RegisterSearchFAQMemberlistUsergroupsLog in
How To: Installing Stebel Nautilus Air Horn

 
Reply to topic    All things Bajaj (Chetak & Legend) Forum Index » Procedures, How To's and Commonly re-asked questions! View previous topic
View next topic

How To: Installing Stebel Nautilus Air Horn
Author Message
beetle94707



Joined: 20 Mar 2008
Posts: 246
Location: San Francisco, CA

Post How To: Installing Stebel Nautilus Air Horn Reply with quote
First, let me just say that this is my first post with pics and instructions, so I welcome any suggestions to make anything more clear. Please do not hesitate to provide feedback.

I installed the horn over about 3 days, putting in a couple to several hours each day. I had never taken on a project like this, so it took me longer than it might take someone else with more experience.

I hope this helps, and that others post some other suggestions for horn location, wiring help, etc. I'm quite happy with the end product, and thankful for the Modern Vespa Forum.

Without further adieu

Items Needed:
    1. Stebel Nautilus Air Horn – Can be purchased at several online retailers. I got mine online from Scooter Works, about $35.
    2. Long zip ties – I got 14.5 inch, but probably could have used shorter ones.
    3. 10 feet of 12 gauge wire (some people use 14 or 16, the stock wires for the horn are definitely not 12 gauge)
    4. ¼ inch Terminal Insulated ring for 12G wire (used to connect to battery terminal)
    5. 12G Butt Connectors (used to wire inline fuse holder)
    6. ¼ inch 12G insulated Quick Disconnects (I used male and female, but depending on how you wire everything up, you may only need male)
    7. 20 Amp / 32 Volt blade type fuse and fuse holder (I used the mini blade type, because that was the only holder that I could find that had a cap that closed over the fuse).
    8. A coat hanger or two, un-twisted (for fishing the wire through the floor channel)
    9. Tools, screwdrivers, wire cutters / crimpers, wrenches, etc…



The Process

    1. First I removed the horncast, there are 8 screws (6 inside the glove box)
    2. Then I removed the stock horn and the mounting bracket for the turn signal beeper (I had already disconnected the turn signal beeper and didn’t use it, so removing it completely was not a loss to me).





    3. I then took a hacksaw and cut off the mounting bracket from the new horn. I needed to do this in order to get it to fit. (Sorry I forgot to take a pic of this, but you should be able to figure it out. It’s a metal piece that a nut and bolt goes through for mounting)
    4. I then ran the wire through the floor channel. I did this in a few stages, maybe someone else could’ve done it a little more elegantly than I, but it worked.
      a. Remove center rubber floor mat. To do this you will probably need to remove the bolts for the mounting brackets for the crash bars, as the rubber mat is underneath these. The two holes in the center there are where you will access the floor channel.



      b. Take one coat hanger (untwisted) through the front hole and run it up and out the front of the scooter at the steering column, you know, where all the wires are coming through and going to the horn cast. With some pliers, make a loop in the end of the coat hanger that is coming through the front of the scooter. Then tie one end of your wire to this loop, and pull the coat hanger and wire through to the hole in the floor channel. It’s probably a good idea to tie the other end of the wire onto one of the wire bundles in the front so that you don’t accidently pull your wire all the way through.




These pictures show the wire after it has been pulled through. (Notice I hadn’t taken off the rubber mat completely yet. I tried to run the wire without taking it completely off, but realized it would much easier if I did, so I did…)

      c. I then had to get the wire from the front hole in the floor channel back through the hole near the battery where all the wires come out. I did this by taking another coat hanger (untwisted) and pushed it through the hole near the battery and with some bending and coercing managed to get it out through where this rubber cover is that covers something that I don’t know what it is, but seems to be some kind of filter. (My camera batteries died at this point, so I don’t have pics of the coat hanger running through, only where I ran it through.)



Remove this rubber cover




      d. I took a second coat hanger and ran it from where this filter thing is down through the hole in the floor channel where I had already ran the wire from the front of the scooter. Now I have two coat hangers coming out of where this filter thingy is, one that goes to the front of the floor channel and one that goes back to the rear and out to where the wires for the battery are. Again, tie the wire onto the coat hanger, and pull it through in two stages. First from the floor channel to the filter thing then from the filter thing to the battery.


Wire coming through at the battery. I had to pull the coat hanger pretty hard to get the wire through this hole, but I got it…Now I’ve got the wire running from the front of the scooter all the way through the floor channel and back to the battery.

    5. Take a Butt connector and wire the fuse holder to the wire that you just ran through the floor channel at the end near the battery. With another Butt Connector, wire the other end of the fuse holder to an insulated terminal ring that you will attach to the (+) lead on your battery (but don’t connect it yet). (sorry still no batteries in camera)


Now we’re going to go back up to the front of the scooter, mount the horn and the relay switch to the horn cast and wire it up…

    6. I mounted the horn using a plastic zip tie through the mounting holes for the turn signal beeper mount. I placed the horn “upside down”. This provided the best fit for everything, and it seems to be working fine. (Note: you can kind of see in these pics where I cut off the mounting bracket from the air horn) The horn was kind of floppy with just this one mounting point, but once I put the horn cast back on, it felt pretty solid in there.





    7. I mounted the relay switch to one of the mounting holes where the old horn was, using one of the old horn’s mounting nut and bolt. I mounted it on the right turn signal side, this gave me more room on the left turn signal side to cram wires and such. (Although I wired it all up and then mounted it…)





Wiring



    9. On our Chetaks the Red wire from the old horn is (+) and the white wire is the ground (–). So, the wire you ran to the battery with the inline fuse, connects to terminal 30 on the relay, the red wire from the old horn connects to terminal 86, terminal 87 connects to the (+) on the new horn, and the white wire from the old horn is going to get split and one will connect to the (–) on the new horn, and the other to terminal 85 on the relay. You will use your blade style quick disconnects for all of these.

    10. When I wired the ground, I took a short length of wire and attached a female blade quick disconnect to one end. This end is going to attach to the white wire from the old horn. On the other end, I separated the wires in to two groups, and wired butt connectors on to each.



Butt connectors go on the two exposed wires above…

    11. I then attached the two ground wires to the two butt connectors and put male blade quick disconnects on the ends, one of them goes to the horn, one goes to the relay. I did also get a good suggestion (thanks dwestmodesto) of taking the white wire from the old horn to the (–) on the new horn, and grounding the relay (from terminal 85) to the inside of the glove box where one of the horn cast mounting screws goes, and use a star washer that will cut into the paint and make a connection with the metal. This sounds like a much better idea than what I did, but I had already wired everything up and put everything back together before I got this suggestion. Next time I open it up, I may make that change.




These pics show the ground connected to the white wire from the old horn and to the relay, the other ground will connect to the (-) terminal on the new horn

    12. Finally, before putting everything back together, I moved some of the wire bundles coming out of the front of the scooter. When standing facing the scooter with the horncast off, you will see that there is one bundle coming out on your left (right turn signal side). Since there was more room on your right side (left turn signal side), I wanted the wires over there. I disconnected all the wires (thankfully they are all easily color coded) and rerouted the bundle around the back of the steering column and out on the other side. You can see in the pic below, the red wire bundle near my middle finger, is the one that got rerouted to the other side of the steering column. Sorry I don’t have pics after I rerouted…I think you’ll be able to figure it out though…




The Stebel Nautilus air horn then fit pretty nicely tucked just up against the steering column. It will take a bit of finagling to get all the wires and everything to fit in there under the horncast, and when I put it back on, I definitely had to push on it a bit, but it’s on, and the horn doesn’t seem like it’s going anywhere. It is loud and it doesn’t sound like a dying goose…oh yeah, don’t forget to stick a fuse in your fuse holder and attach it all up to the (+) battery terminal.

_________________
2005 Chetak
Wed May 28, 2008 11:08 pm View user's profile Send private message
matty_x



Joined: 06 Apr 2007
Posts: 1065

Post Reply with quote
Tell us about the drain on the battery... And is it loud? I used something similar and it sounded like a dying duck because it pulled more current than the battery could provide.

Nice how-to. Great job.

_________________
The "X" stands for ex-Chetak owner.
Thu May 29, 2008 5:22 pm View user's profile Send private message
beetle94707



Joined: 20 Mar 2008
Posts: 246
Location: San Francisco, CA

Post Reply with quote
So far no drain on the battery, but I haven't had it in very long, nor have I used it much. It's much louder than the stock horn, but it doesn't seem as loud as I thought it might. I would say it sounds more like a Cadillac than a semi truck. In my opinion this is good. I was thinking that if I'm riding along and honk a horn that sounds like a semi, drivers will be looking for a big vehicle, not a little scooter. I began to wonder if a loud horn might actually be more dangerous. The conclusion I came to is that if someone is drifting into my lane, a loud horn will cause them a reflex reaction to get back in their lane as opposed to looking around for something big. I love the Stebel!

I'm guessing that because the horn is only used in short blasts, and with my daily commute of 25 miles round trip, that the battery will stay charged. I am also under the impression that the relay switch might help limit the battery drain, but I don't really know anything about electrical systems.

Bailey

_________________
2005 Chetak
Thu May 29, 2008 5:41 pm View user's profile Send private message
Angry J



Joined: 25 Mar 2007
Posts: 496
Location: Kansas City

Post Reply with quote
Thanks so much for this very detailed how-to! I'm making it a sticky. A loud horn really makes a difference in safety, IMO. I had a car horn in my bike until it quit on me. It eventually drained the battery, but a float charger can be had cheaply if you keep an eye out for one. One just has to be vigilant about plugging it in at night.

_________________


Mad Toto Scooter Club
www.madtoto.com
Thu May 29, 2008 10:41 pm View user's profile Send private message Visit poster's website
cowboyrob



Joined: 26 Mar 2007
Posts: 831
Location: Fayetteville, AR

Post Reply with quote
Angry J wrote:
A loud horn really makes a difference in safety, IMO.


Yeah J, that horn on your scooter really sucks! Laughing

For real though, thanks for lettin' me roll on the "menstrual stallion". Matty and I agreed that that scoot of yours shifted slicker than a couple of EELS f***kin' in a bucket of guts. That honey cooler was tuned to the 9's!

_________________
It was just an innocent gas pump fight...who would know it could be dangerous?
Thu May 29, 2008 11:29 pm View user's profile Send private message
Angry J



Joined: 25 Mar 2007
Posts: 496
Location: Kansas City

Post Reply with quote
Laughing

Umm ... Thanks?

_________________


Mad Toto Scooter Club
www.madtoto.com
Fri May 30, 2008 3:30 pm View user's profile Send private message Visit poster's website
matty_x



Joined: 06 Apr 2007
Posts: 1065

Post Reply with quote
Quote:
slicker than a couple of EELS f***kin' in a bucket of guts


He's from Arkansas, J. He can't help it. Wink

_________________
The "X" stands for ex-Chetak owner.
Fri May 30, 2008 5:10 pm View user's profile Send private message
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post why the new wire? and what about a circuit breaker? Reply with quote
Howdy gang...

Interesting deal with the horn... I have several questions/comments... and since I am not incredibly mechanically inclined I
ask that you bare with me...

#1 why run new wire when wire for the original horn was available? Couldn't you just use the same wire that was wired to old horn?

#2 Instead of zip ties.... Have you seen Billy Ray on TV promoting his MIGHTY PUTTY? Shocked Hey...it's just a thought Laughing

#3 I want to see if I am understanding the whole power draining thing... Does this horn drain power when the scooter is
running, or only when it is actually blasting...or both?

This may seem a bit out there but may be a simple solution to power drain ... a circuit breaker... a small simple one you
can toggle on and off, like in an airplane... (sorry, that's my only reference to one I am familiar with)

comments?

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Tue Jul 15, 2008 1:26 am View user's profile Send private message Visit poster's website Yahoo Messenger
twowheels2005



Joined: 04 Apr 2007
Posts: 21
Location: Reno, NV

Post Reply with quote
#1 - The air horn draws a lot more current than the stock horn. That's why you run a bigger wire directly from the battery and control it with a relay. You use the original wire to control the relay. Same theory as horns in most cars.

#2 - ???

#3 - The charging system on these scoots is barely enough to keep the stock equipment going and charge the battery. When the air horn blasts, it draws a LOT of power. If you do this enough and don't ride the scoot enough to completely charge the battery, eventually the battery will be pretty low. If you hook it up correctly, the horn only draws power when blasting.
Tue Jul 15, 2008 6:06 pm View user's profile Send private message Visit poster's website
beetle94707



Joined: 20 Mar 2008
Posts: 246
Location: San Francisco, CA

Post Reply with quote
Well said, Twowheels...

Before I started on this project, I didn't know the importance of re-wiring and putting in a relay. A couple of google / yahoo searches, explained it all to me. There was one explanation that talked about a scrawny guy lifting 50 lbs (the stock horn)...not so hard...but if there are 200 lbs (the Stebel) to be lifted, he needs help from his friend (the relay)...

I have noticed that when I use my horn, my headlight dims (only when the horn is sounding), so, yes, it draws a good amount of power. Like TW said, if you sound the horn a lot and don't ride much you might run into problems with battery drain, but since the horn sounds for very short amounts of time (generally), it hasn't been a problem.

It continues to work great and get me noticed every time...

_________________
2005 Chetak
Wed Jul 23, 2008 1:01 am View user's profile Send private message
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post is there.. a ... Reply with quote
is there a better, louder horn than the "S" horn?...
and the Mighty Putty thing... it's a guy on cable promoting a
magical putty (epoxy) I have it and will deploy it on a project soon.
I guess I think this guy is on TV everywhere... guess not...
Billy Ray pulls an 80,000lb truck with this stuff and he has the most
obnoxious voice you have ever heard...
anyway...
thanks for the info... I am not a real mechanical guy... I have to read it
all to make sense of it...
you guys are awesome... I don't care what you parents say.... Shocked

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Wed Jul 23, 2008 5:23 am View user's profile Send private message Visit poster's website Yahoo Messenger
beetle94707



Joined: 20 Mar 2008
Posts: 246
Location: San Francisco, CA

Post Reply with quote
I know I heard that there are a few other loud horns that people have used, I don't know if the Stebel is the loudest, but it's rated at something like 139 dB...plenty loud...who knows, maybe some of them are even smaller, and easier to mount.

I'm not super mechanical either (yet, anyhow) all that will change as I own my scooter longer...

Yeah, don't know this Might Putty guy...but sounds like he's got a million $ idea...and an infomercial that could drive you crazy

_________________
2005 Chetak
Wed Jul 23, 2008 3:24 pm View user's profile Send private message
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Here..try this.... Reply with quote
whoops

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...

Last edited by cowboydoug on Wed Jul 23, 2008 8:39 pm; edited 1 time in total
Wed Jul 23, 2008 7:10 pm View user's profile Send private message Visit poster's website Yahoo Messenger
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post yikes Reply with quote
Double whoops

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...

Last edited by cowboydoug on Wed Jul 23, 2008 8:39 pm; edited 1 time in total
Wed Jul 23, 2008 7:11 pm View user's profile Send private message Visit poster's website Yahoo Messenger
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post Here..try this.... Reply with quote
It's Billy Mays and his Mighty Putty...
After hearing this guys voice 100's of
time I now go into seizures whenever I hear it. Shocked

http://uk.youtube.com/watch?v=nkuReA-AGa8

I hang my scooter from the rafters in the garage with this stuff:lol:




Sorry about the triple post.... my laptop/internet connection went "Freaky Jason" on me Shocked


Thanks for all the info on the horn and wiring... all I know about electricity is, when I turn the light
switch on there is light... Cool

_________________
Happy Trails,

Cowboydoug


I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Wed Jul 23, 2008 7:13 pm View user's profile Send private message Visit poster's website Yahoo Messenger
Plotts



Joined: 27 Jun 2008
Posts: 52
Location: Chicago

Post Reply with quote
Question. Why not just mount the horn in the back of the scooter, under one of the cowls? That way all of the wiring and relay can be mounted together and you only have to run one wire from the front to the back?

Just a thought. I believe this will be my approach. I mean if it is so loud, I wouldn't think it necessarily has to be at the front of the scoot. That way you could leave the turn signal beeper on if you like as well.
Sun May 24, 2009 12:13 am View user's profile Send private message
questionmarke



Joined: 04 May 2007
Posts: 161
Location: Oklahoma City

Post Reply with quote
That is what I did. Mounted mine right behind the battery, facing down.
Sun May 24, 2009 1:02 pm View user's profile Send private message Visit poster's website AIM Address
Display posts from previous:    

Reply to topic    All things Bajaj (Chetak & Legend) Forum Index » Procedures, How To's and Commonly re-asked questions! All times are GMT
Page 1 of 1

 
Jump to: 
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum


© 2007-2008 Informe.com. Get Free Forum Hosting
Powered by phpBB © 2001, 2005 phpBB Group
 :: 
Design by Freestyle XL / Flowers Online.