12VDC Power Point Mod for '85 VF500 - MacGrubber fans

I do a lot of driving for work and I don't know how I got along without my Garmin GPS. Now that the 500 has been running reliably, I've taken advantage of the warmer days around Denver to use the bike. Unfortunately, I probably only get about 2-3hrs of battery life out of the Garmin so I've set out on a quest to add a 12VDC power point to the bike.

All weather power point picked up from Checker Auto parts for $12


Intended location for mounting, looks accessible with ample clearances


The challenge is finding a good supply of power without creating other problems like tying into a pre existing circuit. Laying in the tool box of spare misc spare parts, I had a power wire with built in fuse I could have connected directly to the battery. This option was not my favorite due to concerns of having the wire chaffe or burn somewhere along the way between the battery and the dash panel.

The factory fuse panel has two empty spaces labeled as "spares." I removed the panel and gently pried off the rear cover. The spares location did not have any electrical connections. Using female spade connectors, the pocket clip from a ball point pen, and two part epoxy, I added connections.


The above picture shows a fuse in the lower right location. In the photo below, the fuse panel is flipped over and the back panel is removed. The new connections are on the lower left (reverse of the top view picture above). The yellow wire is leaving the fused connection and will get routed to the recepticle. The flat metal bar is the pocket clip from the ball point pen soldered to the main buss and also soldered to the spade connector for the fuse. The fuse was put in place with the spade connectors (to hold everything in exactly the right location) and 2 part epoxy added to keep the spades in the correct location when the fuse is removed.


By this afternoon, the epoxy will be setup enough that I can remount the rear cover, mount the panel, and start routing the wire. More to follow.

 

Thanks - and no doubt about it, there's more than one way to "do it right". I had a few reasons for doing it this way some of which I listed in my OP. Another reason I chose to do it this way was that I felt it would make the most sense for any future owner should I sell the bike.

So, it's amazing what a guy can do on a lunch hour. Here's a picture of the fusepanel mounted back down. There wasn't room under the cover to route the wire out the same location as the wire harness. It comes out the lower corner in a notch that was already in the panel housing. At least at this point, the wire is now "fused."



In this side view shot, you should be able to see a glimps of the yellow wire. The front cowl is removed. Where the wire would be visible to the rider or in a position that it could chaffe, I have it running thru that ribbed wire protector and routed with the factory wire bundle. The ground is fastened to the headlight mount bracket, spade connectors are crimped AND soldered, along with shrinktube covering the positive lead spade connection.



Now I just need to run to the hardware store and pick up a few appropriate screws, nuts, and washers, finish bundling up the wires there with zipties, and remount the cowling.

 

Installation complete

Here it is all completed and buttoned back up. Easily accessed, not extreamly obvious, and lots of room for power cords.