had the power leads routed back to the battery, I installed spade connectors. This is where the additional die-sets for the crimper come in handy.

Crimping spade terminal
Crimping spade terminal
Crimping spade terminal
Crimping spade terminal
Crimped spade terminal
Crimped spade terminal

I used a terminal block and jumpers to create my own grounding terminal. I used Velcro to attach it the battery. This makes it much more accessible and convenient than mounting it somewhere under the seat.

Jumpers
Jumpers
Electrical Connections GL1800 Power Plate Fuse Block and grounding terminal
Electrical Connections GL1800 Power Plate Fuse Block and grounding terminal

I gave myself plenty of lead for the right side. Here it is connected prior to remounting the right front shelter. I tested both sockets by plugging in my vest and all was good.

Right side connected
Right side connected

Please follow & like this blog
Facebook
Pinterest
YouTube
Twitter
RSS
Google+
http://focusontheride.com/installing-powerlet-sockets-on-the-wing/

admin

A Goldwing rider from Jacksonville, FL.

Leave a Reply

Your email address will not be published. Required fields are marked *