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Handlebar power plug, my last needed modification

bicyclenut

bicyclenut

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Jun 29, 2016
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Chicago Suburbs, IL
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Finishing up adding a 2port USB power outlet to the handlebar center cover. Purchased an extra cover in case I screwed it up and so I could put back to OEM look if needed. Cut out opening with Dremel tool and mounted port. Purchased plug and harness (see white connector with red shrink wrap in photo) for BMW GPS power outlet located under cover and added auto quick connects- one will power USB port and other GPS or could add other power accessory in future. Since I didn't have matching paint for the cover I had to paint the area for the mount modification black to match the power port. Port is weather resistant and has a cap and they can be found on Amazon or eBay. Will be used to power my mobile phone, Sat. locator or other USB devices with low power draw.

IMG_3284.webpIMG_3285.webpIMG_3286.webp
 
So I had installed this power plug in the center handlebar cover to power my phone and other handlebar mounted devices. I had used the pre-wired plug for the NAV option to power both my BMW NavV and this plug. I liked the final outcome as it almost looked like a stock installation and it worked great. Nice to have a plug for my phone, SAT tracker or camera handy and no interference with cords coming out of glove box. However, my installation was pretty permanent and I didn't take into account what I would need to do if the plug failed. Well, recently one of the USB ports failed to work (saw some reviews on Amazon that mentioned this the other day). To replace mine I'll pretty much need to cut it out or break it off due to way I mounted it with plastic epoxy.

Old plug:
IMG_9561.webp
IMG_9562.webp

New solution was to buy a round "bolt in" USB plug, also available as cigarette lighter type power plugs. All this required was to drill a hole large enough and then bolt this in place and attach connectors from power lead. If the plug fails, it can easily be swapped out with a new one. Not sure why I didn't do it this way before, as it was much easier and less time, just drill the hole and mount. The old one had a nice look but required cutting, mounting, epoxy, shaping and sanding and painting over several days. The round plug method took less than an hour.

New plug:
IMG_9563.webp
IMG_9564.webp

The additional holes are for the NavV factory mount from BMW to allow attachment to handlebar.
 
I bought an additional cover like that so I could mount my GPS bracket. Worked very well but now I'm using my phone GPS so will have to change the mount. I'll attach the new phone mount to the cover that had my GPS bracket. I'll also install a phone charging socket on the cover as well so the phone will stay fully charged. It's very handy having the phone mounted there, I have Bluetooth in my helmet so I can make and receive calls hands free when I'm on the bike as well as listen to the GPS lady.
 
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