ZUMO 550 mount with the Powerlet Powerbar and the Techmount 2 1/2" stem

[Merlin]

As requested...here are the pics of the Powerlet Powerbar and the Techmount 2 1/2" stem mount installed.

I did not want to permanently hard wire the Zumo Bike mount for various reasons battery drain, theft, weather, washing the bike, cleaner look etc. I wanted no wires hanging and a quick and easy disconnect of the Zumo AND the cradle.

While gathering parts I learned of the Techmount 2 1/2" stem mount for the Powerlet Powerbar.
BTW-Both the folks at Techmount and Powerlet have excellent products and were outstanding to work with.

I have 1 ¼ diameter handlebars so the Garmin supplied Ram Mount handlebar mount was too small. I tried the Ram Mount clutch mount. This allowed quick disconnect but I had hanging wires to the cigarette lighter and the HD Radio aux input when using the Zumo. I did not care for the appearance of the hanging wires as well as the safety factor. I was concerned that the hanging wires might catch on something, possibly damaging a component or even worse getting snagged and causing a riding mishap.
This way, No Wires = No Worries.

Here's how it turned out.

The first picture shows the Techmount stem with the Zumo and cradle removed.

Powerbar w/Techmount stem:

Notice the two wire connections at the bottom left of the Powerbar. They go in the handlebars.

With Techmount Quick-disconnect and Zumo bike mount cradle:

Note the two silver washers & both wires in the above pic (audio for output & mic for bluetooth)

With Zumo 550 mounted:

Note the right angle patch cables under the Powerbar in the above picture.
The two right angle cable on the left go into the handlebars.
The two cables from the Zumo (center picture) go into the right side of the barrel connector(s).

For quick disconnect:
Remove the right side barrel connector audio/mic patch cable(s).
Remove the Powerlet connector.
Remove the Techmount Quick-Disconnect w/Zumo attached.
Lock it all up.
Hook up and removal of the Zumo and cradle takes less than 5 seconds!

****************************
Project Parts List

1) Garmin Zumo 550

Direct from Powerlet: (Call 1-877-752-7835)
1) PKT-068 bracket with socket assembly (no wiring harness) – Chrome
1) Techmount Riser 2 ½ inches Chrome Approx $50.00
1) Techmount Accessory Quick Change Adapter $14.95
1) PPC-020-SC GARMIN ZUMO POWER CABLE
Short cable-SC at 12" in length w/Powerlet PPL-002 straight plug $32.95
(I might recommend a 10" cable and a right angle plug. It might be a cleaner look and easier to use.)


1) Sound Professionals SP-SPSC-7 Gold Plated Right Angle Stereo Patch Cable - 8 inches $5? (web site)
1) Radio Shack 274-886 Gold Plated female-female 1/8 coupler $11.00
2) Stainless 4mm screws from Ace Hardware $1.00
2) P clamps Ace Hardware (so cheap they were almost free)
1) Plastic cap (free)

Suppliers:
Sound Professionals
http://www.soundprofessionals.com/cg...item/SP-SPSC-7

Call Techmount directly ask for Dave or Mike Lee
mike@techmounts.com
http://www.techmounts.com
USA toll-free 1 866-341-4192
Local Voice: 407-654-3322
info@techmounts.com

Call Powerlet directly ask for Adam
http://www.powerletproducts.com
USA toll-free 1-877-752-7835
marketing@powerlet.net

Tell 'em Merlin sent ya'
****************************
SPECIAL NOTE:

I have 1 1/4" handlebars.

The "PKT-068 bracket with socket assembly" is for 1 1/4" handlebars!
I do not know what the correct part # is for 1" bars.

Call 'em!

Powerlet:
Adam was great about replying to email and very helpful on the phone.

Techmount:
Dave was outstanding with his knowledge, assistance and direction.

Here's what was done under the Powerbar.

Two longer screws (4mm) to replace the stock screws that hold the Powerbar clamp together.
Two P clamps and the Radio Shack 274-886 (1/8" female-female) covered in black heat shrink wrap.

One Female jack side for the AUX audio cable that comes out of the handlebars and
one side for the Sound Pros SP-SPSC-7 8" cable (shown in photo) for quick connect to the Zumo.

NOTE: The Rat Shack part 274-886 is a bright gold the heat shrink made it black so it was not noticable.

bottom view of Powerbar:



The above pic has only one set of P clamps attached. This would be for audio output only.
By adding a second set (reversed P clamps) you can have both audio and mic quick disconnect cables.
NOTE: Painting the P clamps black before attaching them to the Powerbar helps hide the P clamps.

The Zumo power and audio wires are run inside the handlebars to power source and the back of the HD radio.

I took it a step further and did the AUX input in the back of the HD radio mod.
I recommend doing this mod while you have your fairing off running handlebar wires.

I did this for a bunch of reasons better sound quality, no hanging wires (especially in the front), safety, clean appearance, ability to run audio and power wires inside handlebars etc. I found the instructions on CVOHarley.com. GREAT JOB!

Prior to 06 (Radio Sound)
http://www.cvoharley.com/smf/index.php?topic=7674.0
and 06 and up here (HK)
http://www.cvoharley.com/smf/index.php?topic=10044.0

Boy am I glad I did it! The "AUX input in the back of the HD radio" mod took less than 20 minutes to do.

Things learned:
The screws that were supplied to mount the Techmount Accessory Quick Change Adapter to the Zumo mount were slightly too long. One of the 4 screws stuck out and put a small scratch on my chrome Techmount plate.

Check your clearance BEFORE attaching the Quick Change Adapter.

SOLUTION: You will need to put washers between the Zumo mount and the Accessory Quick
Change Adapter when you attached these together. No more problems. (see second top pic)

Steel sleeves were needed to insert in the bottom of the Powerbar to make the Powerbar bracket secure on the handlebars.

SOLUTION: Two 4mm screws with a long collar so the P clamps can be attached on the bottom of the Powerbar or drill two steel nuts that fit inside the sleeves so the Powerbar can be tightened.

Due to the height of the Powerlet Zumo power connector it is a little difficult to insert/remove from the socket. However, the Powerlet connector is large and easy to attach and remove.

SOLUTION: Slightly shorter Zumo power cable (about 2") and a right angle Powerlet plug.
During mock up the Powerbar I put some good size scratches on the handlebars.

NOTE - Use Electrical tape or duct tape inside the Powerbar handlebar area during mock up.
Luckily the Powerbar did hide the scratches. However if I ever take it off I'm gonna need a cup holder.

SPECIAL NOTE:
I have recently added the HD BOMM Bluetooth module to this setup.
This allows me to use my Zumo for phone calls using the stock HD (or J&M) headset.
This is an additional step to the above information but I recommend doing it at the same time.
Please PM me if you would like for me to post the information on the HD BOMM setup.

MOST OF ALL:
Special thanks to Chopper for all his time, effort, energy and hard work in accomplishing this project for me.

[Merlin]

Things learned:
The screws that were supplied to mount the Techmount Accessory Quick Change Adapter to the Zumo mount were slightly too long. One of the 4 screws stuck out and put a small scratch on my chrome Techmount plate.

Check your clearance BEFORE attaching the Quick Change Adapter.

SOLUTION: You will need to put washers between the Zumo mount and the Accessory Quick
Change Adapter when you attached these together. No more problems.

Here is another top view of the washers that are needed as spacers to eliminate scratching the face plate.

[Merlin]

SPECIAL NOTE:
I have recently added the HD BOMM Bluetooth module to this setup.
This allows me to use my Zumo for phone calls using the stock HD (or J&M) headset.
This is an additional step to the above information but I recommend doing it at the same time.

The HD Bomm is a hard wired Harley Davidson helmet microphone to GPS microphone input interface device.

The HD Bomm isolates and seamlessly routes the audio signal created by the driver and passenger’s helmet mounted Harley or J&M microphone to the audio input of your Road Tech, Garmin Zumo 550/650 or Garmin Nuvi GPS’s audio input port.

This allows you and the passenger to talk on the cell phone that is paired with the GPS’s Bluetooth connection between the GPS unit and the cell phone.

The Audio output of the GPS must be connected to the Aux input port of the Harley’s Radio in order to hear the caller. This port is located on the lower right front of the Radio which is covered by a rubber plug. If you wish you can modify the radio and add an additional Aux input port to the back of the radio, this cleans up the installation.

The HD Bomm does not use a switch as other interfaces. Once you initiate or receive a phone call via the GPS interface just talk in a normal voice, no switch to trigger.

Unlike other interfaces the HD Bomm comes with every thing you need to connect the interface to the bike’s audio system and the GPS you do not need to purchase additional harnesses.

The HD Bomm sells for much less than other interfaces and only has 2 wires to connect.

Click here for more information http://www.hdbomm.com

Tell 'em Merlin sent ya'