Optimate 4 Permanent Charger Lead Layout.

Battery Modification:

One of the first things I discovered was that the terminal bolts on the battery are only just long enough to start in the thread of the anchor nut using the terminal connection on the bike. When extra terminal connectors are added, (as in this instance of fitting the permanent charger lead) it makes the thickness bigger and the terminal bolts do not reach the thread in the anchor nut.
The anchor nut however is a loose fit in the terminal connection and it is gravity that is causing the problem. The solution is to devise a means of lifting the threaded anchor nut so the bolt can reach the thread.
I found that the "off cut" from a cable tie is ideal for making a small spring. Simply cut a piece about 20mm long and fold it in half and place it under the anchor nut, the tension in the plastic is enough to force the anchor nut to the underside of the battery terminal and being made of plastic you do not run the risk of electrical problems. This makes it easier to get a "start" on the thread of the anchor nut even though the terminal connector is now twice as thick.

Homemade spring made from an off cut of cable tie plastic bent in half.

Homemade
Spring.

Battery Anchor
Nut & Terminal.

Bike battery with threaded Anchor nut, (removed from the terminal block) and negative terminal block.

Battery and Anchor nut inserted into negative terminal block as intended without use of the homemade spring.

Battery Anchor
Nut & Terminal.

Battery and Anchor nut inserted into negative terminal block using the homemade spring to raise it to the underside of the battery terminal.

Battery Anchor
Nut & Spring.

Cable Layout:

I was originally intending to run the cable to a point under the seat of the bike but this proved impractical as there was no good fixing point for the block connector plus the lead was to short. I opted to go forwards through the frame following some existing cables with the thought that it must be reasonably safe as it was an existing electrical cable route.
First I had to get to the battery which meant raising the petrol tank, (consult your user guide for this) I then disconnected the battery and positioned the leads in the position they were going to lie, (figure 1). I then threaded the lead with the block connector end on it through the frame taking the same route as an existing cable, (figure 2). Once I was happy with the layout I cable tied the permanent charger cable to the front stay, (figure 3) as this is a non moving part of the bike the cables are less likely to chafe or wear. The next test was to check that I could access the block connector without to much trouble, there is a handy slot in the fairing by the indicator mount to the right of the bike, (when sat on). This is ideal for passing the extension cable (TM-73) for the Optimate 4 battery charger through, (figure 4). Lastly I connected the cable terminals to the battery terminals ensuring the positive and negative connections were the correct way round.
A quick check that the charger worked when it was connected via the planned route and it was a case of putting the bike back together then once again checking everything worked OK not forgetting to re-set the clock on the bike instrument cluster.

The layout of the new permanent charger cable shown here with the battery terminals disconnected ready for re-connection once the charger cable has been routed through the bike.

Battery Terminal Point Layout.
Figure 1.

Cable ties are used to hold the permanent charger cable to the front Stay to keep it out of the way of the steering mechanism and other moving parts.

Cable Tie To Front Stay.
Figure 3.

The charger cable is passed through the bike frame taking a similar route to an existing cable which in theory should be a safe route to take.

Bike Frame Cable Layout
Figure 2.

This picture shows the route the cable takes through the fairing slot to the battery charger by means of the optional 2.5 meter extension cable.

Connect To Optimate 4 Charger.
Figure 4.

In Use - Not In Use:

Already indicated on a previous page the block connector end needed to be placed in a place that was not susceptible to the abuse it could get from the weather such as rain or snow but it needed to be easily accessible for when it was required to be used by the charger.
There is a gap in the plastic surround by the front Stay and light cluster that the block connector can be tucked under when not in use, it is a fairly snug fit so it should not fall out when the bike is ridden due to vibration plus the cable ties on the front Stay help to hold it in place.
When it's use is required it is easy to get to and can be connected to the battery charger using the optional 2.5 meter extension cable, (TM-73). This can then be left in place even when the bike is covered up and charging of the battery can be performed at leisure.

Optimate Charger Bike Battery Connector. Proposed layout for cable and block connector for when it is in use with the charger.

Connector shown in proposed
visible position when in use.

Optimate Charger Bike Battery Connector. Proposed layout for cable and block connector for when it is not in use with the charger. Block connector placed in a relatively shielded place from the elements.

Connector shown in proposed
hidden position when not in use.