Garmin Zumo 590 Cradle butchery - The How-To

Discussion in 'Mapping & Navigation' started by blender, May 9, 2014.

  1. blender

    blender Just another rider

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    The other thread is getting a bit crowded, so I'm posting the how-to here. This might also apply to the 660 cradle.

    Some of us do not need or want the additional data/audio wires Garmin has included with the 590 power supply, all we want is a simple power supply that will be reasonably water-resistant. This post is how I modified my 590 cradle. I'm sure others can/will do a cleaner job.

    You will need: a T5 torx screwdriver, shrinkwrap, some sort of connector-thingy, a simple power cord (I used a spare Zumo 450 power cord I had).

    Step 0. The pristine, unmolested Zumo 590 cradle:
    Step 0.JPG


    Next, use the T5 to remove the cradle back. The screwdriver points to the power plug. The larger plug is the audio/data plug. Remove both of the plugs from the circuit board.
    Step 2  Power Suppy.JPG

    The cradle back removed. Note the silicone (or whatever) gooped in there. You will need to pry that out to remove the wires. There's also a jesus clip securing the cable to the back. Pry that off.
    Step 1 Cover Removed.JPG

    Attached Files:

    #1
  2. blender

    blender Just another rider

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    The back with the wires removed. Note, I have already clipped off the audio/data wires.
    Step 3 .JPG


    At this point I've cut off the old harness and left about 6". That is all of the old harness I'll be using. This photo shows the remaining harness after I've pulled out the unused audio wires.
    Step 5 After Removing data wires.JPG


    This shows how I'll put the new harness together. The middle set of wires is a two-prong SAE connector I picked up at the local auto parts emporium.
    Step 7 Power cables.JPG

    Now put everything together. I used Posilocks to connect the wires, then used shrinkwrap to cover the connections.
    Step 8.JPG
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  3. blender

    blender Just another rider

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    Plug the power clip back into the circuit board, put the jesus clip back on to secure things. I did not add any silicone to waterproof things. We'll see how that works out, I might go back and add some.
    Step 9.JPG

    Now put the back back on. Be careful with those little screws. I sheared one off.
    Step 10.JPG
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  4. blender

    blender Just another rider

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    Now wire the motorcycle power supply in. I use a FuzeBlock to handle the wiring. It has a built-in relay, 30A fuse, and you can change the output power from constant to switched simply by moving the fuse (RH side is switched, LH side is constant).
    Step 11.JPG

    Now for the test. Put the Zumo in the cradle, hook the cradle power to M/C power and fire up:
    Step 12.JPG


    Whoo hoo! Things work and no smoke came out! I still need to put the RAM ball mount back on the cradle and figure out just where I want to mount the thing. Usually I do a handlebar mount, I might explore other options.
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  5. cecilturtle

    cecilturtle Adventurer

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    Thanks! Well done. I may buy another cradle to move around on my secondary bikes and do this so I can just plug into the battery tender plugs. I already have RAM balls on every bike.

    New cradles are $69, yikes! :yikes
    #5
  6. blender

    blender Just another rider

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    That's is another reason I did this: to move the cradle around to different bikes. I see no reason to buy a separate cradle for every bike I want to use the 590 on.

    This way all I need a another power cable to run to the Zumo.
    #6
  7. 9Dave

    9Dave Bazinga!

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    OK - so maybe a dumb question - but why didn't you just attach the SAE connector to the power leads from the cable and tie off the other leads and shrink wrap them?
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  8. blender

    blender Just another rider

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    Because I didn't want all those extra cables. That is a huge bundle, I want a simple two-wire power supply, *no* other cables.
    #8
  9. cecilturtle

    cecilturtle Adventurer

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    What did you use to get the screws out? They look like torx screws but the smallest torx bit I have is a T8 and it's way too big.

    [nevermind I re-read your post - I had to buy a small set to get the T5 torx]
    #9
  10. blender

    blender Just another rider

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    Yeah, trying to find a T5 sucks. I did find mine at Sears, believe it or not.
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  11. cecilturtle

    cecilturtle Adventurer

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    I found a little $4 mini tool at Kmart actually.

    Here's how mine turned out:

    IMG_20140515_200427_683.jpg

    I used an extra Battery Tender lead to get the SAE plug, and connected it to the thicker red/black portion of the harness power wire (with the 2 amp fuse that came with the cradle), and connected that to the smaller lead that goes into the cradle. I think it turned out OK, it's about 5 feet long end to end. I did happen to have a tube of silicone sealant so I put a dab on the connector when I put it back together. Then wrapped the whole wire in electrical tape.

    I thought those data cables would come out of the thicker jacket more easily, I was hoping to use more of that portion of cable but it was a bear with all that shielding and stuff crammed in the cable. I only ended up using a couple inches like you did.

    Just waiting on the AMPS plate to show up and I'll be good to go!
    #11
  12. Rodknee

    Rodknee the post is mightier than the sword...

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    i just got my cradle, and will be hacking into it tomorrow morning.

    garmin, if you are reading this (highly unlikely...) please make a cradle with just power and sell it for $15 less then the existing one... i will buy 2 more!
    #12
  13. Surly

    Surly surly adventurer

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    I was thinking the same thing! I might buy a spare to hack up and leave one in its pristine state. On my thumper all I want is power. On a bigger bike, that I would do miles and hours on, the other stuff makes more sense.

    Anyway. Thanks for the right up. My initial impression, after looking at the cradle, was that the harness detached easily and Garmin would have a "power only" version :lol3 . Anther $69 isn't what I planned to spend at this point.
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  14. Rodknee

    Rodknee the post is mightier than the sword...

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    i decided to split the loom and pull out as much power cable as i could. i left some of the braided cable in the loom,, since i could not cleanly pull it out. this is my progress so far, with the discarded crap on the left:

    [​IMG]
    #14
  15. Rodknee

    Rodknee the post is mightier than the sword...

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    i ended up with a shorter cable run, because of the way it is installed on the bike.

    [​IMG]
    [​IMG]

    on the bike:
    [​IMG]
    [​IMG]
    #15
  16. blender

    blender Just another rider

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    Looks good Rodknee! And yeah, if only Garmin paid attention and sold a power-only cradle, ideally with a detachable power cord....

    BTW, although I was dealing with a relatively short length of cable, I found the "extra" wires pulled out easily. The pliers I used sure helped.
    #16
  17. ROL99

    ROL99 n00b

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    Hi Steve,

    which (power) connector shown at the end of the cable in the middle of the quoted picture did you use.

    Have one laying around and would like to get a second one to connect but have no idea what it is called.

    Thank you
    Roland
    #17
  18. cecilturtle

    cecilturtle Adventurer

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    The connector in his middle photo is an SAE connector. Should be easy to find at a parts store, and they come on battery tender products.

    Sent from my XT907 using Tapatalk
    #18
  19. ROL99

    ROL99 n00b

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    Thank you for the prompt answer, helps to find the correct connector!

    Cheers
    Roland
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  20. blender

    blender Just another rider

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    Yeah, what he said.... Sorry for the late response, I was on a road trip and not checking any forums. Silly me.

    Yes, it's an SAE connector I got at an auto parts store for a couple bucks. West Marine sells one exactly the same but at almost twice the price. I'll add that info to the post.
    #20