I have an old Garmin Streetpilot (monochrome). It has basically been retired from automobile use because we use our blackberry for normal navigation. However it is water resistant and I have decided to permanently mount it to the K100RT. It provides a nice status screen with a nautical compass, current speed and so forth. It also has all major primary and secondary roads in the US in its memory, so it is suitable for navigating just about anywhere I'd care to ride.

A few years ago I also purchased three VDO guages at a swap meet. I think they are from an old VW GTI: volt meter, oil pressure in bars, oil temperature in Celcius. I have decided to mount at least the volt meter and oil pressure, thinking it is probably more important to know oil pressure than oil temperature. However I am undecided as there is already an idiot light for oil pressure on the bike, but nothing for oil temperature.

I began this project by removing the knee panels, fairing pockets and windscreen. Once that is removed, the dash panel that wraps around the back of the fairing can be removed. It sticks a little from the press fit windscreen gasket. Be careful with it; it is very thin. I was excited to see that BMW has already marked where the factory installs guages. I drilled those out with a hole saw. Go slow and don't use a lot of pressure. The plastic is thin. I got a clean cut. My VDO guages mounted right up with no problems.

At this point, I realized that I should give some further consideration to any other projects I'd like to perform while the windscreen is out, so I decided to make a list. I'd like:

remote relays for the headlamp high and low beams
move the relay for the running / driving lamps out of the underseat box and into the fairing
a headlamp flasher
a dash mounted 12v power outlet for charging cell phone

I made up a wiring schematic:



The only question I have is about my headlamp flasher circuit. I thought I could use a standard 12v flasher assembly on the signal side of the high beam relay. Initial tests proved however that the signal side of the relay does not draw enough watts to engage the flasher. I'd have to use a resistor in line to make it work, and that seemed like a poor design idea. So I wonder, are there any ways to make the high beam flash without spending a ton of money on a brand name solid state flasher?

Also, is there a way to incorporate the high beam indicator on the dash so that it blinks along with my high beam (so that I know when the flasher circuit is enabled)??

As you can see from my schematic, I decided that I will need to run a pair of copper 12 guage wires to the fairing direclty from the battery to provide power to all of my lamp relays. I will use a 30 amp inline fuse near the battery as a failsafe. Any problems with this that you can see?

The project continued on with ideas for how I can mount the garmin GPS.

I studied the BMW factory dashboard for clues on how to make my design.



I realized that the BMW dash mounts as a squeeze fit between the windscreen and the fairing gasket. I figured I could use thin sheetmetal, pop rivets and perhaps some 1/8" aluminum sheet to construct a custom dash to hold the Garmin. I am uncertain exactly how to design the dash because I want the Garmin to be a permanent part of the dash, to deter theives. I also thought it would be nice to have some extra shelf space there where I could put some hook/loop fastening tape for a radar detector, ipod, or whatever suits my fancy.

Any input on your ideas to help this stage of the design is much appreciated. I will continue posting updates.

Hi Scottie,
With regard to the relay lighting may I suggest you strongly consider one of the kits from Eastern Beaver http://www.easternbeaver.com/Main/Products/products.html Jim the guy who runs Eastern Beaver (no connection other than as a very satisfied customer) is a really helpful person who puts out VERY high quality relay kits which are constructed of the highest quality components that are deigned to fit perfectly. The relays on the kit I purchased were very high quality Panasonic relays and were totally environmentally sealed by potting resin from the factory. With such a vital job to do (keeping the sole headlight on) nothing but the best is good enough.

Jim also does a good line in power sockets and other accessories plus he will make up custom kits as he has done for some of my friends. Postage from Japan where he lives is extremely fast and reasonably priced too, he also integrates headlight modulators into the kits if required.

When you talk of a headlight flasher what are you trying to achieve? I have probably totally misunderstood your intent so please excuse me if I am off on the wrong track. Headlight flashers are illegal in most if not all US States but headlight modulators are not and there is Federal legislation that permits modulators throughout the US. The crux is they do not flash on and off only up and down in intensity, I have cut and pasted the regulations for the US below. Note some US local Law Enforcement Officers do not understand that they are allowed and have hassled some riders in their States but given you carry a little laminated card it is relatively easy to politely educate them BUT if you had a flasher I suspect you would be toast as the 200 to 280 Hz modulation rate is way faster than a flasher will achieve and will be noticeably different, sort of like driving along with an illuminated sign saying "pick me, pick me".

There are a number of excellent bar mount carriers for GPS units which could be adapted and they have the benefit of being easy to adapt to another brand if the current GPS gives up the ghost sometime.

WAIS Document Retrieval[Code of Federal Regulations]
[Title 49, Volume 5]
[Revised as of October 1, 2001]
From the U.S. Government Printing Office via GPO Access
[CITE: 49CFR571.108]

TITLE 49--TRANSPORTATION

CHAPTER V--NATIONAL HIGHWAY TRAFFIC
SAFETY ADMINISTRATION, DEPARTMENT
OF TRANSPORTATION

PART 571--FEDERAL MOTOR VEHICLE SAFETY STANDARDS--Table of Contents

Subpart B--Federal Motor Vehicle Safety Standards

Sec. 571.108 Standard No. 108; Lamps, reflective devices, and associated equipment.

S7.9.4 Motorcycle headlamp modulation system.
S7.9.4.1 A headlamp on a motorcycle may be wired to modulate either the upper beam or the lower beam from its maximum intensity to a lesser intensity, provided that:
(a) The rate of modulation shall be 240 <plus-minus> 40 cycles per minute.
(b) The headlamp shall be operated at maximum power for 50 to 70 percent of each cycle.
(c) The lowest intensity at any test point shall be not less than 17 percent of the maximum intensity measured at the same point.
(d) The modulator switch shall be wired in the power lead of the beam filament being modulated and not in the ground side of the circuit.
(e) Means shall be provided so that both the lower beam and upper beam remain operable in the event of a modulator failure.
(f) The system shall include a sensor mounted with the axis of its sensing element perpendicular to a horizontal plane. Headlamp modulation shall cease whenever the level of light emitted by a tungsten filament light operating at 3000 deg. Kelvin is either less than 270 lux (25 foot-candles) of direct light for upward pointing sensors or less than 60 lux (5.6 foot-candles) of reflected light for downward pointing sensors. The light is measured by a silicon cell type light meter that is located at the sensor and pointing in the same direction as the sensor. A Kodak Gray Card (Kodak R-27) is placed at ground level to simulate the road surface in testing downward pointing sensors.
(g) When tested in accordance with the test profile shown in Figure 9, the voltage drop across the modulator when the lamp is on at all test conditions for 12 volt systems and 6 volt systems shall not be greater than .45 volt. The modulator shall meet all the provisions of the standard after completion of the test profile shown in Figure 9.
(h) Means shall be provided so that both the lower and upper beam function at design voltage when the headlamp control switch is in either the lower or upper beam position when the modulator is off.
S7.9.4.2(a) Each motorcycle headlamp modulator not intended as original equipment, or its container, shall be labeled with the maximum wattage, and the minimum wattage appropriate for its use. Additionally, each such modulator shall comply with S7.9.4.1 (a) through (g) when connected to a headlamp of the maximum rated power and a headlamp of the minimum rated power, and shall provide means so that the modulated beam functions at design voltage when the modulator is off.
(b) Instructions, with a diagram, shall be provided for mounting the light sensor including location on the motorcycle, distance above the road surface, and orientation with respect to the light.

I have heard nothing but good stuff about Eastern Beaver stuff. The thinkg is, I have a very large quantity of BMW parts here from which I can pick and choose, including quite a variety of BMW Hella relays, factory fuses holders and water proof interconnects. Of course all of this stuff is right up there on the quality scale with the rest of the K100, having been taken from the many BMW cars I've parted out over the years. I was attempting to build something using my palette of existing parts.

Regarding the headlight modulator, I have nothing but the highest regard for the good intentions of the Feds (and no disrespect to you for bringing it to my attention - I appreicate it!) But their history of providing quality engineering information has not been impressive. Remember, these are the same folks that kept an entire nation using dangerous sealed-beam headlamps until the mid 90's while the rest of the world was using high quality H4 halogen lamps. (Bunch of idiots, frankly. :albino: )

In regards to a nightime sensor, I am not going to bother with that. If I am too blind to see that my headlamp is modulating at night, then I shouldn't be piloting a motorcycle in the first place.

I just wanted to be able to design my own circuit with easy to obtain parts, to feel the sense of satisfaction in knowing that I had made something for my bike, well engineered, without relying on a ready-built product (although I'm not too proud to stoop to that level, if I can't fgure something out!)

Scottie,

I bought and installed a headlight modulator and when the modulator is turn on, the high beam indicator is modulating too.
I don't have any photocell, and I use a BMW switch on the dashboard + a relay to divert the circuit to the headlight modulator.(on your schematic, your bypass switch should be replaced by a relay. 30 should come from your headlight switch, 87 should go straight to the headlight high beam (if the coil of the relay burn, you will always have the full high beam), 87A should go to the modulator. The second prong of the regulator should go to the head light high beam.

If you use one of the original 4 ways flashers switch, you could use the internal built in bulb to let you know when the modulator is turn on (They are very powerful and you see them even in full sun light).

The advice of K-bike about carrying the regulation with you is great. I am doing this too. I printed everything at the exception of the requirement to have a sensor and sticked it on the cover of my tool box.

Here is where you could purchase one for cheap
I believe this is the same model as I use.

Nice.

Thank you!