Thursday, March 27, 2014
How to Install a Zumo 550 in a Harley
The Zumo 550 GPS navigation system is made by Garmin for Harley-Davidson. Users and reviewers report the color LED screen is bright even in strong sunlight. The device comes preloaded with maps and directions to every Harley dealer in North America and it is intended to be mounted on the left handlebar next to the clutch lever, headlight dimmer and horn. The details of installation vary slightly between Dynas, Softails, touring models, V-Rods and Sportsters. It mounts on a Dyna as follows.
Instructions
- 1
Remove and discard the original equipment clutch lever clamp mounting screws with an Allen wrench. Retain the clamp.
2Insert the new clamp mounting screws included with the Zumo kit into the GPS
mounting bracket. Insert the screw threads through the holes in the clutch lever clamp and into the clutch lever housing.
3Adjust the hand lever position so it is comfortable. Tighten the new mounting screws to between 60 and 80 inch pounds of torque with an Allen socket and torque wrench.
4Insert the mounting ball stud through the lower holes in the mounting ball clamp and the Zumo mounting bracket. Thread the lock nut onto the stud from behind the mounting bracket and tighten with an Allen socket and torque wrench to between 72 and 144 inch pounds of torque.
5Insert the mounting plate screws included with the kit through the mounting plate and upper ball clamp so the screw heads face away from the rider. Place the upper ball clamp over the mounting ball so the holes align with those in the lower ball clamp.
6Thread the mounting plate screws into the lower ball clamp. Sit on the motorcycle and adjust the mounting plate to the viewing angle that is most visible for you.
7Tighten the mounting plate screws to between 36 and 60 inch pounds of torque with an Allen socket and a torque wrench.
8Attach the cradle mount to the mounting plate with one of the flat head screws included with the Zumo mounting kit. Ensure that the cradle mount weather cap faces down when attached. Insert three more flat head screws through the remaining holes in the cradle. Tighten the screws with an Allen socket and a torque wrench to 20 inch pounds of torque.
9Plug the round 4-pin DIN connector on the Zumo power harness into the front of the cradle and fasten securely with the mounting screws included in the mounting kit and an Allen wrench.
10Route the Zumo power harness following the existing wiring from the left side handlebar switches to the center of the handlebar. Tie the harness in place with the cable straps included with the kit.
11Unfasten the Allen nut that secures the seat tab to the rear fender with an Allen wrench. Remove the seat by pulling up and back.
12Route the Zumo power harness following existing wiring through the triple tree and along the motorcycle frame to a general location under the seat. Fasten the harness to the frame with cable ties included with the kit.
13Remove the hex nut from the ground screw with an open end wrench; the ground screw is located on top of the frame near the fuel tank. Attach a ring terminal from the kit to the ground screw.
14Cut the black wire on Zumo wire harness with side blade pliers and crimp the ring terminal to the black wire with a wire crimping tool. Replace and tighten the ground screw hex nut.
15Turn the handlebars all the way to the left and all the way to the right to ensure that none of the wire harness binds.
16Grasp the electrical side cover on the left side of the bike (near the battery) with both hands and pull to remove. Slice open two inches of the main harness wrap with a sharp knife.
17Cut the orange/white main harness power lead with side blade pliers. Splice the red Zumo wire to the two ends of the orange/white power wire with the blue, sealed, 2-into-1 splice connector included with the kit. Seal the connections with a wire crimping tool.
18Replace the seat, tab washer and Allen bolt. Install the Zumo into the cradle mount following the instructions included in the GPS kit.
