Garmin Zumo 590LM Install - Victory Forums - Victory Motorcycle Forum
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post #1 of 84 (permalink) Old 06-16-2014, 12:37 AM Thread Starter
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Default Garmin Zumo 590LM Install

With a couple of somewhat complex Iron Butt runs coming up next month, I decided it was time to finally get off my wallet and pick up a motorcycle specific GPS. I was planning on getting the Zumo 660 and the associated Victory mounting harness, but when I heard about the 590LM, I was intrigued. Seeing as the Zumo 660 has been around for 5+ years now (old in the tech world) I figured I'd take a chance on trying out the latest and greatest. I was taking a chance twofold. First, unproven technology which is likely to have some bugs. Second, would I be able to wire it up and have it work seamlessly with the factory stereo. Here's how it all played out along with some pictures of the install...

The 590LM (just like the 660) mounts to the handlebars using a Ram ball set-up. I had no concern with that part. The wiring harness is what I wasn't so sure about. Obviously there is no Victory option for the 590LM as it was just introduced. In addition, the wiring harness on the 590LM is different than the stock wiring harness on the 660 as well. Here's what it looks like.

You are provided with about 3 feet of cable from the mount to the splitter. Plenty to reach from the handlebars into the fairing.



After the splitter, the leads are various lengths. You get about 2 feet each for AUDIO IN, AUDIO OUT, and MIC. Power leads with integrated fuse are about 3 feet, and the USB plug is about 5 feet. This is a TON of wire. Not a big issue for a bike like the XC since it has plenty of room in the fairing, but could be an issue for some other models if you're concerned about concealing all the extra wire.



On the bike end of the wiring scenario (as I'm sure most of you already know) there is a plug for the Victory 660 mount / wiring harness. It is a small, light grey plug that can be located in the lower right area (when looking from the front of the bike) of your fairing innards. It most likely has a small black weather cap on it and looks like this.



It's the small rectangular one right in the middle of this picture. (There may be additional wiring in my pic that you don't see on your bike due to some added equipment.)



The plug has 5 wires going into it. Per the wiring diagrams in the Factory Service Manual, the pin out is:

P1 - NAV +12V Switched Power - Red
P2 - NAV Audio (-) - Grey/Dark Blue
P3 - NAV Audio Left (+) - Dark Blue/Orange
P4 - NAV Ground - Black/White
P5 - NAV Audio Right (+) - Dark Blue/Pink



The question was, how to hook up the factory plug to the Garmin harness while doing the least amount of damage possible. The power leads were a no brainer, but I wanted to tie the audio in as cleanly as possible. Here's what I came up with. A good old fashioned 3.5mm to RCA splitter from an old Sony Discman I owned years and years ago. (Admit it, you've got that box of old wires hanging around the garage too...)



I simply plugged it in to the 2ft AUDIO OUT lead on the Garmin harness.



Lined it up so it was even with the 3ft power leads, and then cut off the RCA ends.



to be continued...

'04 Kingpin - Blue w/ Tribal Flames (sold)
'12 Cross Country - Imperial Blue
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post #2 of 84 (permalink) Old 06-16-2014, 12:39 AM Thread Starter
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Your typical 3.5mm to RCA splitter has a right channel and a left channel, each contained within their own insulator. Each insulator is wrapped with a ground, either braided or just twisted as mine was.



Simply untwist / unbraid the ground wires.



And twist them together into their own lead.



Apply some heat shrink tubing, and you now have 5 equal length leads that correspond to the 5 wires in the factory GPS plug.



So now how to connect the two? I searched, and searched, and searched, and could not find the corresponding female plug that mates up with the factory GPS plug. If anyone can track this part down and post it up here, I would be eternally grateful as it would really make this write-up complete. I went with what I thought would be the best alternative, a 5-pin Weatherpack connector for 18-20ga wire. It was $6 on eBay. It worked well, but ended up presenting its own problems which I'll go into later.



Weather seals and pins, crimped and soldered.



And the finished plug. The pin holes are labeled A-E so I matched up the wires according to the FSM pin-out from the original plug in order to save confusion down the road. The power leads are obvious, red + and black -. For the audio, bare is ground, red is right, left is white. If yours aren't color coded like mine were, you can test for continuity between the leads and the 3.5mm plug. The left output with be continuous with the tip of the plug. The right output will be continuous with the ring of the plug, just below the tip. The ground is continuous with the long sleeve portion at the base of the plug, just in case you were curious.



And the finished Zumo 590LM wiring harness.



to be continued...

'04 Kingpin - Blue w/ Tribal Flames (sold)
'12 Cross Country - Imperial Blue
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post #3 of 84 (permalink) Old 06-16-2014, 12:40 AM Thread Starter
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Sadly, since I could not find the mate to the factory GPS connector, I had to cut it off. I saved it in case a source should be discovered by someone in the future. Here's the pin-out again with a better view of the wires.

P1 - NAV +12V Switched Power - Red
P2 - NAV Audio (-) - Grey/Dark Blue
P3 - NAV Audio Left (+) - Dark Blue/Orange
P4 - NAV Ground - Black/White
P5 - NAV Audio Right (+) - Dark Blue/Pink



Same treatment as the Garmin harness, seals and pins crimped and soldered.



And the finished connector. Note that there are no corresponding A-E marks on the female half of the plug, at least not that I could find. Be very careful when inserting the pins that you match up the correct wires with the correct sockets that correspond to the male plug. Once the pins are inserted, you need a special tool to remove them.



So I mentioned earlier there was a problem with this Weatherpack connector I chose to use. Well here it is... It was easy to wire, is weatherproof, and works great. However, it is so much bigger than the original plug that it will not fit between the top triple clamp and the fairing sub-frame when you are attempting to route the wiring. I had to loosen the four bolts that hold the fairing sub-frame to the fork brackets in order to squeeze it in there. Not a deal breaker, but not ideal either...



to be continued...

'04 Kingpin - Blue w/ Tribal Flames (sold)
'12 Cross Country - Imperial Blue
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post #4 of 84 (permalink) Old 06-16-2014, 12:41 AM Thread Starter
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Lastly, here's the mount. Genuine 1" (B Size) RAM parts. The cradle is the one that comes with the Garmin 590LM. Also used the included RAM cradle ball mount and the RAM short arm (it's the powder coated aluminum one if you were curious.) I initially installed it with the included RAM handlebar mount which works, but places the GPS a little higher than I liked. In the following picture, it is installed with the Victory clamp mount and threaded RAM ball. The wire runs nicely down under the handlebars and ties in right where the rest of the control wiring comes together.



All the extra wiring on the Garmin harness gets coiled into about a 6 inch loop, zip tied together, and stashed next to the stereo module inside the fairing.



Not the greatest picture, but here's a front view. You can see there is one additional threaded hole in the front of the clamp mount should you want to thread in another ball, I'm thinking maybe for a cup holder?



Secured the GPS in the cradle and it powers right up. Here's a view of the cockpit with the new Zumo in place.



And a view of the entire handlebar area just to give a size reference for the 590LM's rather large 5" screen.



And for the final test, does it send audio correctly? Obviously can't show you the sound coming through the speakers, but here's the proof that everything is working as it should. Whenever the Zumo makes a sound or gives driving directions, the music mutes and the mode indicator changes from whatever source you're listening to (iPod, XM, FM, etc.) into a black rectangle that says NAV. It works!



I'll save my overall impressions of the 590LM for another thread as this one is specifically about the install. That being said, I don't see why this install info wouldn't work for any GPS. Be it another model of Zumo, another product from the Garmin line, or even a unit from a different manufacturer, so long as the power is hardwired (or can be) and it has an audio out/headphone jack that can be tapped into.

In reading through the forums there really seems to be a lot of mystery regarding the Victory 660 mount and whether or not it is needed to tie a GPS into the factory stereo system. I would have to say no. While that may be the only way to get the factory style connector, I really don't think the system is that smart. It is simply looking for a proper audio source to be hooked up to the connector.

Hope this information is helpful to someone out there. I know I sure could have used it before dropping $800 on a GPS I wasn't totally sure was going to work. If you find a better (smaller) connector to use, please post up, especially if you find the mating connector for the factory plug! Let me know if you have any questions, and I'll do my best to answer them.

Edit: The factory connector has been found!!! See page 4 for details...

'04 Kingpin - Blue w/ Tribal Flames (sold)
'12 Cross Country - Imperial Blue

Last edited by tonygiotta; 07-04-2014 at 02:46 AM. Reason: Added picture - Update on factory connector
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post #5 of 84 (permalink) Old 06-16-2014, 08:08 AM
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I love the play by play, well done sir!

I have a Garmin 665 with weather installed on my 13 XCT, the factory plug Bike and factory plug Garmin made the install great. I did have to swap the "mother Board" inside the mount.
I am wondering if the 590 mount uses the same "mother board"?
The 660/665 mount has two rows of pins I am curious if the 590 mount internals are close to the same as the 665.

Great write up!

Squatch

USN/USCG Vet
2013 Cross Country Tour
Zumo 665 w/weather
Power Commander V
Lloydz Air filter
PTS set to +6*
Hydraulic Clutch
D&D wrapped/RPW baffles
Touring Cams
124 hp/119#ft

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post #6 of 84 (permalink) Old 06-16-2014, 01:53 PM Thread Starter
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I can't say for certain as I've never owned a 660/665, but I have read posts from others who have and they've stated that the cradles have different dimensions. As for the motherboard, I can tell you that the 590 has two rows of 9 pins each (total of 18 pins) but I'm thinking the boards might be different sizes due to the differences in the cradles. Here's a couple pictures of the board I found on ADVrider, look the same?



And a more distant shot to show the entire cradle/board assembly:


'04 Kingpin - Blue w/ Tribal Flames (sold)
'12 Cross Country - Imperial Blue
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post #7 of 84 (permalink) Old 06-16-2014, 03:07 PM
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The boards are different dimensions, but the connectors look the same... Humm got me thinking now.

Squatch

USN/USCG Vet
2013 Cross Country Tour
Zumo 665 w/weather
Power Commander V
Lloydz Air filter
PTS set to +6*
Hydraulic Clutch
D&D wrapped/RPW baffles
Touring Cams
124 hp/119#ft

A country that forgets it's defenders, will itself soon be forgotten
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post #8 of 84 (permalink) Old 06-16-2014, 03:38 PM
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Great write-up and song selection, but Banana Wind is my fave on that "album".

2013 AF Green Crossed Country
TriOval slip ons
Lloydz VM-1 DR Cams
Lloydz PTS +4 degrees
PC V
Lloydz air filter
1/4 turn throttle
99.7 HP/107.2TQ


Now you know how I've felt for the last 8 years:D
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post #9 of 84 (permalink) Old 06-17-2014, 07:22 AM
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Wow! Would you consider making some for those of us "less talented" people?

Mike
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post #10 of 84 (permalink) Old 06-17-2014, 08:17 AM
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Nice write-up, Tony.

Cheers,

Bill P.

2012 XCT (SOLD) : HeliBars; Centramatics; PC-V; Lloydz air filter; 11" Madstad; Rivco LED mirrors; Doran TPMS; Stebel horn; Motolights; CustomLED trunk flasher; KewlHeel shifter; CycleOps trunk rack; BeadRider seat; Vibranator bar ends; Passenger grab handles; Powerlet outlets; Handlebar RAM mount; RicZ laydown plate; Brukus SaddlebagSecure; 14" flexible antenna; RAM cupholder on trunk; shock Schrader valve relocation.

Gallery: http://www.billanddot.com/victory-xct/
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