Mounting Plate Template for a CE 605 Regulator for 2015 F800 GS(A)

Discussion in 'Parallel Universe' started by ADVwxyz, Jan 14, 2016.

  1. ADVwxyz

    ADVwxyz yep Super Supporter

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    Hi all,

    These are my notes on the install of Roadstercycles's CE 605 into a 2015 F800 GSA.

    As most of us are aware the newer GSA models have the OEM R/R inboard, with the air cooling fins facing forward and slanted down whereas the older F8's have the R/R facing outward, with the cooling fins sideways towards the rider's leg.

    I was curious if a CE 605 could fit within current mounting configuration. The answer is "Yes it can!"

    2016-01-14 17.09.44-800x800.jpg

    The 2015 OEM R/R is fastened by one bolt to a clip. This clips to the ABS pressure modulator "instrument carrier" (Part number 34 32 8 530 988 INSTRUMENT CARRIER). If you look at the parts fiche on this you see that the top of the area where the OEM R/R fastens... the bolt does not go though anything that is fastened to the chassis... only the clip... and the clip slips onto the Instrument carrier. At the base of the OEM R/R when it is fastened is a little 1/8th inch supporting node that helps support the mass of the OEM R/R. So, all told, the OEM R/R is fastened, quite honestly, a little lazy. You cannot see the supporting node in the diagram below, but you can see it when you take off your OEM R/R.

    1.jpg
    #1
  2. ADVwxyz

    ADVwxyz yep Super Supporter

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    Fast forward to the CE605... with its added mass and size... and my only concern was getting an install that 1) Fit and 2) was secure.

    The photo below shows the little plastic supporting node which the 1/4' mounting plate is resting on.

    By using the 1/4" mounting plate, it allows you to file a relief notch for the 1/8th supporting node on the Instrument Carrier so you can mount the CE 605 flush on the mounting plate.

    Also, you see how I have my CE605 shifted down on the plate, again, to gain clearance at the cylinder head. More detail to follow.

    2016-01-14 17.10.05-800x800.jpg
    #2
  3. ADVwxyz

    ADVwxyz yep Super Supporter

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    2016-01-14 17.10.31-800x800.jpg

    The main constraint given the footprint of the CE605... is its "height" towards the cylinder head. This is why it is important to notch the plate at the supporting node of the Instrument Carrier... so the mounting plate can slide down 1/16th - 1/8th of an inch. In the photo in post #2 you actually see the bottom edge of the CE605 extending below the Instrument Carrier's supporting node. This, in order to get more clearance from the cylinder head in the below photo. The clearance at the closet point of the CE 605 to the cylinder head is about 1/8th".
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  4. ADVwxyz

    ADVwxyz yep Super Supporter

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    So, the below picture shows me having removed the two outboard bolts holding the CE 605 to the mounting plate. Right now, focus on the supporting node, and what I did there. First, I filed the 1/4" mounting plate down - a lot - so that the hook of the supporting node could reach around.

    2016-01-14 17.12.36-800x800.jpg

    Secondly, and I will show the detail of this as we move forward... I also filed the bottom edge of the mounting plate AT THE supporting node, to let the plate sit further down past the supporting node. Again, the clearance at the cylinder head being the reason why. You can file between 1/16th to 1/8th of the bottom edge at the supporting node's mounting plate edge. Based on the angle of the cylinder head, every 1/16th you file at the node along the supporting bottom edge will get you almost 1/8th clearance at cylinder head.

    2016-01-14 17.12.57-800x800.jpg
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  5. ADVwxyz

    ADVwxyz yep Super Supporter

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    Here you see the mounting plate off... and the detail of the filing for the supporting node to reach around, as well as the mounting plate supporting edge file... in my case... 1/16th. My advice is do not drill the clip bolt hole or any other holes you see in the centre area of the mounting plate until you have all your filing completed.

    2016-01-14 17.15.03-800x800.jpg
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  6. ADVwxyz

    ADVwxyz yep Super Supporter

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    So let us get to the mounting plate dimensions and measurements... now that you understand why the filing has occurred and why it is important. (I spent a lot of time sorting out this solution over the holidays...)

    2016-01-14 17.47.15-800x800.jpg
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  7. ADVwxyz

    ADVwxyz yep Super Supporter

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    And for ease of discussion, I label things here. Regarding a comment above, do not drill and countersink holes 1, 2, or 3, until all your filing is done and you have repeatedly mocked up the plate in situ checking for clearance at the cylinder head. How I drilled the holes for the CE 605 is I taped the CE 605 to the mounting plate. I favored sliding the CE 605 down towards the bottom of the plate... for clearance at the top. See Post #2's photo. I scribed the aluminum with a sharp pointer through the topside of the CE 605, and then, carefully drilled. The bolts are Socket M6 20mm Fine Thread. They are the perfect fit through the aluminum mounting plate. I tapped the mounting plate to receive the threads of the bolts.

    2016-01-14 19.02.57-800x800.jpg
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  8. ADVwxyz

    ADVwxyz yep Super Supporter

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    Here are a series of photos showing the measurements you likely are interested in.

    First width.

    2016-01-14 17.47.15-800x800.jpg
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  9. ADVwxyz

    ADVwxyz yep Super Supporter

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    Height:

    2016-01-14 17.54.05-800x800.jpg
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  10. ADVwxyz

    ADVwxyz yep Super Supporter

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    Width detail from left to right:

    Inset from outside edge to start of filing is 7/8ths. The first photo in Post #4 shows the supporting node is towards the left of centre, see the bolt holes 1, 2, 3,- the supporting node is directly under them.

    2016-01-14 17.49.07-800x800.jpg
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  11. ADVwxyz

    ADVwxyz yep Super Supporter

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    Moving now to the width of the notch I filed to receive the supporting node reach around nib... it is simply the width of my file... 1 1/8th:

    2016-01-14 17.49.18-800x800.jpg
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  12. ADVwxyz

    ADVwxyz yep Super Supporter

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    Lastly, the last right side measure to inside edge:

    2016-01-14 17.50.02-800x800.jpg
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  13. ADVwxyz

    ADVwxyz yep Super Supporter

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    Now, the distance from the top edge to the retaining bolt that goes through the mounting plate and attaches to the clip that is on the instrument carrier. I could have drilled another 1/16th towards the right (down) and still have been ok.

    2016-01-14 17.54.22-800x800.jpg

    2016-01-14 17.54.38-800x800.jpg
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  14. ADVwxyz

    ADVwxyz yep Super Supporter

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    And then the other axis... in from the outside edge is an easy 1 1/2"

    2016-01-14 20.16.17.jpg
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  15. ADVwxyz

    ADVwxyz yep Super Supporter

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    So then... you are likely wondering about holes 2 and 3....

    So, to recap: the CE is big and heavy. It is fastened only onto a clip, and if the mounting plate is created with tight tolerances it sits in the bottom supporting node smartly. But, that top bolt clip could slide upwards. And so, hole number 2 is a counter sunk M6 Fine Thread tapped hole to hold a countersunk phillips head 10 mm M6 fine thread screw... to act as a bit of a "set screw" to push out against the supporting node nub a bit.

    Hole number three is a hole to take a little robertson head wood screw so I could have a mechanical fasten at the bottom for the plate. This way the plate is not going to go anywhere on a big bump with the inertia of the CE 605's mass.

    So these holes can be drilled anywhere... if you think they are needed, along the vertical line 1.5" in from the outside edge.

    2016-01-14 19.02.57-800x800.jpg
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  16. ADVwxyz

    ADVwxyz yep Super Supporter

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    Lastly, the notch detail:

    We can see the shaded relief filing to allow for the reach around for the supporting node.

    And, we see the notch relief edge filing of about 1/16th to 1/8th ... that allows the plate to sit a bit lower down... gaining clearance from the cylinder head.

    2016-01-14 19.03.06-800x800.jpg
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  17. ADVwxyz

    ADVwxyz yep Super Supporter

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    So, the cumulative effect of the 1/16th" / 1/8th" notch relief of the lower mounting plate edge.... AND... scribing the CE 605's bolt holes favoring a lower mounting position on the mounting plate... gains you clearance at the cylinder head.

    My guestimation is you can only cheat the CE 605 down to a max of 1/8th of an inch from the supporting node since you are limited by the overall design of the instrument carrier itself.

    On the inside area... above the plug you see going into the instrument carrier facia facing outward... is a limiting "wall" that the CE605 cannot slide past. (directly behind the zip tie). See the second photo of post #4 which shows the limiting facing facia clearly.

    2016-01-14 17.10.05-800x800.jpg
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  18. ADVwxyz

    ADVwxyz yep Super Supporter

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    So these measurements give me about a 1/16th to 1/8th" on this bottom constraint, as well as 1/8th at the top constraint at the cylinder head.

    2016-01-14 17.09.44-800x800.jpg
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  19. ADVwxyz

    ADVwxyz yep Super Supporter

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    I fastened all four bolts of the CE 605 into the aluminum plate. So then CE 605 is not coming off the plate.

    I then, from the brake reservoir side, fastened a single M10 bolted through to the plate and used thread locker!

    So I am really happy with the install... and after 8 months with it, I just double check the bolt on the brake reservoir side to ensure it has not loosened... and using blue threadlocker, it has not.

    No issues through the summer of 2016 on this install which I undertook in Jan 2016.
    #19
  20. JRWooden

    JRWooden Homeless motorcycle vagabond ... and ... loving it

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    Damn fine work .... :beer
    The older style was MUCH easier ... I didn't realize how good I had it....
    #20