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Garmin Zumo 660 Cradle - Wiring Loom / Cables Modification

The Garmin ZUMO 660 GPS SatNav motorcycle cradle is designed with all of the wiring as an integral part of the cradle i.e. permanently fixed to the cradle. The design of the cable 'loom' is imho lacking in what to me would be two obvious features...

  • the option to unplug the unneeded leads!
  • the option to 'unplug' the cradle and remove it from your bike

Personally all I want is power to the cradle with phone and audio via Bluetooth and as I only use GPS / SatNav occasionally prefer to be able to remove the Zumo 660 cradle altogether when not in use (I made a quick disconnect power lead for my R1200GS previously, Zumo 550 at that time see here)

Garmin Zumo 660 Cradle & Wiring Harness...

Garmin Zumo 660 cradle, power / audio cables and wiring loom
...not very conducive to a tidy motorcycle installation, where are you supposed to neatly (and safely) 'hide' all that cabling?!

As I've already mentioned with the OE Garmin cable set up it's necessary to uninstall the wiring from the motorcycle if you wish to remove the cradle (so ordinarily if you have two motorcycles you need two cradles!).....that coupled with the excessive number and length of cable leads meant...

...I had to give it the chop!! :-O

NB: Reversal of this procedure is not really practical ;-)
(but if the need arose you can always get a replacement cradle....cheaper on eBay;-)

Modifying A Garmin Zumo Cradle Cable / Wiring Loom

NB: Larger version of photos here

July 2010 - I had my new Zumo 660 but I really wasn't happy with the cradle's mass of cables and wires - some time researching on the Interweb provided the DIY solution.

I got all the information I needed from this thread on the ZumoForums, 'The Insides of the Zumo MC mount' and this PDF doc from Touratech (intended as instructions for using their Conversion kit for Garmin motorcycle base mount for ZUMO 660 with separable connecting cable):
Zumo 660 power cable modification (1.16Mb download)
...I basically adapted the Touratech guide to my needs / way of doing things :-)

First thing to do is position the Zumo cradle on your bike where you want to mount it and work out a route for the cable to a suitable point to make the connection to the power source (both for my R1200GS and my Multistrada 1200 / MTS1200, I made up a 'fly-lead' from the bike's dedicated GPS power connector up to a position under the bikes instrument cluster).

Multistrada 1200 GPS custom power lead
...[arrow] with blanking plug for when not in use. Multistrada 1200 GPS Power Connection

BMW R1200GS custom GPS power lead
...on the GS, at the time of this photo I was using a tyre valve cap to seal the connector when not in use :-) GPS Sat Nav Power Connection

Having decided on the point to cut the Zumo 660 cable loom (no going back remember!), give it the chop! Carefully strip back the black outer insulation taking care not to damage the cores in the cable. Only the 2 red and black cores screened with foil are required. These must not be confused with those from the braiding.

Modifying the Zumo 660 cable / wiring

 Note how I've cut the wires that are not needed to different lengths so that there's no chance of an unwanted connection being made inadvertently ;-)

Closer look...

Modifying the Zumo 660 cable / wiring

Insulate the wires that aren't required with heatshrink insulation tube...

Modifying the Zumo 660 cable / wiring

And now solder your electrical connector of choice to the black and red GPS cradle power supply wires and again insulate the connection with heatshrink tube...

Modifying the Zumo 660 cable / wiring

Complete the job with further heatshrink tubing...

Modifying the Zumo 660 cable / wiring

Garmin Zumo 660 GPS cradle with custom power lead

Job done :D

I'm a fussy bugger so the silver bolts supplied by Garmin to attach the cradle to the RAM mount irritated me.....too long for the job and why not black bolts for a much tidier look? Solved with a trip to the local 'Nuts & Bolts' shop....

Modifying the Zumo 660 cable / wiring

 ...see how the threaded bolt end is now flush with the top of the nylock nuts ;-)

Modifying the Zumo 660 cable / wiring

...yeah I know, bit pedantic but I can't help it! lol

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