ROAD TECH ZUMO GLOBAL POSITIONING SYSTEM (GPS) HANDLEBAR MOUNT KIT
J054152016-09-01
GENERAL
Kit Number
76000191B, 76000192B
Models
This kit is required when using a Road Tech™ Zumo 660®, Zumo 665® or Zumo 590® GPS unit on specific model motorcycles.
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
This kit IS NOT compatible with:
  • Auxiliary accessory switch housing kits (left side) (Part No. 70213-02C or 70248-02B).
  • Hand lever bracket clamp-mounted clock (Part No. 75041-03 or 75042-03), OR thermometer (Part No. 75102-04 or 75104-04), when mounted on the clutch lever bracket.
  • The Road Tech™ SiriusXM Satellite Radio Receiver Kit (Part No. 76390-05A).
NOTE
SiriusXM Satellite Radio is available within the continental United States. It is not available in Alaska or Hawaii. An SiriusXM Satellite Radio subscription is required, for an extra fee.
Installation Requirements
A Road Tech Zumo 660 GPS Kit (Part No. 92115-09), Road Tech Zumo North America GPS Kit (Part No. 76000573) or a Road Tech Zumo 665 GPS Kit (Part No. 76000014) is required. These kits are available from a Harley-Davidson dealer.
2014-2016 Touring models require separate purchase of an Electrical Connection Harness (Part No. 69200722).
2017 and later Touring models require separate purchase of an Electrical Connection Harness (Part No. 69201599).
2014 and later XL (Sportster) models require separate purchase of an Electrical Connection Harness (H-D Part No. 72673-11).
2004-2013 XL (Sportster) models require separate purchase of a Hand Control Clamp Screw Service Kit (Part No. 42320-04A) to attach the GPS bracket to the clutch lever clamp.
2011 and later Softail models require separate purchase of an Electrical Connection Harness (Part No. 72673-11).
2012 and later Dyna models require separate purchase of an Electrical Connection Harness (Part No. 72673-11).
An Ultratorch UT-100 (Part No. HD-39969), Robinair Heat Gun (Part No. HD-25070) with Heatshrink Attachment (Part No. HD-41183), or other suitable radiant heating device is required for the proper installation of this kit.
Installation of this kit also requires the use of a terminal crimping tool, and other parts and supplies. Electrical Contact Lube (Part No. 99861-02) or equivalent is required after battery cable disconnection. These items are available from a Harley-Davidson dealer.
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet refers to service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
Electrical Overload
NOTICE
It is possible to overload your vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. See an authorized Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories or for necessary wiring changes. (00211c)
WARNING
When installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a)
Both the Road Tech Zumo 660 and 665 require up to 2.0A more current from the electrical system.
Service Parts
PREPARATION
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
NOTE
  • 2007 and later vehicles equipped with security siren: With security fob present, turn ignition switch ON. After system is disarmed, turn ignition switch OFF. IMMEDIATELY remove the main fuse per the service manual.
  • 2006 and earlier vehicles equipped with security siren: Disarm the siren with the key fob or security code. See the service manual to remove the main fuse.
  • Vehicles WITHOUT security siren: See the service manual to remove the main fuse.
VRSC models only: Remove the air box aluminum cover per service manual instructions.
Refer to the service manual and follow the instructions to remove the main fuse.
EFI models EXCEPT VRSC:
WARNING
To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a)
Purge and disconnect fuel supply line.
Vehicles with main fuse:
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
1. See the service manual to remove the main fuse. Remove and retain the seat and all mounting hardware.
For vehicles with main circuit breaker:
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
1. See the service manual to remove the seat and disconnect the negative (black) battery cable from the negative battery terminal. Retain all seat mounting hardware.
Carbureted models:
WARNING
Gasoline can drain from the carburetor fuel line when disconnected from fuel valve fitting. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00256a)
1. Turn fuel supply valve OFF. Remove fuel line from valve.
ALL models EXCEPT VRSC:
WARNING
When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a)
1. Fuel tank console models: Remove instrument console from fuel tank. See service manual.
2. See the correct section (Carbureted or EFI Engine) of the service manual for fuel tank removal instructions.
MOUNTING BRACKET AND PLATE INSTALLATION
ALL Models:
NOTE
Do not use solvent-based chemicals or waxes directly on plastic or rubber components. Solvent-based chemicals and waxes affect performance and appearance of plastic and rubber.
1. See Figure 16. Get the GPS mounting bracket (1) from the kit.
a. ALL models EXCEPT 2004 and later XL (Sportster): Also get two 1/4-20 x 1-1/8 in long screws (2) from the kit.
b. 2004 and later Sportster models: Also get a Hand Control Clamp Screw Service Kit (Part No. 42320-04, purchased separately).
2. ALL models: Remove and discard the original equipment (OE) clutch lever clamp mounting screws and clamp.
NOTE
2015 and later FLTR models have a post on the handlebar under the stock clamp. Verify that post is positioned inside the recess of the bracket.
3. Insert the new screws into the GPS mounting bracket. Insert the screw threads through the holes in the clutch lever housing.
4. Adjust the hand lever position for rider comfort. Tighten the screws to 6.8–9 N·m (60–80 in-lbs).
5. Get the mounting plate (7), upper ball clamp (5) and three flat head screws (6) from the kit.
6. Insert the screws into the mounting plate and upper ball clamp as shown. Place the upper ball clamp over the mounting ball, lining up the holes with threaded holes in the lower ball clamp. Thread the screws into the lower ball clamp, position the mounting plate to a suitable viewing angle and tighten the screws to 4–6.8 N·m (36–60 in-lbs).
CRADLE MOUNT INSTALLATION
1. Get the cradle mount (A) from the Road Tech Zumo GPS Kit, and four button head screws (8) from this kit.
2. Position the cradle mount to the mounting plate (7) with the power harness exiting to the right. Insert a screw through one of the holes in the cradle and into the corresponding threaded hole in the mounting plate. Do not fully tighten.
3. Insert three screws through the remaining holes in the cradle and into the mounting plate. Alternately tighten four screws to 1.58–2.26 N·m (14–20 in-lbs).
HARNESS ROUTING
NOTE
Route the Zumo power harness along the outside of the handlebar, even on internally wired handlebars.
1. Route the unconnected end of the harness:
a. Follow the existing wiring from the left side handlebar switches over to the center of the handlebar. Use cable straps (19) from the kit to tie the harness in place as the harness is routed along the handlebar to the center. For some models, removal of a handlebar cover, instruments or other accessory items is necessary. Refer to the service manual or accessory instructions as needed.
2.
NOTE
For some VRSC models, the headlamp or instrument panel shroud must be loosened or removed to access the wiring path.
Follow the existing wiring to route the Zumo power harness:
a. Through, across or around the upper fork bracket (fork bracket)
b. Along the motorcycle frame
c. To a general location under the seat
d. VRSC models only: Route the red wire near the battery positive terminal, located toward the front right side of the frame.
3. Use cable straps (19) from the kit to fasten the Zumo power harness to the wire harnesses along the vehicle frame.
HARNESS CONNECTION
GENERAL
Splicing of wire leads is necessary in the installation of the Zumo handlebar mount to the motorcycle. Find the instructions for a specific model in the sections that follow. Refer to the service manual appendix for proper wire splicing procedures.
WARNING
Be sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)
  • Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/explosion resulting in death or serious injury.
  • Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed.
  • Always keep hands away from tool tip area and heat shrink attachment.
For 2014 and later Touring models: Proceed to RED LEAD CONNECTION TO SWITCHED POWER SOURCE.
For 2014 and later Sportster models: See next section.
For 2011 and later Softail models: See next section.
For 2012 and later Dyna models: See next section.
For ALL OTHER models:Proceed to BLACK LEAD CONNECTION for the specific model.
2014 and Later SPORTSTER, 2011 and Later SOFTAIL, and 2012 and Later DYNA Models
NOTE
Requires separate purchase of Electrical Connection Harness (Part No. 72673-11).
1. Locate the Digital Technician connector [91A] (a gray six-way Deutsch pin connector with a rubber boot): Under the seat on Softail models, or in the electrical caddy, under the left side cover, on Dyna and Sportster models. Place the Electrical Connection Harness at connector [91A], but DO NOT connect now.
2. Route the Zumo power harness wires over to the Electrical Connection Harness. DO NOT cut off the in-line fuse holder on the red wire. Cut the wires to a suitable length to reach the sealed splice connectors on the Electrical Connection Harness easily.
3. Splice the black Zumo wire to the black wires in the Electrical Connection Harness.
4. Splice the red Zumo wire to the red/yellow wires in the Electrical Connection Harness.
5. Use a heat gun or suitable radiant-heating device to shrink the connector to the wires.
6. Use the heat gun or heating device to seal the open end of the sealed splice connector on the red/blue wires in the Electrical Connection Harness.
7. Pull the rubber boot out from the gray Digital Technician pin connector [91A]. Cut the boot off the wires.
8. Connect the socket housing of the Electrical Connection Harness to connector [91A].
9. Insert the rubber boot into the open pin connector of the Electrical Connection Harness.
10.
a. Softail models, loosen or remove the four screws holding the ECM to the mounting bracket. Route the Electrical Connection Harness under the ECM connector. Tighten four screws:
Torque: 5.1–6.2 N·m (45–55 in-lbs) Hex socket screw
b. Dyna models, install the left side cover.
11. Proceed to the COMPLETION section.
BLACK LEAD CONNECTION TO GROUND
2011 and Earlier Dyna Models
1. Remove the nut from the ground screw, on the top of the frame, under the seat near the fuel tank.
2. Select the correct ring terminal (13 or 14) from the kit to fit the ground screw.
3. See Figure 1. Cut the black wire on the Zumo wire harness to reach the ground location easily. Crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix.
4. Install the ring terminal to the ground connection. Secure per the torque specification in the service manual.
5. Proceed to ALL models in this section.
1Tail lamp harness (orange/white wire)
2Ground terminal (black wire)
Figure 1. Power and Ground Connections (Dyna Models)
2010 and Earlier Softail Models
1. Remove the ground screw, on the top of the frame, under the seat near the fuel tank.
2. Select the correct ring terminal (13 or 14) from the kit to fit the ground screw.
3. Cut the black wire on the Zumo wire harness to reach the ground location easily. Crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix.
4. See Figure 2. Install the ring terminal onto the ground screw threads. Fasten the ground screw to the frame (2). Secure per the torque specification in the service manual.
5. Proceed to ALL models in this section.
1Tail lamp harness (orange/white wire)
2Ground terminal (black wire)
3Battery
Figure 2. Power and Ground Connections (Softail Models)
2013 and Earlier Sportster Models
1. Remove the electrical side cover, on the left side near the battery.
2. Route the Zumo wire harness through the top of the frame under the seat to the circuit breaker on the inside of the electrical side cover.
3. See Figure 3. Remove the ground screw (1), located:
a. Under the seat on some 1996-2003 models
b. Near the swingarm on 1995 or earlier models, and 1996-2003 models without a screw under the seat
c. On the engine near the starter on 2004-2013 models
4. Select the correct ring terminal (13 or 14) from the kit to fit the ground screw.
5. Cut the black wire on the Zumo wire harness to reach the ground location easily. Crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix.
6. Install the ring terminal onto the ground screw threads. Fasten the ground screw at the original location. Secure per the torque specification in the service manual.
7. Proceed to ALL models in this section.
1Ground screws (black wire)
Figure 3. Ground Connections (Sportster Models)
2003 and Earlier Touring Models
WARNING
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
1. If the negative battery cable WAS NOT disconnected at the beginning of the installation, refer to the service manual to remove the seat and disconnect the negative (black) battery cable from the negative battery terminal. Retain all seat mounting hardware. Refer to the service manual to disconnect the positive battery cable.
2. Remove vehicle battery.
NOTE
Leave the black wire long enough so the battery fits into the battery well without stressing or stretching the wire.
3. See Figure 4. Cut the black wire on the Zumo wire harness to reach the ground stud (2) easily. The ground stud is located below the circuit breaker in the battery well under the seat.
4. Select the correct ring terminal (13 or 14) from the kit to fit the ground stud.
5. Crimp the ring terminal to the wire end per the Packard crimping tool instructions in the service manual appendix.
1Circuit breaker silver terminal (red wire)
2Ground terminal (black wire)
Figure 4. Connections (with battery removed) - 2003 or Earlier Touring Models (2003 FLHTCU shown)
6. Install the ring terminal to the ground stud. Secure per the torque specification in the service manual.
7. Proceed to ALL models in this section.
2004 and Later Touring Models
1. Locate the main harness chassis ground stud (there are two, under the seat in front of the battery).
2. Remove the nut from one of the chassis ground studs.
3. Select the correct ring terminal (13 or 14) from the kit to fit the ground stud.
4. Cut the black wire on the Zumo wire harness to reach the ground location easily. Crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix.
5. Install the ring terminal to the ground connection. Secure per the torque specification in the service manual.
6. Proceed to ALL models in this section.
2006 and Earlier V-Rod Models
1. See Figure 5. Remove the screw (1, under the seat) that fastens the ignition switch (2) to the right side of the frame.
2. Scrape the paint from the top of the frame where the screw was removed, to make a strong ground contact.
3. Select the correct ring terminal (13 or 14) from the kit to fit the ignition switch screw.
4. Cut the black wire on the Zumo wire harness to reach the ground location easily. Crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix.
5. Install the black wire ring terminal onto the threads of the ignition switch screw. Install the screw to the ignition switch. Tighten to 6–10 N·m (53–88 in-lbs).
6. Proceed to ALL models in this section.
1Screw
2Ignition switch
Figure 5. Ground Connection (2006 and Earlier V-Rod Models)
2007 and Later V-Rod Models
The Zumo harness black wire connects directly to the battery negative terminal.
1. Select the correct ring terminal (13 or 14) from the kit to fit the negative terminal fastener on the battery.
2. Cut the Zumo harness black wire to within easy reach of the battery negative terminal. Crimp the ring terminal to the end of the black wire per the Packard crimping tool instructions in the service manual appendix.
3. Fasten the black wire ring terminal to the negative terminal mounting post on the battery. Tighten the terminal fastener to 7–10 N·m (60–96 in-lbs).
ALL models
Make sure that there is sufficient slack in the black lead so that handlebar movement is not restricted.
Proceed to the RED LEAD CONNECTION section for the specific model.
RED LEAD CONNECTION TO SWITCHED POWER SOURCE
Use the service manual wiring diagrams for the specific model and year vehicle to locate a power source fed through the ignition switch.
2003 and Earlier Dyna Models
The Zumo switched power source is an orange/white (O/W) main harness power lead inside the electrical side cover.
1. Remove the electrical side cover, on the left side near the battery.
2. See Figure 1. Carefully slice open an area of the main harness wrap inside the side cover at an accessible point. Cut an orange/white main harness power lead.
3. Cut the excess length from the red power lead of the Zumo wire harness to within easy reach of the cut orange/white wires inside the side cover. DO NOT cut off the in-line fuse holder.
4. See Figure 16. Get the blue sealed splice connector (17) from the kit. See Figure 6. the "two into one" splice configuration. Splice the Zumo wire harness power lead to the main harness orange/white wires per the instructions in the service manual appendix.
5. Proceed to ALL models in this section.
1"one into one" splice
2"two into one" splice
3"three into one" splice
Figure 6. Splice Configurations
2004-2011 Dyna Models
The Zumo switched power source is an open fuse position on the fuse panel. See the FUSES section of the service manual and the correct wiring diagram in the service manual appendix.
1. Remove the electrical side cover, on the left side near the battery. While firmly grasping both sides, pull outward.
2. Remove the electrical panel from the vehicle per service manual instructions.
3. See Figure 16. Get the orange/white fuse block adapter wire (15) from the kit. Note the terminal on each end ( See Figure 7. ). Only the terminal with the spring tabs fits into this fuse block. Carefully cut the unused terminal from the wire and discard it.
4. See Figure 8. Locate the fuse cavity (1) indicated as "OPEN" on the fuse block cover in the right fuse block. Insert the terminal on the orange/white adapter wire until it stops. Refer to a nearby factory installed terminal for comparison to verify proper orientation and depth.
5. Cut the excess length from the red power lead of the Zumo wire harness to within easy reach of the adapter wire. DO NOT cut off the in-line fuse holder.
6. See Figure 16. Get the blue sealed splice connector (17) from the kit. See See Figure 6. , the "one into one" splice configuration. Splice the Zumo wire harness power lead to the adapter wire per the instructions in the service manual appendix.
7. Install the 2A fuse (18) from the kit into the "OPEN" fuse cavity to complete the circuit.
8. Install the electrical panel per the instructions in the service manual. Install the electrical panel cover. Align the pins with the rubber bushings in the electrical panel. Push firmly into place.
9. Proceed to ALL models in this section.
1CUT this terminal from wire
2LEAVE this terminal on wire
3Spring tabs (2)
Figure 7. Fuse Block Adapter Wire (Dyna and Softail)
Figure 8. "OPEN" Fuse Block Cavity (2004-Later Dyna)
2003 and Earlier Softail Models
The Zumo switched power source is the orange/white (O/W) wire in the tail lamp harness under the seat.
1. See Figure 2. Carefully slice open an area of the tail lamp harness (1) wrap at an accessible point under the seat. Cut the orange/white wire.
2. Cut the excess length from the red power lead of the Zumo wire harness to within easy reach of the cut orange/white wires under the seat. DO NOT cut off the in-line fuse holder.
3. See Figure 16. Get the blue sealed splice connector (17) from the kit. See Figure 6. , the "two into one" splice configuration. Splice the Zumo wire harness power lead to the cut orange/white wires per the instructions in the service manual appendix.
4. Proceed to ALL models in this section.
2004-2010 Softail Models
The Zumo switched power source is an open fuse position on the fuse panel. See the FUSES section of the service manual and the correct wiring diagram in the service manual appendix.
  1. Remove the fuse block cover. Remove the 2 hex head screws fastening the fuse block bracket. Pull the bracket and fuse block assembly away from the vehicle frame.
  2. Press the tab retaining the left fuse block. Slide the block out of the mounting slots.
  3. See Figure 16. Get the orange/white fuse block adapter wire (15) from the kit. Note the terminal on each end (see Figure 7 ). Only the terminal with the spring tabs fits into this fuse block. Carefully cut the unused terminal from the wire and discard it.
  4. See Figure 9. Locate the fuse cavity (1) indicated as "P&A IGN" on the fuse block cover in the right fuse block. Insert the terminal on the orange/white adapter wire until it stops. Refer to a nearby factory installed terminal for comparison to verify proper orientation and depth.
  5. Cut the excess length from the red power lead of the Zumo wire harness to within easy reach of the adapter wire. DO NOT cut off the in-line fuse holder.
  6. See Figure 16. Get the blue sealed splice connector (17) from the kit. See Figure 6 , the "one into one" splice configuration. Splice the Zumo wire harness power lead to the adapter wire per the instructions in the service manual appendix.
  7. See Figure 16. Install the 2A fuse (18) from the kit into the "P&A IGN" fuse cavity to complete the circuit.
  8. Slide the fuse block into the mounting slots in the fuse block bracket until it clicks firmly into place. Install the bracket and fuse block assembly into position and fasten with the 2 hex head screws removed earlier. Tighten securely.
  9. Proceed to ALL models in this section.
Figure 9. "P&A IGN" Fuse Block Cavity (2004-2010 Softail)
Sportster Models
The Zumo switched power source is an orange/white (O/W) main harness power lead inside the electrical side cover or under the seat.
1. See Figure 10. Carefully slice open an area of the main harness wrap inside the electrical side cover or under the seat at an accessible point. Cut an orange/white main harness power lead.
1Left side cover containing circuit breaker silver terminal (red wire)
2Stock wire harness (orange/white wire)
Figure 10. Power Connections (XL Models)
2. Cut the excess length from the red power lead of the Zumo wire harness to within easy reach of the cut orange/white wires inside the side cover or under the seat. DO NOT cut off the in-line fuse holder.
3. See Figure 16. Get the blue sealed splice connector (17) from the kit. See Figure 6 , the "two into one" splice configuration. Splice the Zumo wire harness power lead to the main harness orange/white wires per the instructions in the service manual appendix.
4. Proceed to ALL models in this section.
2003 and Earlier Touring Models
The Zumo switched power source is an orange/white (O/W) main harness power lead inside the right side cover, near the top.
1. See Figure 11. Carefully slice open an area of the main harness wrap inside the electrical side cover at an accessible point. Cut an orange/white main harness power lead.
1Fuse box harness (orange/white wire)
Figure 11. Fuse Box Harness Behind Left-Hand Side Cover, 2003 or Earlier Touring Models (FLHTCUI Shown)
2. Cut the excess length from the red power lead of the Zumo wire harness to within easy reach of the cut orange/white wires inside the side cover. DO NOT cut off the in-line fuse holder.
3. See Figure 16. Get the blue sealed splice connector (17) from the kit. See Figure 6 , the "two into one" splice configuration. Splice the Zumo wire harness power lead to the main harness orange/white wires per the instructions in the service manual appendix.
4. Proceed to ALL models in this section.
2004-2007 Touring Models
The Zumo switched power source is an open fuse position on the fuse panel. See the FUSES section of the service manual and the correct wiring diagram in the service manual appendix.
1.
a. For 2004-2006 models: Remove the left side cover per service manual instructions to access the fuse box.
b. For 2007 models: Remove the right side cover per service manual instructions to access the fuse box.
c. For 2004-2007 models: Remove the main fuse holder, fuse block and dust cover from the vehicle per service manual instructions.
2. Get the orange/white fuse block adapter wire (15) from the kit.
a. For 2004 through 2006 models: See Figure 12. (upper view). Note the terminal on each end Only the terminal WITHOUT the spring tabs fits into the fuse cavity. Carefully cut the terminal WITH spring tabs from the wire and discard it.
b. For 2007 models: See Figure 12. (lower view). Note the terminal on each end. Only the terminal WITH the spring tabs fits into the fuse cavity. Carefully cut the terminal WITHOUT spring tabs from the wire and discard it.
3. 2004-2007 models: See Figure 13. Locate the fuse cavity marked "P&A IGN", "2A MAX" (1). Remove the three fuses (2) currently installed in this row, noting their location.
4. Gently remove the orange plastic secondary lock from the fuse block. Insert the terminal on the orange/white adapter wire until it stops. Refer to a nearby factory installed terminal for comparison to verify proper orientation and depth. Install the secondary lock.
5. Install the three fuses removed in Step 3.
6. See Figure 16. Cut the excess length from the orange/white Zumo harness wire. Using the blue sealed splice connector (17) from the kit, splice that wire to the adapter wire installed in Step 4.
7. Install the 2A fuse (18) from the kit into the fuse cavity marked "P&A IGN", "2A MAX" to complete the circuit.
8. Proceed to ALL models in this section.
1CUT this terminal from wire
2LEAVE this terminal on wire
3Spring tabs (2)
Figure 12. Fuse Block Adapter Wire (FL Touring)
1P&A IGN fuse location
2Remove these fuses (3)
Figure 13. P&A IGN Fuse Cavity (2004-2007 Touring Models)
2008-2013 Touring Models
The Zumo switched power source is an open fuse position on the fuse panel. See the FUSES section of the service manual and the correct wiring diagram in the service manual appendix.
1. Remove the left side cover per service manual instructions to access the fuse box. Remove the left side electrical caddy from the vehicle. Remove the fuse blocks from the back of the caddy per service manual instructions.
2. Get the orange/white fuse block adapter wire (15) from the kit.
a. See Figure 12. (Upper view). Note the terminal on each end. Only the terminal WITH the spring tabs fits into the fuse cavity. Carefully cut the terminal WITHOUT spring tabs from the wire and discard it.
3. See Figure 14. Locate fuse cavity 1A-1B (marked "P&A IGN", "2A MAX" on the cover) on the lower fuse block (1). Remove the brake relay (2) and fuse (3, if present) currently installed in column A-B, noting their location.
4. Gently remove the orange plastic secondary lock from column A-B. Insert the terminal on the orange/white adapter wire into the empty cavity until it stops. Refer to a nearby factory installed terminal for comparison to verify proper orientation and depth. Install the secondary lock.
5. Install the relay (and fuse, if equipped) removed in Step 3.
6. See Figure 16. Cut the excess length from the orange/white Zumo harness wire. Using the blue sealed splice connector (17) from the kit, splice that wire to the adapter wire installed in Step 4.
7. Install the 2A fuse (18) from the kit into fuse cavity 1A-1B ( See Figure 14. , Item 4) to complete the circuit.
8. Proceed to ALL models in this section.
1Lower fuse block column A-B
2Brake relay
3Fuse (if present)
4Fuse cavity 1A-1B
Figure 14. P&A IGN Fuse Cavity (2008-2013 Touring Models)
2014-2016 Touring Models
NOTE
Electrical connectors are identified in the service manual by the number and letter shown here within brackets.
1. Locate connector [4A] a gray eight-way Molex pin connector under the left side cover in the electrical caddy, directly above the Digital Technician connector [91A] (a gray eight-way Deutsch pin connector with a rubber boot).
2. If installing the Electrical Connection Harness (Part No. 69200722, available separately): Route the harness per the instructions in that kit, but DO NOT plug into connector [4A] now. If the electrical connection harness is already installed: Unplug the harness from connector [4A].
NOTE
The Zumo power harness wires connect to two of the sealed cap ends of the electrical connection harness. DO NOT REMOVE the sealed cap from the RED/BLUE wire.
  • If accessory wires have already been spliced to the electrical connection harness in a previous accessory installation, cut off the splices. Refer to HARNESS CONNECTION - GENERAL, earlier in these instructions. Refer to the service manual appendix for proper wire splicing procedures.
  • Up to three accessories can be spliced to the electrical connection harness. For multiple splice configurations See Figure 6.
3. Make sure the harness has been unplugged from connector [4A].
a. Clip the cap off the Black wire, strip back, crimp and seal to the BLACK wire of the wire harness from this kit.
b. Clip the cap off the Violet/Blue wire, strip back, crimp and seal to the Orange/White wire of the wire harness from this kit.
c. DO NOT REMOVE the sealed cap from the RED/BLUE wire.
4. Plug the harness into connector [4A]. Proceed to ALL models in this section.
2017 and Later Touring Models
NOTE
Electrical connectors are identified in the service manual by the number and letter shown here within brackets.
1. Locate connector [325B] a gray three-way Molex pin connector under the right side cover in the electrical caddy.
2. If installing the Electrical Connection Harness (Part No. 69201599, available separately): Route the harness per the instructions in that kit, but DO NOT plug into connector [325B] now. If the electrical connection harness is already installed: Unplug the harness from connector [325B].
NOTE
The Zumo power harness wires connect to two of the sealed cap ends of the electrical connection harness. DO NOT REMOVE the sealed cap from the RED/BLUE wire.
  • If accessory wires have already been spliced to the electrical connection harness in a previous accessory installation, cut off the splices. Refer to HARNESS CONNECTION - GENERAL, earlier in these instructions. Refer to the service manual appendix for proper wire splicing procedures.
  • Up to three accessories can be spliced to the electrical connection harness. For multiple splice configurations See Figure 6.
3. Make sure the harness has been unplugged from connector [325B].
a. Clip the cap off the Black wire, strip back, crimp and seal to the BLACK wire of the wire harness from this kit.
b. Clip the cap off the Violet/Blue wire, strip back, crimp and seal to the Orange/White wire of the wire harness from this kit.
c. DO NOT REMOVE the sealed cap from the RED/BLUE wire.
4. Plug the harness into connector [325B]. Proceed to ALL models in this section.
V-Rod Models
The Zumo switched power source is an orange/white (O/W) main harness power lead coming from the fuse block.
1. See Figure 15. Carefully slice open an area of the main harness wrap near the fuse block (2) at an accessible point. Cut the orange/white main harness wire leading to the fuse cavity (1) marked:
a. ACCESSORIES on 2002-2006 models
b. P&A IGNITION on 2007 and later models
2. Cut the excess length from the red power lead of the Zumo wire harness to within easy reach of the cut orange/white wires at the fuse block. DO NOT cut off the in-line fuse holder.
3. See Figure 16. Get the blue sealed splice connector (17) from the kit. See Figure 6. the "two into one" splice configuration. Splice the Zumo wire harness power lead to the main harness orange/white wires per the instructions in the service manual appendix.
4. Install the 2A fuse (18) from the kit into the fuse cavity to complete the circuit.
1Accessories fuse
2Fuse block
Figure 15. Accessory Fuse Locations (V-Rod Models)
ALL models
Make sure that there is sufficient slack in the red lead so handlebar movement is not restricted.
Proceed to the next section.
COMPLETION
NOTE
DO NOT perform the following steps until the Zumo and all related wiring have been installed per the procedures outlined in this instruction sheet for the specific model motorcycle.
1. Install the Road Tech Zumo GPS unit into the cradle mount per the instructions in the GPS kit.
NOTE
Verify that the ignition switch is OFF before installing the main fuse or attaching the battery cables.
WARNING
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
2. 2003 and earlier Touring models only: Refer to the service manual to attach the battery cables, positive cable first. Apply a light coat of petroleum jelly or corrosion retardant material to battery terminals. ALL OTHER models:Models with main fuse: Refer to the service manual to install the main fuse. Models with main circuit breaker (EXCEPT Sportster): Refer to the service manual to attach the negative battery cable. Apply a light coat of petroleum jelly or corrosion retardant material to battery terminals. Sportster models with main circuit breaker: Refer to the service manual to connect the negative battery cable at the engine crankcase.
3. V-Rod models only: Install the air box aluminum cover per service manual instructions. ALL OTHER models: Install the fuel tank per the service manual.
4. Install the handlebar cover, riser cover or outer fairing if equipped, per service manual instructions.
5. Turn the ignition switch ON, but do not start the motorcycle. Test the Road Tech Zumo unit for proper operation.
6. See the service manual. Install seat. After installing seat, pull up on the seat to be sure it is secure.
SERVICE PARTS
Figure 16. Service Parts, Road Tech Zumo 660 and Zumo 665 GPS Handlebar Mount Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Bracket, mounting, Road Tech Zumo 660/665 (chrome)
76000189A
Bracket, mounting, Road Tech Zumo 660/665 (black)
Not Sold Separately
2
Cap screw, button head, 1/4-20 x 28.6 mm (1⅛ in) long (2) (chrome)
4293
Cap screw, button head, 1/4-20 x 28.6 mm (1⅛ in) long (2) (black)
4132
3
Mounting ball
Not sold separately
4
Ball clamp, lower
Not sold separately
5
Ball clamp, upper
Not sold separately
6
Screw, hex socket, flat head, #10-24 x 25 mm (1 in) long (3)
Not sold separately
7
Mounting plate, Zumo 660/665 GPS
Not sold separately
8
Screw, button head, M4 (4)
Not sold separately
9
Earphone Kit (includes items 10 and 11)
91771-04
10
  • Earphone
Not sold separately
11
  • Cable, extension
Not sold separately
12
Clip, adhesive-backed (3)
10271
13
Ring terminal, #18-22 AWG (1/4 inch stud)
9858
14
Ring terminal, #18-22 AWG (5/16 inch stud)
9859
15
Fuse block adapter wire, orange/white
70329-04
16
Sealed splice connector, #18-20 AWG (red)
70585-93
17
Sealed splice connector, #14-16 AWG (blue)
70586-93
18
Fuse, blade type, 2A (2)
54305-98
19
Cable strap (10)
10006
Items mentioned in text, but not included in kit (Zumo 660/665 shown):
A
Cradle mount, Zumo 660/665 GPS
B
Zumo 660/665 GPS unit