Garmin Zumo 590 Cradle butchery - The How-To

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

  1. BlackBeast

    BlackBeast Been here awhile

    Joined:
    Jul 7, 2006
    Oddometer:
    987
    Location:
    Ontario, CANADA
    Slightly off topic - being winter here, I have the cradle sitting on my workbench and haven't installed it as yet. Can you charge an iphone or other device from the USB connector attached to the 590's wiring harness? Unsure of whether to cut it off as well or save it.
    #41
  2. cecilturtle

    cecilturtle Adventurer

    Joined:
    Jan 5, 2014
    Oddometer:
    23
    Location:
    Pennsylvania
    I wasn't able to charge an Android device off of it. YMMV.

    Sent from my XT1254 using Tapatalk
    #42
  3. BlackBeast

    BlackBeast Been here awhile

    Joined:
    Jul 7, 2006
    Oddometer:
    987
    Location:
    Ontario, CANADA
    Typical Garmin!
    #43
  4. AndyCBR

    AndyCBR Been here awhile

    Joined:
    Sep 13, 2009
    Oddometer:
    167
    Location:
    Baton Rouge, LA
    595 vs 395

    I am assuming the hardware that converts 12v to the 5v the gps needs is inside the cradle on the 595lm? On my 395lm this circuitry appears to reside in a rather clunky black box on a very long power lead I don't want to have to manage.

    All I want is a short SAE cord to move the gps and cradle from bike to bike. I am assuming I would need to buy a 595 cradle and perform the above mods in order to be able to do that?
    #44
  5. cecilturtle

    cecilturtle Adventurer

    Joined:
    Jan 5, 2014
    Oddometer:
    23
    Location:
    Pennsylvania
    The circuitry is either in the cradle or the GPS itself, but either way the answer to your question is yes, you will need to buy the extra cradle and connect your SAE lead. A few different ways are listed here, all seem to be successful.

    Sent from my XT1585 using Tapatalk
    #45
  6. AndyCBR

    AndyCBR Been here awhile

    Joined:
    Sep 13, 2009
    Oddometer:
    167
    Location:
    Baton Rouge, LA

    Actually I got to looking further and the 590/595 cradle does not appear to be compatible. The 590/595 connect to the cradle via a large vertical strip of contacts. The 390/395 use just two horizontal pins in the cradle.

    Oh well I'll just live with the dongle and zip tie it up as best I can.
    #46
  7. leethal

    leethal 3 wheel Monarch #37

    Joined:
    Oct 14, 2008
    Oddometer:
    284
    Location:
    Mornington peninsula, Melbourne
    Yes.....IPhone will charge from the USB cable on 595.
    just installed mine and noted.....
    .....no power at cradle pins until device installed to cradle.
    .....no power at USB plug until device is turned on...

    a bit bloody tricky heh !
    #47
  8. BlackBeast

    BlackBeast Been here awhile

    Joined:
    Jul 7, 2006
    Oddometer:
    987
    Location:
    Ontario, CANADA
    Thanks for the update. Hopefully it would help others. I butchered my cable just to keep the cradle powered and a smaller harness to the fuse block.
    #48
  9. Spyderrider

    Spyderrider Been here awhile

    Joined:
    Dec 11, 2014
    Oddometer:
    238
    Soooo, here is my damn story!!! I have a Garmin 590 cradle on my CanAm Spyder and my DL650 Vstrom. I now have a WR250R and want to use it on it too. I ordered a cradle from GPS city. I decided to just clip all the unnecessary cables from the main cabling where the four wires come out, saving the power cable / fuse holder intact. I did not want to open it up as I figured cutting the data, USB and Audio would be fine leaving the GPS to still work fine. I removed the fairings and gas tank and ran all necessary wires and secured. Buttoned everything up and tried the GPS. Damn, this is when I found out they shipped a 660 cradle - not one for the 590. Im sure now its butchered, return will be impossible! I will call them tomorrow and see if they can expedite me the correct one.

    My question is was my thinking correct regarding cutting wiring except for power - correct?? I hope to simply cut cabling off new cradle and and use a SAE disconnect to connect to the wiring I have already installed. Am I close to OK doing it this way???

    Please say I am good to go!!!!
    #49
  10. Spyderrider

    Spyderrider Been here awhile

    Joined:
    Dec 11, 2014
    Oddometer:
    238
    So, nobody out there??
    #50
  11. Precis

    Precis Maladroit malcontent

    Joined:
    Oct 13, 2009
    Oddometer:
    4,896
    Location:
    Body's back home, but soul is in the Andes
    Well, the title of the thread includes the word 'butchery' and it sounds like that's exactly what you've done. Sadly, you've butchered the wrong thing and it's now no longer any good to man nor beast. I s'pose you can try and sell it to someone else, to save them hacking into an otherwise perfectly good harness, but only if you trust your workmanship to be up to commercial quality.
    I have a nagging suspicion - and it's only that, mind - that merely splicing a plug into the harness MAY not work - I think there's something tricky about Garmin's harnesses that involves wires going to pins not being as they are expected to be, to force owners to buy Garmin's proprietary equipment.
    Me, I just conceded defeat and found a place to tuck the unwanted extra cabling away on the bike, and stuck an extra pin into my Garmin designer voodoo doll...
    #51
  12. Spyderrider

    Spyderrider Been here awhile

    Joined:
    Dec 11, 2014
    Oddometer:
    238
    So, do I have it correct? I cannot cut unneeded wires off? The red/black power cables run all the way from inside the cradle to the battery end of the cable system. Why would cutting the unnecessary unused wires off be a problem if the red/black is continuous thru the cable? Now I have the 590 cradle $$$ ouch, I may just try to hook up the new gps cradle complete to the installed butchers harness red/black and see if the gps fires up. Since I am installing it on a WR250R, there is little room to bundle the unused wiring and keep it intact.
    #52
  13. Precis

    Precis Maladroit malcontent

    Joined:
    Oct 13, 2009
    Oddometer:
    4,896
    Location:
    Body's back home, but soul is in the Andes
    No idea - I have installed two different Garmins onto two of our DR650s and the harnesses and cradles were completely different. In the interests of varying opinions when seeking routes in foreign countries, I'll probably fit a TomTom to the third bike.
    People here have obviously cut out extra wires quite successfully, but as our bikes will be going well outside the reach of streetlights and across 24 countries, I need maximum reliability with minimum opportunity for a failure created by my own ineptitude.
    Details of my Garmin installations are now hazy, but one of the harnesses had a bundle of surperfluous wires which I coiled up in a cranny beside the battery somewhere, the other had less wires but included an inconvenient black box along its length that I eventually concealed somewhere. Of most importance is that both systems work.
    Good luck!
    #53
  14. Spyderrider

    Spyderrider Been here awhile

    Joined:
    Dec 11, 2014
    Oddometer:
    238
    So yesterday I installed the new 590 cradle on my WR250R. When I installed the wrong harness, I cut off all unnecessary leads leaving only the red/black power cable. Before running all the 590 cabling (this time keeping it all intact) i simply hooked the red/black from new cradle to the butchered installed 660 cabling and it worked fine. Sooooo, simply cutting the unneeded cables off does not make the power connections inoperable. I did proceed and install unbutchered 590 cradle cabling and hid wires not needed. It comes with a standard USB cable that was long enough to route back up to handlebar / tank bag position that I will use for charging cell phone. I installed it so its unswitched to make charging easier. Maybe wordy but hopefully informative.
    #54
    Precis likes this.
  15. leethal

    leethal 3 wheel Monarch #37

    Joined:
    Oct 14, 2008
    Oddometer:
    284
    Location:
    Mornington peninsula, Melbourne
    Just remember your phone won't charge unless your GPS is in the cradle and turned on.....
    #55
    Precis likes this.
  16. pnewb

    pnewb n00b

    Joined:
    Jun 2, 2011
    Oddometer:
    4
    Might be 2 years too late, but in case anyone else comes looking for the data, that is indeed the exact measurements of the power plug.

    #56
  17. dad2bike

    dad2bike Retired! Cranky Old Fart

    Joined:
    Aug 12, 2007
    Oddometer:
    10,572
    Location:
    Las Vegas, NV
    Thanks to the OP for starting this cradle mod thread.
    I just got a 590LM and was shocked at the size of that wiring harness for the cradle. No way do I want all that crap tied up under the dash.
    This thread got me looking to ways of making a lighter power only .

    One of the things I'm Anal about is I like to make modifications in a manner than can be easily reverted back to near original.

    Here's how mine progressed.

    I happen to have a little multi-bit tools from some dollar rack. It had a T-5 bit and even a smaller one.
    The sealing goop appears to be Hot Glue. It prys out with a simple pic.

    Here's the assembly unplugged and glue pried out.

    [​IMG]

    The little strain relief holding clip simply pulls right out.
    [​IMG]

    The entire harness separates nicely and can be stored intact for when I go to sell the unit.

    [​IMG]

    I happen to have a box of car alarm stuff including some extra LED's like this. Snip and I have small power cable
    [​IMG]

    The plug is not the correct size. A little big. So I took my rotary file to it to size it to fit the PCB socket. I also tied a nice knot for strain relief.

    [​IMG]

    Fresh Hot glue in the cavity. I added shrink tubing over the wires up into the cavity first to protect them.

    [​IMG]

    At this point the unit can be connected to any power cable you choose.
    In my case I have the BMW pigtail so it is now wired directly to the pigtail. It all tests out functional.

    This leaves me with a harness I can put back on in the future.

    Total cost to me- $0.00

    Some may think the wire I used is too small. It is comparable to the wire in the harness. It's at least twice the diameter to the wires on my 276c.

    I hope this is a helpful addition to this thread.
    #57
    Precis and 1coolbanana like this.
  18. blender

    blender Just another rider

    Joined:
    Jul 27, 2004
    Oddometer:
    769
    Location:
    The Middle Coast
    Howdy, the OP here. When I submitted the original post I *knew* there were others who could do a cleaner "butchery", this this a great example!

    The big issue I see with saving the original harness is finding an appropriate size power connector to fab your own power supply. dad2bike was fortunate to find a plug in his parts box, many of us don't have that option. Radio Shack just doesn't carry these parts anymore....

    This video (in Dutch ? with subtitles) has another idea.



    I think the power plug he references is a JST PH 2.0. I've order a small batch from China, when they arrive I'll post back if they actually fit.

    Steve in Madison
    #58
    dad2bike likes this.
  19. dad2bike

    dad2bike Retired! Cranky Old Fart

    Joined:
    Aug 12, 2007
    Oddometer:
    10,572
    Location:
    Las Vegas, NV
    That looks like a nice simple setup. I believe you are correct on the plug required. Mine was a simple car alarm LED that I filed down to fit. They are available on ebay.
    I've got several bundles of them. If somebody wants one I'll mail to them for nothing. You get to do your own filing though. :thumbup

    The correct plug with long enough pigtails would be best of course. :super
    #59
  20. SauronFZ1

    SauronFZ1 n00b

    Joined:
    Sep 22, 2015
    Oddometer:
    1
    Location:
    Orlando
    Did the cablectomy on a 'spare' cradle I bought, and then attached the Pigtail from my Multistrada to the end.

    Thanks for the pics and info, was very helpful! Made doing this a snap with some water proof heat shrink/solder butt splices, and some more heat shrink.
    #60