GSX-8R/8S USB-C Charging Socket

For some reason the OEM USB connector costs $80 here and I had a bunch of Sumitomo connectors sitting around, so I decided to DIY a USB port that sits in the same spot. Fitment should be perfect as I designed the parts off a perspective-corrected photograph.

Features:

• Installs into the OEM socket's intended location
• water-resistant thanks to waterproof panel-mount USB socket
• Plugs into OEM harness (make sure to check the polarity of the connector before wiring!!!)
• NOT fast charging. It probably wouldn't be hard to make it fast charge, but the OEM one doesn't fast charge either, I didn't want to chance overloading the accessory fuse.

Parts:

• 1x LM2596 Voltage Regulator Board (I bought these a long time ago, but they are available off Amazon / Aliexpress). These support up to 2.1A charging. Configure it to 5v.
• 1x Sumitomo MT090 Female Connector - This connects to the wiring harness
• 1x Waterproof Male Connector & 1x Waterproof Female Connector - you can use the above Sumitomo connectors. I had another type sitting around so I used those. The socket will not fit through the designated hole in the fairing, so it's important to have these connectors between the regulator box and the panel-mount USB port.
• 1x Waterproof USB-C Panel-Mount USB-C Port
• Some kind of wire 18AWG or narrower. I had good luck with 20AWG. Find ones with shielding, or you can just heat-shrink it all like I did.

Tools:

• Soldering Iron & Heat Shrink Tubing
• Crimping Tool for the Sumitomo connectors - something that has 1.5mm should work
• Hot Glue Gun - for strain relief and a little dab behind the hole in the case designed to let the LM2596's LED shine through.
• Medium CA Glue (Accelerator spray recommended) - for gluing the regulator's case together. You want it to be waterproof.
• Industrial Strength Velcro - For mounting the regulator box in the panel under the front cowling. I bought a big roll of this off Aliexpress 10 years ago and have not run out yet.

Installation:

Refer to the accessory manual on Suzuki's Installation Manual website first. That said, I didn't take out the entire front dash; just the fairing under the front cowling, above the front wheel's fender. Your mileage may vary, depending on how small your fingers are.

After sliding the panel into the hole in the fairing, run the cable through the hole in the center of usbClasp and snap usbClasp into place behind the fairing. the two prongs on usbClasp press against the back of the fairing, keeping it in place. Handles have been designed into usbClasp in case you need to remove it.

The rest of the instructions are identical to the manual on Suzuki's website.

Notes:

• PETG recommended due to superior UV resistance over PLA
• Maya exports the files 1/10th the size for some reason, even though I have the scene set to mm. Just set the scale in your slicer to 1000% or 10x size
• gsx8r_usbPort_ver2 and volt_lid_with_hole should be printed upside-down from the file's orientation. The other two files can be printed in the file's orientation
• None of the files needed any support on my Ender 3S, but usbClasp needed a brim to stay on the build plate.
• I recommend hot gluing the back of the panel mount USB connector inside gsx8r_usbPort_ver2. This should keep the bolt from backing out and the connector from rotating in the housing unwanted.