Step by Step/Battery Charger/Powerlet Socket Install

firearmsdoc · 04-06-2010, 05:10 PM

The S1000RR deserves more than a $9.00 pig tail for the electrical connection!

I have had this same set-up on my 2007 BMW R1200GS Adventurer, with 100% Can Bus system, since 2007 with zero problems. I have also had this on my S1000RR for a month now with zero problems. So please keep your theoretical electrical discussions to the "Battery Tender" thread in the maintenance section.

My BMW dealer so liked my S1000RR Powerlet install that he is copying it. So I do not foresee any warranty issues unless you do something really stupid like arc a wrench between the positive battery post and the frame during installation. It may be only be 12 volts, but it's the amps that bite.

Here is what you need depending on if you are going to use the Mil-Spec, waterproof, green socket; or the spring loaded, black, BMW look alike socket:

1. For either installation you are going to need:
a. drill
b. Dremel tool with abrasive cut-off disc.
c. Automatic center punch
d. Multi-Step drill bit with 11/16" step like this one: #59003 at this link:
Klein Unibit Step Drill Bits, Klein 59001, Klein 59002
e. Torx T25 tool to remove and replace seat
f. some roll of tape, I like blue painter's tape
g. 1/16" drill bit or smaller
h. shrink-wrap, 1/4" and 1/2"

2. For the Mil-Spec waterproof install:
a. Powerlet #PKT-105-24 (this kit comes with 24" electrical leads, you
will only use the first half (12") for the install.)
b. Powerlet #PMI-008

3. For the black BMW look alike install:
a. Powerlet #PKT-046-12
b. Powerlet #PMI-008

Easy installation steps:

1. Pull seat IAW owner's manual.
2. Tear-off four 1"x2" pieces of tape and place them close to battery so you can get to them with one hand.
3. Unhook Neg. cable, maintain Neg. cable away from terminals, place one piece of tape over battery terminal and second piece over cable end so both pieces are insulated.
4. Repeat step three above with Pos. cable, make damn you touch it to nothing prior to insulating both the terminal and post.
5. Pull Battery, place where you won't stump your toe on it or kick it over.
6. Looking at inside of battery box, use your best guess to the exact center of where you want the socket to be. Use automatic punch on inside of battery box and place a dimple at that location.
7. Drill a 1/16" hole in that dimple from the inside to the outside of battery box.
8. Go to outside of battery box and make any necessary corrections to the center of where you want the plug to go. So if the hole isn't exactly centered up and down, just make a correction and place a new dimple with automatic center punch as close to drilled hole as possible. It should be close to perfect.
9. Wrap tape around multi-step drill bit so 11/16" is the largest hole you can drill (3/4" is usually next size) and drill a 11/16" hole from outside to inside.
10. Do trial install of plug. On the inside of battery box, you should see that a 1"x1" piece of plastic must be cut out of battery box to allow room for plug. Cut piece out with Dremel tool and abrasive disc. Touch up with Dremel sanding drum for professional look.
11. Place Powerlet part #PMI-008 on either plug, remove wires from plastic connector, put wires through hole, then push socket into hole and screw on nut from inside of battery box tight. (below)

12. Blow out or vaccum battery box. Place shrink-wrap on wires with terminals, the 1/2" shrink-wrap around both wires. Apply heat to shrink-wrap at connections on back of socket. (below)

13. Open fuse holder now, then route wires as in picture. (below)

14. Reattach battery cables and Powerlet wires to battery at the same time insuring you hook up Pos. first, then Neg. last. Don't ground metal tools from battery to any metal. In the big boy's world, that is called welding.
15. Double check all wiring. Place fuse in Powerlet fuze holder. (below)

16. Hook-up Battery Charger with BMWS style plug to ensure it is working correctly. (below)

17. Re-install seat.
18. Be done!

P.S. Any questions, just PM me. I do not work on a computer so I only get on the board once a day or so. I will answer. I also have one new Powerlet part #PKT-046-12 and #PMI-008 for sale if anyone wants it. PM me.